Eliminate Downtime: How virtual testing can optimize your CIP systems
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Challenge
To optimize the Clean-In-Place (CIP) systems of a plant. Physical testing-based optimization is both costly and time-consuming, largely because complex plant layouts make it difficult—if not impossible—to access certain equipment or ducting without expensive downtime. Commissioning and testing CIP systems on-site demands substantial additional resources. Aerotak’s virtual testing method overcomes these hurdles by ensuring full cleaning coverage, regulatory compliance, and a First Time Right installation—all in a fraction of the time required by physical testing.
Approach
Together with the project’s client, our specialists will model all equipment and ducts in the plant that come into contact with the product in very high detail. With our proprietary ray-tracing method, we are able to pinpoint areas with elevated risk of sub-optimal cleaning in a matter of hours. The ray-tracing method sets the foundation for our high-fidelity CIP simulations where water-jet impacts and water-film flows are simulated, to give a highly accurate picture of the cleaning process.
Result
The CIP simulations yield a detailed report of key risk areas in the production line, as well as suggestions for improvements of the CIP system. (Highest risk areas are those where neither direct water jets nor the falling water-film on the walls can reach). The resulting data is used to either validate that the CIP system works as intended, or to improve the CIP system so it meets the requirements. Aerotak also provides the client with a way for them to inspect the plant’s internal spaces and CIP system in a virtual environment themselves, compatible with VR headsets and computer screens.
Simulation of a CIP system involving water jets and water-film flow of cleaning agent has been simulated by Aerotak
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