Clean-in-Place System Modernization for Animal Health Manufacturing

This case study details a Clean-in-Place (CIP) system modernization using modern SCADA and configurable control.

The image above is for illustrative purposes only and may not accurately represent the appearance of the client's facility.

Client Overview

A global animal health manufacturer producing pharmaceuticals and vaccines for livestock, poultry, and companion animals partnered with Cybertrol Engineering to modernize and standardize Clean-in-Place (CIP) operations at one of its manufacturing facilities. The site supports both small-train and large-train CIP processes and required a flexible, scalable control platform capable of meeting stringent quality, compliance, and traceability requirements while integrating with existing plant systems.

Project Objectives

The manufacturer sought to enhance the performance, usability, and long-term maintainability of its CIP systems while minimizing operational disruption. Key objectives included:

• Deploying Cybertrol’s configurable, scalable CIP control solution supporting multiple process trains
• Consolidating CIP operations into a unified, modern SCADA environment
• Improving operator usability, alarm management, and system visibility
• Strengthening traceability, auditability, and reporting for quality and compliance
• Establishing a future-ready platform capable of expansion and ongoing optimization

Cybertrol’s Solution

Cybertrol Engineering delivered a comprehensive CIP modernization built on Rockwell Automation technologies and industry best practices. The solution standardized CIP control, enhanced operator interaction, and provided a robust foundation for future growth.

Solution Highlights

• Unified SCADA Environment
  Implemented FactoryTalk® View Site Edition (SE) SCADA with unlimited displays, consolidating previously separate CIP applications into a centralized control and monitoring platform. SmartSights’ Win-911 software was integrated to deliver automated alarm notifications via email, SMS, and voice.
• Configurable CIP Control Architecture
  Deployed Cybertrol’s configurable CIP system that supports multiple CIP recipes, circuits, and valve-pulsing strategies, enabling consistent execution across both small-train and large-train processes.
• Legacy Application Migration and Modernization
  Migrated existing Ignition Perspective and FactoryTalk® View ME CIP applications into the new FactoryTalk® View SE environment. Large-train HMI screens were reformatted for a 23-inch industrial touchscreen, while all interfaces were redesigned in alignment with ISA-101 HMI standards.
• Security, Traceability, and Data Management
  Integrated FactoryTalk Security and RFID badge login for role-based access control. FactoryTalk® AssetCentre provides version control and auditability, while FactoryTalk Historian captures continuous process data for analysis and reporting.
• Advanced Reporting and Audit Capabilities
  Delivered web-based, exportable audit reports capturing wash events, operator actions, recipe selections, and comments—supporting quality assurance and regulatory compliance.
• Development and Deployment Approach
  All system development and testing were completed on Cybertrol’s internal development servers. The final solution was delivered via virtual machines and migrated to the customer’s infrastructure prior to installation, reducing on-site risk and downtime.

Results and Benefits

The modernized CIP system delivered measurable operational and organizational value:

• Operational Flexibility
  Plant personnel can create, edit, and manage up to 124 wash recipes and 30 CIP circuits directly from the HMI, reducing dependence on external programming support.
• Improved Visibility and Control
  Centralized SCADA provides real-time and historical visibility into CIP operations across both process trains.
• Enhanced Operator Experience
  Standardized HMI design, intuitive navigation, and improved alarm management support faster response and more consistent execution.
• Stronger Traceability and Compliance
  Automated audit trails, historian data, and reporting tools support quality requirements and regulatory expectations.
• Future-Ready Architecture
  The scalable, standardized platform allows for straightforward expansion, additional recipes, new circuits, and integration with future manufacturing initiatives.

Key System Features

• Configurable valve pulsing and circuit management
• Operator and QA “Hold for Acknowledge” steps
• Role-based access with RFID badge support
• Real-time and historical data visualization
• Automated alarm notifications and audit reporting

Project Value

This project demonstrates Cybertrol Engineering’s ability to deliver modern, configurable CIP solutions that balance operational flexibility with compliance, reliability, and long-term maintainability. By standardizing CIP control and unifying system architecture, the manufacturer gained a robust platform that empowers operators, supports quality objectives, and positions the facility for continued evolution.