If you’re still using sight glass, time control, or volume acquisition for the CIP process at your dairy, you’re losing money. Product waste is a reality in any dairy, but with the continually shrinking profit margins you face year-after-year, the need to reduce product waste is also a reality.
CIP usage has four main cost factors:
If you’re using sight, time control or volume acquisition for your CIP process, you’re losing money in each of these four areas. Overall, your processing costs are going to be higher with these older methods.
To put this into perspective, an ice cream maker replaced a time-based system with turbidity sensors. Once the ITM-3 (now ITM-51) was fully integrated and running, the plant witnessed a thirty second difference between the old timer based method and the new turbidity based method when they reviewed changeovers recorded on their PLC system. Before they implemented the ITM-3 (now ITM-51) in their production process, correction batches were commonly done to deal with diluted production batches that brought their final mix out of spec (6 hours per week). Today, they have tighter control of their process with the ITM-3A (now ITM-51) and don’t have to do adjustment batches to correct for flush water getting into finished product and diluting their final mix.
During Clean in Place (CIP) the ITM‐3 (now ITM-51) is also used for pre-rinse to confirm that their piping system has been flushed clean. Prior to its use, this was done manually until an operator saw clear water; or by using a timer that was based on a piping configuration and flow rate that has more than likely
changed.
In addition to reducing their water usage by 19,500 to 39,000 gallons every year (at single flush point), they reduced their total loss per flush/changeover (fresh water, lost product, wastewater charges) by $639 per day. Their net actual annual cost savings after payback of the system was $16,281.80.
Optimizing Cleaning-in-Place (CIP) for Dairy and Ice Cream Manufacturing
In dairy production, ensuring that all equipment in contact with milk-based products is thoroughly cleaned is essential for preventing bacterial contamination. Cleaning-In-Place (CIP) systems allow tanks, piping, and other equipment to be cleaned without dismantling, maintaining high availability for production processes.
CIP involves four main cost factors: time, water, energy, and chemicals. Each of these can be optimized with the right technology, particularly with the use of reliable turbidity sensors.
Time: Knowing precisely when the system is clean can significantly reduce wash times. Traditional time-based methods offer only rough estimates, whereas turbidity sensors provide real-time feedback, allowing you to stop the cycle as soon as the soil is flushed, reducing cleaning duration.
Water: TTS-Ciptec in Europe estimates that the average CIP cycle consumes between eight and 12 cubic feet of water. By using a highly accurate turbidity sensor, manufacturers can save up to 20% of their water usage, contributing to both cost savings and environmental sustainability.
Energy: Heating cleaning agents and water accounts for a large portion of CIP energy consumption. Reducing CIP cycle times not only saves water but also cuts down on energy costs associated with heating, as shorter cycles mean less heating is required.
Chemicals: Chemical costs can vary, especially with newer additive chemicals designed to reduce energy and water usage. However, after each wash, a portion of these chemicals is lost to wastewater. Turbidity sensors help monitor the flow of solvents and reduce chemical waste by optimizing cycle times, ensuring minimal loss and maximum efficiency.
The automation of the CIP process relies on robust turbidity sensors that can withstand exposure to harsh chemicals like acids and bases, as well as frequent temperature fluctuations. These sensors are key to improving cleaning efficiency, reducing costs, and ensuring that the equipment is consistently safe and sanitary.
Turbidity is the phenomenon where by a specific portion of a light beam passing through a liquid medium is reflected by undissolved particles. The sensor measures the light that is reflected by these particles to determine their concentration in the liquid. Purified water would have close to zero undissolved particles, while ice cream mix has a high concentration of undissolved particles. An inline turbidity sensor is installed at leverage points in the dairy product (see Fig. 1) handling process to facilitate instant detection of the following phase changes:
The turbidity sensor allows instant and accurate monitoring of product changeovers or CIP programs. During the phase separation of the media or during the start-up and emptying of the process, the media must be differentiated. The turbidity sensor can detect the instant a liquid media reaches a pre-defined specification, automatically switching media to its appropriate container. The benefit to a CIP system comes from having a good control pre-rinse. The turbidity sensor determines when the pre-rinse has flushed the soil from the system. If the water runs to long, you use far too much water and don’t know where your soil or high BOD comes in. If the first rinse is done correctly, the rest of the wash cycle is predictable with corresponding chemical savings. The CIP process monitors the flow of solvents for the pre-rinsing, cleaning and final rinsing operations which are performed with acids, bases and water. The process includes the following process steps:
To eliminate the risk of bacteriological contamination, CIP is sometimes followed by sterilization with steam via a process known as SIP (sterilization-in-place). Most semi-modern CIP processes are known as recovery systems where every attempt is made to re-use the cleaning agents as many times as possible for both cost and environmental considerations. When starting up, running empty or transferring between tanks, the milk product must be differentiated from the rinse water remaining in the piping. The infrared light is directed to the center of the pipe. This eliminates any potential variances caused by temperature, changes in viscosity, or build-up on the pipe. The measurements are always accurate and repeatable.
For example, here are the principles of operation of the ITM-3 (now ITM-51) turbidity sensor:
Using the Anderson Negele ITM-51, even minor changes to the dairy product can be detected and acted upon by the system – automatically and instantly. Your personnel and systems can be in total control and Instrument outputs automatically recorded for quality control records.
The stainless steel sensor resists corrosion, and the highly resistant sapphire glass optics provides incredible precision and a lifetime of five years or more (versus the required annual maintenance of quartz glass).
Overall, you’ll see:
The improvement oversight, time control or volume acquisition is immediate and consistent. Aside from increased productivity, you will see higher product quality, the reduction in energy and fresh water requirements and better environmental protection.
Generally, the ITM-51 is easy to install because it is a fully-contained unit. It is extremely durable and rarely fails in the dairy environment. In the unlikely event of a failure you won’t have to wait long for a replacement sensor because the Anderson-Negele ITM-51 is always available.
Comparing Turbidity Sensors: Key Questions to Ask
With so many turbidity sensors on the market, how do you make an informed decision? Whether you’re speaking with your Anderson-Negele Regional Sales Manager or your dairy process control integrator, here are essential questions to consider when selecting the right turbidity sensor:
Cost: While budget is important, more expensive doesn’t always mean better. Think of it like comparing a high-performance sports car to a reliable pickup truck—both will get you where you need to go, but one might come with unnecessary features for your day-to-day needs. Ensure the sensor meets your specific operational requirements while staying cost-effective.
Reliability and Maintenance: Consider the durability of the sensor, especially in a dairy environment. What type of glass is used, and how does this impact long-term maintenance? Is there a built-in mechanism, such as a lens extension, to keep it clean and prevent buildup?
Why Choose the Anderson-Negele ITM-51?
The Anderson-Negele ITM-51 Turbidity Sensor stands out by delivering the fastest ROI in the industry, costing 40% less than comparable models. Built on over 80 years of experience in dairy processing, the ITM-51 is specifically engineered to meet the unique demands of dairy operations.
No other sensor on the market matches the ITM-51 in accurately detecting phase transitions for product optimization, CIP efficiency, and BOD reduction. That’s why dairy process control integrators consistently rely on the ITM-51—offering superior reliability, accuracy, and value, making it the clear choice for optimizing dairy processes.
The ITM-51 is located in the CIP return line before the drain valve. During the pre-rinse step of the CIP cycle the water returning from the cleaning loop is monitored by the ITM-51. The ITM-51 produces an analog output proportional to the relative turbidity of the returning rinse water. An automatic control (PLC) acts upon the input based on a setpoint that represents the optimal turbidity for the pre-rinse to be complete. Once the signal from the ITM matches the setpoint the control closes the drain valve and advances to the wash step of the cleaning cycle.
Talk to your dairy process control integrator or Anderson-Negele Regional Sales Manager today to find out if the Anderson-Negele ITM-51 is the right solution for your operation.
With installation in as little as three to four weeks, you can quickly reduce product loss and start seeing a return on investment in no time. The ITM-51 is the easiest turbidity sensor to install and implement, offering the fastest, most reliable way to minimize waste and increase profits—without altering your production process or product mix.
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