I've worked in the food and beverage industry for over 30 years and have seen the emphasis shift toward efficiency and sustainability. It is constantly evolving; being shaped by economic, scientific, technological and environmental forces. With many companies consolidating operations, efficiency becomes more important than ever before. Clean-in-place (CIP) systems, often overused, present an opportunity to reduce cleaning time, water consumption, chemical usage and operating spend.
When looking for ways to boost efficiency, plant managers often turn to CIP. While CIP presents opportunities to conserve resources, the process still inherently requires a certain amount of water, chemicals and energy. With that in mind, managers should take a holistic approach to optimize their CIP system and process.
Consider taking the following steps toward CIP optimization:
Assess the situation: Managers should ask: Is my CIP system underperforming compared to industry standards? The majority of CIP systems run unvalidated, using the original settings, which means many systems haven't been fine-tuned to perform optimally or adjust to changes in the plant's production process. Evaluating where a plant stacks up involves auditing current cleaning procedures and measuring the current water, energy and chemical usage, as well as cycle time. Diversey's CIPCheck is a knowledge-based solution designed to assess and improve cleaning results, maintain microbiological standards and safeguard food safety. Using CIPCheck and working with a sector specialist will provide an accurate picture of how a plant's CIP system is performing and create a clear path forward to optimization.
Monitor progress: Once managers have decided on next steps, the best way to see if the adjustments are paying off is to analyze the data. Accurately measuring flow, conductivity and temperature can indicate that the cleaning cycle has met certain parameters, but those attributes alone do not measure cleanliness levels. Another Diversey solution, CIPTEC, gathers data on soil levels using spectrophotometer sensors. When the sensor data is combined with traditional metrics, it enables a thorough analysis of the CIP cycle in dairy processors.
Keep up with trends: As managers focus on CIP in their quest for efficiency, innovations will continue to push the industry in new directions. Diversey Intelligent CIP monitors key parameter and operating data, processes it in the cloud and then presents it via a simple and engaging user interface that tracks compliance and uncovers potential hygiene issues. This is a fast and effective way to discover anomalies in the CIP process and correct them right away. Keep in mind that data and emerging technologies like artificial intelligence will continue to shape the way food and beverage plants operate and managers will need to adjust accordingly to compete.
CIP optimization has taken center stage in food and beverage manufacturing as efficiency and sustainability has become top priorities for businesses. Managers should seize opportunities to reduce costs and water usage by actively assessing and improving their CIP systems. They should work with a specialist to access their wealth of knowledge and bring in an extra set of eyes. Through it all, plant managers, and anyone involved in food and beverage, should stay apprised of trends and technologies rapidly reshaping the industry.
I've been with Diversey since 1986 and now oversee a team of sector specialists that help our customers across the food and beverage industry. I was involved in the rollout of Diversey's DryTech solution for beverage processors, which eliminates the need for water as a delivery vehicle in conveyor lubrication. In the U.S., droughts in Georgia and Texas created demand for this solution and reminded the industry that water is a finite resource.
Over the years, I have seen firsthand the power of a team of experts with experience-driven knowledge. Without an extra informed set of eyes, plants risk overlooking and perpetuating wasteful or unsanitary practices. This happens frequently, especially in the realm of CIP. Sector specialists employ a depth of knowledge to overcome issues and create value by optimizing operations. They manage long-term projects and educate sales representatives on good manufacturing practices so they can provide the most productive interaction possible in customer-facing situations.
