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Types of Brewery CIP Systems

Types of Brewery CIP Systems

CIP systems are a must for the craft beverage industry to deliver quality products to a competitive market. The need to produce the highest quality products in the craft beverage sector is only going to get stronger. Using food-grade stainless steel to manufacture equipment is an important step in ensuring high-quality product hygiene and preventing infection. A clean-in-place (CIP) system is a must-have tool for every craft beverage producer to ensure every drink is of high quality.
Types of CIP Systems
Types of CIP systems can be differentiated by the number of tanks and whether they need to be moved. There is a Pump on a Cart, Mobile CIP Skid, and a Centralized CIP System according to whether it needs to be moved. According to the number of tanks, it can be divided into the single-tank system, two-tank system, three-tank system, four-tank system. Let’s take some time to understand each option and advantage.

Distinguish by type of movement

Pump on a Cart

Pump on a Cart

This is the most cost-effective option for beer production. Many microbrewery startups start with this type of CIP cart. Pump trucks are often multipurpose, used for transfer processes and CIP cleaning activities.
The advantage of a fully mobile pump truck is that it can be used anywhere on the equipment, but it is a manual option. The disadvantage of a pump truck is that it cannot heat or maintain the temperature of cleaning chemicals. Manufacturers must use temperatures above the chemical’s recommended temperature so that the chemical remains within the operational range when it comes into contact with the equipment. Without the ability to monitor temperature, the effectiveness of a CIP system cannot be guaranteed.
When you choose a pump truck as a solution, it is important to ensure that the equipment has a VFD to control the speed of the pump, which ensures proper flow rate and surface contact for any chemicals being pumped by the CIP.
Mobile CIP Skid

Mobile CIP Skid

This type of design provides the mobility of a pump truck and the practicality of custom equipment. Typically, mobile CIP skids have one or more heating vessels.
A CIP system of this design has several advantages:
  • Chemicals can be captured for multiple recycling, reducing costs and the brewery’s environmental impact.
  • Providing heat and maintaining easy temperatures allows brewers to know that chemicals are within their operating range.
  • The CIP skid with multiple reservoirs allows for prefilling and preheating during the CIP process.
  • Multiple solution types are allowed to create the best cleaning solution.
  • Removable, ideal solution for remote equipment.
Centralized CIP System

Centralized CIP System

This is the best choice for large production facilities, where the centralized CIP system delivers cleaning agents throughout the facility. This CIP system is fully automated and has multiple hard pipe cleaning circuits. In addition, it is equipped with various monitoring equipment, including:
  • Temperature Sensor
  • Pressure Sensor
  • Flowmeter
  • Liquid Level Sensor
These systems also typically feature automated logging capabilities that create documentation for even the most stringent quality assurance programs.

Distinguish according to the number of tanks

The size and number of CIP tanks in a brewery vary depending on the type of CIP cycle and the size of the brewery. Tanks can be used for a variety of CIP applications, including fresh water, caustic, acid, reuse (washing and rinsing), and disinfectants. Tanks are usually fabricated from corrosion-resistant stainless steel 304 or 316.
single-tank system

Single-tank system

Single-tank systems are the most common, requiring only a simple circuit for cleaning and/or rinsing. After a single pass, each cycle is dumped down the drain.

Advantage

  • Often used to avoid allergen and cross-contamination issues, as each cycle is dumped down the drain after a single pass.
  • Single-tank systems require a lower initial investment than multi-tank systems.
  • Requires less space and can be easily mounted on a cart for easy mobility.

Precautions

  • The same tank must be used for each cycle.
  • Not recommended for multiple cycles or city use strategies.
  • Cleaning cycles require more time to refill and heat the tank for each cycle.
  • The use of water and chemicals is higher in a single tank system because each wash and rinse has to be drained out when done.
two-tanks system

Two-tank system

Typically, one tank in a two-tank system is used for water (pre-rinse and final rinse) and one tank is used for caustic wash solution.

Advantage

  • In many cases, the caustic wash can be returned to the tank and reused multiple times, which significantly reduces water, chemical, and energy costs compared to single-tank systems.
  • Each tank can be prefilled and preheated as needed before starting the cleaning cycle, reducing cleaning time.
  • Can be mounted on a cart for easy mobility.

Precautions

  • Need more space.
  • Mobility is lower than single-tank systems.
there-tanks system

There-tank system

Systems with three tanks offer more cleaning options than single- and dual-tank systems.

Advantage

  • The water/caustic/acid cycle is very common in many cleaning applications because it includes pre-filling and preheating of all solutions, reducing cleaning time.
  • Caustic and acid washes can be recovered and reused, depending on the amount of soil in the treatment system.
  • Water/Alkaline/Reuse: If pickling is not required, a reuse tank can capture moderately contaminated caustic washes and use them as an effective pre-rinse for the next cleaning program. This strategy saves water helps recover residual caustic solution in the wash liquor and allows for the next pre-rinse, giving a great head start on chemical cleaning operations.
  • Water/caustic/alternative caustic: For cleaning multiple circuits with different types of product fouling that require different types or concentrations of caustic cleaners.

Precautions

  • Need more space.
  • Not suitable for vehicle movement.

four-tanks system

Four-tank system

Additional tanks in a four-tank system provide the flexibility to recover and reuse solutions without sacrificing the convenience of a single caustic and acid solution tank.

Advantage

  • Sophisticated fully automated systems include valves and gauges that monitor key variables and provide data for system validation and validation.
  • Water/Caustic/Acid/Reuse is a typical four-tank setup that allows pre-fill and preheat for each wash, with the option of re-use washes.
  • The water/caustic/alternative caustic/reuse cycle can clean soils with different types of products and require multiple loops of caustic scrubbing at different concentrations. All without sacrificing reuse options.

Precautions

  • Space requirements.
  • More complex systems.
  • Generally not suitable for vehicle movement.
  • The more initial investment may be required.
Depending on the application of the CIP system, the cleaning system can be designed in various types. To determine the number of tanks in a brewery’s CIP system, designers analyze water, chemical, and energy usage, as well as the potential time savings of adding tanks. They also analyze the brewing process and brewing equipment from mashing to boiling, filtration, and fermentation, and then design the CIP to meet hygiene requirements in the most efficient way.
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