Tanzania Breweries Limited in Arusha put in place advanced CIP system automation to fix important tank cleaning problems. Specifically, the project automated Clean-In-Place processes for caustic, acid, and water tanks. This improvement made hygiene better and raised work efficiency. This new CIP system automation removed hand cleaning needs while keeping strict industry safety rules.
Cleaning System Problems
CIP systems are very important for safe food and drink handling, stopping product contamination. Usually, these systems have chemical tanks, water tanks, valves, and pipes. However, TBL Arusha faced big issues when their CIP tanks got scale buildup. This problem created risks that needed quick action from the engineering team.
Hand Cleaning Issues
The scale buildup hurt level sensors in chemical and water tanks, needing regular hand cleaning. Each cleaning required emptying tanks, which caused much water and chemical loss. This method was not efficient and cost much money, pushing the need for a better answer from our automation knowledge.
Automated Answer Development
Problem Finding and Planning
First, the engineering team found the root causes of the scale problems. They made a detailed flow chart and process plan for automatic cleaning. This design used existing valves, pumps, and PLC control systems to create an efficient answer.
Custom System Design
TBL experts worked together to make a system made for their special factory needs. By adding advanced tank setups and automatic cleaning cycles, they ensured complete cleaning coverage. The planned system fixed all found cleaning problems well.
Advanced Programming Work
Next, skilled programmers built the system software using TIA Portal V12 with WinCC Professional. They created an easy-to-use screen that put together automation and control parts smoothly. This programming set up smart yet simple controls for CIP system management.
System Setup and Testing
Full Commissioning
The project ended with complete testing and starting of the automatic CIP system. Each step was carefully planned and done to make sure all goals were met. The testing checked system reliability and performance under real working conditions.
Quality Checking
Thorough testing made sure the system met all cleaning and work standards. This careful way ensured the automatic answer would work well in daily brewing operations.
Important Benefits Gained
Better Work Efficiency
The automatic system removed hand cleaning needs and related production stops. This change greatly raised work efficiency and cut labor costs.
Less Resource Waste
By removing tank emptying for hand cleaning, the system reduced water and chemical losses. This saving gave both money and earth benefits for TBL Arusha.
Improved Cleaning Standards
The steady automatic cleaning ensured higher cleaning standards were kept. This reliability stopped product contamination and ensured drink quality.
Conclusion: Successful Automation Done
This new CIP system automation has changed cleaning work at TBL Arusha. The automatic answer gives reliable performance, lower costs, and better safety standards. This project shows IAES’s ability in making custom automation answers for the food and drink industry. With this setup, TBL Arusha now has efficient, automatic cleaning processes that support their production excellence goals according to food safety standards.
