The cleaning and sanitizing frequency of internal and external surfaces is defined as the maximum production time allocated between two CIPs. Frequency is determined based on the product, process type, and equipment. CIP frequency is also dependent on many factors and must be re-evaluated periodically by the plant to confirm the program’s effectiveness in maintaining a sanitary environment.The maximum CIP frequency for product contact (internal) surfaces has been established for each PepsiCo product/ process produced on the respective equipment. The baseline CIP frequency for all production lines in all Sanitation categories (including new systems) is 24 hours.CIP frequencies can be extended by a single 24 hour interval (or 12 hour interval in some cases) at a time with validation from successful micro data. CIP extensions enable a facility to increase the production run time between CIP intervals. Prior to beginning a CIP extension process, the facility must meet the respective pre-requisite requirements. A general extension CIP protocol has been defined for PepsiCo products as well as specific protocols for Bottled Water and Aseptic processes. The overall extension process includes four key steps:• Baseline – Micro data must be established as a baseline prior to production, after every 24 hours of production, and at the end of production.• Test – CIP extension is tested in 24 hour intervals with micro data being compared to the baseline.• Validation – Extended CIP runs will be evaluated to ensure the micro data remains consistent and within specification in order to maintain the extended production status.• Monitor – Once a facility reaches the maximum production length, regular monitoring is required.When a process is held idle for a certain period of time (i.e. the filler stops), a new CIP may be required prior to re-starting the production in order to maintain the sanitary condition of the equipment. CIP frequencies for product contact (internal) surfaces of equipment following unplanned downtime are defined for each PepsiCo product/ process produced on the respective equipment. In these cases, the commercial sterility of the filling environment has not been compromised; however the product is in contact with the filling valves for an extended period of time.The maximum CIP frequency for non-product contact (external) surfaces has been established to reduce the likelihood of contamination within the production area. In addition to the recommended minimum cleaning & sanitizing frequency, external foam cleaning is required every 24 hours. This is a requirement for Hot Fill Production lines and is a recommended best practice for Category 1, 2, and 3 lines.CIP Changeover Guidelines are to be followed when changing from one product type to another for minimizing any flavor, color, or other carryover effects. To minimize carryover effects when producing beverage products, the proper sequencing of production is very important. For example, flavor products should be produced from light, non-pungent products to dark, pungent products. Diet products are to be produced before sugared products and caffeine-free products before caffeine containing ones.Depending on the product type, minimum sanitation procedures may be required to minimize carryover effects. In some cases a water flush may be sufficient and in other cases a full CIP may be required. The minimum sanitation procedures for select product changeover types have been defined
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