For the food and beverage industry, satisfying consumers’ insatiable appetite for new products is just one part of a complex equation. Equally important is protecting the food supply and maintaining compliance with the Food Safety Modernization Act (FSMA), Title 21 CFR Part 11, S88 and other regulatory mandates.
The latest standards have directly impacted equipment cleaning processes and heightened food and beverage companies’ expectations of their clean-in-place (CIP) systems. CIP systems are designed to efficiently clean the interior surfaces of process equipment without disassembling it.
Stepping up to the challenge is Central States Industrial (CSI), a Rockwell Automation OEM Partner and equipment supplier focused on providing value-added components and systems for hygienic processes. The family-owned business, headquartered in Springfield, Missouri, serves a global customer base ranging from Fortune 500 food companies to craft breweries and family farms.
A Smarter Way to Clean
With its modular CIP 2.0 system, CSI is aligned to meet both industry and regulatory demands. Designed for food, dairy and beverage plants and delivered on scalable skids, CIP 2.0 incorporates smart machine technology to enhance performance, flexibility and reporting.
“The core programming of our system makes CIP 2.0 smarter than previous generations of equipment,” says Trent Bullock, manager, engineering services, CSI. “Historically, CIP systems relied on time-based cleaning cycles — and many still do. CIP 2.0 controls the cycles using process parameters.”
From pre-wash to final rinse, each cycle within the system is configured to reach predetermined setpoints for flow, temperature and chemical concentration. Additional sensors can be added to the system to control the duration of the cycle.
“For example, we can add turbidity sensors to a pre-wash cycle as a configurable option,” Bullock explains. “So we can actually prewash until an acceptable level of soils is removed from the line.”
Relying on process parameters delivers a more accurate and repeatable process than a strictly time-based approach. In addition, a process-based system minimizes overuse of chemicals, water and other resources.
Optimization Improves Efficiency
CSI also works with end users to improve cycle times further by offering additional configurable options, such as incorporating a hot water supply or direct steam injection.
“In plants that must clean-in-place 8 to 2 times a day, accelerating cycle time by 30 or 40 minutes can have a dramatic impact on overall productivity,” notes Bullock.
To maintain efficient operation, the system allows operators to configure, monitor and run washes in real time from the recipe-driven interface. Trend charts and maintenance manuals also are digitally stored and accessible through the human-machine interface (HMI) to streamline troubleshooting.
“The CIP system also incorporates automated record keeping,” Bullock says. “This functionality is designed to help customers comply with regulatory standards, including the Food Safety Modernization Act.”
CIP 2.0 also facilitates connectivity to enterprise-level systems through the control environment.
Standardization Speeds Deployment
A standard approach to control system design provides the same functionality for all CIP 2.0 installations — whether it’s a single-supply, one-tank skid or dual-supply, four-tank system.
CIP 2.0 is based on a Rockwell Automation® control platform featuring Allen-Bradley® CompactLogix™ 5370 controllers and Allen-Bradley PowerFlex® 755 AC drives. Integrated on an EtherNet/IP™ network, the system includes Stratix® managed switches with network address translation (NAT). An Allen-Bradley solid-state integrated display computer running on a Windows® 7 operating system and FactoryTalk® View HMI software help monitor the system.
“Our standard, modular approach provides customers with cost-effective options for various areas of their plant,” Bullock explains. “And because all run on the same platform, operators are automatically cross-trained.”
A standard control platform also allows CSI to make incremental improvements more easily, which have resulted in a more robust system overall. End users often request configurable options.
“A one-week turnaround for a quote has become the norm in the food and beverage industry,” Bullock says. “Because we have a robust standard, we can typically deliver quotes that meet strict requirements within one day or less.”
Standardization also speeds deployment. Rockwell Automation assembles, programs and wires the control panels, which allows CSI to reduce design time and related costs.
“We aim for cost-effective, forward-looking designs,” notes Bullock. “For example, currently we offer remote monitoring as an option. We are also exploring ways to incorporate cloud-based analytics into our platform to deliver an even more robust monitoring option in the future.”
Rockwell Automation OEM Partner Central States Industrial Equipment (CSI), based in Springfield, Missouri, provides value-added process components and systems for hygienic processes in the pharmaceutical and food and beverage industries.
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