CIP Cleaning Schedule Generation for Modular Process Installations
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Solution Overview
Problem
Existing cleaning-in-place (CIP) processes for process installations are costly and require extensive engineering to ensure effective cleaning, especially for complex installations, and it is difficult to determine if an installation is CIP-compatible without costly evaluation.
Innovation Solution
A system and method that digitally represents a process installation using process modules with self-description information, allowing for the creation of an installation-specific CIP cleaning schedule in a partly automated manner, reducing costs and enabling rapid adaptation to changes in installation configuration or product production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cleaning-in-place (CIP) process is implemented for complex process installations, then cleaning quality can be maintained, but the cost and engineering effort required increase significantly
Solution Approach 1:
The patent creates a digital twin or virtual model of the process installation that replicates the physical system's geometry, components, and cleaning paths. This digital copy allows for simulation, evaluation, and optimization of CIP processes without requiring physical testing or extensive engineering documentation, thereby reducing engineering effort while maintaining cleaning quality
Solution Approach 2:
The system automatically evaluates CIP compatibility and generates cleaning process documentation by querying the digital model and performing simulations. The process installation's digital representation serves itself to provide cleaning information without requiring external engineering analysis, reducing the engineering effort needed to implement and validate CIP processes
2Reliability
If extensive engineering is performed to ensure effective CIP cleaning, then cleaning effectiveness is improved, but the cost increases
Solution Approach 1:
The system performs preliminary evaluation of CIP compatibility and cleaning effectiveness using the digital model before actual implementation. By simulating cleaning processes and identifying potential issues in advance, the system avoids costly trial-and-error testing and rework, ensuring cleaning effectiveness while reducing overall costs
Solution Approach 2:
The digital twin allows virtual testing and optimization of cleaning processes at no physical cost. Engineering evaluations, cleaning path optimizations, and effectiveness assessments are performed in the digital domain, eliminating the need for expensive physical prototypes, test cleaning runs, and extensive documentation preparation
3Adaptability or versatility
If the installation configuration or product production changes, then adaptability is improved, but the cost of re-evaluation and re-engineering increases
Solution Approach 1:
The digital model can be dynamically updated to reflect changes in installation configuration or product production. When modifications occur, the digital twin is updated accordingly, and the system automatically re-evaluates CIP compatibility and generates updated cleaning processes, enabling rapid adaptation without extensive re-engineering
Solution Approach 2:
The digital copy serves as a flexible template that can be modified to represent changed conditions. Rather than re-engineering physical systems, the digital model is updated to reflect new configurations or products, and cleaning processes are automatically regenerated based on the updated digital representation, reducing re-engineering effort
Data Source
AI summary
Method and system for creating and implementing a cleaning-in-place installation cleaning process for a process installation, wherein an installation to be cleaned is represented as process modules that each include an item of self-description information with respect to the respective cleaning properties and that are each configured to transmit the self-description information, where the system has at least one auxiliary module that provides auxiliary services for the installation cleaning process, and a process planning unit that has an item of cleaning process information having cleaning steps needed at least for the installation cleaning process and model descriptions of cleaning efficiency for each cleaning step, and the process planning unit determines a cleaning schedule in a partially automated manner on a system-specific basis based on the cleaning process information supplemented with self-description information relating to the process modules and taking into account information relating to the at least one auxiliary module.