automatic control of coconut milk production
TRANSCRIPT
Automatic Control Of Coconut Milk Production
Laura Duque Vélez - [email protected] Miguel González Botero – [email protected]
Martin Llano Botero - [email protected] Luis Miguel Mesa Ruiz - [email protected]
David Russi Botero - [email protected] and Camilo Villegas Jiménez – [email protected]
I. INTRODUCTION
Tropical Milk is a company dedicated to the production
of coconut milk in glass containers. Our product is aimed
at lactose intolerant families, who have a taste for natural
drinks, with no artificial flavor and that can be served straight
to the table. Raw coconut enters our production line, goes
through certain automated steps, and leaves as a tasty bottle
of coconut milk. Our company produces (200?) bottles of
1000 mL, daily (on average). Tropical Milk is the first
Colombian company that has a 100 percent automated plant
in all its processes with the help of seven operators, of
which one supervises the machines compared to the other
companies where you might have more than 20 people
actively working on the production line.
Problems that come along with an automated plant, in-
clude mistiming of conveyor belts, coordination between sub-
processes, failure in detection when it is required, amongst
others. The objective when creating this automated plant,
is to overcome these problems and deliver a highly precise
production line with minimal waste of time and great effec-
tiveness. This will be done through the study of the process
and the implementation of several Programable Logic Con-
trollers (PLC) all throughout it, severe testing and correction
of each of the automated subprocesses, and constant control
in order to receive feedback regarding production times and
effectiveness in case any corrections or improvements need
to take place.
Every step throughout the entire process will be auto-
mated, starting when the raw coconuts are place at the
beginning of the line. This includes the cutting of the pulp,
the cleaning, grinding, crushing, squeezing, pasteurizing,
bottling, labeling, and finally, packing of the final product.
The intention is to increase productivity regarding the pro-
duction of coconut milk. It is very common to see plants that
might be too “handmade”. With an automated plant, one can
increase its daily production, meaning one can increase daily
profits. With the implementation of sensors, actuators, DACs,
and PLCs (all discussed later in the report), the so desired
automated coconut milk production plant will come to life.
Up next, you will find a clear breakdown of the entire
plan to make this plant a reality. Different sections in this
report include the description of our general and specific
processes, the instrumentation used, and our entire protocol
for the plant.
.
II. PROCESS DESCRIPTION
A. Flowchart
B. Layout
C. Productive Process
The production process consists of the following steps:
Coconut endosperm (pulp) reaches the plant in bags. Using
a forklift, they get off the truck and are placed in a hopper,
which unloads the raw material into a band that leads to a
refrigerator. Thisis meantto keep the pulp refrigerated while
production is notoperating. Once they leave the refrigerator,
an operator is responsible for unpacking the pieces of pulp
from the bags and releasing them on a conveyor belt.
The pulp is washed withperaceticacid and also in a steam
cleaning machine. Once cleaned and disinfected, it enters a
crushing machine and then a grinder. Consequently, it enters
a compression extractor of the grindedpulp, with coconut
milk and bagasse being separated. Then they enter a tank
where mineral water, sugar and preservatives are added. The
milk goes through a filtering process, in which the bagasse
and milk are separated again with their ingredients, the
bagasse is stored and the milk enters a tank with a specific
amount of bagasse. The remaining bagasse after filtering is
stored in a container and then sold as raw material for other
food products. Thenthe milkenters the last filtering process,
in which we finish with the coconut milk as such, which
enters the pasteurization process to eliminate the pollutants
and continues towards a storage tank at8 degrees Celsius.
Finally, the product enters the bottling and labeling process.
After this, the product ispacked and ready for distribution
and consumption.
D. Subprocesses
1. Fridge: Pulp bags are stored here.
2. Automatic washing with peracetic acid: Bath in per-
acetic acid to eliminate bacteria.
3. Steam cleaning machine: Inlays dirt present in the pulp.
4. Coconut crushing machine: Splits the pulp into small
pieces.
5. Grinding machine: Turns the pulp pieces into shred.
6. Compression extracting machine: Presses the pulp
shred, turning it into bagasse and coconut milk.
7. Bagasse storage: After the compression extracting ma-
chine, the bagasse and the milk are separated and the bagasse
goes to a storage tank.
8. Mixing tank: Exact cuantity of Bagasse, coconut milk,
mineral water, sweetener and preservatives, begin a homog-
enization process.
9. Filtering: Separate milk from bagasse.
10. Used bagasse storage: After filtering, the used bagasse
goes to a tank that store it for another use.
11. Pasteurization: The milk is heated to 80 degrees celsius
and rapidly cooled to eliminate microorganisms present.
12. Chiller tanks: milk is stored at 8 degrees celsius.
13. Bottling: Finished milk is bottled.
14. Labeling: Bottles filled with coconut milk are labeled
and ready.
15. Stacking: bottles are piled up in specific quantities.
16. Packing: the bottles after being piled up are packaged.
17. Final storage: the bottles are ready to go.
E. Location argument
The way the plant is arranged was designed in order
to fulfill requirements such as saving space, follow the
specific order to the production of the coconut milk, and
allow controlling operators to access machines in case of an
eventuality. If we take a look at the plant layout above, it is
clear that all the machines are confined in a not so massive
space, which means the costs of construction for the building
will be lowered and the monitoring times will be reduced.
Below, we can see a 3D reference image of the entire plant.
F. Processes and Subprocesses Illustration
III. INSTRUMENTATION
A. SCADA Diagram
B. Actuators and Sensors Flowchart
C. PLCs
The number of PLC selected for the entirety of the
production line, is four. Reason being, the selected type of
PLC (FX3GE – 40 MR/ES) has a vast amount of digital
inputs and outputs. Each of the PLC’s used, can have up to
24 digital inputs and 16 digital outputs. This benefits us in
the sense that once combined, we dispose of 96 inputs and
64 outputs. We are able to control quite a good amount of
our process through each of these 4 PLC’s, making it pretty
segmented for us.
D. Actuators and Sensors Chart
E. DAC and ADC Converters
The 4 PLCs are specified with their intended use and
its digital input variables, the ADC systems are used to
convert the analog signals into digital, what subprocesses
are programmed in which PLC and what are the outputs.
F. Graphics
IV. PROTOCOL
A. Protocol Description and Steps
1. Hopper – Fridge: It is a fridge with a pulp reception
hopper on top. This unit has 4 actuators: A hatch for the
entry of coconuts into the refrigerator, another hatch for the
exit of coconuts to the conveyor belt, a light that indicates
when the refrigerator is full and a motor that turns on the
cooling system. For the input signals there are 6 sensors:
The presence sensor in the hopper that indicates when there
are coconuts in it to open the refrigerator’s inlet gate, the
maximum level sensor that turns on the light that tells the
operator that the refrigerator is full and that it should not
empty more coconuts, the maximum cooling temperature
sensor that tells the engine to start so that it reaches the ideal
temperature which is indicated by the minimum temperature
sensor, the start signal that tells the output gate to open so
that coconuts enter the conveyor belt 1 to start the process
and the stop signal that tells the exit gate to close.
2. Conveyor Belt 1: There is a presence sensor which tells
the engine to start.
3. Peracetic Acid Bath: It is a peracetic acid irrigation
system that has 3 actuators: An acid spraying solenoid valve,
a motor that moves the pump to increase the acid pressure
in the system fed from a tank and a tank level warning light.
This is a circulatory system. It has 5 sensors which are:
Presence to indicate to the solenoid valve to open to wash
the coconuts, some maximum and minimum pressure sensors
that tell the engine to maintain a certain flow of acid in the
pipe and some sensors of minimum level and maximum level
of acid in the reserve tank that indicate activates a warning
light if it is necessary to fill the reserve tank.
4. Conveyor Belt 2: There is a presence sensor which tells
the engine to start.
5. Steam Cleaning: In the steam washing system there
are 3 actuators: An electric heater to heat the water and
transform it into steam, a water filling valve and a steam
outlet valve. For the input of information there are 6 sensors:
The presence that indicates when the coconuts enter the
chamber to open the steam solenoid valve, the maximum and
minimum pressure sensors indicate the resistance whether it
has to turn on to generate steam, the minimum temperature
sensor indicates the resistance the minimum temperature it
must maintain in order to turn the water into steam, and the
sensors of maximum level and minimum level of water tell
the filling valve to open or close.
6. Conveyor Belt 3: There is a presence sensor which tells
the engine to start.
7. Crusher: There is a presence sensor which tells the
engine to start.
8. Grinder: There is a presence sensor which tells the
engine to start.
9. Conveyor Belt 4: There is a presence sensor which tells
the engine to start.
10. Compression Extractor: There is a presence sensor
which tells the engine to start.
11. Pipeline 1: The milk is transported through a pipe that
is driven by a motor pump, it turns on when the presence
sensor indicates it and turns off when the maximum pressure
sensor activates.
12. Conveyor Belt 5: There is a presence sensor which
tells the engine to start.
13. Bagasse Storage 1: It has a maximum level sensor that
turns on a light informing that it is filled.
14. Pipeline 2: The milk is transported through a pipe that
is driven by a motor pump, it turns on when the presence
sensor indicates it and turns off when the maximum pressure
sensor activates
15. Mixing tank: In the milk mixing system there are 7
actuators that are: The motor, the ingredients input solenoid
valves, and the mixture outlet solenoid valve. For this unit
there are 2 sensors that are: Minimum level that indicate
that they can open the ingredients input solenoid valves,
the maximum level sensor that indicates that these solenoid
valves are closed and that the engine is turned on, and it
receives a signal from a timer so that it turns off after a
certain time and the mixing outlet solenoid valve is opened.
16. Pipeline 3: The milk is transported through a pipe that
is driven by a motor pump, it turns on when the presence
sensor indicates it and turns off when the maximum pressure
sensor activates.
17. Filtering: The mixture falls into a strainer which has
a maximum bagasse weight sensor that tells the engine to
move the mechanism to empty it in bagasse storage 2.
18. Conveyor Belt 6: There is a presence sensor which
tells the engine to start.
19.Bagasse Storage 2: The bagasse arrives through con-
veyor belt 8, a presence sensor informs the pneumatic
solenoid valve 1 to activate the passage of compressed air
to the hydraulic piston of gate 1 to enable the entry of the
bagasse for storage.
20. Pipeline 4: The milk is transported through a pipe that
is driven by a motor pump, it turns on when the presence
sensor indicates it and turns off when the maximum pressure
sensor activates.
21. Pasteurization: It has 3 actuators: a filling valve, an
output valve and an electric resistance. These are operated
under the information of 5 signals that are: minimum level
that indicates that the tank is filled, a maximum level
that indicates that the filling is stopped, one of minimum
temperature that indicates that the resistance should turn on
and one of maximum temperature that indicates that the
resistance should turn off, and a timer that indicates that
the outlet solenoid valve is opened.
22. Pipeline 5: The milk is transported through a pipe that
is driven by a motor pump, it turns on when the presence
sensor indicates it and turns off when the maximum pressure
sensor activates.
23. Chiller Tank: There are 3 actuators: A filling valve,
and exit valve, and an engine of a cooling system, which is
operated under the information of 5 signals that are: mini-
mum level that indicates that the tank is filled, a maximum
level that indicates to stop filling the tank, one of minimum
temperature that indicates that the engine is turned off and
one of maximum temperature that indicates that the cooling
engine is turned on and a timer that indicates that the outlet
solenoid valve is opened.
24. Pipeline 6: The milk is transported through a pipe that
is driven by a motor pump, it turns on when the presence
sensor indicates it and turns off when the maximum pressure
sensor activates.
25. Bottling Process: There is a pipe that maintains a
maximum pressure, when the pressure sensor detects a bottle,
it tells the filling solenoid valve to open, therefore the
pressure decreases when the minimum pressure is activated,
the motor pump starts and turns off when it arrives at
maximum pressure.
26. Conveyor Belt 7: There is a presence sensor which
tells the engine to start.
27. Labeling Process: There is a presence sensor which
tells the engine to move a mechanism that prints the label
on the package.
28. Conveyor Belt 8: There is a presence sensor which
tells the engine to start.
29. Pile Up: There is a mechanism that is moved by a
motor that is activated with a presence sensor.
30. Conveyor Belt 9: There is a presence sensor which
tells the engine to start.
31. Packing: There is a mechanism that is mobilized by
an engine which is activated with the presence sensor.
32. Conveyor Belt 10: There is a presence sensor which
tells the engine to start.
33. Final Storage – Fridge: It is a fridge. In this unit there
are 3 actuators: A gate to enter the refrigerator, a light that
indicates when the refrigerator is full and an engine that
turns on the cooling system. For the input signals there are
3 sensors: The maximum level sensor that turns on the light
that indicates that it is already at its maximum capacity, the
maximum cooling temperature sensor that tells the engine
to turn on so that it reaches the ideal temperature which is
indicated by the minimum temperature sensor.
B. Function Blocks
C. MEFs
D. Undefined Variables
E. Notation
The ¡ symbol is used to indicate that the variable is to
be negated. The + and * signs indicate disjunction and
copulative conjunctions.
V. IMPLEMENTATION
A. MEFs Implementation in the PLCs
B. PLC Folder Guide
In the Coconut Milk MEFs folder, you will find the
different programs for the operation of each machine in its
respective PLC. When you enter the GX-WORKS Software,
the project button is selected and you go directly to the
Global where all the general variables that enter and leave the
Function Blocks are written, similar to a black box. Inside
the POU folder, there is an option called “program”, in which
the created function blocks are added. Each Function Block
has its inputs and outputs.
If you want to see what makes up the programming of
each Function Block, go to the User Library module, where
the PLC’s are distributed, in which each Function Block will
be located, that is, each machine it represents. When PLC1 is
selected, the “Program” part and Local Labels are displayed.
The Program section describes the internal programming of
each function block and each machine. In the “Local Label”
part, the input and output variables, and the states that make
up each function block and each variable that is described
in the program were entered.
C. Screenshots
Conveyot Belt
Pipieline
Steam Cleaning
Crusher
Grinder
Compression Extractor
Bagasse Storage
Chiller Tank
Pile Up
D. IHM
VI. CONCLUSIONS
After completing this progress report, one realizes the
great magnitude of research that had to be performed in
order to have a clear image of the entirety of the general
process and each subprocess. Each unit may differ from one
another and having a precise idea of how each one works,
may allow the programmers and controlling personnel to
identify problems (if any) in an effective manner.
Furthermore, after analyzing our production line proposal,
it can be inferred the idea has great potential for becoming
a real business. The area covered by the entire line is not
too big, the employees required are few, our product is in-
line with today’s tendencies, and the raw material needed is
achievable. This means costs will not be too high.
Finally, it is certain there is room for improvement along
the production line proposal. But then again, we are under-
going a learning process which will help us figure this out.
REFERENCES
[1] Production process video:https://www.youtube.com/watch?v=W8YqTMmFUc
[2] Lewin, Jo. “¿Cuáles Son Las Bondades De La Leche De Coco?” BBC NewsMundo, BBC, 7 Dec. 2014,
www.bbc.com/mundo/noticias/2014/12/141202bondadeslechecocof indedv[3] “Datos Técnicos .” Datos Técnicos - Mitsubishi Electric Factory Automation
- Spain,es3a.mitsubishielectric.com/fa/es/shared/img/producttables/2PLCmainunit
FX3GFX3GEFX3GC.
[4] Sensores Fotoeléctricos. www.fegaut.com/es/productos/sensores-de-presencia-sensores-fotoelectricos/2-9/.
[5] Electrovalvulas. ph.parker.com/co/es/solenoid-valves.[6] Pressure Transmitters. www.te.com/usa-en/products/sensors/pressure-
sensors/pressure-transducers.html?tab=pgp-story.[7] Temperature Sensors. www.smith-systems-inc.com/products/temperature-
sensors/.[8] Indicator Lights. www.xindali.com/a/il/.[9] “Motores Eléctricos De Corriente Alterna AC.” Motores Electricos y Mo-
torreductores Moverica, www.moverica.com/motores-electricos/corriente-alterna.
[10] “Exportando Un Gráfico o Tabla De LabVIEW a UnArchivo De Imagen.” Exportando Un Gráfico o Tabla DeLabVIEW a Un Archivo De Imagen - National Instruments,knowledge.ni.com/KnowledgeArticleDetails?id=kA00Z0000019SPLSA2l=es-CO.
VII. ANNEXES
In the leche-coco folder there is a file called A.1, which
contains all the attachments for the realization of this report.