Calculator 01 — Pipe Flow Rate & Turbulence Check
Calculator 01
Pipe Flow Rate & Turbulence Check
Select pipe size and CIP temperature to verify design velocity meets the 1.5 m/s minimum and achieves turbulent flow (Re > 10,000) at the circuit's largest diameter.
Circuit Parameters
20°C55°C90°C
Design Rule
Minimum 1.5 m/s at the largest diameter in the circuit. Design target 2.0 m/s. Above 4.0 m/s yields diminishing returns and accelerates seal and fitting wear. Pump must be sized for the largest element in the circuit.
Flow Results
Inner Diameter
50mm
Required Flow Rate
14.1m³/h
Flow Rate
235L/min
Reynolds Number
250,000
Flow Regime
Kinematic Viscosity
0.413× 10−&sup6; m²/s
Min Pump Capacity (+20%)
Design flow × 1.20 → see Pump tab
16.9 m³/h
EHEDG 50 / 3-A 605
Overall Design Status
Velocity ≥ 1.5 m/s minimum
Turbulent flow (Re ≥ 10,000)
Velocity ≤ 4.0 m/s practical max
Dead Leg Check — 1D Rule
Max Allowed (1×D)
—
Status
All DIN 11851 Sizes — Current Velocity & Temp
| Pipe | Flow (m³/h) | Re | Regime |
|---|
Calculator 02 — Pump Sizing & Pressure Drop
Calculator 02
Pump Sizing & Pressure Drop
Size your CIP supply pump and calculate total dynamic head (TDH) using Darcy-Weisbach. Pipe selection syncs from Tab 01.
Circuit Configuration
Spray Device Reference
Static Spray Ball
Low impact · high flow · fixed pattern · 1–2 bar
2–5 m³/h
Rotating Spray Ball
Medium impact · full coverage · 2–4 bar
3–8 m³/h
High-Impact Jet Head
High impact · small jet · many cycles · 3–8 bar
5–15 m³/h
Retractable Spray Ball
Large bore pipes or piggable circuits
Supplier spec
Pump Flow Results
Base Flow (2.0 m/s)
14.1m³/h
Spray Device Flow
—m³/h
Controlling Flow
14.1m³/h
Circuits × Margin
×1 +20%
Return Pump (supply ×1.30)
21.9m³/h
Min Supply Pump Specification
Controlling flow × circuits × margin
16.9 m³/h
Pressure Drop & Pump Head (Darcy-Weisbach)
Friction Head Loss
—m
Static Head
3.0m
Total Dynamic Head (TDH)
—m
Friction Pressure Drop
—bar
Recommended Pump Head (+15%)
—m
Basis
Pipe roughness ε = 0.0015 mm (sanitary SS). Add heat exchanger, strainer and valve pressure drops from supplier datasheets for final pump head specification.
Calculator 03 — CIP Tank Volume Sizing
Calculator 03
CIP Tank Volume Sizing
Minimum chemical and rinse water tank volumes based on circuit volume. Tanks must never overflow under normal or anticipated abnormal conditions.
Tank Parameters
0.1100200 m³
Standard References
Chemical: circuit + 20% (single) or 30% reserve. Multi-circuit: 150% of largest. Rinse: circuit + 10%. All tanks must include overflow protection and high-high level shutdown.
Volume Results
Circuit Volume
2.0 m³
2,000 litres
Minimum Tank Volume
2.4 m³
Circuit + 20%
Recommended Tank Volume
3.0 m³
Circuit + 50%
Recommended in Litres
3,000 L
Dump / Refresh Criteria
Caustic: Dump after 50 cycles or COD > 3,000 mg/L or carbonate > 4–5%
Acid: Dump after 30 cycles or suspended solids > 1%
Rinse water: Once-through — never reuse as final rinse
Acid: Dump after 30 cycles or suspended solids > 1%
Rinse water: Once-through — never reuse as final rinse
Calculator 04 — CIP Heating Capacity
Calculator 04
CIP Heating Capacity
Calculate heating power required to reach target temperature within the required time. Used for heat exchanger sizing and steam valve specification.
Heating Parameters
Calculation Basis
Q = V × ρ × Cp × ΔT / t — ρ = 1,000 kg/m³, Cp = 4.18 kJ/(kg·K). Design capacity adds heat loss allowance plus 20% engineering margin.
Heating Results
Temperature Rise (ΔT)
60°C
Net Heating Power
—kW
Heat Loss Allowance
—kW
Gross Power (incl. loss)
—kW
Energy per Heating Cycle
—kWh
Steam Consumption Rate
—kg/h
Recommended Heater / HX Capacity
Gross power + 20% engineering margin
— kW
Heater Type Guidance
Plate heat exchanger: Compact, easy to clean, preferred for continuous flow heating. 316L SS on CIP side.
Shell & tube: Higher capacity for large tanks. 316L SS CIP side; titanium if chlorinated chemicals used.
Electric immersion: Simple control, limited to smaller volumes. Never use direct steam sparging — dilutes solution and introduces iron.
Control system must maintain temperature within ±5°C of target via modulating steam valve.
Shell & tube: Higher capacity for large tanks. 316L SS CIP side; titanium if chlorinated chemicals used.
Electric immersion: Simple control, limited to smaller volumes. Never use direct steam sparging — dilutes solution and introduces iron.
Control system must maintain temperature within ±5°C of target via modulating steam valve.
Reference 07 — CIP Programme Sequence & Engineering Reference
Reference 07
CIP Programme Sequence
Standard step parameters based on EHEDG Guideline 50 and 3-A Standard 605.
Valve Pulsing Requirements (Seat Valves)
Pre-Rinse
2–3times active
Main Wash
4–6times active
Post Rinse
3–4times active
Dead Leg Rule — 1D Maximum
Any branch beyond 1× the pipe inner diameter from the centreline is a stagnation zone. Branches must face the incoming flow direction. Never top (traps air) or bottom (traps soil).
| Nominal Pipe | Inner Diameter | Max Branch |
|---|---|---|
| DN25 | 26 mm | 26 mm |
| DN40 | 38 mm | 38 mm |
| DN50 | 50 mm | 50 mm |
| DN65 | 66 mm | 66 mm |
| DN100 | 100 mm | 100 mm |
Chemical Reference
Conductivity vs Concentration
Approximate values at 25°C (temperature-compensated). Starting point for PLC conductivity setpoints — always validate against your chemical supplier's data. Highlighted rows indicate typical CIP range.
NaOH — Sodium Hydroxide (Caustic)
| Concentration | Conductivity (mS/cm) | Typical Use |
|---|---|---|
| 0.2% | ~8 | Light soil, short circuits |
| 0.5% | ~18 | Light dairy / beverage |
| 1.0% | ~32 | Standard food CIP |
| 1.5% | ~46 | Protein-heavy processes |
| 2.0% | ~58 | Heavy soil, long circuits |
| 3.0% | ~77 | High-fat, extended CIP |
| 4.0% | ~90 | Extreme soil conditions |
HNO&sub3; — Nitric Acid
| Concentration | Conductivity (mS/cm) | Typical Use |
|---|---|---|
| 0.5% | ~22 | Light scale removal |
| 1.0% | ~40 | Standard acid step |
| 1.5% | ~55 | Hard water, dairy stone |
| 2.0% | ~68 | Heavy mineral deposits |
H&sub3;PO&sub4; — Phosphoric Acid
| Concentration | Conductivity (mS/cm) | Typical Use |
|---|---|---|
| 0.5% | ~10 | Mild acid step |
| 1.0% | ~18 | Beverage, dairy |
| 2.0% | ~30 | Heavy scale, brewery |
Proof of Rinse
Final Rinse Conductivity Setpoints
Return-line conductivity must confirm chemical neutrality before the cycle closes. If not achieved at timeout, the system must halt and raise a fault — not log a pass.
Rinse Acceptance Criteria by Process Type
| Process | Max Return Conductivity | pH |
|---|---|---|
| General food (non-RTE) | < 200 μS/cm | 6.0–8.0 |
| RTE / high-risk | < 100 μS/cm | 6.5–7.5 |
| Dairy / infant formula | < 50 μS/cm | 6.8–7.2 |
| Pharmaceutical-grade | < 10 μS/cm | 6.8–7.2 |
Context is critical
Your supply water conductivity sets the practical floor. If supply water is 400 μS/cm, a 100 μS/cm return target is unreachable. Always validate setpoints against actual water quality.
Typical Supply Water Conductivity
| Water Type | Conductivity | Hardness (CaCO&sub3;) |
|---|---|---|
| Demineralised / RO | 1–50 μS/cm | < 5 mg/L |
| Soft water | 50–200 μS/cm | 5–60 mg/L |
| Typical mains (NL) | 200–500 μS/cm | 60–200 mg/L |
| Hard water | 500–800 μS/cm | 200–400 mg/L |
| Very hard water | > 800 μS/cm | > 400 mg/L |
⚠ Hard water (> 200 mg/L CaCO&sub3;) makes the acid wash step non-optional and accelerates milkstone formation in dairy and heat-exchange circuits.
Framework
TACT Parameter Quick Reference
T — TEMPERATURE
Heat
Alk: 70–80°C
Chlor-alk: 55–65°C
Acid: 40–70°C
Pre-rinse: 35–43°C
Chlor-alk: 55–65°C
Acid: 40–70°C
Pre-rinse: 35–43°C
A — ACTION
Flow
Min: 1.5 m/s
Design: 2.0 m/s
Re > 10,000
Max: ~4.0 m/s
Design: 2.0 m/s
Re > 10,000
Max: ~4.0 m/s
C — CONCENTRATION
Chemistry
Per supplier spec
Conductivity control
Temp-compensated
Measured on return
Conductivity control
Temp-compensated
Measured on return
T — TIME
Duration
Tanks: 10–20 min
Lines: 20–30 min
Compliant time only
Soil-type dependent
Lines: 20–30 min
Compliant time only
Soil-type dependent
Interactive Calculator
Conductivity ↔ Concentration
Enter a conductivity reading to estimate working concentration, or enter a target concentration to get the expected conductivity. Linear interpolation between calibrated data points at 25°C. Validate against your supplier's specific product sheet before setting PLC setpoints.
Lookup Inputs
Temperature correction
All values at 25°C. Modern transmitters apply automatic temperature compensation (ATC). At 70°C, conductivity is ~30–40% higher than at 25°C — ATC-corrected readings are directly comparable to these values.
Result
Estimated Concentration
—%
Expected Conductivity
—mS/cm
Typical CIP Operating Range
0.5 – 2.0 %
Conductivity is temperature-dependent. ATC-corrected transmitters on the return line provide reliable real-time concentration monitoring without sampling delay. Supply-side tank conductivity alone is insufficient — always monitor on return line.
Estimator
CIP Cycle Time Estimator
Estimate total CIP cycle duration from circuit volume, flow rate, and step sequence. Rinse steps are volume-based; wash steps are timed. Includes transition and ramp-up allowances.
Circuit Configuration
Step Durations
Cycle Breakdown
01 Pre-Rinse
—min
02 Alkaline Wash
—min
03 Intermediate Rinse
—min
04 Acid Wash
—min
05 Post-Acid Rinse
—min
06 Sanitise
—min
07 Final Rinse
—min
Transitions & Ramp
—min
Estimated Total Cycle Time
Volume-based rinses + fixed wash steps + transitions
— min
Operational Throughput
Max cycles — 8-hour shift
—cycles
Max cycles — 12-hour shift
—cycles
Controls
Mandatory Monitoring — Every Cycle
Calculator 05 — Chemical Dosing
Calculator 05
Chemical Dosing Calculator
Calculate the exact volume of chemical concentrate to dose into your CIP tank to reach target working concentration. Vendor-neutral — works with any supplier's product. Verify with return-line conductivity before starting wash step.
Dosing Parameters
50% w/w solution · density 1.52 kg/L
Standard Product Specifications
| Chemical | Typical Conc. | Density |
|---|---|---|
| NaOH (Caustic) | 50% w/w | 1.52 kg/L |
| HNO&sub3; (Nitric) | 65% w/w | 1.39 kg/L |
| H&sub3;PO&sub4; (Phosphoric) | 85% w/w | 1.68 kg/L |
| PAA (Peracetic) | 15% w/w | 1.12 kg/L |
⚠ Safety: Always add chemical to water — never water to acid. Use appropriate PPE. Check SDS for each product before handling.
Dosing Results
Tank Volume
2,000L
Active Chemical Required
—kg
Product Volume to Dose
—L
Expected Conductivity
—mS/cm
Dosing Rate — 1% concentration
—L/m³
Dose Into Tank (total)
Add to water — verify with conductivity meter
— L
Dosing Verification
Verify concentration range
—
Typical PLC conductivity setpoint
—mS/cm
Conductivity ± 20% tolerance band
—
Calculator 06 — CIP Cost Per Cycle
Calculator 06
CIP Cost Per Cycle
Total cost of one CIP cycle — water, chemicals, and energy — annualised by cleaning frequency. Use this to justify investment in recovery systems, optimise step sequence, or benchmark against industry norms.
Getting started
Default values below are illustrative. Update the unit rates to match your site tariffs and enter the chemical dose volumes from Tab 05 to get accurate costs for your process.
Circuit & Frequency
Unit Rates
Per-Cycle Quantities — from other tabs
Cost Breakdown — Per Cycle
Water (3 rinse×circuit vol)
€—
Caustic Chemical
€—
Acid Chemical
€—
Heating Energy
€—
Water volume used
—m³
Total Cost per CIP Cycle
Water + chemicals + energy
€—
Annualised Cost
Cost per day (2 cycles)
€—
Cost per month
€—
Cost per year (300 days)
€—
Water consumption — annual
—m³
Chemical spend — annual
€—
Optimisation levers
Recovering intermediate rinse water for the next pre-rinse reduces water use by 25–35%. Recovering hot wash water reduces heating energy by 15–20%. Re-using caustic over multiple cycles (with conductivity top-up) cuts chemical cost by 50% or more.