01 trust in quality - endress+hauser · • time saving in phase shift operations more up time for...
TRANSCRIPT
10/10/2018
Products Solutions Services
Trust in quality
Focus on the Food & Beverage industry
Slide 1 JG
10/10/2018
From process
Trust in quality
to instrumentation
Slide 2 JG
10/10/2018
The 3 pillars of hygienic instrumentation
Trust in quality
The instrument should not effect the process
The instrument should not effect the cleaning
The process and the cleaning should not
effect the instrument
Hygienic instrumentation
Slide 3 JG
10/10/2018
Typical conditions for instruments in Food
• Cold standard is around 0°C, down to -80°C
• Hot 120°C production, Cleaning around 90°C, Sterilization up to 150°C
• Caustics around 2% between 55 and 90°C
• Acid below 1%, mostly cold use, can be up to 60°C
• Dust in silo areas and dry dosing
• Vibrations at any pipe due to pumps and valves
• Water and condensate anywhere anytime
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Slide 4 JG
10/10/2018
Products Solutions Services
Hygienic Design
Ensuring food safety
Slide 5 JG
10/10/2018
Benefits of hygienic design
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• The safety and quality:
• Less danger or product mixing
• Less microbiological threats
• The costs:
• Time saving in phase shift operations more up time for production
• Less mixed phases less product losses, less waste load
• Less chemical use in CIP less direct costs and less waste load
• Lower temperatures needed to heat up really everything direct cost
• Faster cleaning more up time for production
• Research in the TUM* showed reductions in cleaning efforts of more then 30% if hygienic design is used
*Technical University Munich
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10/10/2018
Is this hygienic?
DRD Welding adapter
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JGSlide 7
10/10/2018
Trust in quality
Hygienic design and the impact on cleaning
Shadow Dead end zones
Extensions Reduction
Slide 9 JG
10/10/2018
Example: Microbiological danger in processes
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• What sizes are we talking about?• dirt • germs • bacteria
µm
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
-0
human hair100 µmBiofilm, made of fat,
solids, yeast70µm
Du
st
50
-60
µm
fat
bu
bb
les
2-1
2µ
m
Fin
ge
rpri
nt
10
µm
Yea
st
5-1
0 µ
m
Ba
cte
ria
1
-6 µ
m
Pro
tein
s 3
µm
E-C
oli
1
µm
Slide 10 JG
10/10/2018
Trust in quality
Organizations taking care of hygienic processes
• What has an effect?
• Material
• Surface
• Design, inside and housings
• Installation
European /American organizations
Cleanability Material Construction
Slide 11 JG
10/10/2018
Trust in quality
European certificates
• European Hygienic Engineering and Design Group founded in 1989.
• It is a consortium of:
• equipment supplier
• the food industry
• research institutes
• public health authorities
• Target is to improve the safety and performance of food plants
• by the use of dedicated equipment.
• The EHEDG supplies test for different purposes
• The most important is the one about clean ability
• This test is supplied in the Netherlands by the TNO
• Certified equipment is listed on the www.ehedg.org page
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10/10/2018
EHEDG Certification
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• EHEDG evaluates and certifies instruments for the food industry
• Cleaning
• Soiling
• Cleaning CIP
• Verification
• Inspection
• Certification
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10/10/2018
Hygienic Process connections
• Dairy Connection acc. to DIN 11851
• Aseptic connection acc. to DIN 11864
• SMS - connection
• DRD Welding adapter
• Varivent connections
• APV connections
• Welding adapter for Deltapilot S
• ++++
• Tri-Clamp acc. to DIN 32676/ISO 2852
• NEUMO BioConnect & Aseptic
• Welding adapter „F“ for Liquiphant
• Process connection DN 25 Ingold
• I - Line Clamp - Fitting ; Cherry Burell
• Rosemount/Foxboro tank spud
• KingGage / Anderson Tank Spud
• ++++
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Slide 14 JG
10/10/2018
Example: Microbiological danger in processes
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Heating phase Cooling phase
Expansion Contraction
Microorganism
• O-Ring far from the process: • Danger of reservoirs for product and micro organisms.
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10/10/2018
Hygienic Construction: Seals
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Fixed by hand
Fixed by tools
gap
Weak points for hygienic
Milk pipe connection (DIN 11851)
Hygienic
T-ring screwing(ISO 2853)
centering
stop
no deep gap.
Slide 16 JG
10/10/2018
Trust in quality
Endress+Hauser hygienic design
• All hygienic rated sensors in Endress+Hauser follow the requirements of the named
standards and can be supplied with the relevant certificates
• We look for open, wide and well treated surfaces < 0,8µm
• 316L used as standard for wetted parts
• No dead corners, no edges
• We offer hygienic rated process connection
• We supply the necessary information for best installation positions
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Products Solutions Services
Core processes in the food and beverage industry
• Applications and instrumentation
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10/10/2018
Products Solutions Services
Raw material reception
• Monitoring volume flow and raw material
quality
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10/10/2018
Raw material reception
• Monitoring the quality and quantity of material flows in the process
starts from the moment the raw materials are received
• This area of the facility is of particular importance as it directly
influences calculation of the facility's output
• Efficient and extremely reliable measuring technology are thus
required in this area
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Slide 20 JG
10/10/2018
Monitoring of volume- and mass flow
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t-mass F, I
Promass F,
A, I, E, H, S,
Dosimass
Prowirl W, F
Prosonic Flow
W, P, U, C
Proline –Simply clever
The transmitter platform meeting
your demands
Promag W, P, H,
Dosimag
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10/10/2018
Proline – Simply clever
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Data storage concept
Operation concept (HMI)
Seamless system integration
W@MHeartbeat Technology™
Web server
Simply unforgettable
Device operation and data access made easy
Device integration independent of fieldbus
technology
Simplicitythrough uniformity
For efficient life-cycle management
Reliable self-monitoring for all Proline measuring
technologies
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10/10/2018
Promag H 100 – the hygienic flow meter
Trust in quality
• Compact design for easy skid integration
• Seamless system integration
• Multi variable measurements of volume,
temperature and conductivity
• Meets all hygienic requirements (3A,
EHEDG)
• Temperature rating of 150 °C and process
pressure up to 40 bar
• High measuring accuracy
• CIP/ SIP cleanable
Promag H is the preferred sensor for applications with highest requirements in the food and life science industries. Best measuring performance even under harsh process and environment conditions is ensured by solid sensor design and edge cutting digital signal processing.
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10/10/2018
The new Picomag
DMA 15/20/25
DMA 50
–10 to +70 °C
2 free configurable outputs incl.
Measuring accuracy: ±2% o.r + 0.5% o.f.sRepeatability: ±0.2% o.f.s
Flow and temperature measurement
No service needed
Stocked product
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Slide 24 JG
10/10/2018
Innovative technology
Intuitive commissioning and operation via SmartBlue App
User-friendly and auto-rotatable display
Knock functionality
• Knock 1: Overview of configured parameters
• Knock 2: Change Bluetooth status ON
Trust in quality
Slide 25 JG
10/10/2018
Promass S 100 – the sanitary flow meter
• Multivariable flow measurement in compact design
• Measurement of mass flow, temperature and density
• Meets all hygienic requirements (3A, EHEDG)
• CIP/ SIP cleanable and piggable
• Easy installation without taking inlet and outlet
runs into consideration
• Ultra compact design foreasy skids integration with
IP69K rating
• Seamless system integration
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Promass S is the preferred sensor for the food and beverage industry. It is an industry-optimized sensor design capable of handling the stringent CIP/SIP processes offering one single instrument for multivariable measurement.
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10/10/2018
Trust in quality
Promass Q
Slide 27 JG
10/10/2018
Multi-Frequency Technology
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Slide 28 JG
10/10/2018
Trust in quality
Applications for Promass Q
Food & Beverage
Density/concentration measurement
Milk loading/unloading
Ice cream and other “whipped” products
Starches/pastes/high viscous foods
Binders/soaps/detergents (LS)
Repeatability specification±0.025% “out of the box” without need for any optional calibrations.
Density specification±0.2 kg/m3 “out-of the box” without the need to purchase “Special Density Calibration” nor to perform a “Field Calibration”
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10/10/2018
Ceramax CPS341D pH Measurement
• Long-term stability over many years
• Hygienic design: Suitable for cleaning in place (CIP) and
sterilization in place (SIP)
• High mechanical stability due to pH-sensitive enamel
on a steel carrier
• Insensitive to soiling thanks to large pH measuring
surface
• Maximum process safety through non-contact inductive
signal transmission
• Enables predictive maintenance due to storage of
sensor and process-specific data
• Reduced operating costs due to minimized process
downtime and extended sensor lifetime
Trust in quality
Slide 30 JG
10/10/2018
Monitoring quality of raw material - Memosens
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• Inductive coupling between cable and sensor, no open contacts - no chance for moisture, salt bridges and corrosion.
• Bidirectional data transmission between sensor and transmitter. Transfer of energy to the sensor head by inductive principle
• Calibration data are stored in the sensor head directly, therefore allowing calibration in the laboratory.
• While operating, the sensor stores a numerous amount of different operational data in the sensor head for assessment and evaluation.
Inductive data transmission
Inductive energy transmission
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10/10/2018
Products Solutions Services
Storage management
• Level measurement
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10/10/2018
Storage management
• Good inventory management of raw materials and cleaning products
is key to the optimum control of production and supply
• The tanks must be equipped with reliable and accurate level
measuring instruments for this purpose
Trust in quality
Slide 33 JG
10/10/2018
The ideal solution for your measuring task
Trust in quality
Advantages 1GHz• Guided radar suitable for
applications involving foam and low dielectric constant values
• Interface measurement gas phase compensation, bypass applications
Advantages 6GHz• Strong condensate
generation, turbulences• Stilling well applications
Advantages 26GHz• Good focusing, suitable
for 90% of applications• Good in turbulences
Advantages 80GHz• Best focusing with 3°
emitting angle• Large measuring range
up to 125m• Highest accuracy up to
0.5mm (NMR81)
Slide 34 JG
10/10/2018
Level measurement measuring principle
Trust in quality
• Emission of ultrasound- or microwave-pulses
• Reflection of the pulses from the product surface
• Receiving of the reflected pulses
• Measurement of the Time of Flightcalculation of the distance between the deviceand the product surface by e
mit
tin
g
rece
ivin
g
00.40
2d = c
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10/10/2018
Products Solutions Services
Micropilot FMR10/FMR20
Radar steps into new dimensions !
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10/10/2018
Micropilot FMR10/FMR20 – Features
• Compact design
• Thanks to Endress+Hauser invented direct emitting radar chip
• Full PVDF body
• Ingress protection class IP 66, 68 / NEMA4x, 6P (FMR20)
• Hermetically sealed housing and wiring
• Fully potted electronics
• Large variation for process connection
• Flush mounted via screw-in / slip-over flange
• Hanging with screw-in flange
• Ceiling-/ wall mounting, hanging
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Slide 37 JG
10/10/2018
Possibilities for configuration and communication
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• Password prompt
• Device info
first page after connection
all relevant information in one view
Wireless remote access via SmartBlue app
• Live list
indication of reachable devices
quick view on device status, measured value and Bluetooth® signal strength
BT signal strength
device identificationstatus
measuredlevel
devices in range
device information device
status
measured
values
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10/10/2018
Micropilot FMR52 – non-contact level measurement
• For level measurement in aggressive liquids or applications with
hygiene requirements
Trust in quality
WHG
FMR52 – For highest hygienic requirements
• Flush mounted and gap-free design according to ASME BPE (CoC)
• Parts in contact with the medium are FDA-listedaccording to USP Class VI
• Hygiene process connections
• Proven biological compatibilityfor Micropilot or Levelflex
• Process temperature -40…+200°C/-40…+392°F
• Process pressure -1…+16bar/-14.5…+232psi
• Max. measuring range: up to 60m/197ft
• Accuracy up to ±2mm/0.078inch
• K-Band 26GHz
FMR52
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10/10/2018
• For aggressive media
• Available with protective coating (PFA)
• Flange or hygienic process connection: PTFE clad
• All wetted parts welded gapless and out of FDA listed materials
• Measuring range up to 45m (148ft)
• Temperature: -50…+200°C (-58…+392°F)
• Suitable for CIP/SIP cleaning
• Process connections: flange from DN40, Tri-Clamp, 11851
• Protection class IP69K withstands cleaning with high pressure hoses
Levelflex FMP52 – guided wave radar measurement
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Slide 40 JG
10/10/2018
Measurement signal reflections in solids
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Free emitted signal Guided wave radar signal
Slide 41 JG
10/10/2018
• FMB50
• Condensate resistant Contite
measuring cell
• For liquid and paste-like media in
open or closed containers and
unaffected by possible foam
formation.
Hydrostatic pressure measurement
• PMC51
• Exceptional long-term reliability
even in damp environments
• Dry, oil-free ceramic measuring
cell prevents contamination of
the process in the event of a
diaphragm rupture
• Membrane breakage detection
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Slide 42 JG
10/10/2018
Contite measuring cell: Metal vs. Ceramic
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Differential sensor(absolute tight)
Membrane for atmospheric compensation
Reference air tube
Reference air tube
compensate atmospheric
pressure
Dehydration module
Trap for moisture
Inner spiral reference air capillary
Acts as water trap
Slide 43 JG
10/10/2018
Additional information available:
• Level
• Differential pressure
• Head pressure
• Sensor temperature
Try something better and new –Deltabar electronic dp!
Proven established technologyutilized in a new innovative way
The save differential pressure measurement
Trust in quality
Slide 44 JG
10/10/2018
Products Solutions Services
Production preparation
• Detection of levels
Slide 45 JG
10/10/2018
Production preparation
• Components are filled into the production containers in this section
of production
• Filling must be monitored precisely to ensure that the container does
not overflow and to prevent the pumps from running dry
• It may be necessary during this production step to check the quality
of the components online, e.g. with density or viscosity measuring
devices
Trust in quality
Slide 46 JG
10/10/2018
Switch portfolio
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FTL33 FTW33 FTL5xH
LiquiphantLiquipointLiquiphantLiquipoint
FTW23
Water-based media without build-up
All liquids with light build-up
All liquids also with strong build-up
All liquids with light build-up
Allrounder SwitchClassic SwitchEconomic Switch Modular Switch
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10/10/2018
Liquipoint FTW33 – measuring principle
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Conductive & CapacitiveReliability & User friendliness!
• Liquipoint FTW33 uses a combined measuring principle.
• The sensor can compensate build-up, even non-conductive up to certain limits
Electrodes 316Lwith PEEK isolation
Guard ring
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10/10/2018
Proven-in-use build-up compensation
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Liquipoint FTW33
Very good build-up compensation over the entire application range, no product specific adjustments needed!
Slide 49 JG
10/10/2018
Liquipoint FTW33 – measuring range
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Slide 50 JG
10/10/2018
Products Solutions Services
Thermal treatment
• Reliable measuring devices guarantee optimum
process safety
Slide 52 JG
10/10/2018
Thermal treatment
• Thermal processes such as pasteurization are critical production
steps requiring very accurate monitoring and observation
• Only quality measuring devices fitted with the latest technology can
guarantee a high product quality measuring reliability and optimum
process safety all at the same time
Trust in quality
Slide 53 JG
10/10/2018
iTHERM® TM411: Hygienic temperature sensors
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Slide 54 JG
10/10/2018
Loop re-calibration without QuickNeck
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Mobile calibration bath
PLC
100.02 °CReferenceThermometer
100.02 °C1. Open terminal head2. Detach connection cable 3. Detach and remove insert4. Attach cable again for loop calibration5. Recalibration in oil bath6. Re-install insert again in reverse order
Time and cost intensive process Long downtimes Risk of damages, false connections, loss
of mounting parts, risk of water ingress
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10/10/2018
Loop re-calibration with new iTHERM® QuickNeck
Trust in quality
Mobile calibration bath
100.02 °CReferenceThermometer
Massive time savings, less downtime Cost savings No risk of damages, loss of parts,
water ingress or connection errors
1. Remove insert w/o tools. Just turn the head by 90° and pull it out!
100.02 °C
PLC
2. Recalibration in oil bath3. Re-install insert again in reverse order
Slide 56 JG
10/10/2018
iTHERM® QuickNeck – Patent pending
Trust in quality
0%
50%
100%
Therometer withstandard neck tube
iTHERM® QuickNeck
Recalibration costs / time
>50% saving potential!
Saving potential (sample calculation Europe)
• Average saving per calibration: ~20 minutes• Hourly wage of technician: ~60 €
→ Savings per calibration: ~20 €/sensor
Slide 57 JG
10/10/2018
Cerabar PMP23: New hygienic pressure sensor
Trust in quality
• Fully welded sensors ensures highest hygienic requirements
• To ensure a safe and most effective yield of production, the
specific hygienic design and surface roughness fulfills all
hygienic requirements, proven by EHEDG and 3-A
• The Cerabar PMP23 offers compliance to
• Regulation (EC) No. 1935/2004 on materials
• TSE all materials are free from animal origin
• FDA
• Our quality system fulfills the Regulation EC 2023/ 2006
(GMP), Traceability is given
• Cleanabilty from outside is given with a IP69K version, also
Ecolab testing has been successful performed
• An easy and fast cleaning through CIP or SIP is possible
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10/10/2018
Memograph RSG45: Audit-proof data storage
• High degree of data security: tamper-proof data storage of heating
process data and personalized access authorization with electronic
signature (FDA 21 CFR 11)
• Providing documentary evidence of an intact process and proof of
product safety
• Integrated web server means that operation, visualization and curve
presentation are not only possible onsite. The data can be made
available to all authorized personnel within the company via the
Ethernet output.
Trust in quality
Slide 59 JG
10/10/2018
Products Solutions Services
Cleaning and disposal
• Cleaning production facilities and reducing
material waste
Slide 60 JG
10/10/2018
Cleaning and disposal
• To ensure safety, processing systems must be kept clean and free of
undesired microorganisms
• At the same time it is important to minimize product loss
• Every liter of milk that gets into the wastewater not only reduces sales
revenue but also leads to additional costs in wastewater treatment
Trust in quality
Slide 61 JG
10/10/2018
CIP system Layout
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Slide 62 JG
10/10/2018
Trust in quality
Conductivity measuring instruments
Applications:
• Clean in Place (CIP) control
• Phase separation
• Bottle cleaning
• Product monitoring
Electrolytic conductivity
Capability of a liquid to conduct current.
This depends on the quantity of ions in the
liquid.
Liquiline CM44x with Indumax CLS54D
Compact instrument Smartec CLD134
Compact instrument Smartec CLD18
Slide 63 JG
10/10/2018
Trust in quality
OUSAF11: Optical measurement
• Hygienic and CIP/SIP-resistant design for for food applications
such as phase separation, interphase detection, etc
• Flexible installation: immersion sensor for open tanks and basins,
insertion sensor with Triclamp and Varivent connections for pipes
and vessels
• Low-voltage lamp for a long service life and stable operation
• Robust stainless steel body and fouling-resistant sensor head
• Up to two sensors with graphical transmitter Memograph CM44P
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10/10/2018
Trust in quality
Optical measurement – measuring principle
Wavelength l
Absorbance
Spectrometer:
Concentration
Absorbance at specificwavelength
Photometer:
A = ε · c · OPL
Slide 65 JG
10/10/2018
Trust in quality
OUSAF11 optical measurement: Minimizing product loss
The milk specialist
OUSAF11 with CM44P
Applications
• Milk detection in CIP solutions• Phase separation milk/water• Product loss detection in effluent
• Product loss in the waste water causes a lot of costs
• Costs due to product loss and higher waste water treatment costs
• A milk loss detection in the different effluents helps to determine
the product loss faster
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Products Solutions Services
Conclusion
• One partner for all your needs
Slide 67 JG
10/10/2018
One partner for all your needs
Trust in quality
• Products designed to be used
in hygienic applications
• Certificated hygienic design,
following EHEDG, 3A, FDA, EN 1935…
• A full basket of products compliant
to these international standards
• Single source instrumentation supply
for all areas, from utilities
and production to packaging
• Best support across the life cycle
from engineering right through
to calibration
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10/10/2018
Products Solutions Services
Thank you very much for your attention
One partner for all your needs
Slide 69 JG