At the beginning of the development of CIP Tecnology, piping system design was non-existent, the flow path being established at the whim of the dairy employee responsible for installing the "take-down" piping components. As technology developed, regulatory personnel recognized the need for drawings to define the CIP circuits. The engineers (or installers) that made those first drawings used conventional drafting techniques. Piping run lengths were scaled with the Engineers Rule, fittings were counted, an adding machine was the means of determining totals, and the computation of head-loss was with a slide rule. The adding machine and slide rule gave way to the calculator, and in todays world of CAD (possible even on a Laptop), on completion of the design, the components may be automatically determined.
Throughout the period of nearly 50 years, however, the head loss in a piping system has remained always proportional to the square of the velocity in the line. Mr. Seiberling has successfully applied that basic and fundamental rule when guiding CIP system designs in many different process and product environments.
Dairy Facility and Process Design - Early efforts to apply CIP to existing processes designed to be manually cleaned made it obvious that optimum results could be achieved only by first designing the process, and the facility, to take maximum advantage of the developing technology. Design activity was extended in the early 60's to include the responsibility for the the functional operations of Receiving, Raw Storage, Meter-based and Load-Cell based batching systems, HTST processing, continuous standardizing, and the related centrifugal machine and homogenization processes, as well as the variations downstream encountered in fluid milk processes, ice cream and novelty operations, and a broad spectrum of cultured products processes. Considerable experience has been enjoyed in designing infant formula processes for products of dairy and non-dairy formulation.
The fluid milk projects of the last two decades have applied a combination of concepts to produce "extended shelf-life" products, via the combination of conventional heat treatment and packaging in systems which maximize control and application of cleaning and sanitizing procedures.
Brewing and Wine Processing - CIP was successfully applied to the entire brewing process in the mid-1960's, and Mr. Seiberling and his associates contributed to the design of several new breweries in this nation and abroad, and to the CIP cleaning of a major portion of the beer transportation tankers placed into operation in England in the late 60-s and early 70's.
Non-Dairy Food Processes - The earliest non-dairy food processes included a variety of dried products, meat-based pet foods, and edible oil processes which included a broad range of cookers, conveyors, and screw feeders. The subsequent expansion to candy, snack food and cereal processes required the development CIPable multi-belt dryers, ovens, and tote dumping and filling equipment. Later projects included sterile systems for aseptic processing of fruit drinks and CIP of processes for the production of mayonnaise, margarine, and liquid dressings.
Pharmaceutical and Biotech Processes - The initial experience in this industry included two IV Solutions process which combined mixing tanks and powder blending systems designed to CIP standards, but cleaned by rinsing and Steaming. Both projects incorporated all-welded process piping, U-bend transfer panels with proximity sensors, and computer-based control. The first CIP cleaned processes were for sterile albumin and lipid solutions and these also combined full CIPable design with all-welded piping and U-bend transfer panels with proximity sensors. The albumin Process was designed for off-site fabrication to simplify and speed-up the final installation. A fully automated and CIP cleaned Blood Fractionation Process was initiated in the mid-80's at about the time this industry awakened to the value of CIPable process design. Subsequent project experience was enjoyed with dry drug production, oral drugs, an emulsion process and then the full complement of biotech processes including several R&D pilot-plant projects. A new BSF process provided the opportunity to modify a CIP unit for use as a drug mixing system and use mixproof valved piping for all connections to the hold tanks and BSF fillers.
High Potency Agricultural Chemicals - Especially challenging was the redesign of an industrial chemical process to produce high potency compounds on a "campaign" basis. CIPable design was applied to prevent cross-contamination, improve worker safety, and prevent discharge of high-potency product residues to the environment.
Related Experience- The above described areas of activity have provided many opportunities to work with equipment suppliers to re-design traditional equipment be CIP cleanable. Also, the above projects provided many opportunities to address the environmental issues such as the water requirement, BOD discharge, and chemical utilization and discharge for the specific projects. Design for regulatory approval and acceptance has been a basic requirement for all of the above work and the knowledge and understanding developed from decades of work with regulatory groups at the state and federal level, as well as 3A Sub-Committee work, has been applied to every aspect of every process design, in every industry served.