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Pharmaceutical manufacturer saves 40% in CIP costs

29 March 2011

Converting a manual clean-in-place (CIP) process to automatic across 80 reaction vessels, using pressure transmitters, condition sensors and flow meters, has enabled a UK-based pharmaceutical manufacturer to achieve savings of £120,000 per annum.

Prior to the installation of the system by Burkert, the reaction tanks were each cleaned for 6 hours, being constantly flushed to drain with hot water at 700°C. This was a purely manual process, based upon operator experience, rather than positive signals from the process that the cleaning procedure was complete.

The weekly costs for this procedure were substantial: energy costs were running at around £4,000, with water at approximately £1,000 and effluent costs approaching the same figure. In total, the combined weekly figure across all activities included in the cleaning was £5,900.
Keen to reduce costs, engineers contacted Burkert to undertake a site visit to view the manual CIP process. Following the visit Burkert suggested a solution for each reaction vessel based upon a Type 8311 pressure transmitter, a Type 8222 condition sensor and a Type 8041 flow sensor. These products were installed on a test group of the vessels and linked to the plants SCADA system.

The CIP process was then undertaken in an automatic mode, with the 8222 condition monitor providing effective feedback of when the water in the vessel was clean – and hence the vessel itself – to the SCADA system, which terminated the process.

On the basis of the initial tests, engineers calculated that the CIP costs would be reduced by 40% using the Burkert equipment.


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