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2 Steam sparser
3 Cleaning tank level sensor
4 Circulation pump
ICU Integrated Cleaning Unit
14 Regulating valve
15 Flow meter
16 Shutoff valve
17 Connector for refilling
20 Rinsing valve
21 Refilling valve acid/alkali
22 Acid container
23 Alkali container
Denominations
Technical Training Centre
Lund, Sweden
16 16
14
8
ICU TP A3/CF
Chemical return
17 17
9
18 18
26
19 19
6 20 20
Issue
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21 21
25
10 22 23
24 24
2 1
OH 2370:1
12
11
13
4
5
Compressed air
ICU Integrated Cleaning Unit Steam
Filling tank
Technical Training Centre
Lund, Sweden
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Machine type
ICU TP A3/CF
Chemical return
Issue
1/1102
High level
Low level
OH 2370: 2
Compressed air
ICU Integrated Cleaning Unit Steam
Prerinsing
Technical Training Centre
Lund, Sweden
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Machine type
ICU TP A3/CF
Chemical return
Issue
1/1102
OH 2370: 3
Compressed air
ICU Integrated Cleaning Unit Steam
Heat circulation
Technical Training Centre
Lund, Sweden
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Machine type
ICU TP A3/CF
Chemical return
Issue
1/1102
OH 2370: 4
Compressed air
ICU Integrated Cleaning Unit Steam
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Machine type
ICU TP A3/CF
Chemical return
Issue
1/1102
High level
Low level
OH 2370: 5
Compressed air
ICU Integrated Cleaning Unit Steam
Alkali circulation
Technical Training Centre
Lund, Sweden
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Machine type
ICU TP A3/CF
Chemical return
Issue
1/1102
OH 2370:6
Compressed air
ICU Integrated Cleaning Unit Steam
Acid circulation
Technical Training Centre
Lund, Sweden
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Machine type
ICU TP A3/CF
Chemical return
Issue
1/1102
OH 2370:7
Compressed air
ICU Integrated Cleaning Unit Steam
Emptying system
Technical Training Centre
Lund, Sweden
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Machine type
ICU TP A3/CF
Chemical return
Issue
1/1102
OH 2370:8
Compressed air
ICU Integrated Cleaning Unit Steam
Emptying rinsing
Technical Training Centre
Lund, Sweden
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Machine type
ICU TP A3/CF
Chemical return
Issue
1/1102
High level
Low level
OH 2370: 9
Compressed air
ICU Integrated Cleaning Unit Steam
Circulation
Technical Training Centre
Lund, Sweden
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Machine type
ICU TP A3/CF
Chemical return
Issue
1/1102
OH 2370:10
Compressed air
ICU Integrated Cleaning Unit Steam
Final draining
Technical Training Centre
Lund, Sweden
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Machine type
ICU TP A3/CF
Chemical return
Issue
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OH 2370:11
ICU Integrated Cleaning Unit
Positions
Technical Training Centre
Lund, Sweden
Sterile air
15
Machine type
16 16
14
8
ICU TP A3/CF
Chemical return
17 17
9
18 18
26
19 19
6 20 20
Issue
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21 21
25
10 22 23
24 24
2 1
OH 2370:12
12
11
13
4
5
Textbook
MT-83134-1
Issue 1/1102
Training Document
This Training Document is intended for
Training purposes only, and must not be
used for any other purpose.
The Training Document does not replace
any instructions or procedures (e.g. OM,
MM, TeM, IM, SPC) intended for specific
equipment, and must not be used as such.
Note!
For safe and proper procedures, refer to
the equipment specific documentation.
This description of the Integrated Cleaning Unit, is from now on called the
ICU.
The following topics are included:
An introduction to cleaning of a Tetra Brik Aseptic (TBA) filling machine
A general description of the ICU
An overview of the components in the ICU
A description of all the program steps of the ICU
A brief description of the Cleaning In Place (CIP) Drying
Sequence diagrams for the ICU of the TP A3/CompactFlex 0200
Technical Training Centre 1/1102 MT-83134-1 Training Document. For training purpose only. 3
About cleaning
It it essential to clean the equipment properly. The sterilisation process -
which follows the cleaning - is only effective on clean and dry surfaces. There
is a risk of product contamination if the cleaning is not performed properly.
CIP
Cleaning In Place (CIP) is a method used for cleaning filling machines and
process equipment without having to disassemble them.
A production cycle is always followed by a CIP. It is important to clean as
soon as possible after the end of production to prevent the product from drying
on the surface. Dried-in product on the equipment makes the CIP more difficult.
4 MT-83134-1 Training Document. For training purpose only. Technical Training Centre 1/1102
Cleaning factors
There are four important cleaning factors:
Flow
A turbulent flow of cleaning liquid is required to remove product residues.
This is achieved by the speed of the cleaning liquid which is 1.5-3.0 m/s.
The flow must be at least 8000 l/h in order to reach this speed in the AP-
valve.
Concentration
Chemicals are used to dissolve the product residues. The concentration of
the cleaning liquid must be correct.
Temperature
Correct temperature of the cleaning liquid is important to dissolve the
product residues.
Time
It is essential that the cleaning liquid maintains contact with the product
residues long enough in order to dissolve them.
what solution
WATE
ID
Salt
AC
R
and
mineral Sugar
Protein Fat
ALK ALI
Technical Training Centre 1/1102 MT-83134-1 Training Document. For training purpose only. 5
The cleaning steps
Two cleaning programmes are used: daily cleaning and weekly cleaning.
Acid rinse
Acid cleaning
Alkali rinse
Alkali cleaning
Warm rinse
Pre-rinse
Daily cleaning
Weekly cleaning
The cleaning steps
Daily cleaning is performed after each production or as often as required. Daily cleaning
Daily cleaning includes the following steps:
1. Pre-rinse
Cold water forces product residues out of the pipes.
2. Warm rinse
Warm water dissolves sugar.
3. Alkali cleaning
Alkali dissolves fat and proteins.
4. Alkali rinse
Cold water forces alkali residues out of the pipes.
Rinsing goes on until the conductivity of the rinsing water is equal or
lower than a predefined value.
Weekly cleaning is scheduled individually for each plant. How often it is Weekly cleaning
performed depends on the product and on the hardness of the water.
Weekly cleaning includes the following steps in addition to the daily cleaning:
5. Acid cleaning
Acid cleaning dissolves salt and minerals.
6. Acid rinse
Cold water forces acid residues out of the pipes.
CIP Drying
The sterilisation process is only effective on clean and dry surfaces.
It is therefore important to get the pipes dry again after the rinsing is finished.
CIP Drying is not a part of the ICU program, but is to be performed within a
certain time after the ICU program is finished. Warm air is circulated through
the filling system and any water remaining in the system is evaporated.
The evaporated water follows the air out of the system.
6 MT-83134-1 Training Document. For training purpose only. Technical Training Centre 1/1102
Intermediate cleaning and final cleaning
There are two types of CIP cleaning methods: intermediate cleaning and final
AP = Aseptic product cleaning. The difference between the two methods is constituted by the
position of the AP-valve.
Intermediate cleaning
Steam
Product
Water
Air
Detergent
Final cleaning
Steam
Water
Air
Detergent
Detergent (In this case the product
line is cleaned at the same time)
The AP-valve during final cleaning
Final cleaning is performed when there is no product in the product line, which
means that none of the machines in the line are operating. Final cleaning
should be performed at least once a day.
In this position of the AP-valve, the steam barrier space is cleaned as well.
Technical Training Centre 1/1102 MT-83134-1 Training Document. For training purpose only. 7
The ICU
The Integrated Cleaning Unit (ICU) is integrated in the filling machine. Location
It is located in the machine as follows:
The cleaning tank with the pump belongs to the superstructure module.
The two containers with acid and alkali detergent and the dosing pumps are
located in the chemical module.
On the service unit, there is a separate water connection for the ICU. Water supply
The water is drained through the draining pipe under the final folder unit. Water drainage
Water
drainage
The alkali and acid solutions are drained through the chemical return outlet, Alkali/Acid drainage
which has to be connected to a suitable waste tank. The chemical solutions are Chemical
to be handled according to the legislation. Alkali or acid must never be return
re-used. outlet
(For further information see the chapter Safety Precautions in the MM)
If the level of alkali or acid detergent in a container is too low, an alarm is Refilling of alkali and acid
triggered on the TPOP. In order to refill the container, the appropriate filling detergent
pipe must first be connected to the appropriate connection for refilling acid/
alkali (see page 11, figure 19). The refilling is to be initiated by means of the
TPOP. The pump stops when the container is full .
Built-in recorder
8 MT-83134-1 Training Document. For training purpose only. Technical Training Centre 1/1102
Components of the ICU
Superstructure Cleaning tank and pump located in the superstructure module.
3 1. Cleaning tank
2. Sample tap
3. Cleaning tank level sensor
4. Circulation pump
6 5. Pump draining valve
4 1 6. Water inlet valve
Chemical module Containers with detergent and dosing pump, located in the right hand side of
final folder unit, below package conveyor (containers) and above package
conveyor (dosing pumps).
7. Refilling valve acid/alkali
13 8. By-pass valve acid/alkali
13 9. Acid/alkali pump
10. Acid/alkali level sensor
14 11. Acid container
12. Alkali container
14 13. Rinsing valve
14. Shut-off valve
8 8
9
9
7
7
10 10
12
11
Technical Training Centre 1/1102 MT-83134-1 Training Document. For training purpose only. 9
At CIP, the ICU is connected to the filling system according to the diagram CIP diagram
below.
Sterile air
14
7
15
16 16
25
8
Chemical return 17
9 18 18 17
19 19
20 20
26 3
6 21 21
25 22 23
10
24 24
2 1
13 12 11 4
1. Cleaning tank
2. Steam sparser
3. Cleaning tank level sensor
4. Circulation pump
5. Pump draining valve
6. Water inlet valve
7. Swing pipe
8. Switch valve
9. Steam inlet valve
10. Steam pressure regulator
11. Conductivity probe and temperature sensor
12. Main drain valve
13. Cleaning cup
14. Regulating valve
15. Flow meter
16. Shut-off valve
17. Connector for refilling acid/alkali
18. By-pass valve acid/alkali pump
19. Acid/alkali pump
20. Rinsing valve
21. Refilling valve acid/alkali
22. Acid container
23. Alkali container
24. Acid/alkali level sensor
25. Constant flow valve
26. Steam flushing valve
10 MT-83134-1 Training Document. For training purpose only. Technical Training Centre 1/1102
The ICU program steps
Compressed air
Steam
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Chemical return
High level
Low level
Filling tank In this program step, the cleaning tank is filled with water. The water inlet
valve closes when the high level is reached.
Technical Training Centre 1/1102 MT-83134-1 Training Document. For training purpose only. 11
Compressed air
Steam
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Chemical return
In this program step, cold water forces the remaining product residues out of Pre-rinsing
the filling system.
The circulation pump - which is controlled by a variable frequency drive -
ramps up the flow rate to fill the system without pressure shocks which could
destroy the membrane of the regulating valve. The PLC monitors the flow rate
by means of the flow meter.
The level of the cleaning tank is continuously monitored by the cleaning tank
level sensor. When the measured level is down to low level, the pump stops
and the tank is filled with fresh water. This routine is repeated a number of
times in order to remove all product residues.
The main drain valve is open to drain the system from a mix of cold water and
product residues.
12 MT-83134-1 Training Document. For training purpose only. Technical Training Centre 1/1102
Compressed air
Steam
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Chemical return
High level
Low level
Filling cleaning system In this program step, the CIP system is filled up with water.
The level of the cleaning tank is continuously monitored by the cleaning tank
level sensor. When required, the water inlet valve opens to top up the water.
The program step will finish when the water has the minimum required flow
and the level in the tank is stable for a certain time.
The switch valve directs the water to the tank, i.e. the water circulates in a
closed loop.
Technical Training Centre 1/1102 MT-83134-1 Training Document. For training purpose only. 13
Compressed air
Steam
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Chemical return
In this program step, warm water dissolves sugar, melts fat build-ups and Heat circulation
removes these residues from the filling system.
The system has already been filled with water during the program step Filling
cleaning system.
The pump continues to run.
The steam inlet valve opens and steam enters the tank to warm up the water
until the correct temperature is reached.
When the temperature and flow parameters are reached, circulation goes on
for a predefined time.
The pump stops when the circulation is finished. The next program step is the
Emptying system.
Alarm conditions:
The temperature does not reach the setpoint within the time limits.
The flow rate is too low.
14 MT-83134-1 Training Document. For training purpose only. Technical Training Centre 1/1102
Compressed air
Steam
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Chemical return
Circulation alkali In this program step, alkali solution dissolves organic residues (fat and protein).
The steam inlet valve opens. Steam heats up the water until the correct
temperature is reached.
Then the alkali pump runs until the concentration of the cleaning solution is
correct. The concentration is monitored by the conductivity sensor.
When temperature, concentration and flow rate are correct, the circulation of
the cleaning liquid goes on for a predefined time.
Alarm conditions:
If the temperature is not maintained within the time limits.
If the concentration does not reach the setpoint within time limits.
The flow rate is too low.
Technical Training Centre 1/1102 MT-83134-1 Training Document. For training purpose only. 15
Compressed air
Steam
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Chemical return
In this program step, acid solution dissolves mineral deposits. Circulation acid
The steam inlet valve opens. Steam heats up the water until the correct
temperature is reached.
Then the acid pump runs until the concentration of the cleaning solution is
correct. The concentration is monitored by the conductivity sensor.
When temperature, concentration and flow rate are correct, the circulation of
the cleaning liquid goes on for a predefined time.
Alarm conditions:
If the temperature is not maintained within the time limits.
If the concentration do not reach the setpoint within the time limits.
The flow rate is too low.
16 MT-83134-1 Training Document. For training purpose only. Technical Training Centre 1/1102
Compressed air
Steam
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Chemical return
High level
Low level
Emptying rinsing In this program step, cold water forces the remaining cleaning solution out of
the filling system.
The switch valve changes position and directs the cleaning liquid to the
chemical return outlet. The cleaning tank is refilled with water to maintain a
correct level.
The rinsing goes on until the conductivity of the rinsing water is lower than a
predefined value. After that, the circulation pump continues running for an
additional time and then stops.
The program steps Filling tank, Filling cleaning system and Cold circulation
are always followed by step Emptying Rinsing (see page 25).
The pump speed is controlled to obtain a correct flow at a predefined rate to
ensure that the water supply is sufficient to maintain the tank level.
The rinsing valve opens to remove remaining chemicals from the acid/alkali
pump and the pipes.
Technical Training Centre 1/1102 MT-83134-1 Training Document. For training purpose only. 17
Compressed air
Steam
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Chemical return
In this program step, water circulates in the system to verify dilution of the Cold circulation
cleaning solution.
The concentration of detergent in the rinsing water is measured by the
conductivity sensor. The conductivity of the rinsing water must be less than
the defined value, otherwise the system is drained and the program repeats the
program steps Filling tank, Filling cleaning system and Cold circulation.
18 MT-83134-1 Training Document. For training purpose only. Technical Training Centre 1/1102
Compressed air
Steam
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Chemical return
Emptying system In this program step, the cleaning tank is emptied from water.
The main drain valve and the pump drain valve open to drain off the water.
The program step Emptying system is finished if the minimum level is reached
in the tank and a predefined time has elapsed.
This is the last program step of the cleaning steps Pre-rinse, Warm rinse and
Alkali rinse.
Technical Training Centre 1/1102 MT-83134-1 Training Document. For training purpose only. 19
Compressed air
Steam
Cold water
Hot water
Sterile air
Acid concentrate/solution
Alkali concentrate/solution
Chemical return
In this program step, the cleaning system is emptied from water. Final draining
The main drain valve and the pump drain valve open to drain off the water.
The switch valve directs the cleaning liquid from the chemical return in order
to empty it.
The program step Final draining continues for a predefined time to empty the
system.
20 MT-83134-1 Training Document. For training purpose only. Technical Training Centre 1/1102
Cold water
Acid concentrate/solution
Alkali concentrate/solution
Refilling of acid/alkali The acid/alkali container is to be refilled when the level becomes too low.
An alarm on the TPOP signals when refilling needs to be done.
The refilling pipe is connected to the connector for refilling. The acid/alkali
pump runs in reverse direction to pump the concentrated acid/alkali from the
storage vessel into the acid/alkali container.
Technical Training Centre 1/1102 MT-83134-1 Training Document. For training purpose only. 21
CIP Drying
Air
Hot air
Preheated air
alt. cooled air
Steam
Product
Water
Peroxide
Compressed air 1
Cleaning liquid
This step does not belong to the ICU program steps, but should be CIP Drying
performed ASAP after the ICU program is finished.
Any remaining water in the system is dried by means of warm air.
It is important to dry the system thoroughly, since water in the filling system
might compromize the sterilization effect.
Before the filling machine is stepped up to CIP Drying, the swing pipe (1) has
to be shifted from the cleaning liquid connection to the sterile air connection.
The water ring compressor (2) starts circulating air and the air superheater (3)
is switched on. After reaching 50C on the product pipe temperature sensor,
air superheater is switched off. Air circulation continues for next minutes to
reach predefined time.
Any remaining water in the system is evaporated and follows the air out of the
system (4).
22 MT-83134-1 Training Document. For training purpose only. Technical Training Centre 1/1102
Sequence diagram ICU TP A3
Main cleaning steps Pre-rinse Warm rinse Alkali cleaning Alkali rinse Acid cleaning Acid rinse
Technical Training Centre 1/1102
Emptying system
Emptying system
Emptying system
Emptying rinsing
Emptying rinsing
Circulation alkali
Sub-steps...
Heat circulation
Circulation acid
Cold circulation
Cold circulation
Ready to clean
Cleaning OFF
Filling system
Filling system
Filling system
Filling system
Filling system
Final draining
Pre-rinsing
Filling tank
Filling tank
Filling tank
Filling tank
Filling tank
Filling tank
...Components
Ch.r
Switch valve Ch. ret. Chemical return Chemical return
Flow meter
Conductivity sensor
Repeat
All parameters OK timer start
3 times
Daily cleaning
Weekly cleaning
23
24 MT-83134-1 Training Document. For training purpose only. Technical Training Centre 1/1102