Liquids & Drinks · Beer & Brewing

CIP Cycle Optimization

Replace fixed-timer rinse steps with sensor-confirmed clean endpoints to recover 2+ production hours per day.

−32%

CIP Duration

Sensor-confirmed clean endpoint replaced fixed timer, cutting average circuit time from 81 to 56 minutes

−24%

Chemical Costs

Closed-loop caustic concentration control eliminated over-dosing: $180K annual saving

+2.1 hrs/day

Production Uptime

Shorter CIP windows returned an average of 2.1 production hours per day across 3 filling circuits

How Allie Works Here

From signal to action in real time.

Production PlanningEnergy OptimizationProcess Control

The Process Control agent monitors Hach turbidity and conductivity in real time during the rinse phase and terminates the rinse step when turbidity drops below 3 NTU, replacing the fixed 15-minute rinse timer. The Production Planning agent schedules CIP windows aligned with production plan gaps rather than fixed shift boundaries, presenting operators with a predicted CIP-complete time based on current queue and circuit soil load estimate. The Energy Optimization agent reduces hot water temperature setpoint from 85°C to 75°C for lightly-soiled circuits and sequences circuits to reuse heat from preceding runs.

Machines & Connectivity

OT-connected, protocol-native.

Sani-Matic CIP System

Sani-Matic

OPC-UA

Central CIP skid distributing caustic, acid, and rinse circuits to fermenter vessels and packaging lines

Hach Digital Analyzer

Hach

Modbus TCP

Real-time turbidity and conductivity measurement in CIP return line to validate circuit cleanliness

ABB IRC5 Automation Controller

ABB

OPC-UA

Manages CIP valve sequencing and chemical dosing across 12 circuits simultaneously

Process Variables

The signals Allie monitors and moves.

Signal Name	Historian Tag	Unit	Baseline	Optimized	Target
Caustic Concentration in Circuit	`CIP01.CAUS.CONC`	%	1.5–2.5	1.9–2.1	Tighter
Return Turbidity at Rinse End	`CIP01.TURB.RET`	NTU	≤8	≤3	Lower
Total CIP Duration per Circuit	`CIP01.DUR.CIRC`	min	68–95	52–62	Lower
Hot Water Consumption per Circuit	`CIP01.H2O.CIRC`	L	840–1200	680–780	Lower

Caustic Concentration in CircuitTighter

CIP01.CAUS.CONC

Baseline: 1.5–2.5 %→ 1.9–2.1 %

Return Turbidity at Rinse EndLower

CIP01.TURB.RET

Baseline: ≤8 NTU→ ≤3 NTU

Total CIP Duration per CircuitLower

CIP01.DUR.CIRC

Baseline: 68–95 min→ 52–62 min

Hot Water Consumption per CircuitLower

CIP01.H2O.CIRC

Baseline: 840–1200 L→ 680–780 L

In the Field

"a beverage company running 12 CIP circuits across fermentation and packaging blocks at a greenfield facility"

Deployed at a beverage company running 12 CIP circuits across fermentation and packaging blocks at a greenfield facility. The results above reflect production data from the 60–90 day period following full deployment.

−32%cip duration

−24%chemical costs

+2.1 hrs/dayproduction uptime

Next Step

See what your lines are actually capable of.

A 30-minute operational assessment. We review your OT/IT setup, identify the highest-ROI deployment, and deliver a scoped pilot proposal.

Book a Discovery Call