Authors : Ranganathan S.; Athappan V.; Venkata Prasath D.

Volume/Issue : Volume 11 - 2026, Issue 5 - May

Google Scholar : https://tinyurl.com/mrpu3xet

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DOI : https://doi.org/10.38124/ijisrt/26May269

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Abstract : Clean-in-place (CIP) systems are essential for maintaining hygiene and food safety in dairy processing plants; however, conventional CIP operations are often resource-intensive and highly dependent on operator intervention. This study presents the design, implementation, and analytical evaluation of a fully automated CIP system controlled by a Siemens programmable logic controller (PLC) and human–machine interface (HMI) for an industrial dairy processing facility. The developed system integrates four dedicated cleaning media tanks (normal water, hot water, acid, and caustic), three process tanks operating in cyclic mode, and multiple CIP strategies, including three-stage, five-stage, and seven-stage cleaning sequences. Automation logic incorporates retentive timers, RTD-based temperature-controlled hot water recirculation, and selective reuse of rinse water to enhance sustainability and operational consistency. System performance was analytically compared with conventional manual CIP practices using standard industry operating conditions. The automated CIP system achieved reductions of approximately 20–25% in CIP cycle time, 35–40% in water consumption, and 30–35% in energy usage. In addition, standardized sequencing and closed-loop temperature control improved cleaning repeatability and minimized operator dependency. The results demonstrate that industrial-scale PLC-based automation provides a practical, scalable, and industry-ready solution for sustainable CIP implementation in dairy processing plants.

Keywords : Clean-in-Place (CIP); Dairy Processing; PLC Automation; Water and Energy Conservation; Process Hygiene; Industrial Sanitation.

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