Steps. Shows the recipe steps as they are configured and allows operators to insert, delete, or edit steps as needed. When editing, operators access an interface that takes them to “Time Temp and Flow” or “Flow Plate Routing” so they can configure the exact devices that are active during each step. With maximum flexibility, operators can perform complete configurability right down to the individual devices—valves, pumps, proximity switches, temperature, and flow control, for example.
With maximum flexibility, operators can perform complete configurability right down to the individual devices…
Flow plate routing. Allows operator to select the path the flow should take. In this example, when the CIP solution reaches a flow plate, it traverses through the middle port. The ports on the outside branch to different areas of the facility (see diagram). Once the operator selects the path, there is a proximity switch in place to validate that the swing (the pipe that goes from the middle to the branches on the perimeter) is in the correct position. This is a requirement before the system can run and it prevents cleaning solution from flowing where it’s not intended to be should an operator incorrectly position the swing.
In this diagram, valve V5853 has been configured to turn on during the step based on its orange color. This means that solution will come from CIP (at left), through valve V5853, then through the flow plate to the port supplying TK 24, 25, 26. This is how the entire circuit is defined.
Of course, ensuring compliance with food safety regulations requires documentation. Therefore, the right CIP solution is one that can collect documented evidence of proper sanitization and also provide key insights into optimization opportunities. Some relevant reports that can be helpful include:
- Revision report: captures every activity (change) made for a specific revision of a wash cycle;
- Revision history: shows the history of all recipe versions for every wash;
- Operator activity report: shows activity on every system, including when washes were started, stopped, and reset; tracks system events, like alarms or operator comments that can be entered ad hoc at any time; and shows when operators step sequences forward or backward;
- Exceptions report: presents a record of exceptions/problems that occurred during wash cycles, including pump malfunctions, operator-initiated emergency stops, longer-than-normal time spent heating up to temperature, or any number of other alarm conditions; and
- Completed circuits report: provides a history of washes that occurred for each system, showing the circuits that were washed, when they were washed, the number of times an operator stepped forward or back in the sequence, or if the wash cycle was aborted (ended prematurely by the operator before the entire wash sequence could complete).
By leveraging user-configurable automation so as to enhance CIP, today’s manufacturers can reap many benefits. They include the ability to create flexible security control levels and recipe configurations without relying on engineering resources to implement the changes, obtain complete recipe traceability, gain detailed trending, reduce cleaning times, improve safety, log events and configurations, generate reports, and monitor performance over time using manufacturing information system tools.
In other words, with more control over CIP comes more productivity, lower costs, stronger compliance, greater self-reliance and added quality assurance.
Tertin, the director of manufacturing information solutions at ESE, Inc., is credited with developing ESE’s MIS solution suite and for expanding the adoption of MIS solutions within ESE’s customer base. Reach him at firstname.lastname@example.org.