Cleaning and Hygiene in Packaging: A Comparison of CIP-Capable Machines

Cleanliness Means Availability

Every cleaning cycle takes time—and every minute saved on cleaning is time gained for production. During product changeovers in the food industry (allergens, flavors), cleaning time counts double: It determines how many changeovers per shift are economically feasible. There are three cleaning concepts to choose from, and the machine’s design determines which one is feasible.

The Three Cleaning Approaches

Manual disassembly: the standard

The product path is opened and parts are cleaned by hand—the filling chute, format parts, and dosing contact surfaces. The time required depends on the design: tool-less quick-release fasteners and easily accessible screws reduce the time from two hours to 30 minutes. This is sufficient for plants with one product change per day; with three changes per shift, the disassembly process eats into capacity.

COP: Modules for the Washing Machine

Modular machines allow the product-contact modules—dosing screw, filling tube, weighing pans—to be removed, and replacing them with cleaned modules takes only a few minutes. The removed modules are cleaned simultaneously in an industrial washing machine. COP is worthwhile for frequent product changes, but requires a second set of modules.

CIP: Cleaning Without Opening

CIP-capable machines clean while sealed: Tanks, pumps, and spray heads rinse the product path using controlled temperatures and cleaning agents. The advantage is speed and repeatability—the cleaning cycle is programmed and can be validated. CIP is standard for liquid and paste production lines, for powder lines that come into contact with milk powder or protein, and wherever proof of cleaning is required. The limitation: Closed systems are more expensive to purchase, and not every product path can be completely flushed—dead spaces must be eliminated through design.

How to Recognize Hygienic Construction Practices

1. Material Grade: SS304 stainless steel is the minimum requirement for product-contact surfaces; SS316 is required for products exposed to acids or salts. Aluminum and painted surfaces must not be present in the product zone.
2. Surface finish: Polished surfaces with low roughness (typical Ra value below 0.8 µm in the product zone) can be cleaned thoroughly—rough surfaces harbor biofilms.
3. Weld Design: Smoothly ground seams without gaps or burn-through indentations; visible weld beads in the product area constitute a design defect.
4. Screws and Gaskets: Covered screw heads, sealed feed-throughs, food-grade sealing materials with certification.
5. Dead Zones: No cavities where product can get trapped—evident from the smooth, unobstructed product path with no dead ends.
6. Waste and Slope: Machine stands and tables with drainage options; machine housings with a slope so that cleaning water drains away instead of pooling.

The reference for these criteria is the EHEDG design principles and the IFS requirements for food audits—it is standard practice to include both of these as requirements in the specification.

Cleaning Schedule: What Well-Organized Businesses Do

• Formulation of the cleaning plan for each product change: Dry (brushing, vacuuming), damp (wiping and disinfecting), or wet cleaning—a change in allergens requires the more rigorous approach, as documented.
• Daily wet cleaning of the product zone when handling moist and greasy products, dry cleaning for dusty items—incorrect wet cleaning of powder turns it into a paste.
• Weekly deep cleaning, including areas outside the product zone, monthly inspection of seals and seal lubrication.
• Spare Parts Gasket Set in Stock: Seals are wear parts in the hygiene sector—a porous seal is an audit finding.

Buying CIP-compatible products: the right questions to ask

When specifying CIP capability, ask specifically: Which areas are rinsed and which are not (request a list)? Which cleaning agents is the machine compatible with (list of compatible materials)? How long does a standard CIP cycle take (specify the time in the quote)? And: Is there a validation document confirming the effectiveness of the cleaning process? Answers to these four questions distinguish marketing-driven CIP from verified CIP. In Powder Production Lines Ventilation is part of the same test: Only by reliably extracting dust can you actually keep the product area clean.

Frequently Asked Questions

What exactly does “CIP-compatible” mean?

The machine cleans its product path in a closed, programmed cycle using cleaning agents—without disassembly. The list of areas that are rinsed is crucial: Some CIP-capable machines clean only the dosing path, not the bag former.

How long does a CIP cleaning take?

Typically 5 to 20 minutes per cycle, including rinsing and drying, followed by optional disinfection. The cycle runs concurrently with the preparation of the next batch.

Do I need CIP for every type of food packaging?

No. Dry bulk materials with one product per line only require manual weekly cleaning. CIP becomes necessary for economic and quality reasons in cases of frequent product changes, allergen management, moist or fatty products, and audit requirements.

How much more does the CIP version cost compared to the standard version?

The additional costs result from the closed-loop product delivery system, spray and dosing technology, and the control system expansion—the specific amount should be included in the request along with the cleaning schedule. The offsetting benefit is the number of cleaning minutes saved, multiplied by the number of changes per year.

Related pages: Pouch-filling machine for powders | VFFS Guide | Guide to Bag Packaging Machines | Powder Packaging Solution

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