Improvement and Verification of the Effectiveness of a CIP System in a Production Tank : Influence of the Spray Ball Alignment and Pump Settings on Cleaning Efficiency

Abstract

This study examines the cleanability of stainless steel production tanks used in the manufacture of liposomal dietary supplements, with a focus on the effectiveness of the existing Clean-in- Place (CIP) procedure. The investigation was conducted on-site at Plantacorp GmbH's production facilities to ensure the practical relevance and applicability of the results. To ensure hygienic conditions in compliance with food safety standards such as ISO 22000 and Hazard Analysis and Critical Control Points (HACCP), various experimental methods were applied, including riboflavin spray shadow testing, ultrasonic flow rate measurements, surface roughness analysis, and microbiological as well as Adenosine triphosphate (ATP) swab tests. The results showed that feed pump pressure and spray ball orientation significantly influence the cleaning performance. A minimum feed pump pressure of 9 bar was identified as necessary to achieve sufficient mechanical cleaning action and spray coverage, especially in geometrically complex areas. However, due to the current technical limitations of the CIP system in place, production cleaning is still performed at 7 bar, which leads to visible residue at certain points. Despite this, microbiological and ATP tests remained within acceptable limits. The study also identified potential design-related hygiene risks, such as liquid retention in unused outlet cavities and persistent residues on the stirrer. Based on a structured risk assessment following DIN EN ISO 12100:2011, targeted recommendations were proposed, including system upgrades to enable higher flow rates, improved spray ball positioning, and further verification under real CIP conditions. The approach and methodology presented in this thesis not only provide practical value for internal optimization at PlantaCorp GmbH but also serve as a transferable model for other companies seeking to validate and enhance their CIP processes in hygienically critical applications.