CIP System Upgradation and Digitalisation for Improved Plant Efficiency

A Goose Solutions Case Study

How Goose Solutions Upgraded and Digitalised CIP Systems to Enhance Cleaning, Productivity, and Energy Efficiency Across Indian Process Plants

Overview

In India’s fast-growing food and dairy automation sector, efficient cleaning and sanitisation are vital for maintaining product quality and operational reliability. Clean-in-Place (CIP) systems play a central role in ensuring hygiene and consistency.

However, many process plants continue to rely on outdated or manual systems, leading to high downtime, excessive water and chemical consumption, and inconsistent cleaning performance.

This case study explores how Goose Solutions, a leading name in process plant modernisation and CIP upgradation in India, transformed traditional CIP systems into fully automated, digitalised, and energy-efficient solutions using Siemens PLC SCADA CIP technology and Goose Flow Meters.

Why CIP system Upgradation and Digitalisation Matter

An upgraded and digital CIP system significantly improves:

• Cleaning quality and repeatability

• Plant uptime and productivity

• Water and chemical savings

• Energy efficiency and resource optimisation

• Data traceability and compliance

Through CIP system automation and digitalisation, food, dairy, and beverage plants can achieve better control, transparency, and sustainability in their cleaning operations.

The Challenge: Before Upgradation

Before partnering with Goose Solutions, several Indian process plants faced persistent issues with their legacy CIP systems:

• Manual operation and long cleaning cycles

• Lack of real-time visibility into flow, temperature, and conductivity trends

• High consumption of water, steam, and cleaning chemicals

• Frequent CIP failures and contamination risks

• Poor data traceability and inconsistent cleaning records

These challenges impacted overall plant efficiency and product quality.

Goose’s Step-by-Step CIP Upgradation and Digitalisation Approach

1. Site Audit & System Study

Comprehensive assessment of existing CIP setups, including process lines, pump sizing, valve matrices, and sensor health.

2. Data Collection & Benchmarking

Baseline data on cycle times, energy use, and cleaning performance were collected for comparison.

3. Process Redesign

Optimisation of CIP loops, elimination of dead legs, and improvement of flow velocity for consistent and effective cleaning.

4. Instrumentation Upgrade

• Installation of new Goose Flow Meters, conductivity and temperature sensors, and level transmitters.

• Integration with Siemens PLC systems.

• Replacement of existing heat exchangers with Goose Tubular Heat Exchangers and installation of SPX valve clusters.

5. Automation & Control Integration

Advanced logic programming in Siemens TIA Portal for sequence control, alarm management, and adaptive cleaning cycles.

6. SCADA Visualisation & Dashboards

Centralised real-time monitoring using Siemens WinCC SCADA, featuring trend graphs, batch reports, and cleaning validation.

7. Flow Meter Integration

Goose Flow Meters ensured precision dosing, rinse volume control, and optimised recovery, backed by a 2-year warranty.

8. Digital Data Logging

Automatic recording of all critical parameters — temperature, time, conductivity, and flow rate; stored in plant historians or the cloud for complete CIP

digitalisation and traceability.

9. Operator Training & Validation

Hands-on training for operations and maintenance teams to ensure smooth adoption of the new digital CIP system.

10. Performance Monitoring & Continuous Optimisation

Post-commissioning audits to track resource savings and maintain CIP energy efficiency and reliability over time.

Results Achieved After Upgradation

Following the CIP system automation and modernisation, plants achieved measurable improvements:

• 25–30% reduction in cleaning cycle time

• Up to 20% energy savings from optimised heating and pump control

• 15–25% savings in chemical and water use

• Enhanced cleaning consistency (up to 99.8%), ensuring superior product quality

• Complete digital traceability for audits and compliance

Case Study Snapshot

Goose Solutions has successfully upgraded multiple CIP stations for leading brands, including Lactalis India, Milma Dairies, Janata Dairy, and Purity Agro Foods.

Each project featured Siemens PLC-based control, Goose Flow Meters, remote monitoring dashboards, and real-time analytics. These implementations reduced downtime and improved cleaning predictability across pasteurisation, storage, and filling operations.

Key Benefits of Goose Digital CIP Systems

• Automated CIP sequence for reduced manual dependency

• Real-time visibility into cleaning parameters

• Lower energy and resource usage

• Faster turnaround between production batches

• Digital batch and cleaning reports for regulatory compliance

• Seamless integration of Goose Flow Meters with Siemens PLCs for precise data acquisition

Why Choose Goose Solutions for CIP Upgradation in India

• Authorised Siemens System Integrator with deep expertise in CIP system automation

• Proven track record of 40+ successful CIP modernisation projects across India

• In-house engineering, panel manufacturing, and SCADA development at the Goose Engineering Centre, Pune

• 2-year replacement warranty on Goose Flow Meters

• Dedicated service teams across Kochi, Pune, Chennai, Bangalore, and Noida for commissioning and support

Ready to Modernise Your CIP System?

If your existing CIP system is slowing down production or consuming excessive resources, it’s time to modernise.

Goose Solutions offers proven expertise in CIP upgradation in India, combining Siemens PLC SCADA CIP technology with Goose Flow Meters to deliver smarter, cleaner, and more efficient process plants.

Boost your CIP energy efficiency, save water and chemicals, and achieve complete process visibility with Goose Solutions’ digital CIP system.

👉 Transform your cleaning process today — contact Goose Solutions to start your CIP improvement journey.

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