industrial technology and automation’s research project

Company: LAIVE

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26 DE SEPTIEMBRE DE 2013memberS:

ADANAQUE GUERRERO, DIANA GRACE - 201012428 Kumagai human, javier kenta - 201212301 DURAND

YUCRA , SARA - 20UNIVERSIDAD PERUANA DE CIENCIAS APLICADAS

EXECUTIVE SUMMARY

The objective we pose is provide valuable information on the application of the core

concepts of process technology and industrial automation. The specific objective is

centered on a real processand the necessary control loops for the automation of that

process.

Suggesting improvements in industrial automation is not only relatively complex

because of the number of solutions possible, but also, and above all, because of the

variety of applications. Ironically, these in turn are responsible for the multitude of

solutions available. If the analysis of the basic needs is relatively standard, as they will

always involve connecting sensors, actuators, and field controllers with each other, the

options in architecture are numerous and can impose the need for certain services.

The required performances expected fundamentally depend on the applications.

This paper traces the aplication and develop in an organization. The principal stages of

development are mentioned, from the initial requirement specifications to the current

state of standardization. The diverse technical solutions are then analyzed and

classified. In particular, we study the general aspects, the medium access control

protocols, and application relationships.

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INDEXEXECUTIVE SUMMARY.................................................................................................................1

1. INTRODUCTION....................................................................................................................3

2. GENERAL DESCRIPTION........................................................................................................4

MISSION...................................................................................................................................4

VISION......................................................................................................................................4

DISTRIBUTION PLANT...............................................................................................................4

3. DESCRIPTION OF THE PROCESS TO BE AUTOMATED............................................................6

I. Pasteurization:..................................................................................................................7

4. ANALYSIS CONTROL OF LOOPS, MEASURES AND MANIPULATES VARIABLES.......................8

5. PROCESS AND INSTRUMENTS DIAGRAMAS (ISA S5.1)........................................................10

6. SELECTION OF AUTOMATIC CONTROL COMPONENTS (Sensors, controllers, actuators). . .12

7. COST ANALYSIS...................................................................................................................14

8. CONCLUSIONS AND RECOMMENDATIONS.........................................................................19

9. SOURCES OF INFORMATION...............................................................................................19

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1. INTRODUCTION

Nowadays because of the technology and commercial advancement, we confirm

that we are facing a highly competitive and demanding market, which requires

varied products to increasingly smaller cycles, that is why companies are looking up

to expand their market share by adopting various measures which make them

more competitive. These organizations have discovered that industrial automation

plays a key rolle in industrial plants, so the implementation of automated systems

contributes to an increase in efficiency, effectiveness, quality and safety in facilities

in the whole organization.

The subject of Industrial Technology y Automation allows to develop concrete

improvement plants for the industrial sector, applying new technologies, especially

industrial automated systems that integrate and contribute to the competitiveness

of the whole organization.

For this reason, we will use these concepts to make a decision regarding the

analysis of a real process and the necessary control loops for the automation of

that process.

The company is Laive S.A., their commitment is to offer high quality products at

low prices. So, we're going to improve their dairy processes to make the company

more competitive.

In the following paragraphs, we will present the progress of the research project

applying the basic concepts of the course in the company and the context in which

it is located.

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2. GENERAL DESCRIPTION

Company’s name: LAIVE S.A.

R.U.C.: 20100095450

Sector: Dairy processing.

Location: Av. Nicolás de Piérola 601

Laive is an efficient and innovative dairy company, which offers products with

guaranteed quality and recognized brand contributing a proper nutrition to their

costumers.

This company is committed to be the best strategic agent to their costumers and

suppliers; and an excellent oportunity of profitability to the shareholders.

At the same time, Laive is committed to contribute to the growth of their

employees and the welfare of the community operating with social responsibility.

Laive wants to be recognized as a leading food company in innovation, technology

with consumer-oriented products of assured quality.

MISSION

Be innovative, efficient and socially responsible company, composed of

committed people to produce and sell guaranteed food through trusted brands

contributing to healthy food for costumers.

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VISION

Be the leader in innovation of healthy dairy products.

BLOCK DIAGRAM

DOP

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DISTRIBUTION PLANT

The facilities of the yogurt processing plant are divided into five zones,

separated by walls with spaces that allow free communication between areas:

Zone 1 which adjusts content of pretreated milk solids.

Zone 2: there occurs homogenization and pasteurization.

Zone 3 is the area of inoculum preparation, fermentation and cooling.

Zone 4: in this area is carried out the addition of flavors, colors and stabilizers.

Zone 5: where is packaged and cooled in yogurt in their respective containers.

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3.DESCRIPTION OF THE PROCESS TO BE AUTOMATED

YOGHURT MANUFACTURING FLOWCHART:

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Source: Personal compilation

Here we will have a general description of the process. Firstly, the company verifies

that the milk is clean, then strain the milk in a sieve with care. Secondly, the

company prepares the ingredients, flavoring and coloring, soon starts the

pasteurisation which mean bringing the milk at high temperature and the lowering

the temperature quickly. Next, we mantain a stable temperature during

fermentación. The product quality depends on, fermentation time. Gel formation

process takes place together with viscosity changes. Later, homogenisation

prevents the formation of cream and improves flavor and consistency. It is done

sharply to prevent further acidification yogurt. Finally, we sweeteners, stabilizers,

and fruit juices are added, according to product and close the airtight container to

maintain the safety. It is important to remember that conservation of the cold

chain ensures healthy quality after the products leaves the production site.

I. Pasteurization:

Pasteurization of the yoghurt base has two purposes: to reduce the initial bacterial

population to ensure a controlled fermentation after inoculation of the starter cultures

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and to inactivate and denature some enzymes such as lipases, whose actions affect the

stability of the base.

Pasteurization is performed in three stages: heating, holding and cooling. In the case of

yogurt, the treatment involves rapid heating - 9 s - to a temperature of 85 ° C sustained

for a minute, followed by cooling to 45 ° C which is the temperature of fermentation.

HTST pasteurization takes place in heat exchangers, plate or double-tube, which are

configured to integrate the heat fluxes, using the heat of the base leaving the support

stage and to be cooled to

preheat incoming base

exchanger. Thus it is possible

to save energy advantage

about 90% of the energy

transferred to the base.

IDEAL PASTEURIZATION CYCLE

ACTUAL PASTEURIZATION CYCLE

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4. ANALYSIS CONTROL OF LOOPS, MEASURES AND MANIPULATES VARIABLES

a) There is one control loop (0303) on the given diagram that consists on the valve

(actuator) that is between the heat exchanger and the deodorizer. This a

cascade control because we only have one manipulated variable (by the pump)

and more than one manipulates variables (base product flow and

temperature). Based in the base product temperature the flow that will go to

the deodorizer will be manipulated. This control analyzes the quality (pH and

concentration of lactic acid) of the base product obtained by the pasteurization

process of the heat exchangers that will regulate the base product that will go

directly to the fermentation tanks or that will be send back as a reflux to the

deodorizer.

Measured Values: the process is controlled by following the pH and the

concentration of lactic acid

Manipulated variables:

- Base product flow

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- Fermentation tank level

- Base product temperature

b) Another control loop is placed in the homogenization tank that consists in

another cascade control. Based in the flow of the base product after

pasteurization the temperature will be regulated in the heat exchanger and will

determine if there will be a return to the pasteurization process. The controller

will determine if the base product temperature is between the parameters

needed to the homogenization. In case it doesn’t have the established

temperature, the base product will be send back to the heat exchangers.

Measured values: Base product temperature

Manipulated variables:

- Base product flow in pasteurization

- Pressure in homogenization tank (homogenizator)

- Temperature in heat exchangers

- Level in homogenization tank

C) Has been added a new control loop (0301) on the beginning, regulating the

feed of pretreated milk. It now has a weight meter at the beginning that will weigh

the milk entering to the system and a pump that will send the milk though the

pipes. The relay will activate the pump depending of the signal send by the weigh

meter that will also activate the entering line valve.

- Manipulated variable: weight of pretreated milk entering to the line

- Flow of mixed milk, cream and sugar to the deodorizer

D) Like the last added control loop, has been added another (0308) but to the

cream feed of the system.

- Manipulated variable: flow of cream entering to the system

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E) Control loop 0301 A/B is a feed forward control that flow of mixed milk, sugar and

cream entering to the heat exchangers that will begin the fermentation process. This is

a feed forward control.

5. PROCESS AND INSTRUMENTS DIAGRAMAS (ISA S5.1)

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6. SELECTION OF AUTOMATIC CONTROL COMPONENTS (Sensors, controllers, actuators)

Among the many choices of precision measuring devices in the market, we decided to

propose a comprehensive action which consists in an implementation for future

automation. In the next lines, it shows the principal elements that support our proposal:

I. Sensors:

Temperature Transmitter: A temperature

transmitter is an electrical instrument that

interfaces a temperature sensor (e.g.

thermocouple, RTD, or thermistor) to a

measurement or control device (e.g. PLC, DCS, PC,

loop controller, data logger, display, recorder,

etc.). Typically, temperature transmitters isolate,

amplify, filter noise, linearize, and convert the input signal from the sensor then

send (transmit) a standardized output signal to the control device.

Pressure Transmitter: A pressure

sensor measures pressure, typically

of gases or liquids. Pressure is an expression of

the force required to stop a fluid from

expanding, and is usually stated in terms of

force per unit area. A pressure sensor usually

acts as a transducer; it generates a signal as

a function of the pressure imposed. For the

purposes of this article, such a signal is

electrical.

II. Controllers:

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Temperature controller: Temperature Controllers Analog / Digital (PID), offer a

quick adjustment and provide precise temperature management and control well

for a variety of applications to provide the best price, design and easy operation.

They will be the ultimate choice for your successful control in any temperature

application.

Pressure controller: Is a primary element connected to the pressure to be

controlled, transforms through a mechanical-pneumatic tire on a control signal.

This signal is amplified in flow and pressure for a

driver that produces the output signal.

III. Actuators:

Solenoid Valves: To open and close the valves

that allow the output to the valve inputs.

Centrifugal pump: For the transportation of

inputs

7. COST ANALYSIS

TRIBLENDER

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Machine Cost ($) 8500

Maintenance Cost (c/3meses) ($) 80Setup Fee (3 Technicians) ($) 220Training Cost (2 operators - 2 Days) ($) 70Hours Cost - Men (2 operators) ($) 0Energy Cost ($) 7Total Cost ($) 8877

DESODORIZADORMachine Cost ($) 15000

Maintenance Cost (c/3meses) ($) 100Setup Fee (3 Technicians) ($) 330Training Cost (2 operators - 2 Days) ($) 70Hours Cost - Men (2 operators) ($) 0Energy Cost ($) 9Total Cost ($) 15509

INTERCAMBIADOR DE CALOR

Machine Cost ($)12000

Maintenance Cost (c/3meses) ($)90

Setup Fee (3 Technicians) ($) 450Training Cost (2 operators - 2 Days) ($) 0Hours Cost - Men (2 operators) ($) 0Energy Cost ($) 3Total Cost ($) 12543

BOMBA DOSIFICADORAMachine Cost ($) 450

10

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Maintenance Cost (c/3meses) ($)Setup Fee (3 Technicians) ($) 1Training Cost (2 operators - 2 Days) ($) 0Hours Cost - Men (2 operators) ($) 0Energy Cost ($) 2Total Cost ($) 463

PURCHASE OF EQUIPMENT AND MACHINES

To purchase the above machines, application must be made to list each one so that the

vendor give us the specifications of each team and the terms of purchase. Then, we

perform an analysis to gauge the feasibility of implementing these machines, this will be

done by IRR and NPV analysis. For the above analysis, it was developed the company's

balance sheet. We must also coordinate with the supplier to reach an agreement that

specified and determined by what means and how it can be delivered the product

(machinery and equipment) and what is the medium that suits us.

Below is the balance sheet of the company:

Balance Sheet

Expressed in soles

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TANQUE DE FERMENTACIONMachine Cost ($) 4000

Maintenance Cost (c/3meses) ($)12

Setup Fee (3 Technicians) ($) 5Training Cost (2 operators - 2 Days) ($) 13Hours Cost - Men (4 operators) ($) 7Energy Cost ($) 6Total Cost ($) 4043

Activo corriente Pasivo CorrienteCaja Banco S/. 70,000.00 Proveedores S/. 30,000.00Clientes S/. 250,000.00 Remuneraciones S/. 30,500.00Mercadería S/. 500,000.00 Impuestos por pagar S/. 10,000.00Envases y embalajes S/. 200,000.00 T. Pasivo Corriente S/. 70,500.00

Pasivo no corrienteT. Activo Corriente S/.

1020,000.00Deuda largo plazo S/. 6

000,000.00Intereses y comisiones S/. 10,150.00

Activo no corriente T. Pasivo no corriente S/. 610,150.00Edificios e instalaciones S/. 1

000,000.00Vehículos S/.

1500,000.00Total Pasivo S/. 680,650.00

Herramientas y equipos S/. 50,000.00Terrenos PatrimonioMobiliario S/. 700,000.00 Capital S/.

3580,350.00Reservas

T. Activo no corriente S/. 3250,000.00

Resultados acumulados

T. Patrimonio S/. 3580,350.00

Total Activo S/. 4270,000.00

Total pasivo y patrimonio S/. 4270,000.00

Below is an analysis of the costs that will be incurred for the purchase of machinery and

equipment important and necessary to be implemented in the company.

SIGNIFICANT COSTSMachine Cost ($) 27950Maintenance Cost (c/3meses) ($) 292Setup Fee (3 Technicians) ($) 450Training Cost (2 operators - 2 Days) ($) 100Hours Cost - Men - Month (2 operators) ($) 500

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Energy Cost - Month ($) 163Total Cost ($) 29455

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CÁLCULO DEL TIR Y EL VANAños Hoy 0 1 2 3 4Inversión -40983

Costo (S/.) 4 4 4 4 4.16 4.16Producción promedio a la semana 200,000 200,000 210000 220500 231525 243101.25

Ingresos 800000 800000 840000 882000 963144 1011301.2

Costos mensuales 98,650 98650 103582.5 108761.625 114199.706 119909.692Depreciación -8196.6 -8196.6 -8196.6 -8196.6 -8196.6

Margen Bruto 701350 693153.4 728220.9765041.775

840747.694

883194.908

Gastos Administrativos y Ventas 35200 35200 36960 38808 40748.4 42785.82Utilidades antes de Impuestos 666150 657953.4 691260.9 726233.775 799999.294 840409.088

Impuesto a la Renta (30%) 199845 197386.02 207378.27 217870.133 239999.788 252122.727

Utilidad Neta 466305 460567.38 483882.63508363.643

559999.506

588286.362

Depreciación (+) 8196.6 8196.6 8196.6 8196.6 8196.6

Flujo de caja 466305 468763.98 492079.23516560.243

568196.106

596482.962

Tasa de descuento 0.1 0.1 0.1 0.1 0.1 0.1Flujo de descuento -40983 426149.073 406677.05 388099.356 388085.585 370368.99VAN 193839.053

-1938397.053 468764.08 492079.33 516560.343 568196.206 596483.062TIR 11%

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8. CONCLUSIONS AND RECOMMENDATIONS

The automation's proposal of the production process of the company LAIVE,

generates an investment of S/ 40,983, which is accesible to the company.

The production size and profitability will sustain such investment

The possibility to automate the processes can eliminate the employees's

limitations in their operations, as well as the delays.

But, most important, reduces human error in the processes by using

standardized process that allows have disponibility and diversity of production,

and reach the costumer satisfaction.

The implementation save manpower and allows greater efficiency and

accuracy.

9. SOURCES OF INFORMATION

http://laiveesvida.com/ http://www.qo.fcen.uba.ar/Cursos/TecnoII/guia.pdf http://www.sisman.utm.edu.ec/libros/FACULTAD%20DE%20CIENCIAS%20MATEM

%C3%81TICAS%20F%C3%8DSICAS%20Y%20QU%C3%8DMICAS/INGENIER%C3%8DA%20INDUSTRIAL/03/PROCESAMIENTO%20%20LATEOS/YOGURT.pdf

Slides’s course.