A single dairy production plant manufactures various milk and dairy products. But still, have you ever thought about how the taste of each variant of dairy products is maintained perfectly? How come butter holds its signature taste while cheese tastes the way it should? CIP in advanced dairy plants is one of the crucial processes that help dairy products hold their signature taste even though they come from the same production equipment and machinery of the same factory.
CIP stands for Clean-In-Place. It is a process of cleaning and sanitizing dairy production plants without the need to disassemble or move equipment. CIP systems use high-pressure water and chemicals to remove bacteria, biofilms, and other contaminants from surfaces. CIP systems are becoming increasingly popular in dairy production plants in India due to their efficiency and effectiveness. This process helps to improve product quality, reduce the risk of contamination, and help dairy production units deliver the same quality products from every batch they produce.
CIP in Advanced Dairy Manufacturing Plants: STEPS
The 7-step CIP Process that we Dairy Production Plants follow comprises the following steps:
Step 1: Pre-rinse
This step is the flushing of clean water at high velocity through the milk tanks and manufacturing lines to remove loose soil or debris.
Step 2: Caustic/Detergent Wash
A specially formulated non-foaming cleaning agent circulates the system to effectively break down and remove fats, proteins & mineral deposits in production lines and cavities.
Step 3: Soak/Contact Isolation
The system is left to soak the cleaning agent for a specific time (as per requirements) to work on stubborn residues.
Step 4: Agitation/Scrubbing
Using rotating brushes or jets, equipment with internal parts is mechanically scrubbed or agitated.
Step 5: Hot Water Rinse
After the soak time, there’s rinsing of the production lines and systems thoroughly with clean and hot water until the complete elimination of cleaning agents and debris from the system.
Step 6: Acid Rinse
To remove alkaline residues and prevent the buildup of mineral deposits, an acid solution (0.5-2% concentration) is circulated throughout the system. Additionally, this ensures the pH balance of the system.
Step 7: Sanitization Rinse
Chlorine-based or hot water sanitizing solution is circulated to eliminate any remaining bacteria or pathogens in the system.
Benefits of CIP for Dairy Plants
Clean-in-Place (CIP) is a crucial process, especially in large dairy manufacturing plants like Dollon’s for several reasons:
Hygiene and Food Safety
Dairy products are highly susceptible to contamination by microorganisms, such as bacteria and pathogens. Furthermore, CIP helps advanced dairy plants maintain a high level of cleanliness and hygiene by effectively cleaning and sanitizing equipment, pipelines, and storage tanks, reducing the risk of contamination and ensuring food safety.
Preventing Cross-Contamination
Dairy plants often process various dairy products, such as milk, cheese, yogurt, and butter. CIP systems help prevent cross-contamination between different products or batches, ensuring that one product does not carry over into another. This is essential for maintaining product integrity and meeting quality and safety standards.
Compliance with Regulations
Dairy manufacturing is subject to strict regulatory requirements to ensure the safety and quality of dairy products. CIP helps dairy plants comply with these regulations by providing a consistent and documented cleaning process.
Enhances Efficiency
Dairy processing involves a wide range of equipment, such as pasteurizers, homogenizers, storage tanks, and filling machines. CIP systems are efficient and save time and labor, allowing for thorough cleaning without the need for disassembly or manual cleaning of each component. This efficiency is crucial for maintaining a continuous production flow.
Quality Assurance
CIP processes help maintain the quality of dairy products by preventing spoilage, the growth of undesirable microorganisms, and the development of off-flavors. This ensures that dairy products meet consumer expectations.
Equipment Longevity
Regular and proper CIP maintenance extends the lifespan of processing equipment by preventing the buildup of deposits, corrosion, and microbial growth. Additionally, this reduces maintenance and replacement costs.
The Bottomline
It’s not only the dairy plants that benefit from the CIP. Consumers share equal privilege out of the same. They receive healthy and safe dairy products on their every purchase. It is the responsibility of every dairy manufacturing unit to deliver safe products to the consumers, and therefore, overlooking CIP will not only be the greatest but a fatal mistake affecting their business continuity.
