TL;DR
A blocked CIP spray nozzle leaves an area of equipment uncleaned. Identify the blocked nozzle, remove it, clean the orifice, and verify coverage with a visual spray test.
What you might see
- CIP circuit coverage incomplete
- spray nozzle pressure drop above normal
- visual inspection shows nozzle not rotating or not spraying
- post-CIP swab ATP results elevated at a specific location
Likely causes
Scale or product buildup blocking the nozzle orifice
Foreign material from the CIP circuit lodged in the nozzle body
Nozzle rotation mechanism stuck from scale or corrosion
Incorrect nozzle type installed with too small an orifice for the supply pressure
Required tools
- Chemical-resistant gloves and eye protection
- Nozzle cleaning pin or soft brush
- Descaling solution (compatible with nozzle material)
- LOTO kit
Safety first
- Residual CIP chemical is present in spray lines after a cycle. Wear eye protection and chemical gloves when removing nozzles.
- Incomplete CIP coverage is a food safety risk. Do not return equipment to production until spray coverage is verified and any affected area has been re-cleaned.
Procedure
- 1
Identify the nozzle with coverage failure from the CIP coverage map or the ATP result location.[1]
- 2
Stop the CIP cycle and lock out the CIP pump. Depressurize the circuit.[1]
- 3
Remove the blocked nozzle. Wear chemical-resistant gloves.
Warning: Residual CIP chemical in the spray ball circuit can spray out when a nozzle is removed. Face away from the nozzle while loosening it and wear eye protection. - 4
Soak the nozzle in warm water or a dilute acid descaling solution to dissolve scale blockage.
- 5
Use a soft brush or a nozzle-cleaning pin to clear the orifice. Do not use metal tools that could damage the orifice geometry.
- 6
For rotating spray heads, confirm the rotation mechanism turns freely by hand after cleaning.
- 7
Reinstall the nozzle and run a short visual test cycle with water to confirm full coverage before the next CIP cycle.
Sources
Tetra Pak Sani-Matic CIP-100 / 200 CIP / SIP System general technical documentation, Tetra Pak
Sani-Matic CIP-100 / 200 CIP system general spray nozzle inspection and blockage procedures (general)
More guides for Tetra Pak Sani-Matic CIP-100 / 200
How to fix chemical concentration deviation on a Sani-Matic CIP-100 / 200 CIP system
Chemical concentration out of range means the CIP is not cleaning or is over-chemical. Check the dosing pump, tank level, and conductivity sensor calibration.
How to fix pump cavitation on a Sani-Matic CIP-100 / 200 CIP system
CIP pump cavitation reduces flow rate and can damage the impeller. Check the inlet strainer, suction conditions, and tank level before adjusting the pump.
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