CIP (Cleaning In Place) Protocol for the Food Industry

The CIP (Cleaning In Place) protocol is the recirculation cleaning system for tanks, vessels and closed circuits in the food industry, carried out without dismantling the installation. It consists of circulating, in succession, water, an alkaline solution, an acid solution and a disinfectant, with intermediate rinses, to remove organic soil, mineral scale and the microbial load. This protocol is based on the doses, temperatures and contact times given in the technical data sheets of Instaquim products and forms part of the cleaning and disinfection plan required by Regulation (EC) No 852/2004 on the hygiene of foodstuffs and by each plant's HACCP system.

Indicative time: around 2 hours (the contact times for each product are given in each phase) | Sector: Food industry (dairy, beverages, juices, process circuits) | Frequency: according to the plant's HACCP plan, usually at the end of production and at every product changeover

Materials required

Alcalino Pro 3 – controlled-foam alkaline detergent with high sequestering capacity for the alkaline wash (1-3 % in recirculation, 60-70 °C, 20-45 min)
Alcalino Pro 2 (1-5 %, 45-70 °C, 20-45 min) or Alcalino Pro 6 (0.5-5 %, 45-70 °C, 20-45 min) as alternatives for the alkaline wash
Nitracip Pro – strongly acidic non-foaming descaler for the acid wash (0.5-1 %, 15-20 min, 40-60 °C)
Acid Pro – controlled-foam acid descaling detergent, alternative for automatic cleaning and CIP (1-3 %, 40-70 °C)
Oxa Per – bactericidal and fungicidal disinfectant based on peracetic acid (1 %, 15 min, 20-50 °C)
Ten Cip and Enzim Pro – enzymatic biofilm treatment in CIP systems (Ten Cip 0.2-0.5 % + Enzim Pro 0.05 %)
Enzi NF – non-foaming enzymatic detergent for the prevention and removal of biofilm (1-3 %)
Defoamer Pro – antifoam emulsion for when excess foam forms (0.5-2 %)
Mains water for the pre-rinse, intermediate rinses, preparation of solutions and the final rinse
CIP recirculation pump and solution tanks, with flow rate and pressure according to the design of the installation
Heating system with temperature control
Dosing system (dosing pump or graduated containers)
Thermometer, pH meter or pH strips and a cleaning record sheet

Step-by-step procedure

Pre-rinse with water: Circulate water through the circuit to flush out product residues and loose soil before introducing any chemical product. The technical data sheets of the alkaline and acid detergents expressly specify this prior rinse with water. Keep circulating until the drain water runs clear.
Alkaline wash with Alcalino Pro 3 (20-45 minutes): Prepare the solution at 1-3 % (recirculation dose) and circulate it at 60-70 °C for 20-45 minutes depending on the degree of soiling. Alcalino Pro 3 is a controlled-foam detergent with high sequestering capacity that keeps circuits free of scale. As alternatives, Alcalino Pro 2 is used at 1-5 % and the very low-foam Alcalino Pro 6 at 0.5-5 %, both at 45-70 °C for 20-45 minutes. For short automatic wash cycles, Alcalino Pro 5 works at 1-4 % with a contact time of 10-20 minutes. None of the Alcalino Pro products may be used on aluminium. If excess foam appears during recirculation, add Defoamer Pro at 0.5-2 %.
Intermediate rinse: Drain the alkaline solution and rinse with water until all detergent residue is removed. This rinse prevents residual alkali from neutralising the acid solution in the next phase and reducing its effectiveness.
Acid wash with Nitracip Pro (15-20 minutes): Circulate Nitracip Pro at 0.5-1 % for around 15-20 minutes at 40-60 °C. This strongly acidic descaler, formulated for circuits and CIP systems in the food industry, removes limescale deposits caused by water hardness, mineral soil deposits and the residues left by alkaline detergents. As an alternative, Acid Pro is used at 1-3 % in automatic cleaning and CIP at 40-70 °C and does not attack chrome-plated or enamelled materials, rubber seals or plastic.
Rinse after the acid: Rinse with plenty of water until all acid solution residue is removed before introducing the disinfectant.
Disinfection with Oxa Per (15 minutes): Circulate Oxa Per diluted to 1 % for around 15 minutes, at a use temperature of 20-50 °C. Oxa Per is a bactericidal and fungicidal disinfectant based on peracetic acid, indicated for the disinfection of food-industry installations, including by recirculation (CIP). It complies with standard UNE-EN 13697 under clean conditions against Escherichia coli, Staphylococcus aureus, Enterococcus hirae, Pseudomonas aeruginosa and Saccharomyces cerevisiae, and holds registration number 17-20/40-05521-HA.
Final rinse and record: Rinse thoroughly with water until the outlet water shows no foam and its pH matches that of the mains water. Record the product, concentration, temperature, contact time and operator for each phase in the cleaning record.

Biofilm treatment

When verification detects biofilm, or the installation requires it as a preventive measure, an enzymatic recirculation treatment is inserted into the programme. Ten Cip, a non-foaming detergent for the enzymatic treatment of CIP systems, is diluted to 0.2-0.5 % in combination with Enzim Pro at 0.05 %, and the mixture is circulated for 20-60 minutes at 40-55 °C before rinsing with water. Enzi NF, a non-foaming enzymatic detergent especially indicated for CIP systems, is used at 1-3 % depending on the degree of contamination, circulating for 30-120 minutes at 40-50 °C; it can be used on its own or combined with Enzim Pro in shock treatments. In both cases, if necessary, a cleaning with the usual detergent is carried out beforehand and, after the treatment, the disinfectant is applied.

Verification and control

Verification of the CIP cycle is based on three pieces of evidence. Rinse water: the outlet water from the final rinse must run clear, with no foam or turbidity, and with a pH equal to that of the mains water, which confirms the absence of alkaline detergent, acid or disinfectant residues. Cycle parameters: the concentration, temperature and contact time of each phase must have remained within the ranges specified in the technical data sheet of the product used; any deviation requires the affected phase to be repeated. Record: each cycle is recorded with date, circuit, products, doses, temperature, time and responsible operator, as documentary evidence for the HACCP plan and for the hygiene obligations of Regulation (EC) No 852/2004. The microbiological controls established by the plant's plan complete the verification.

Safety and PPE

Alkaline detergents (Alcalino Pro) and acid detergents (Nitracip Pro, Acid Pro) are corrosive products that cause severe skin burns and serious eye damage: wear protective gloves, clothing and eye protection when handling the concentrate and preparing the solutions.
Preferably dose with closed automatic systems to reduce handling of the concentrate.
Never mix chemical products with one another, in particular acids with chlorinated products; observe the intermediate rinses between the alkaline phase, the acid phase and disinfection.
Oxa Per contains peracetic acid and hydrogen peroxide: handle with eye protection and gloves, in a ventilated area, and rinse thoroughly with water after disinfection.
Wash contaminated clothing before reuse and provide an accessible eye-wash station in the preparation area.
Consult the technical data sheet and the safety data sheet of each product before use and follow the precautionary statements on the label.

Recommended Instaquim products

For the alkaline wash in recirculation, the Alcalino Pro range offers Alcalino Pro 3 with high sequestering capacity, Alcalino Pro 2, the very low-foam Alcalino Pro 6 and Alcalino Pro 5 (1-4 %, 10-20 min) for short automatic wash cycles. If the circuit includes aluminium parts, the non-foaming detergent Alcalino incorporates corrosion inhibitors and can be used on this metal (1-4 %, max. 60 °C). As a non-foaming chlorinated alkaline detergent for cleaning and hygiene by recirculation, Clor Df is used at 5-10 g/l for 5-10 minutes at 40-60 °C.

For the acid wash, Nitracip Pro is the strongly acidic descaler specific to circuits and CIP systems, and Acid Pro the controlled-foam alternative. For disinfection by recirculation, Oxa Per complies with standard UNE-EN 13697 under clean conditions. For biofilm, Ten Cip with Enzim Pro and Enzi NF complete the programme, and Defoamer Pro controls foam whenever it is undesirable.

Applicable regulations: Regulation (EC) No 852/2004 on the hygiene of foodstuffs and the plant's HACCP (Hazard Analysis and Critical Control Points) system, which sets the frequency, records and verification of the cleaning and disinfection programme.

Frequently asked questions

What dose of alkaline detergent is used in a CIP?

It depends on the product. According to the Instaquim technical data sheets: Alcalino Pro 3, 1-3 % in recirculation at 60-70 °C for 20-45 minutes; Alcalino Pro 2, 1-5 % at 45-70 °C for 20-45 minutes; Alcalino Pro 6, 0.5-5 % at 45-70 °C for 20-45 minutes; and Alcalino Pro 5, 1-4 % with a contact time of 10-20 minutes. Within each range, the dose is adjusted to the degree of soiling.

When should an acid cycle be included in the CIP?

When the circuit accumulates limescale deposits caused by water hardness, mineral soil deposits or residues left by alkaline detergents. Nitracip Pro is used at 0.5-1 % for 15-20 minutes at 40-60 °C, always with a prior rinse with water and a final rinse with plenty of water. Acid Pro is the alternative at 1-3 % at 40-70 °C for automatic cleaning and CIP.

How is biofilm removed from a CIP circuit?

With an enzymatic recirculation treatment. Ten Cip is diluted to 0.2-0.5 % in combination with Enzim Pro at 0.05 % and circulated for 20-60 minutes at 40-55 °C. Enzi NF is used at 1-3 % depending on the degree of contamination, for 30-120 minutes at 40-50 °C, on its own or combined with Enzim Pro in shock treatments. If necessary, clean beforehand with the usual detergent and apply the disinfectant after the treatment.

Can Alcalino Pro be used on aluminium?

No. The technical data sheets of Alcalino Pro 2, Alcalino Pro 3 and Alcalino Pro 5 expressly state that they must not be used on aluminium. For aluminium equipment, the non-foaming detergent Alcalino incorporates corrosion inhibitors and can be used on aluminium, at a dose of 1-4 % and a maximum temperature of 60 °C.

Which disinfectant is used in a food-industry CIP?

Oxa Per, a bactericidal and fungicidal disinfectant based on peracetic acid, indicated for the disinfection of food-industry installations, including by recirculation (CIP). It is applied at 1 % for around 15 minutes at 20-50 °C and rinsed thoroughly with water. It complies with standard UNE-EN 13697 under clean conditions and holds registration number 17-20/40-05521-HA.

How often should a CIP be carried out?

The frequency is set by each plant's HACCP plan depending on the product processed, the production time between cleanings and the verification results. In practice, the full CIP is scheduled at the end of each production day or shift and at every product changeover, and the enzymatic biofilm treatment is applied as a shock treatment whenever verification requires it.

What should I do if a lot of foam forms during recirculation?

Choose a low-foam alkaline such as Alcalino Pro 6 and, if excess foam still appears, add the antifoam emulsion Defoamer Pro at a dose of 0.5-2 %.

How is the final rinse verified as correct?

By checking that the outlet water shows no foam or turbidity and that its pH matches that of the mains water, and by recording the concentration, temperature and contact time of each phase. Any deviation from the technical data sheet requires the affected phase to be repeated.

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