SIP: Avoid errors and achieve stable sterility in pharma and food

Steam In Place (SIP) is essential for sterile processes in pharma and food production. But what happens when the temperature isn't right - and how do you avoid having to repeat the process?

What is SIP - and why is it important?

When producing food or medicine, the facility must be completely clean - not just clean to look at, but free from any kind of microbiological activity. This is where SIP (Steam in Place) comes in.

SIP is a process where pure steam sterilisises the entire plant. It takes place after CIP (Clean in Place) cleaning and before the next batch. The goal? To ensure that every drop running through the system has a sterile environment all the way.

For the SIP process to be approved, the temperature must be documented. The system must maintain at least 121°C for 30 minutes - without interruption. If the temperature falls below the limit, it is registered as a validation failure and SIP must be restarted.

Three typical causes of temperature validation errors

It's almost always condensate that interferes with the temperature sensor:

• If there is not enough space between sensor and water discharger
• If a faulty water discharger lets steam through
• If multiple water dischargers share the same condensate system

... the condensate can collect and cool down the sensor - and then the validation fails.

Fortunately, there are several solutions:

• Use water dischargers with low subcooling
• Ensure 300-450 mm between sensor and water discharger
• Replace faulty components quickly
• Design the condensate system with capacity for peak loads

When there is no space - do this

In many installations - especially under tanks - there is no room for the ideal pipe run. Here there are two ways forward:

1. Utilise horizontal space: Even short, slightly inclined horizontal pipes can form a buffer that protects the sensor.
2. Install a sanitary condenser: This is where the SSC - the sanitary condenser - comes in.

SSC collects and cools the condensate before it reaches the water discharger - and that makes a world of difference.

The benefits in practice:

• Eliminates the risk of validation errors
• Shortens heating time
• Requires minimal space

The SSC has cooling fins and a large surface area that effectively extracts heat from the condensate - so the steam bellows work as it should. And you can get validation the first time, every time.