food talkline cip and inventory

talkline

Issue 15 • Volume 9

Contains 100% pure safety and reliability.

Stay ahead in a competitive food and beverage marketPage 2 Save money with simple CIP enhancements Page 3 Rising commodity costs drive the need for better supply chain managementPage 4 Case study: poultry producer avoids surcharge and saves on chemical treatmentPage 5 Combined strengths: deliver real customer value through integrated architecture Page 6 How proper calibration positively impacts profit

�

CIP enhancements reduce costsSteps to plant cost reductions by simple enhancements to CIP systemMany food processors still operate Clean in Place (CIP) systems with little or no instrumentation, usually relying on a pure timing based process and manual verification of the CIP cycles. In an increasingly competitive market it is becoming a must to install real-time monitoring and control to improve process efficiency.

By incorporating some basic measurements, enhanced food safety and cost savings that go beyond the CIP system can be realized. For example: reduced down time for cleaning, reduced water and detergent usage, reduced detergent heating cost and less water to treat.

Examples of the primary measurements and their benefits:• Conductivity (% concentration) on return line - don’t run your system longer than required once at concentration. The results are less energy used for heating of detergent, less detergent used and potentially less water and wastewater. Savings compared to pure timing based system can be up to 30%. Endress+Hauser solution: Conductivity sensor CLS54/CLD134

• Temperature on return line - always required to verify cleaning. Use a high accuracy transmitter and keep it calibrated. Running only � to 5 degrees higher than required is a large unnecessary cost.Endress+Hauser solution: TH17/TH�7

• Magnetic flowmeter - run at optimized flow velocity to achieve best scrubbing action while managing power consumption of pumps. Endress+Hauser solution: Promag 50H

• Level and concentration of detergent in make-up tanks - know what is available before starting a cycle. Adding too much or too little affects the detergent’s efficiency. Endress+Hauser solution: Capacitance level sensor FMI51 and conductivity sensor CLS54/CLD134

• Recorder for easy retrieval of CIP records - a basic stand alone videographic recorder with Ethernet connectivity allows for simple verification on the plant floor while providing traceable records. Endress+Hauser solution: Memograph MMemograph M

CLS54

TH27

Promag 50H

FMI51

CIP - Return flow 1

CIP - Return flow 2

Make-up water

CIP- line 1

CIP- line 2

Sanitizer solution

Conductivity measuring for % concentration with CLS 54

Water To heat exchanger

DrainY

Conductivity measurement in the return flow with CLS 54

CausticAcid

�

Temperature measurement in the return flow

Promag 50H flow measurement

3

Inventory and supply chain managementRising commodities drives the need for real-time information

Accounting of bulk inventory kept in tanks and silos have traditionally not had high priority. This is particularly true for bulk material such as sugar, flour and grains. However, with the rapidly rising value of these commodities it is becoming more and more important to have a current status of inventory levels to allow for planning and advanced purchasing techniques.

Endress+Hauser can provide scalable, turnkey solutions for your plant with simple, local monitoring or full integration into your ERP system. Installation costs can be kept to a minimum using wireless solutions or Ethernet connection. Solutions are available for single or multiple site applications.

Inventory can be managed by traditional level measurement or mass-balance (in-out) of tanks using metering skids.

3

Internal Infrastructure - In Plant Monitoring

Ethernet/Land line/GSM/GPRSfor connection of remote location

Ethernet

Installation at our Customer location

Intranet/ERP Integration Data visibility

for our CUSTOMER

CIP - Return flow 1

CIP - Return flow 2

Make-up water

CIP- line 1

CIP- line 2

Sanitizer solution

Conductivity measuring for % concentration with CLS 54

Water To heat exchanger

DrainY

Conductivity measurement in the return flow with CLS 54

CausticAcid

�

Temperature measurement in the return flow

Promag 50H flow measurement

Typical application: Flour, grain, sugar, PET, oils, syrup, CIP chemicals

FMB70 Hydrostatic pressure

FMP40Guided radar

level

Promass 83FCoriolis mass flow

FMR250radar level

4

Poultry production Producer avoids $�5K surcharge and saves on chemical treatment

The problem:A poultry producer was facing a $�5,000 surcharge from the local municipality if they did not address the high amounts of solids in their wastewater. Their existing system to control the dosing of coagulants did not work satisfactorily which resulted in the waste of coagulants and frequent releases of high BOD/solid waste to the municipality.

The solution:By installing a simple system consisting of three Promag 50H electromagnetic flowmeters and three CUS31 turbidity sensors from Endress+Hauser, the dosing of coagulants to the waste bins were accurately controlled.

Added benefit: By avoiding the $�5,000 surcharge, the entire installation paid for itself. In addition, the chemical usage is now approximately �0% less than before, even though the plant has increased it’s throughput.

CUS31 Turbidity sensor

People forProcess Automation

Shop online for low-cost instruments, devices and components at:www.e-direct.us

Level

Pressure

Flow

Temperature

Liquid Analysis

Recorders

Components

Service

Solutions

5

Integration - get more from your instrumentationIntegration tools offer step-by-step guidance to ease installation of intelligent instrumentation and improve ability to visualize diagnostics

Endress+Hauser and Rockwell Automation offer preferred integration to reduce installation time and life cycle costs for process automation.

View integration manuals at www.rockwellautomation.com/solutions/process/integrationdocs.html

Increase value of investment • Access and monitor secondary/tertiary measurement variables such as temperature, density, min/max values, etc.Reduce downtime • With online diagnostics, let the instrument tell you how it is doing, allowing you to plan ahead. Upload and store configuration for faster unit replacementsLabor and time savings • Faster and less labor intensive start-up. Perform loop checks and configuration from control room (or remote office location)Safety • Access and troubleshoot instruments in hard to reach areasMinimize travel costs • Configure network for remote access and have your in-house or external expert access unit remotely

Endress+Hauser• Process instruments with 4-�0 mA HART® output. Most instruments include this as standard. Endress+Hauser also offers integration services for Profibus® and Foundation Fieldbus™. www.us.endress.com

Rockwell Automation• HART in-rack card model 1756-IF8H for ControlLogix or for other platforms - 1794 Flex HART I/O

Free integration manuals• Jointly developed by Endress+Hauser and Rockwell Automation to integrate the additional information provided by the instruments via HART. See link below

3 simple steps:

Value to you:

6

Maintenance and calibrationDriven by the knowledge that powers a global company.

Flow calibration rig, located in Greenwood, IN, is accredited to international standards and helps us respond to the fast delivery times that are sometimes required by our customers. www.us.endress.com/calibration

The benefits of calibration are not always recognized. Calibration is often associated simply with cost rather than it’s impact on profit.

Demonstrated below is an actual scenario researched in cooperation with a food processor where we see the potential impact of poor calibration on the bottom line.

Importance of calibration

Thanks to our numerous calibration laboratory and primary facilities, we have carried out more than one million calibrations. Above all we see our calibration service as part of your repair and maintenance planning. Our aim is to provide you with complete calibration management solutions. At the forefront of this is the tuning of calibration cycles, planning dates for carrying out calibration work, the coordination of personnel and certified calibration equipment.

Calibrationspecification

CalibrationSOPs

TestEquipment

Trained Employees

CalibrationWork

CalibrationDocumentation

Calibrationsoftware

1 2

3

45

6

7Circle of quality

calibration

Case study:UHT module for heat-sensitive products such as milk, milk products, formulated milk, soy, ice cream mixture, dairy deserts and extended shelf life (ESL) products.• Temperature transmitter indicates �84º F.• Actual temperature is �86º F.• �º F difference corresponds to 44 lb/h steam usage 44 lb/h x 5,000h x .046/lb = $10,1�0 per year loss

1Calibration specification - We will help you to assess your metrology plan by establishing your calibration specifications.

2Calibration SOPs - We offer a full range of Standard Operating Procedures to support on-site work.

3Test equipment - Local service centers provide a one-stop-shop calibration and repair service for a wide range of test, measurement and process control instrumentation.

4Trained employees - On site calibration is performed by specialized, highly trained staff to relieve your in-house maintenance staff from routine tasks.

5Calibration work - Our primary calibration facilities operate and are accredited to ISO/IEC 170�5.

6Calibration documentation - We support our service with certified and traceable documentation.

7Calibration management software - CompuCal™ is a high performance scheduling software tool for your installed base, providing traceable records for audits.

Mobile flow calibration cart for on site calibration helps you to reduce maintenance, shipping costs and more importantly, greatly reduces process down time.

7

Maintenance and calibration

Delays and production losses can far exceed the costs of planned start-up! A high percentage of instrument problems can be traced to start-up by unqualified personnel. These can be prevented by scheduling a trained Endress+Hauser service technician to be on-site during start-up.

Basic factory warranty is extended from 1 to 3 years when start-up is purchased on your instrumentation order. Ask for start-up to be quoted with your new instruments. www.us.endress.com/start-up

Technology is changing rapidly. Are you and your staff keep-ing up with the changes? We can help with schools designed to teach fundamental, theoretical, and practical knowledge about instrumentation and application technology, with an emphasis on service and maintenance of the instrumentation.

Training, combined with hands-on experience, is a powerful combination that will help you better manage your life cycle costs. To contact us for training schedules or to obtain a quote for on-site sessions, call 800-64�-8737 or visit us online.www.us.endress.com/training

Endress+Hauser’s Service Department is dedicated to keeping your plant working efficiently seven days-a-week, 24 hours-a-day. Technicians are located throughout the country to provide various levels of support for you and your instruments.

Service from Endress+Hauser

School of instrument maintenanceStart-up service

Preventative Maintenance AgreementsPlanned maintenance lowers costsTo ensure optimum performance and help extend the life of your instruments, our skilled service engineers perform periodic checks (including any necessary adjustments), and issue a report confirming the instrument’s performance. Additionally, we provide specific recommendations for maintenance of the equipment under the agreement.www.us.endress.com/contracts

Long-term maintenance offers more savingsThe Endress+Hauser Installed Base Audit (IBA) service provides a long-term plan to a more reliable operating plant, cost-effective maintenance, and gives a basis for complete life cycle management of your instrumentation.www.us.endress.com/IBA

7

CP994B/�4/ae/1.09AE/INDD CS

1.09/SC USA

ISO 9001:�000 Certified

Your local partner:

USA

Endress+Hauser, Inc.�350 Endress PlaceGreenwood, IN 46143Tel. 317-535-7138Sales 888-ENDRESSService 800-64�-8737Fax [email protected]

Canada

Endress+Hauser Canada1075 Sutton DriveBurlington, ON L7L 5Z8.Tel. 905-681-9�9�800-668-3199Fax [email protected]

Mexico

Endress+Hauser México S.A. de C.V.Fernando Montes de Oca �1 Edificio A Piso 3Fracc. Industrial San Nicolás 54030. Tlalnepantla de BazEstado de MéxicoPhone: +5� 55 53�1 �080Fax: +5� 55 53�1 �[email protected]

AlabamaTriNova, Inc.Mobile, AL�51-378-7837

TriNova, Inc.Bessemer, AL�05-4�6-0494

AlaskaArtic Controls, Inc.Anchorage, AK907-�77-7555

ArizonaIndustrial Automation ServicesChandler, AZ480-413-0899

ArkansasTriNova, Inc.Mobile, AL�51-378-7837

Endress+HauserHouston, TX713-300-6�00

M & D ControlsTulsa, OK918-664-7511

CaliforniaIPT GroupSan Francisco, CA415-8�4-3679

Process Instruments & Controls, LLCBakersfield, CA661-617-6000

ProFlow DynamicsCorona, CA951-�79-5500

Endress+HauserBrea, CA714-5�4-8391

FOR MUNICIPAL INDUSTRYMRC TechnologiesNewbury Park, CA805-498-3811

ColoradoBeabout CompanyLittleton, CO303-795-1000

ConnecticutKentrol/SEVCOWinslow, ME800-45�-19�8

DelawareEndress+HauserChalfont, PA�15-8��-4710

Philip R. Walker & AssociatesCockeysville, MD410-666-�14�

FOR MUNICIPAL INDUSTRYLRM Inc.Souderton, PA�15-7�1-4840

FloridaAMJ Equipment Corp.Lakeland, FL863-68�-4500

TriNova, Inc.Mobile, AL�51-378-7837

GeorgiaAMJ Equipment Corp.Savannah, GA91�-898-0388

HawaiiIPT GroupSan Francisco, CA415-956-9005

IdahoTourangeau Nor WesTualatin, OR503-691-6100

Weidner & AssociatesMidvale, UT801-565-9595

IllinoisAntel CorporationWillowbrook, IL630-887-8910

George E. Booth Co., Inc.Indianapolis, IN317-�47-0100

Miller Mechanical Specialties, Inc.Des Moines, IA515-�43-4�87

R.L. Weisheimer & Assoc.Columbia, IL618-�81-4148

IndianaGeorge E. Booth Co., Inc.Indianapolis, IN317-�47-0100

Antel CorporationWillowbrook, IL630-887-8910

IowaMiller Mechanical Specialties, Inc.Des Moines, IA515-�43-4�87

KansasCompass Controls and InstrumentationShawnee, KS913-441-9779

KentuckyGeorge E. Booth Co., Inc.Indianapolis, IN317-�47-0100

LH BolekyCoraopolis, PA41�-�64-07�9

LouisianaTriNova, Inc.Baton Rouge, LA��5-753-4�64

MaineKentrol/SEVCOWinslow, ME800-45�-19�8

MarylandPhilip R. Walker & AssociatesCockeysville, MD410-666-�14�

MassachusettsKentrol/SEVCO - OSISutton, MA508-865-5600

MichiganDurable ControlsHartland, WI�6�-367-4900

Forberg Scientific, Inc.Troy, MI�48-�88-5330

MinnesotaEngineered Sales CompanyBloomington, MN95�-888-1131

MississippiTriNova, Inc.Mobile, AL�51-378-7837

FOR MUNICIPAL INDUSTRYRieth CorporationGretna, LA504-36�-7604

MissouriCompass Controls andInstrumentationShawnee, KS913-441-9779

R.L. Weisheimer & Assoc.Columbia, IL618-�81-4148

MontanaBrock Easley, LLCBillings, MT406-�5�-1515

NebraskaMiller Mechanical Specialties, Inc.Des Moines, IA515-�43-4�87

NevadaIPT GroupSan Francisco, CA415-8�4-3679


MRC TechnologiesNewbury Park, CA805-498-3811

New HampshireKentrol/SEVCOWinslow, ME800-45�-19�8

New JerseyEndress+HauserChalfont, PA�15-8��-4710

FOR MUNICIPAL INDUSTRYDave HeinerAssociates, Inc.Parsippany, NJ973-�99-9990

LRM Inc.Souderton, PA�15-7�1-4840

New MexicoBeabout CompanyLittleton, CO303-795-1000 Industrial Automation ServicesChandler, AZ480-413-0899

Pan-Tech ControlsArlington, TX817-640-3�3�

New YorkBurnsCascade Controls & Instrumentation Syracuse, NY315-4��-0�61

Endress+HauserChalfont, PA�15-8��-4710

FOR MUNICIPAL INDUSTRYBurgh & SchoenenbergerPavillion, NY585-584-3768

Dave HeinerAssociates, Inc.Parsippany, NJ973-�99-9990

North CarolinaEndress+HauserCharlotte, NC704-969-7974

FOR MUNICIPAL INDUSTRYJohnston, Inc.Indian Trail, NC704-8�1-6777

North DakotaEngineered Sales CompanyBloomington, MN95�-888-1131

OhioForberg Scientific, Inc.Cleveland, OH�16-71�-6600

George E. Booth Co., Inc.Indianapolis, IN317-�47-0100

OklahomaM & D ControlsTulsa, OK918-664-7511

OregonTourangeau Nor WesTualatin, OR503-691-6100

PennsylvaniaLH BolekyCoraopolis, PA41�-�64-07�9

Endress+HauserChalfont, PA�15-8��-4710

Forberg Scientific, Inc.Cleveland, OH�16-71�-6600

FOR MUNICIPAL INDUSTRYLRM Inc.Souderton, PA�15-7�1-4840

Rhode IslandKentrol/SEVCOWinslow, ME800-45�-19�8

South CarolinaEndress+HauserCharlotte, NC704-969-7974

South DakotaEngineered Sales CompanyBloomington, MN95�-888-1131

TennesseeAMJ Equipment Corp.Greeneville, TN4�3-639-3800

TriNova, Inc.Memphis, TN901-684-7099

TexasEndress+HauserHouston, TX713-300-6�00

C.B. Marketing, LLCLago Vista, TX51�-�67-9596

M & D ControlsTulsa, OK918-664-7511

Measurement ResourcesCorpus Christi, TX361-88�-3444

Pan-Tech ControlsArlington, TX817-640-3�3�

UtahWeidner & AssociatesMidvale, UT 801-565-9595

VermontKentrol/SEVCOWinslow, ME800-45�-19�8

VirginiaApplied Engineering, Inc.Midlothian, VA804-378-3550

Philip R. Walker & AssociatesCockeysville, MD410-666-�14�

WashingtonTourangeau Nor WesTualatin, OR503-691-6100

Washington D.C.Philip R. Walker & AssociatesCockeysville, MD410-666-�14�

West VirginiaLH BolekyCoraopolis, PA41�-�64-07�9

WisconsinDurable ControlsHartland, WI�6�-367-4900

Engineered Sales CompanyBloomington, MN95�-888-1131

WyomingBeabout CompanyLittleton, CO303-795-1000


Puerto RicoEngineered Parts & Services, Inc.Vega Alta, PR787-883-8880

food talkline cip and inventory

Documents