Clean-In-Place (CIP) System Industrial Automation System Design, Control Modification & Expansion

EPIC designed, manufactured, and integrated a Clean-In-Place (CIP) process system for a Fortune 500 cosmetics company. The customer needed complete industrial automation system design, engineering, installation, and commissioning. EPIC’s in-house automation team and process experts ensured that the systems were delivered according to specifications, on time, and on budget.

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Hygienic Process System Design

Project

Overview

  • Industry: Consumer Goods (Cosmetics)
  • Company Size: $1B – $10B
  • Location: USA
  • Customer Use Case: Process System Controls and Integration

Customer’s

Challenge

A leading cosmetics manufacturer faced persistent issues with their existing Clean-In-Place (CIP) system. The system had never fully passed qualification due to inaccurate controls. The existing automated setup was not designed to operate two CIP systems independently, causing operational inefficiencies and hindering production scalability. Additionally, the pharmaceutical-grade operating environment mandated extensive documentation, checkout, and validation, adding complexity to the project. The manufacturer urgently needed a solution to rectify eliminate errors, integrate a new CIP system seamlessly, and comply with regulatory standards, all within a tight timeframe. 

Epic

Solution

Recognizing the urgency of the situation, EPIC assembled a dedicated team of automation engineers with expertise in process design and control systems. The solution involved the design, manufacturing, and integration of a comprehensive CIP process system tailored to the customer’s needs.   

To accommodate the dual CIP systems and ensure operational efficiency, EPIC implemented a strategic approach by dividing the controls into three distinct systems:  

  • one for the existing CIP skid, 
  • a second for the additional system, 
  • and a third acting as a gateway to synchronize the two systems seamlessly. 

EPIC’s team standardized the industrial automation system design across all three control panels, facilitating future expansions and system modifications. This standardized approach not only enhanced operational efficiency but also simplified maintenance and troubleshooting processes. 

In preparation for FDA compliance, EPIC prepared an extensive 8,000-page turnover package to support system validation efforts. The team of engineers provided comprehensive assistance throughout the installation, commissioning, and validation phases, ensuring regulatory adherence and operational readiness. 

Project

Impact

  • Enhanced Regulatory Compliance: By successfully passing validation for both CIP systems, including the newly integrated one and the re-programmed system, the customer was able to meet stringent FDA regulations, ensuring product quality and consumer safety.
  • Increased Production Efficiency: The seamless integration of dual CIP systems has significantly boosted production capacity and streamlined product changeovers, allowing the customer to meet growing demand and maximize operational efficiency.
  • Improved Flexibility and Adaptability: With standardized industrial automation systems in place, future expansions and system modifications are now simpler and more cost-effective, enabling the customer to adapt quickly to evolving market needs and maintain a competitive edge.
  • Streamlined Maintenance and Compliance Processes: The comprehensive turnover package prepared by EPIC and the standardized system design have simplified maintenance tasks and regulatory compliance efforts, reducing downtime and operational risks.

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EPIC Systems is a multidisciplinary engineering integrator specialized in industrial automation for process manufacturers. We deliver solutions in the following areas:

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