Automation in the Food Industry Automation in the Food Industry Edited by C.A. MOORE B.Sc., C.Eng., FlEE Divisional Director - Engineering AMEC Design and Construction Ltd. Stratford-upon-A von Blackie Glasgow and London Published in the USA by avi, an imprint of Van Nostrand Reinhold New York B1ackie and Son Ltd Bishopbriggs, Glasgow G64 2NZ and 7 Leicester Place, London WC2H 7BP Published in the United States of America by AV I, an imprint of Van Nostrand Reinhold 115 Fifth Avenue New York, New York 10003 Distributed in Canada by Nelson Canada 1120 Birchmount Road Scarborough, Ontario M I K 5G4, Canada 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 ISBN-13: 978-1-4615-6510-9 e-ISBN-13: 978-1-4615-6508-6 DOl: 10 .1007/978-1-4615-6508-6 © 1991 Blackie and Son Ltd Softcover reprint of the hardcover I st edition 1991 First published 1991 All rights reserved. No part of this publication may be reproduced. stored in a retrieval system. or transmitted. in any form or by any means- graphic, electronic or mechanical, including photocopying. recording, taping - without the written permission of the Publishers British Library Cataloguing in Publication Data Automation in the food industry. 1. Food. Processing. Use of automatic control systems I. Moore, C.A. (Colin A.) 664.02 Library of Congress Cataloging-in-Publication Data Automation in the food industry / edited by C.A. Moore. p. cm. Includes bibliographical references and index. 1. Food industry and trade-Automation. I. Moore. c.A. (Colin Anthony), 1952- TP372.8.A88 1991 664----dc20 91-164 CIP Phototypesetting by Thomson Press (India) Limited, New Delhi Preface This book is designed to be everything its title suggests-a practical guide to automation within the food industry. It is the first book to offer practical advice on what can be a most bewildering subject in an industry where the use of effective automation is of paramount importance. There are many books dealing with the theory and practice of control systems in both the food and other industries. However, these tend to offer too much detail in both areas to be classed as overviews, or cover too much of the more obvious detail and gloss over, or avoid, the elements where the decisions are hard-even though these are the areas which are fundamental to successful and expansive projects. This book identifies those elements of any automation scheme which have to be considered first, and that form the foundations for any successful project. The editorial introduction outlines the content of the book and is a useful starting point. Examples are used, wherever possible, to show what can be done, how it can be achieved, and what to avoid. A glossary of definitions is included at the end of the book. All the chapters have been written by engineers, with many years' experience in this field, who have been able to express their views freely. The result is a book which covers the key areas of the subject, using a minimum of the technical jargon with which this subject abounds, in a readable, practical manner. This book is intended for process engineers, electrical engineers and food technologists working in the food industry. It will also serve as an essential source of reference for production managers considering the purchase of new equipment. Acknowledgements I would like to pass my sincere thanks to all the contributors who have put in many hours of hard work to make this book not only possible but also useful. It is their breadth of knowledge and real engineering experience which makes their chapters valuable and enables this book to meet the objectives established right at the start. I must also express my gratitude to AMEC Design and Construction Ltd. who have tolerated the inevitable disturbances that editing this book has created, and I thank them for their support during this venture. C.A.M Contributors Ian M. Baker AMEC Design and Construction Ltd., Timothy's Bridge Road, Straiford-upon-Avon, Warwickshire CV37 9NJ. Ian Baker has gained his wealth of experience in roles directly connected with the design and implementation of electronic or microprocessor based control systems in the food and beverage industry. After completing his engineering apprenticeship with a company in the Marryat Group he became an Application Engineer with them until 1975. He progressed from this to become Chief Application Engineer, then Commercial Manager and Sales Director with Systems Integrators, and Sales Manager for a leading UK programmable controller manufacturer. Projects he has been involved with in the food and beverage industries include milk pasteurisers, kegging and bottling lines, brewhouse automation, chocolate and meat products using programmable controllers and supervisory computers. In addition to food industry experience he has worked on control systems in chemical process, materials handling and has extensive experience in the motor industry. Tony Dodd Expert Systems Limited, Unit 12, 7, West Way, Oxford OX2 OJB. Tony Dodd read Mathematics and Philosophy at Oxford and then spent the years 1973 to 1978 doing research into set theory, gaining an M.Sc. in 1974 and a D.Phil. in 1978. From 1978 to 1983 he was a research fellow first of New College and then of Merton College in Oxford. He published a monograph on constructible sets in 1982. He first became interested in computing while doing research in logic and developed an interest in the theory of formal languages and compilation. He joined Expert Systems Ltd. (as it then was) in 1983 to work on Prolog-l. In 1984 he designed and led the implementation of Prolog-2, and in 1985 became Technical Director of the company. He led the design team that produced the Prometheus expert system shell, is an active member of the BSI Prolog standardisation committee and secretary of the UK Association for Logic Programming. His book 'Prolog: a logical approach' is due to be published by OUP in 1990. In 1989 Tony joined Chemical Design Ltd. as Expert System Product Manager, and early in 1990, together with three other employees, set up Expert Systems Ltd., of which he is Chairman and Managing Director. Tom W. Greeves Cambridge Consultants Limited, Unit 3, Lighting Way, Alvechurch Road, West Heath, Birmingham B31 3TH. Tom Greeves is a Director of Cambridge Consultants (Systems Engineering) Ltd. based in Birmingham, UK; a division of Cambridge Consultants Ltd. of Cambridge. Tom has degrees in Mechanical and Electrical Engineering from Queen's University, Belfast, and an Open University degree in Mathematics and Electronics. After a short period with Rolls-Royce in Derby he moved to Cadbury Ltd. in Birmingham where he held a number of senior positions including the management of large projects for the viii CONTRIBUTORS introduction of new plant and processes, running the facility for the development of new processes for existing and new products, having responsibility for in-house engineering research and development, and setting up and running a corporate systems engineering department with a special remit for packaging systems. In 1987 Tom and a senior colleague completed a buyout which gave Cambridge Consultants majority ownership of the Systems Engineering unit and has enabled the team of mechanical, electrical and software engineers to gain experience of solving production problems in a variety of industries, especially in consumer orientated industries such as food, confectionery, pharmaceutical and health care. Tom is able to draw on some 35 years' industrial experience. John Holoway Dowty Systems Integration Ltd., Marshfield, Chippenham, Wiltshire SNI48NN. John Holoway is a Principal Consultant with Dowty Systems Integration Ltd. Current duties include responsibility for IT Strategy Development Feasibility Studies and Integration Consultancy with particular emphasis on the management of information flows within distributed or service critical environments. Formerly a leading Consult ant with Logica Energy and Industry Systems Ltd., and the Managing Director of an in-house systems company associated with a major multi-national air express organisation, he has worked within the IT industry for over twenty years. During this time he has been associated with leading edge technology in such diverse applications as graphic arts, office automation, telecommunications, and logistics systems. He has concentrated on developing practical methods of implementing Integration Inform ation Systems in the food and pharmaceutical sectors. lain A. Lindsay Allen Bradley, Denbeigh Road, Bletchley, Milton Keynes MKIIEP. lain Lindsay graduated from the University of Bath in 1981 where he specialised in Systems Engineering disciplines. During time spent working in various system engineering roles for the Dowty Group and General Electric (USA) he gained experience of automation in a wide range of industries. In 1988 he joined the Systems Engineering Division of Allen Bradley where he is currently Technical Manager. Derek Mack GEC Industrial Controls Limited, Kidsgrove, Stoke-on-Trent, Sw{ fordshire ST7 ITW Derek Mack served an apprenticeship from 1960 to 1966 with the English Electric Company which later became one of the constituent companies of the General Electric Company. On completion of his apprenticeship he became a control engineer involved in the design of d.c. variable speed motor control equipment and also a.c. motor starter panels. The applications were concerned mostly with the heavy engineering industries. Following a period in the commercial world of sales and contracts he became a founder member of the GEM 80 Programmable Controller Division of GEC Industries Controls Ltd. concerned with both commercial and applications engineering. In this role he was involved in the engineering of programmable controllers across the whole range of industry including a number of applications in food processing. These covered various aspects of confectionery, brewing including maltings, beverages and milling. He is currently special assignments engineer for GEM 80 programmable controllers and is concerned with all aspects ofthe application ofthe range of GEM 80 controllers where unusual conditions exist or where special control activities are being under- CONTRIBUTORS IX taken. He has special responsibility within the company for the safety and reliability aspects of programmable systems and has presented various papers on the topic at seminars organised by HSE and the lEE. Colin A. Moore AMEC Design and Construction Ltd., Timothy's Bridge Road, StratJord-upon-Avon, Warwickshire CV39 9NJ. Colin A. Moore graduated in Control Engineering and spent a number of years with the British Steel Corporation engaged on all aspects of the design and construction of multi-discipline projects throughout the Steelworks Division. During this time he expanded his understanding of business operations by gaining a diploma in Account ing and Finance. In 1981 he joined IDC Limited where he became involved with the design and construction of electrical and control systems for major projects. He was directly responsible for the successful completion ofthese, a large number of which were within the food industry. He was appointed Divisional Director-Engineering in 1985, and in this role has assisted the company to strengthen its standing in the food industry in particular, and in other industries in general. In 1990 he became responsible for all Process, Control and Systems Engineering aspects within IDC Limited (now AMEC Design and Construction Ltd.) Hilkan Moran SattControl Automation AB, S-20522, Malmo, Sweden. Hiikan Moran is Marketing Manager for food-processing automation at SattControl AB, a member of the Alfa-Laval Group. He has specialised in applications for the food industry since 1980 and operates as a project manager as well as a systems engineer for a number of major installations. More than 20 years ago, SattControl designed the first PLC to be produced in Europe and has since established an international reputation as a market-driven innovator. The SattGraph operator system has recently been launched together with SattLine, a distributed system for integration of control systems at all levels. SattControl automation systems are used in the food and beverage industry for a wide range of applications, including grain mills, dairies, breweries, fruit-juice lines and meat-processing plants. Mauro Novaresio Fata Automation, 10152 Torino, Italy. Mauro Novaresio attended the University of Turin, where at the age of 22 he was awarded a degree in Computer Science following a dissertation about simulation. His first working experience was in the offices of Fiat in Turin. He then moved to factory automation and participated in some of the first innovating projects in both Northern and Southern Italy. His main role was the analysis of complex systems using the most advanced hardware/software technology for the automation of material handling lines and AS/RS systems. He has been in charge of the automation projects carried out by the FATA European Group in both the USA and USSR for over four years, and is involved in the preparation of the templates for the CIM projects. Furthermore, he coordinates the activities of the Group Task Force appointed to CAD/CAM development and CAD/simulator interfaces. Roger Pilkington AMEC Design and Construction Ltd., Timothy's Bridge Road, Straiford-upon-Avon, Warwickshire CV37 9NJ. After graduating from University College of Swansea in Electrical Engineering in 1973, Roger Pilkington joined Crompton Electricals and was involved in the design and x CONTRIBUTORS application of d.c. based control systems for electric vehicles. Upon completing four years with that company, he joined Thames Board Mills Ltd. and commenced his career in project engineering. At Thames Board Mills he was involved with the application of d.c. drives, a.c. motor control equipment and general electrical distribution schemes. During this time he was part of a large project team involved with the design and installation of a new card-board machine. He joined IDC Ltd. (now AMEC Design and Construction Ltd.) in 1984 as a Senior Engineer, working on control systems for process applications. He is currently Technical Manager, responsible for all the Control and Systems Engineering operations. Roger Pilkington has had considerable experience on food industry projects involving complex control systems. Derek J. Spencer GEC Industrial Controls, Kidsgrove, Stoke-on-Trent, Staffordshire ST71TW, Derek Spencer joined the English Electric Company as a technician apprentice in 1957, working in the Relay Development Laboratory on electronic distance protection. Later he joined Field Engineering to work on power-station commission ing and then computer-systems commissioning. Since 1968 he has been firmly committed to automation. He became Head of Engineering of the Automation Division at GEC Electrical Projects Ltd. in 1982 and Divisional Manager in 1984. In 1988 he transferred to GEC Industrial Controls Ltd., Kidsgrove as Manager of the newly formed Control and Process Systems Division. Contents Editorial introduction xvii 1 Introduction to food processing Tom Greeves 1.1 Introduction 1 1.2 Raw materials handling and storage 3 1.2.1 Categories of materials 3 1.2.2 Identifying incoming materials 4 1.2.3 Control and information requirements 5 1.2.4 Example of tank farm 5 1.2.5 Example of flour blending 7 1.2.6 Example of milk reception and storage with CIP system 9 1.3 Primary processing 11 1.3.1 Batch versus continuous processes 11 1.3.2 Modularity 12 1.3.3 Mixing 12 1.3.4 Evaporators and heat exchangers 13 1.3.5 Vacuum and pressure cooking 14 1.3.6 Variable flow rates 14 1.3.7 Effiuent 15 1.3.8 Dispensing and container handling 15 1.3.9 Shaping and forming 16 1.3.10 Example of a confectionery assortment 17 1.4 Secondary processing 18 1.4.1 Packaging systems 19 1.4.2 Machine control and coordination 20 1.4.3 Assembly automation 21 1.4.4 Example of confectionery assortment packing 22 1.4.5 Finished goods storage and despatch 23 1.5 Weighing and metering 24 1.5.1 Weighing 24 1.5.2 Metering 25 1.5.3 Example of a 'loss in weight' metering system 26 1.6 Summary 27 Further reading 2g 2 Total systems 29 John Holoway 2.1 Introduction 29 2.2 Current systems concepts 30 2.3 General requirements 31 xii CONTENTS 2.3.1 The pragmatic approach 31 2.3.2 Utilise existing technology 31 2.3.3 Identify measurable benefits 31 2.3.4 Commonality of use 32 2.3.5 Transfer of information 32 2.3.6 Utilise a modular platform 32 2.3.7 Resilience 32 2.3.8 Adaptability and expandibility 33 2.3.9 Use industry recognised vendors 33 2.3.10 Maintainability 33 2.3.11 Allow for external factors 33 2.4 Food processing industry issues 33 2.4.1 Conversion factors 34 2.4.2 Quality 34 2.4.3 Safety 34 2.4.4 Cost 35 2.4.5 Repeatability 35 2.5 Manufacturing process system 35 2.5.1 Pre-production issues 36 2.5.2 Production issues 36 2.5.3 Post-production issues 36 2.6 Total systems 37 2.6.1 Functional blocks 38 2.6.2 Method of implementation 38 2.6.3 Benefits of total systems 38 2.6.4 Engineering the facility 39 2.6.5 Training and education 39 2.7 Examples of total systems approach 40 2.7.1 Example 1: the design phase 40 2.7.2 Example 2: the planning phase 42 2.7.3 Example 3: the implementation phase 44 2.8 Summary 46 Further reading 47 3 Integrated factory systems 48 Mauro Novaresio 3.1 Introduction 48 3.2 Integration objectives 48 3.3 Integration phases 49 3.4 Process control and factory automation 52 3.5 Human interface 57 3.6 Summary 57 Further reading 58 4 Specification for success 59 Roger Pilkington 4.1 Introduction 59 4.2 Control system concepts 59 4.3 Hardware requirements 63 4.4 Software requirements 66 4.5 Case studies 70