Application for Mass flow measurements for those over 18 years old!

03/03/2015

When thinking of alcoholic products that are produced in Britain, a fine malt Whiskey may spring to mind or perhaps beer brewed in one of the numerous breweries that can be found dotted around the country. How many people however, would immediately think of Vodka?

English_VodkaWell, nestled in the Herefordshire countryside, the family run Chase distillery (entry only to over 18 year olds!) thinks a lot about Vodka, in fact it produces the award winning Chase Vodka which is the World’s first super premium English potato Vodka.

The entire process from seed to bottle takes place on the Chase estate ensuring that a close eye can be kept on all stages from growing the potatoes to distilling and bottling. It was at the distilling stage that Chase was looking for a flowmeter that was capable of measuring the flow rate of fermented potato mash. After careful consideration, they decided on Krohne’s OPTIMASS 1300 Coriolis mass flowmeter.

The fermentation process is started with the mashing of potatoes and the addition of a brewer’s yeast. After about a week, the fermented potato mash is distilled four times in a bespoke copper batch pot and then twice more in a rectification column. It is here that the OPTIMASS 1300 is installed in a vertical pipe run feeding the distillation column. The density of the medium going through the meter can vary from 0.95 to 1.1kg/litre and flows at a rate of 2000 l/hr with pressure of 1BarG at a temperature of 30C.

Krohne_VodkaWith the available space being limited, Chase required a meter that had a small installation envelope, but could still measure accurately and was capable of being CIP cleaned at 65C. The OPTIMASS 1300 has a dual straight tube design which makes it ideal for use in hygienic applications as there are no crevices or bends for bacteria to gather and the meter can be easily drained and cleaned. Due to the hygienic nature of the application the OPTIMASS 1300 was supplied with hygienic fittings and also has all of the necessary hygienic industry approvals.

Prior to installing the OPTIMASS 1300, Chase used a manual method to monitor the flow of fermented potato mash into the distillation column, however they were looking for a mass flow meter to automate the process. The OPTIMASS 1300 has enabled Chase to monitor the feedstock to finished product ratio accurately and since installation it has also reduced production time by highlighting an underperforming feed pump that was increasing the mash charging time which in turn lengthened the production time.

Tim Nolan, engineering manager at Chase is very pleased with the performance of the OPTIMASS 1300, “Installing the KROHNE meter has meant that we can automate the process and ultimately reduce production time.  It also allows us increased flexibility as we can install the meter on other parts of the process to verify efficiency,” he continues, “KROHNE have supplied us with a meter that complies to our hygienic requirements and has proved to be very reliable.”

Initially, the OPTIMASS 1300 will be used with a local display, however in the future it is planned to interface the meter with the PLC using mA outputs to measure volumetric flow, density and temperature.

Chase_Bosca


Quieter, more efficient, and improved controllability!

02/06/2014
Dr. Petr Osipov, Product Management Motors, Kollmorgen (D) tells how Multivac relies on Kollmorgen for pneumatic to electric transition

An increasing number of companies in the packaging machine industry have chosen electrical servo technology – mainly to replace motion axes previously powered by pneumatic systems. “Servo technology increases controllability and reduces noise emission. These systems also help us to increase the number of production cycles”, Guido Spix, CTO Multivac, recently emphasized during a packaging show. The packaging machine company uses motion control solutions from Kollmorgen to reduce energy consumption, increase the overall machine effectiveness and improve safety of packaging processes.

Author: Dr. Petr Osipov, Product Manager Motors, Killmorgen.

Author: Dr. Petr Osipov, Product Manager Motors, Killmorgen.

Optimised motorgear box combination.

Optimised motorgear box combination.

From meat stock to finished packaging…and all processed electrically. Compared to traditional, mostly pneumatic-driven lifting units, the new lines of R2XX to R5XX machines utilise a motor-gearbox combination to deep draw and seal the foils.

From meat stock to finished packaging…and all processed electrically. Compared to traditional, mostly pneumatic-driven lifting units, the new lines of R2XX to R5XX machines utilise a motor-gearbox combination to deep draw & seal the foils.

A motor-gearbox combination achieves a bonding pressure of 20 tons in the high performance R535 packaging machine. Being a strategic motion control partner for Multivac, Kollmorgen implemented a compact unit of their AKM servo motor series and a cycloidal gear drive for the lifting axis. The high power density of this unit allows for compact dimensions.

A motor-gearbox combination achieves a bonding pressure of 20 tons in the high performance R535 packaging machine. Being a strategic motion control partner for Multivac, Kollmorgen implemented a compact unit of their AKM servo motor series and a cycloidal gear drive for the lifting axis. The high power density of this unit allows for compact dimensions.

Kollmorgen was able to cover most of the transportation and rotary applications in meat processing and subsequent packaging processes with two standardized solutions: The AKM servo motors with washdown and food grade option – available also with the innovative single-cable technology.

Kollmorgen was able to cover most of the transportation & rotary applications in meat processing and subsequent packaging processes with two standardized solutions: The AKM servo motors with washdown and food grade option – available also with the innovative single-cable technology.

The AKMH™ stainless steel motors (http://www.kollmorgen.com/en-gb/products/motors/servo/akmh-series/akmh-stainless-steel-series/) provide a scalable solutions portfolio for motion applications in the packaging, food processing & pharmaceutical industries.

The AKMH™ stainless steel motors provide a scalable solutions portfolio for motion applications in the packaging, food processing & pharmaceutical industries.

Secure packaging:
Besides machine and operator safety, for Multivac, this also includes safe packaging processes. The excellent traceability and controllability of Kollmorgen’s servo technology for example, helped Multivac to design a more efficient sealing process for deep drawn packages with the additional benefit of improved food safety. This solution is currently used on the high performance deep draw machines, designed for mid-size to large loads.

Compared to traditional mostly pneumatic-driven lifting units, the new lines of R2XX to R5XX machines utilize a motor-gearbox combination to deep draw and seal the foil. These units utilise a knee lever mechanism to lift the molding tools – some weighing several hundred kilograms. They withstand the high bonding pressure of up to 20 tons, ensuring the two foils seal securely. Being a strategic motion control partner for Multivac, Kollmorgen implemented a compact unit consisting of an AKM® servo motor  and a cycloidal gear drive for the lifting axis. Kollmorgen calculated and selected the optimal motor size and gear drive type in close cooperation with Multivac’s engineering development teams.

Two important aspects for the drive train selection were the overall unit length and overload capacity. The model HKS03 six-point lift unit features a servo gear motor with brake having a total length of 307mm and an acceleration torque of 1400 Nm. These results are possible thanks to the high power density of the AKM servo motors, the ideal overall length of the cycloidal gear drive and the fact that the unit comes without end bells and clutches. Piston rods convert the rotary to linear lifting motion. This solution has three significant advantages. Firstly, the energy efficiency of the machine increases because the pneumatic system was replaced as the power source to create the required pressure for the deep draw and sealing operation. Secondly, the geometry of the piston rods creates an extreme closing force at the end of travel which improves food safety. Finally, the high sealing force results in a more secure and thus reliable sealing process.

“Perfectly Clean” inside and out
The two-component epoxy coat used for the hygienic design conforms with FDA 21 CFR 175.300 and is resistant against acids, bases and established cleaning agents with a pH range of 2 to 12. In a long term test performed by the company EcoLab, this coat withstood exposure to an equivalent of more than 2000 washdown cycles including disinfecting treatments. Kollmorgen’s washdown gear motor comes standard with a white coating, significantly improving the machine operators’ ability to detect dirt and biofilms on the surface during cleaning operations.

A stainless steel-like coating is offered as an option. The surface of both coats is water repellent (hydrophobic) and aqueous liquids will run off more easily, which leads to decreased formation of residue on the surface. Hence, Kollmorgen’s standard of a “perfectly clean” gear motor can seamlessly be incorporated in the MULTIVAC Hygienic Design™ concept that is rigorously applied to all deep draw packaging machines.

From Co-Engineering to Production
Multivac has a global distribution network with about 60 subsidiaries and offers a variety of different machine models with different features. Managing this variety with extensive standardization requires strategic partners that are able to cover a large range of machine applications with their technologies. The Kollmorgen washdown gear motor solution is a perfect example for how a project based custom-designed and custom-built product becomes a standardized, ready-to-install module. The concept of the current motion and automation technology used on the deep draw machine follows the requirements of the new Multivac solution: more flexibility by being able to combine several axes interchangeably and at the same time, smaller control units, plus an increase in dynamic performance for better productivity. In summary, thanks to Multivac’s and Kollmorgen’s close cooperation in this project, the entire pneumatic system was replaced by a highly efficient electrical solution. After the first successful practice runs, Multivac determined a reduction in energy consumption for the R 095 e-concept of at least 20 percent compared to similar models.


Smart solution with frequency sweep technology – A level switch for all media!

20/11/2013

Fill levels must be recognized in countless storage, buffer and holding tanks in the process industry, food industry, and even in wind power plants or other fields. The level switches used are normally as different as the various media being monitored. With the CleverLevel LBFS/LFFS switch, Baumer has developed a true all-rounder that uses frequency sweep technology. This method capitalizes on the fact that every material, regardless of its consistency, has a dielectric constant specific to that medium. This makes the new level switch suitable for practically all media, including liquids, granulates and even electrostatic media. At the same time, it is unaffected by adhesive substances or foams that may lead to switching errors with other technologies. Furthermore, it can distinguish between different media. This makes the CleverLevel more than merely a replacement for the traditional vibrating fork used in level control. Configuration is possible using Teach-in. It is more convenient with Flex Programmer software, which enables visualization at the same time. The displayed information can be communicated to a higher-level controller if required and interpreted there in accordance with the operation phase.

Level control in a container

Level control in a container

Level detection is of great importance in the process industry. They monitor maximum and minimum values of material fill levels in tanks or as protection against overflow or dry operation. A number of limit switches are available, based on different technologies. The specific application determines the selection, because until now it was not possible to cover all applications with one level switch. Things are different now. A new level switch that uses frequency sweep technology now proves to be a practice-oriented all-rounder for almost every conceivable medium.

The demands on level switches can vary considerably, depending upon application. There are therefore numerous application-specific factors to consider, such as foam formation, aggressiveness or flammability of the media to be detected, adhesive substances, unfavorable installation conditions, the speed of the filling process and, naturally, the accuracy required. The widely used vibrating forks do not necessarily offer the best conditions. Some have quite large components that extend far into the material being measured. Measuring errors can arise, since high viscosity materials tend to stick to these forks. Coarse granular media can easily become lodged between the forks and also cause measuring errors. The forks and difficult to clean and liquid and powder substances require different versions. It was impossible to cover all applications with one level switch, until now.

Versatile sensor with elegant configuration

The CleverLevel series of level switches use frequency sweep technology and can reliably detect extremely different media. The readings are not affected by adhesive substances or foam.

The CleverLevel series of level switches use frequency sweep technology and can reliably detect extremely different media. The readings are not affected by adhesive substances or foam.

Now the Baumer CleverLevel series of level switches fill this gap. They are based on frequency sweep technology. The sensor analyses the resonance frequency of the oscillating circuit affected by the dielectric constant of the medium below the sensor tip. This allows adhesive substance on the sensor tip or foam to be suppressed. High sensitivity over a large measurement range for dielectric constants from 1.5 to over 100 enables limit detection for all sorts of powders, granulates and liquids. And setup is easy.

The default setting already recognizes most media. The Teach-in function helps in case of doubt and more complex configuration becomes child’s play with the FlexProgrammer software, because the user can practically “see” the same thing as the sensor. The switching range can be adjusted as required to ignore foams in maximum or minimum monitoring, for example. The same applies if the sensor needs to ignore adhesive substances. Tanks with liquid chocolate are a typical example. Even when empty, the sensor and container walls are coated with chocolate. When configured accordingly, the CleverLevel still switches only when the tank is really full or empty. Electrostatic adhesion, which must frequently be taken into account in the detection of powdery substances, can also be ignored by appropriate definition of the switching range.

The simple, graphic configuration software really adds to the user-friendliness. For example, it is possible to observe the sensor’s internal signal while the thresholds are adjusted by mouse click within the graphic representation. This not only makes the configuration method intuitive and thus easily learned, but also considerably improves the reliability of the results, because they can be checked graphically at any time. This is also possible with extended setting methods that take medium conductivity into account, even if two media have the same dielectric constant.

Supported by the FlexProgrammer, the CleverLevel series can perform even complex filling level detection tasks.

Supported by the FlexProgrammer, the CleverLevel series can perform even complex filling level detection tasks.

Even different media in the same process line or process tank can be detected in order to differentiate the end product. For example, different types of fish sauce, different beers, etc. For this purpose a measuring signal can be output so that different dielectric constants through different media, foams or adhesive substances can be differentiated in the control. This makes it possible to detect if a medium is polluted with another medium, e.g. oil polluted with water.

Assessment of measurement results and maintenance planning

The information that is visualized with the help of software can also be transferred to the higher-level controller. It can then evaluate the measuring signal. It ultimately knows if the position of the switching point shifts because another medium is in the tank during flushing, for example. Dirt in the tank can also be detected in this way and cleaning can be scheduled accordingly. Today, many application areas are dependent upon this information. Wind power plants are a typical example of this, because “spontaneous” maintenance of lubricant containers is extremely costly and can only be carried out at unjustifiable expense. The same applies to locomotives, ships or mobile implements in agriculture, for example.

Using the Flex Programmer software, the switching range can be adjusted as required to ignore foam during maximum or minimum monitoring.

Using the Flex Programmer software, the switching range can be adjusted as required to ignore foam during maximum or minimum monitoring.

A further strength of the level-monitoring sensor is particularly evident in mobile tanks. It normally works with a response time of 0.1 sec., which permits high-speed filling processes and the precise maintenance of filling levels. However, this becomes a disadvantage if the tank is in motion and the contents slosh around. In such cases, a switching delay of up to 10 sec. can be set to avoid false signals due to tank movement.

Robust, hygienic, with ATEX approval

But the new CleverLevel series offers even more. The level switches can be installed in any position, even in rather inaccessible locations. The LED that signals the switching process is highly visible in all directions. The sensor works silently, compliance with protection class IP67 requirements is standard, and it is suitable for ambient temperatures between -40°C und +200°C. Operation is also unaffected by vibrations. For example, the latter is important if the level switch is placed close to a pump as protection against dry running. The small penetration depth of only 15 mm is also a positive feature in these circumstances. Flow and pressure are hardly affected. In addition, thanks to gap-free installation and the smooth tip, nothing can adhere to the sensor.

There are countless areas of application for this fill level sensor all-rounder, such as filling liquid chocolate.

There are countless areas of application for this fill level sensor all-rounder, such as filling liquid chocolate.

In addition to the industrial process connections, there are also versions with EHEDG approval and an ATEX version for Ex areas for applications with stringent hygiene requirements. There are countless application possibilities for this all-rounder level switch. The food and beverage industry can benefit from its possibilities as much as every other industry, from pharmaceuticals, chemicals, petrochemicals, and process engineering all the way to the water supply and wastewater fields. Further areas of application are found in wind power plants, mobile machinery, cereal mills or cleaning facilities and pumping systems.


Automation is key to successful food and beverage strategies. #PAuto

03/12/2012
Innovation and flawless and timely execution have helped leading companies make manufacturing a competitive advantage.

Automation expenditures in the food and beverage industry are expected to reach $7 billion by 2016. “The information architecture is extending its reach all the way to the consumer by way of social networks and a new generation of 3D virtual on-line shopping and on-line product customization tools. It is becoming an important solution in the drive toward mass customization and has begun to change the way consumer facing business is conducted,” according to Principal Analyst for the CPG Industries John Blanchard, the principal author of ARC’s Automation Expenditures for Food and Beverage Industry Global Market Research Study”.

The major areas of focus in food and beverage manufacturing are margin protection and cost containment, innovation and time to profitability, food safety, more sustainable manufacturing focused on energy usage and waste reduction, and minimizing brand risk. Packaging is becoming increasingly important as an emotional selling point due to intense competition and more difficulty in achieving sustainable competitive advantage via functional differentiation. Since most CPG companies have similar business strategies, flawless and timely execution differentiates leading companies from their competitors. Innovation and flawless and timely execution have helped leading companies make manufacturing a competitive advantage. The convergence of food safety, sustainable manufacturing, and new regulatory requirements is leading to un-precedented levels of accountability and the evolution to the transparent enterprise.

ARC’s “Automation Expenditures for Food and Beverage Industry Global Market Research Study” will help users learn what others in the industry are doing and the capabilities of each supplier. The study discusses strategies and tactics for suppliers and user manufacturers to be successful in the rapidly changing environment of the worldwide food and beverage industry

Opportunities and Challenges

Some key questions food and beverage manufacturers are trying to answer are:

• How do I address the fluctuating price and availability of commodities?
• How do I reduce my energy and other utilities costs and ensure the long term availability of these resources?
• How do I find and evaluate new technology that will support innovation and speed time-to-market?
• How do I find and evaluate technology that will improve my manufacturing efficiency and effectiveness?
• How do I come up with new ideas or equipment that allow multi-tasking and that can reduce change over time?
• How do I reduce my manufacturing cycle time?
• What are the best metrics to support future manufacturing requirements?
• What are the leading best practices in the industry, in manufacturing in general, for sustainable manufacturing?
• What is my competition doing?
• How do I support my ever expanding manufacturing and business automation systems and networks?
• What are other companies doing to improve the skill sets of their operators and staffs?