SlideShare uma empresa Scribd logo
1 de 4
Baixar para ler offline
Supplementing Lab Analysis with
Inline Measurements
Reduce production down time, off-spec product and time-consuming
manual grab sampling in food plants with inline instrumentation
By Ola Wesstrom, Food & Beverage Industry Manager – Endress+Hauser
Food plant managers are faced with many challenges today, not the least of which is ensuring product quality. Depending on
the product being made, they may have to meet the requirements of the Food & Drug Administration (FDA), European Union
(EU), and an alphabet soup of other agencies and regulations, including cGMP, GFSI, ISO, HACCP, SQF, SID, etc. These
regulations specify proper ingredients, chemical and biological hazards, procedures and sanitary conditions.
Food plant managers also have to meet the expectations of consumers for proper taste and texture. For example, the pH of
certain products is critical, because it can affect taste as well as food safety. When adding citric acid to jams, beverages and
other products for acidification, pH must be carefully controlled.
On top of the obvious food safety and product quality challenges, a
plant manager also needs to address operational issues and goals
such as:
•	 Product loss reductions
•	 Variable in raw materials
•	 Resource conservation such as energy and water reductions
•	 Loss of qualified operators and maintenance people
•	 Need to reduce operating and maintenance budgets
•	 Prepare and manage documentation for internal and external
audits
Currently, food plants rely on laboratory analysis (Figure 1) of
samples collected manually to ensure product quality at various
points in a process. Lab technicians periodically take a grab sample,
hurry back to the lab for a quick analysis, and communicate the result
to plant personnel. Operators and maintenance personnel then make
adjustments and corrections to improve control of the process, or to
make repairs when required.
The challenge with relying on lab analyses is that it’s not done in real
time, it’s time-consuming, it’s labor intensive and it has possibility for
manual errors. If it takes 30 minutes to grab a sample and analyze it,
then the result represents where the process was 30 minutes ago
— not now. The result could be a spoiled batch. If the measurement
had been done inline, a sudden deviation would be detected, allowing
for instant corrective action that could save the batch.
Figure 1: Taking samples from the process for analysis in the
plant’s lab is the tried-and-true method for ensuring quality
control. It’s also expensive and not a real-time measurement.
In this article, we’ll show examples how readily available instrumentation can be used for online quality control to supplement
or replace laboratory testing, speed up measurements, enable immediate corrective actions, and automate the parts of the
quality control system.
Inline Analyzers
Inline analyzers are not available for every type of measurement in the food industry, but are available for many of the common
measurements now being performed in labs. Table 1 is a list of typical measurements available with inline instruments.
Table 1: Inline Analytical Measurements
•	 Mass flow for accurate recipe management
•	 Density, Brix, Plato, Baumé,˚SAL, rate of fermentation
•	 % concentration (solids, alcohol, etc.)
•	 pH (using non glass pH sensors)
•	 Viscosity
•	 Conductivity
•	 Dissolved oxygen
•	 Chlorine
•	 Turbidity
•	 Color
•	 Specific gravity
Using inline analyzers helps management deal with many issues. For example, the amount of disinfectant used on a hydro
cooker for canned food needs to be closely controlled to ensure food safety, as overdosing can cause corrosion and waste of
chemicals, while too little can compromise food safety. One plant previously monitored disinfectant by taking grab samples to a
lab for analysis twice an hour.
Inline analyzers were installed to measure free chlorine, pH, and conductivity of the disinfectant. Real-time measurement saved
$13,000 annually in disinfectant costs by eliminating overdosing. These measurements also allowed the automation system to
add makeup water based on measured values, saving on heat energy and water usage, and producing less wastewater. The
inline analyzers also eliminated the need to send a lab worker to the hydro cooker two times an hour to take grab samples. The
bottom line was a payback period of just seven months.
In a similar example of how inline analyzers can cut expenses, a cheese plant performed five clean-in-place (CIP) operations
per day. The chemicals cost $1,771 for a 30-gallon drum, and the plant used three to four drums per month.
The plant installed an Endress+Hauser OUSAF11 optical phase separation sensor. Using visible and near-infrared wavelengths
of light, the OUSAF11 can be used for product loss detection, interface detection, and suspended solids and turbidity
measurements.
By measuring phase separation between whey, water and CIP detergent in the line, operators were able to determine when the
pre-rinse and CIP was complete, instead of relying on lab measurements and timing. Each CIP cycle was reduced by 15 minutes
and the plant used 32% less CIP chemicals. The cost savings were $5,300 in the first three months on chemicals alone, plus
savings from reduced energy and water use. The plant also increased equipment availability for processing by more than one
hour per day.
Inline analyzers are nothing new, of course. Many of these measurements have been available for several years and used for
traditional process control. What’s new today is increased reliability, along with new features and capabilities:
Improved Reliability:
Experiences in the industry with analyzers have been mixed. Trying to apply equipment designed for use in the lab directly in a
process usually led to disappointments. Washdown, high temperatures, aggressive cleaning chemicals and other environmental
factors often resulted in equipment failures and maintenance nightmares. These problems have been rectified by designing
analyzers and other inline instrumentation from the ground up for use on the plant floor and in the field.
Seamless Integration:
Traditionally, instruments were analog devices with a single 4-20mA output. Today, the availability of digital outputs such as
EtherNet/IP™, Profibus®, Foundation™ Fieldbus and Hart® is making integration of information into automation and
information systems very easy, and also allowing multiple parameters to be obtained from a single device. For example, a
Coriolis flowmeter can provide mass flow, volume flow, multiple totalizer values, density, viscosity and temperature
2
measurements along with diagnostic information over one set of wires (or wireless). These digital protocols also help improve
accuracy by eliminating A/D conversions and loss in resolution of signal transmission in an analog 4-20mA signal.
Simplified Calibration:
With the expansion of digital sensor technology, the lab can now take responsibility for calibration of quality-related
measurements. For example, to calibrate a pH sensor in the past, calibration equipment had to be brought into the plant.
Today, this calibration can be done in the lab in a controlled environment, and the pre-calibrated sensors can be easily placed in
operation. Endress+Hauser Memosens® and other similar technologies make this possible for pH, DO, conductivity, turbidity,
chlorine and many other parameters.
Hygienic design:
One of the limiting factors for inline quality monitoring has been the lack of
instruments meeting hygienic design requirements and resistant to thermal
processing and CIP chemicals. Today, most instruments meet with EHEDG or 3-A
sanitary standards and are designed for use in the food industry. An example is pH
measurement, which most people associate with glass sensors—a big problem in
food processing as glass sensors can break and end up as foreign objects in the
final product. Now there are reliable non-glass pH sensors that meet food
processing requirements.
Coriolis Flowmeter Provide Multiple Measurements
A single Coriolis flowmeter can measure a number of parameters simultaneously,
often eliminating the need for multiple instruments, and their highly accurate
measurement of mass flow and density (up to 0.05% on mass flow and 0.0005g/
cm3 for density) makes Coriolis ideal for many process control applications.
Often overlooked by many instrument and process engineers is the ability of
Coriolis flowmeters to be used for quality control. For example, the flowmeter’s
density function can be used to measure Brix and Plato values to ensure quality of
ingredients being used. The viscosity option provides continuous measurement to
minimize off-spec product between lab measurements.
One food plant installed a Coriolis flowmeter (Figure 2) in a continuous bypass line
of a batter mixing tank. The batter, consisting of flour, water and additives, is
mixed until the correct viscosity is reached, and then pumped to the production
tank for processing. The resulting savings in ingredients and the improvement in
product quality paid for the installation in less than six months.
Instrument Diagnostics Detect Problems
Diagnostics enhance measurements by alerting operators to
abnormal process conditions or upsets. For example, entrained
air in the line can cause process problems. An operator needs to
know if external air is being drawn in through a leaking seal, a
cavitating pump or an empty balance tank, because air in the
process can affect product quality.
A Coriolis flowmeter does not operate properly with large
amounts of entrained air, so it has diagnostics to detect this
condition. In an Endress+Hauser Coriolis meter, a diagnostic
value shows that tube oscillation is in a good range, indicating
no entrained air. If air appears in the line, the diagnostic value
will change (Figure 3), setting off an alarm to the operator.
The same function can be used to improve accuracy when
starting from an empty line. The automation system can use the
diagnostic information in combination with a downstream
control valve to automatically increase back pressure during
start up, and then gradually decrease back pressure once the air
is gone from the system.
3
Figure 3: Diagnostics in a Coriolis flowmeter can determine if
entrained air is present (purple trace in the figure). This data can be
used as an operator alarm and to help during setup.
Figure 2: A Coriolis flowmeter installed in a
bypass line, such as Endress+Hauser’s Promass
83I, measures viscosity of the batter as it’s
being mixed.
WP01005B/24/EN/01.13
Endress+Hauser, Inc.
2350 Endress Place
Greenwood, IN 46143
Tel: 317-535-7138
Sales: 888-ENDRESS (888-363-7377)
Service: 800-642-8737
Fax: 317-535-8498
inquiry@us.endress.com
www.us.endress.com
Getting Started
The first step is to evaluate all the lab measurements and determine what can be replaced or supplemented with inline
instrumentation. The goal is to help the lab focus on the final and critical food safety and quality measurements, while the
instrumentation is used for real-time operations. Considerations here include:
•	 How much time is being spent taking manual grab samples?
•	 How much time is being spent running lab analyses?
•	 How many workers are needed for these tasks?
•	 How quickly does manual sampling detect process changes?
•	 How much does the delay in obtaining manual results affect product costs?
The hydro cooker application discussed above is a good example of a plant that saved worker’s time by eliminating two
grab samples per hour, and then saved on disinfectant chemical costs with timelier inline analysis.
The next step is asking: Which of the inline measurements would benefit a particular process?
For example, dissolved oxygen measurements in brewing, wine and juice production minimize oxidation of the product.
Measuring the Brix of tomato paste can help control the amount of paste to be added during cutting. Viscosity
measurements can improve the product consistency of batter coating for beans, onions, meat, poultry and other products.
Inline process analyzers cannot replace all the functions of a modern lab in a food plant, as certain measurements can’t yet
be reliably made by inline analyzers and instruments. However, modern inline process analyzers and instruments can
reliably replace or supplement many of the measurements traditionally made in a lab.
Moving from offline to inline measurements cuts labor costs by eliminating manual sampling and analysis, and it adds
consistency by automating the measurement process. Inline measurement delivers results in real-time, allowing
automation systems to continually adjust process parameters to optimize quality and increase throughput.
Ola Wesstrom began his career with Endress+Hauser in 1992 at the Singapore facility, serving as the Product Manager for Level and Pressure.
Since 2000, Ola has served as the Senior Industry Manager for the Food and Beverage Industry. With a degree in Process Measurement and
Automation from Sweden’s National Pulp and Paper Institute, Ola started his professional career with a process signal conditioning manufacturer
in Sweden.

Mais conteúdo relacionado

Mais procurados

Clean In Place Technlogies BioPharma Facilities
Clean In Place Technlogies BioPharma FacilitiesClean In Place Technlogies BioPharma Facilities
Clean In Place Technlogies BioPharma FacilitiesRanjeet Kumar
 
Clean-in-place: how to ensure food safety while maintaining equipment effecti...
Clean-in-place: how to ensure food safety while maintaining equipment effecti...Clean-in-place: how to ensure food safety while maintaining equipment effecti...
Clean-in-place: how to ensure food safety while maintaining equipment effecti...Design World
 
C22 3 cleaning-in-place_final-web
C22 3 cleaning-in-place_final-webC22 3 cleaning-in-place_final-web
C22 3 cleaning-in-place_final-webDir Jan
 
Clean In Place - Cycle Development
Clean In Place - Cycle DevelopmentClean In Place - Cycle Development
Clean In Place - Cycle DevelopmentRanjeet Kumar
 
HVAC & Water in Pharmaceutical Manufacturing; From Theory to Application
HVAC & Water in Pharmaceutical Manufacturing; From Theory to ApplicationHVAC & Water in Pharmaceutical Manufacturing; From Theory to Application
HVAC & Water in Pharmaceutical Manufacturing; From Theory to ApplicationObaid Ali / Roohi B. Obaid
 
Suncombe cip overview presentation
Suncombe cip overview presentationSuncombe cip overview presentation
Suncombe cip overview presentationKyriakos Michalaki
 
Cip sip-ctd solution-ivt_presentation
Cip sip-ctd solution-ivt_presentationCip sip-ctd solution-ivt_presentation
Cip sip-ctd solution-ivt_presentationAraik Ambartsumyan
 
One slider for qualification and validation of depyrogenation and sterilizati...
One slider for qualification and validation of depyrogenation and sterilizati...One slider for qualification and validation of depyrogenation and sterilizati...
One slider for qualification and validation of depyrogenation and sterilizati...Palash Das
 
CIP vs COP - Hygienic Pumps and Meeting Government Regulations - Carotek Proc...
CIP vs COP - Hygienic Pumps and Meeting Government Regulations - Carotek Proc...CIP vs COP - Hygienic Pumps and Meeting Government Regulations - Carotek Proc...
CIP vs COP - Hygienic Pumps and Meeting Government Regulations - Carotek Proc...Carotek
 
Utilizing Online TOC Monitoring to Control Industrial Water Quality
Utilizing Online TOC Monitoring to Control Industrial Water QualityUtilizing Online TOC Monitoring to Control Industrial Water Quality
Utilizing Online TOC Monitoring to Control Industrial Water QualityMuhammad Naeem Ashraf
 
Industrial Hygiene and PSM in Pharma industries Hangzhou, China 2013
Industrial Hygiene and PSM in Pharma industries   Hangzhou, China 2013Industrial Hygiene and PSM in Pharma industries   Hangzhou, China 2013
Industrial Hygiene and PSM in Pharma industries Hangzhou, China 2013Kartik Vora
 
Sahilhusen utility service
Sahilhusen utility serviceSahilhusen utility service
Sahilhusen utility servicesahilhusen
 
C22 4 product recovery_final-web
C22 4 product recovery_final-webC22 4 product recovery_final-web
C22 4 product recovery_final-webDir Jan
 
Clean in-place-cip-buying-guide
Clean in-place-cip-buying-guideClean in-place-cip-buying-guide
Clean in-place-cip-buying-guideChevronelle
 
Dipti cleaning ppt
Dipti cleaning pptDipti cleaning ppt
Dipti cleaning pptNeha Suresh
 

Mais procurados (19)

Clean In Place Technlogies BioPharma Facilities
Clean In Place Technlogies BioPharma FacilitiesClean In Place Technlogies BioPharma Facilities
Clean In Place Technlogies BioPharma Facilities
 
Clean-in-place: how to ensure food safety while maintaining equipment effecti...
Clean-in-place: how to ensure food safety while maintaining equipment effecti...Clean-in-place: how to ensure food safety while maintaining equipment effecti...
Clean-in-place: how to ensure food safety while maintaining equipment effecti...
 
C22 3 cleaning-in-place_final-web
C22 3 cleaning-in-place_final-webC22 3 cleaning-in-place_final-web
C22 3 cleaning-in-place_final-web
 
Clean In Place - Cycle Development
Clean In Place - Cycle DevelopmentClean In Place - Cycle Development
Clean In Place - Cycle Development
 
Clean in-place (cip) systems
Clean  in-place (cip) systemsClean  in-place (cip) systems
Clean in-place (cip) systems
 
HVAC & Water in Pharmaceutical Manufacturing; From Theory to Application
HVAC & Water in Pharmaceutical Manufacturing; From Theory to ApplicationHVAC & Water in Pharmaceutical Manufacturing; From Theory to Application
HVAC & Water in Pharmaceutical Manufacturing; From Theory to Application
 
Suncombe cip overview presentation
Suncombe cip overview presentationSuncombe cip overview presentation
Suncombe cip overview presentation
 
Cip sip-ctd solution-ivt_presentation
Cip sip-ctd solution-ivt_presentationCip sip-ctd solution-ivt_presentation
Cip sip-ctd solution-ivt_presentation
 
One slider for qualification and validation of depyrogenation and sterilizati...
One slider for qualification and validation of depyrogenation and sterilizati...One slider for qualification and validation of depyrogenation and sterilizati...
One slider for qualification and validation of depyrogenation and sterilizati...
 
CIP vs COP - Hygienic Pumps and Meeting Government Regulations - Carotek Proc...
CIP vs COP - Hygienic Pumps and Meeting Government Regulations - Carotek Proc...CIP vs COP - Hygienic Pumps and Meeting Government Regulations - Carotek Proc...
CIP vs COP - Hygienic Pumps and Meeting Government Regulations - Carotek Proc...
 
Utilizing Online TOC Monitoring to Control Industrial Water Quality
Utilizing Online TOC Monitoring to Control Industrial Water QualityUtilizing Online TOC Monitoring to Control Industrial Water Quality
Utilizing Online TOC Monitoring to Control Industrial Water Quality
 
Industrial Hygiene and PSM in Pharma industries Hangzhou, China 2013
Industrial Hygiene and PSM in Pharma industries   Hangzhou, China 2013Industrial Hygiene and PSM in Pharma industries   Hangzhou, China 2013
Industrial Hygiene and PSM in Pharma industries Hangzhou, China 2013
 
Sahilhusen utility service
Sahilhusen utility serviceSahilhusen utility service
Sahilhusen utility service
 
C22 4 product recovery_final-web
C22 4 product recovery_final-webC22 4 product recovery_final-web
C22 4 product recovery_final-web
 
Water system validation.
Water system validation.Water system validation.
Water system validation.
 
Self-Optimising Clean-in-Place
Self-Optimising Clean-in-PlaceSelf-Optimising Clean-in-Place
Self-Optimising Clean-in-Place
 
Clean in-place-cip-buying-guide
Clean in-place-cip-buying-guideClean in-place-cip-buying-guide
Clean in-place-cip-buying-guide
 
Dipti cleaning ppt
Dipti cleaning pptDipti cleaning ppt
Dipti cleaning ppt
 
HGA 02-Headspace-Gas-Analyzer
HGA 02-Headspace-Gas-AnalyzerHGA 02-Headspace-Gas-Analyzer
HGA 02-Headspace-Gas-Analyzer
 

Destaque

Emi lab manual_vthsem_ece
Emi lab manual_vthsem_eceEmi lab manual_vthsem_ece
Emi lab manual_vthsem_eceAshish Duvey
 
process control instrumentation lab and labview report
process control  instrumentation lab and labview  reportprocess control  instrumentation lab and labview  report
process control instrumentation lab and labview reportHari Krishna
 
Hands-On Lab: Smart Instrumentation
Hands-On Lab: Smart InstrumentationHands-On Lab: Smart Instrumentation
Hands-On Lab: Smart InstrumentationCA Technologies
 
Power electronics-lab-manual
Power electronics-lab-manualPower electronics-lab-manual
Power electronics-lab-manualponarun
 
Instrumentation and measurement
Instrumentation and measurementInstrumentation and measurement
Instrumentation and measurementDr.M.Prasad Naidu
 
Lecture1 measurement & intrumentation
Lecture1 measurement & intrumentationLecture1 measurement & intrumentation
Lecture1 measurement & intrumentationasmawi78
 
Introduction, advantages of electronic instrumentation, instrument classifica...
Introduction, advantages of electronic instrumentation, instrument classifica...Introduction, advantages of electronic instrumentation, instrument classifica...
Introduction, advantages of electronic instrumentation, instrument classifica...Engr Ali Mouzam
 
Electrical and electronics Lab Manual
Electrical and electronics Lab ManualElectrical and electronics Lab Manual
Electrical and electronics Lab ManualSachin Airan
 

Destaque (10)

Emi lab manual_vthsem_ece
Emi lab manual_vthsem_eceEmi lab manual_vthsem_ece
Emi lab manual_vthsem_ece
 
process control instrumentation lab and labview report
process control  instrumentation lab and labview  reportprocess control  instrumentation lab and labview  report
process control instrumentation lab and labview report
 
Hands-On Lab: Smart Instrumentation
Hands-On Lab: Smart InstrumentationHands-On Lab: Smart Instrumentation
Hands-On Lab: Smart Instrumentation
 
Power electronics-lab-manual
Power electronics-lab-manualPower electronics-lab-manual
Power electronics-lab-manual
 
Instrumentation and measurement
Instrumentation and measurementInstrumentation and measurement
Instrumentation and measurement
 
Lecture1 measurement & intrumentation
Lecture1 measurement & intrumentationLecture1 measurement & intrumentation
Lecture1 measurement & intrumentation
 
Introduction, advantages of electronic instrumentation, instrument classifica...
Introduction, advantages of electronic instrumentation, instrument classifica...Introduction, advantages of electronic instrumentation, instrument classifica...
Introduction, advantages of electronic instrumentation, instrument classifica...
 
Electrical and electronics Lab Manual
Electrical and electronics Lab ManualElectrical and electronics Lab Manual
Electrical and electronics Lab Manual
 
Virtual instrumentation (LabVIEW)
Virtual instrumentation (LabVIEW)Virtual instrumentation (LabVIEW)
Virtual instrumentation (LabVIEW)
 
Power Electronics lab manual BE EEE
Power Electronics lab manual BE EEEPower Electronics lab manual BE EEE
Power Electronics lab manual BE EEE
 

Semelhante a Supplementing Lab Analysis with Inline Measurements

Supplementing lab analysis with inline quality measurements in food manufactu...
Supplementing lab analysis with inline quality measurements in food manufactu...Supplementing lab analysis with inline quality measurements in food manufactu...
Supplementing lab analysis with inline quality measurements in food manufactu...ola wesstrom
 
How to Optimize Clean-in-Place (CIP) Processes in Food and Beverage Operations
How to Optimize Clean-in-Place (CIP) Processes in Food and Beverage OperationsHow to Optimize Clean-in-Place (CIP) Processes in Food and Beverage Operations
How to Optimize Clean-in-Place (CIP) Processes in Food and Beverage OperationsSchneider Electric
 
What format is best for your laboratory
What format is best for your laboratoryWhat format is best for your laboratory
What format is best for your laboratoryRandox
 
Anthony crasto scaleup techniques & pilot plant
Anthony crasto scaleup techniques & pilot plantAnthony crasto scaleup techniques & pilot plant
Anthony crasto scaleup techniques & pilot plantAnthony Melvin Crasto Ph.D
 
Automated release of water using on line TOC analysis and FDA risk-based cGMP...
Automated release of water using on line TOC analysis and FDA risk-based cGMP...Automated release of water using on line TOC analysis and FDA risk-based cGMP...
Automated release of water using on line TOC analysis and FDA risk-based cGMP...Jalis Muktadir
 
Food Talkline Every Drop
Food Talkline Every DropFood Talkline Every Drop
Food Talkline Every Dropola wesstrom
 
Industrial Bioprocessing webinar.pptx
Industrial Bioprocessing webinar.pptxIndustrial Bioprocessing webinar.pptx
Industrial Bioprocessing webinar.pptxShubham Chinchulkar
 
The power of pH neutral enzyme cleaning EC 660
The power of pH neutral enzyme cleaning  EC 660The power of pH neutral enzyme cleaning  EC 660
The power of pH neutral enzyme cleaning EC 660Jeff Grames
 
The Power of pH Neutral Enzyme Cleaning - EC 660
The Power of pH Neutral Enzyme Cleaning - EC 660The Power of pH Neutral Enzyme Cleaning - EC 660
The Power of pH Neutral Enzyme Cleaning - EC 660Jeff Grames
 
The Fundamentals of Cleaning Validation
The Fundamentals of Cleaning ValidationThe Fundamentals of Cleaning Validation
The Fundamentals of Cleaning ValidationSGS
 
A Guide to Instrumentation for Ethanol Fuel Production
A Guide to Instrumentation for Ethanol Fuel ProductionA Guide to Instrumentation for Ethanol Fuel Production
A Guide to Instrumentation for Ethanol Fuel ProductionMead O'Brien, Inc.
 
Bpr report mavericks
Bpr report  mavericksBpr report  mavericks
Bpr report mavericksSheema Adil
 
Instrumentation solutions for food industry
Instrumentation solutions for food industryInstrumentation solutions for food industry
Instrumentation solutions for food industryola wesstrom
 
Food Talkline Morgan Foods
Food Talkline Morgan FoodsFood Talkline Morgan Foods
Food Talkline Morgan Foodsola wesstrom
 
FST 507 Food Safety (HPP application prp oprp doc and chart).pptx
FST 507 Food Safety (HPP application prp oprp doc and chart).pptxFST 507 Food Safety (HPP application prp oprp doc and chart).pptx
FST 507 Food Safety (HPP application prp oprp doc and chart).pptxsneharoy943267
 
FST 507 Food Safety (HPP application prp oprp doc and chart).pptx
FST 507 Food Safety (HPP application prp oprp doc and chart).pptxFST 507 Food Safety (HPP application prp oprp doc and chart).pptx
FST 507 Food Safety (HPP application prp oprp doc and chart).pptxsneharoy943267
 
Pmtc good cleaning validation practice
Pmtc  good cleaning validation practicePmtc  good cleaning validation practice
Pmtc good cleaning validation practiceRamy Mostafa
 
White paper - Continued process verification methods in cleaning validation
White paper - Continued process verification methods in cleaning validationWhite paper - Continued process verification methods in cleaning validation
White paper - Continued process verification methods in cleaning validationFedegari Group
 

Semelhante a Supplementing Lab Analysis with Inline Measurements (20)

Supplementing lab analysis with inline quality measurements in food manufactu...
Supplementing lab analysis with inline quality measurements in food manufactu...Supplementing lab analysis with inline quality measurements in food manufactu...
Supplementing lab analysis with inline quality measurements in food manufactu...
 
How to Optimize Clean-in-Place (CIP) Processes in Food and Beverage Operations
How to Optimize Clean-in-Place (CIP) Processes in Food and Beverage OperationsHow to Optimize Clean-in-Place (CIP) Processes in Food and Beverage Operations
How to Optimize Clean-in-Place (CIP) Processes in Food and Beverage Operations
 
What format is best for your laboratory
What format is best for your laboratoryWhat format is best for your laboratory
What format is best for your laboratory
 
Anthony crasto scaleup techniques & pilot plant
Anthony crasto scaleup techniques & pilot plantAnthony crasto scaleup techniques & pilot plant
Anthony crasto scaleup techniques & pilot plant
 
Automated release of water using on line TOC analysis and FDA risk-based cGMP...
Automated release of water using on line TOC analysis and FDA risk-based cGMP...Automated release of water using on line TOC analysis and FDA risk-based cGMP...
Automated release of water using on line TOC analysis and FDA risk-based cGMP...
 
Food Talkline Every Drop
Food Talkline Every DropFood Talkline Every Drop
Food Talkline Every Drop
 
Industrial Bioprocessing webinar.pptx
Industrial Bioprocessing webinar.pptxIndustrial Bioprocessing webinar.pptx
Industrial Bioprocessing webinar.pptx
 
Hygienic design of dairy equipment
Hygienic design of dairy equipmentHygienic design of dairy equipment
Hygienic design of dairy equipment
 
The power of pH neutral enzyme cleaning EC 660
The power of pH neutral enzyme cleaning  EC 660The power of pH neutral enzyme cleaning  EC 660
The power of pH neutral enzyme cleaning EC 660
 
The Power of pH Neutral Enzyme Cleaning - EC 660
The Power of pH Neutral Enzyme Cleaning - EC 660The Power of pH Neutral Enzyme Cleaning - EC 660
The Power of pH Neutral Enzyme Cleaning - EC 660
 
The Fundamentals of Cleaning Validation
The Fundamentals of Cleaning ValidationThe Fundamentals of Cleaning Validation
The Fundamentals of Cleaning Validation
 
A Guide to Instrumentation for Ethanol Fuel Production
A Guide to Instrumentation for Ethanol Fuel ProductionA Guide to Instrumentation for Ethanol Fuel Production
A Guide to Instrumentation for Ethanol Fuel Production
 
Bpr report mavericks
Bpr report  mavericksBpr report  mavericks
Bpr report mavericks
 
Instrumentation solutions for food industry
Instrumentation solutions for food industryInstrumentation solutions for food industry
Instrumentation solutions for food industry
 
Food Talkline Morgan Foods
Food Talkline Morgan FoodsFood Talkline Morgan Foods
Food Talkline Morgan Foods
 
FST 507 Food Safety (HPP application prp oprp doc and chart).pptx
FST 507 Food Safety (HPP application prp oprp doc and chart).pptxFST 507 Food Safety (HPP application prp oprp doc and chart).pptx
FST 507 Food Safety (HPP application prp oprp doc and chart).pptx
 
FST 507 Food Safety (HPP application prp oprp doc and chart).pptx
FST 507 Food Safety (HPP application prp oprp doc and chart).pptxFST 507 Food Safety (HPP application prp oprp doc and chart).pptx
FST 507 Food Safety (HPP application prp oprp doc and chart).pptx
 
Pmtc good cleaning validation practice
Pmtc  good cleaning validation practicePmtc  good cleaning validation practice
Pmtc good cleaning validation practice
 
Validation
Validation Validation
Validation
 
White paper - Continued process verification methods in cleaning validation
White paper - Continued process verification methods in cleaning validationWhite paper - Continued process verification methods in cleaning validation
White paper - Continued process verification methods in cleaning validation
 

Mais de E-direct, Division of Endress+Hauser (20)

TTR35
TTR35TTR35
TTR35
 
TTR31
TTR31TTR31
TTR31
 
TST487
TST487TST487
TST487
 
TST187
TST187TST187
TST187
 
TSM487
TSM487TSM487
TSM487
 
TSM187
TSM187TSM187
TSM187
 
TMT127-187-128-188
TMT127-187-128-188TMT127-187-128-188
TMT127-187-128-188
 
TMT80
TMT80TMT80
TMT80
 
TMR35
TMR35TMR35
TMR35
 
TMR31
TMR31TMR31
TMR31
 
RTA421
RTA421RTA421
RTA421
 
RSG30
RSG30RSG30
RSG30
 
RNS221
RNS221RNS221
RNS221
 
RN221N
RN221NRN221N
RN221N
 
RMA42
RMA42RMA42
RMA42
 
RIA452
RIA452RIA452
RIA452
 
RIA2
RIA2RIA2
RIA2
 
RIA46
RIA46RIA46
RIA46
 
RIA45
RIA45RIA45
RIA45
 
RIA14 - RIA16
RIA14 - RIA16RIA14 - RIA16
RIA14 - RIA16
 

Supplementing Lab Analysis with Inline Measurements

  • 1. Supplementing Lab Analysis with Inline Measurements Reduce production down time, off-spec product and time-consuming manual grab sampling in food plants with inline instrumentation By Ola Wesstrom, Food & Beverage Industry Manager – Endress+Hauser Food plant managers are faced with many challenges today, not the least of which is ensuring product quality. Depending on the product being made, they may have to meet the requirements of the Food & Drug Administration (FDA), European Union (EU), and an alphabet soup of other agencies and regulations, including cGMP, GFSI, ISO, HACCP, SQF, SID, etc. These regulations specify proper ingredients, chemical and biological hazards, procedures and sanitary conditions. Food plant managers also have to meet the expectations of consumers for proper taste and texture. For example, the pH of certain products is critical, because it can affect taste as well as food safety. When adding citric acid to jams, beverages and other products for acidification, pH must be carefully controlled. On top of the obvious food safety and product quality challenges, a plant manager also needs to address operational issues and goals such as: • Product loss reductions • Variable in raw materials • Resource conservation such as energy and water reductions • Loss of qualified operators and maintenance people • Need to reduce operating and maintenance budgets • Prepare and manage documentation for internal and external audits Currently, food plants rely on laboratory analysis (Figure 1) of samples collected manually to ensure product quality at various points in a process. Lab technicians periodically take a grab sample, hurry back to the lab for a quick analysis, and communicate the result to plant personnel. Operators and maintenance personnel then make adjustments and corrections to improve control of the process, or to make repairs when required. The challenge with relying on lab analyses is that it’s not done in real time, it’s time-consuming, it’s labor intensive and it has possibility for manual errors. If it takes 30 minutes to grab a sample and analyze it, then the result represents where the process was 30 minutes ago — not now. The result could be a spoiled batch. If the measurement had been done inline, a sudden deviation would be detected, allowing for instant corrective action that could save the batch. Figure 1: Taking samples from the process for analysis in the plant’s lab is the tried-and-true method for ensuring quality control. It’s also expensive and not a real-time measurement.
  • 2. In this article, we’ll show examples how readily available instrumentation can be used for online quality control to supplement or replace laboratory testing, speed up measurements, enable immediate corrective actions, and automate the parts of the quality control system. Inline Analyzers Inline analyzers are not available for every type of measurement in the food industry, but are available for many of the common measurements now being performed in labs. Table 1 is a list of typical measurements available with inline instruments. Table 1: Inline Analytical Measurements • Mass flow for accurate recipe management • Density, Brix, Plato, Baumé,˚SAL, rate of fermentation • % concentration (solids, alcohol, etc.) • pH (using non glass pH sensors) • Viscosity • Conductivity • Dissolved oxygen • Chlorine • Turbidity • Color • Specific gravity Using inline analyzers helps management deal with many issues. For example, the amount of disinfectant used on a hydro cooker for canned food needs to be closely controlled to ensure food safety, as overdosing can cause corrosion and waste of chemicals, while too little can compromise food safety. One plant previously monitored disinfectant by taking grab samples to a lab for analysis twice an hour. Inline analyzers were installed to measure free chlorine, pH, and conductivity of the disinfectant. Real-time measurement saved $13,000 annually in disinfectant costs by eliminating overdosing. These measurements also allowed the automation system to add makeup water based on measured values, saving on heat energy and water usage, and producing less wastewater. The inline analyzers also eliminated the need to send a lab worker to the hydro cooker two times an hour to take grab samples. The bottom line was a payback period of just seven months. In a similar example of how inline analyzers can cut expenses, a cheese plant performed five clean-in-place (CIP) operations per day. The chemicals cost $1,771 for a 30-gallon drum, and the plant used three to four drums per month. The plant installed an Endress+Hauser OUSAF11 optical phase separation sensor. Using visible and near-infrared wavelengths of light, the OUSAF11 can be used for product loss detection, interface detection, and suspended solids and turbidity measurements. By measuring phase separation between whey, water and CIP detergent in the line, operators were able to determine when the pre-rinse and CIP was complete, instead of relying on lab measurements and timing. Each CIP cycle was reduced by 15 minutes and the plant used 32% less CIP chemicals. The cost savings were $5,300 in the first three months on chemicals alone, plus savings from reduced energy and water use. The plant also increased equipment availability for processing by more than one hour per day. Inline analyzers are nothing new, of course. Many of these measurements have been available for several years and used for traditional process control. What’s new today is increased reliability, along with new features and capabilities: Improved Reliability: Experiences in the industry with analyzers have been mixed. Trying to apply equipment designed for use in the lab directly in a process usually led to disappointments. Washdown, high temperatures, aggressive cleaning chemicals and other environmental factors often resulted in equipment failures and maintenance nightmares. These problems have been rectified by designing analyzers and other inline instrumentation from the ground up for use on the plant floor and in the field. Seamless Integration: Traditionally, instruments were analog devices with a single 4-20mA output. Today, the availability of digital outputs such as EtherNet/IP™, Profibus®, Foundation™ Fieldbus and Hart® is making integration of information into automation and information systems very easy, and also allowing multiple parameters to be obtained from a single device. For example, a Coriolis flowmeter can provide mass flow, volume flow, multiple totalizer values, density, viscosity and temperature 2
  • 3. measurements along with diagnostic information over one set of wires (or wireless). These digital protocols also help improve accuracy by eliminating A/D conversions and loss in resolution of signal transmission in an analog 4-20mA signal. Simplified Calibration: With the expansion of digital sensor technology, the lab can now take responsibility for calibration of quality-related measurements. For example, to calibrate a pH sensor in the past, calibration equipment had to be brought into the plant. Today, this calibration can be done in the lab in a controlled environment, and the pre-calibrated sensors can be easily placed in operation. Endress+Hauser Memosens® and other similar technologies make this possible for pH, DO, conductivity, turbidity, chlorine and many other parameters. Hygienic design: One of the limiting factors for inline quality monitoring has been the lack of instruments meeting hygienic design requirements and resistant to thermal processing and CIP chemicals. Today, most instruments meet with EHEDG or 3-A sanitary standards and are designed for use in the food industry. An example is pH measurement, which most people associate with glass sensors—a big problem in food processing as glass sensors can break and end up as foreign objects in the final product. Now there are reliable non-glass pH sensors that meet food processing requirements. Coriolis Flowmeter Provide Multiple Measurements A single Coriolis flowmeter can measure a number of parameters simultaneously, often eliminating the need for multiple instruments, and their highly accurate measurement of mass flow and density (up to 0.05% on mass flow and 0.0005g/ cm3 for density) makes Coriolis ideal for many process control applications. Often overlooked by many instrument and process engineers is the ability of Coriolis flowmeters to be used for quality control. For example, the flowmeter’s density function can be used to measure Brix and Plato values to ensure quality of ingredients being used. The viscosity option provides continuous measurement to minimize off-spec product between lab measurements. One food plant installed a Coriolis flowmeter (Figure 2) in a continuous bypass line of a batter mixing tank. The batter, consisting of flour, water and additives, is mixed until the correct viscosity is reached, and then pumped to the production tank for processing. The resulting savings in ingredients and the improvement in product quality paid for the installation in less than six months. Instrument Diagnostics Detect Problems Diagnostics enhance measurements by alerting operators to abnormal process conditions or upsets. For example, entrained air in the line can cause process problems. An operator needs to know if external air is being drawn in through a leaking seal, a cavitating pump or an empty balance tank, because air in the process can affect product quality. A Coriolis flowmeter does not operate properly with large amounts of entrained air, so it has diagnostics to detect this condition. In an Endress+Hauser Coriolis meter, a diagnostic value shows that tube oscillation is in a good range, indicating no entrained air. If air appears in the line, the diagnostic value will change (Figure 3), setting off an alarm to the operator. The same function can be used to improve accuracy when starting from an empty line. The automation system can use the diagnostic information in combination with a downstream control valve to automatically increase back pressure during start up, and then gradually decrease back pressure once the air is gone from the system. 3 Figure 3: Diagnostics in a Coriolis flowmeter can determine if entrained air is present (purple trace in the figure). This data can be used as an operator alarm and to help during setup. Figure 2: A Coriolis flowmeter installed in a bypass line, such as Endress+Hauser’s Promass 83I, measures viscosity of the batter as it’s being mixed.
  • 4. WP01005B/24/EN/01.13 Endress+Hauser, Inc. 2350 Endress Place Greenwood, IN 46143 Tel: 317-535-7138 Sales: 888-ENDRESS (888-363-7377) Service: 800-642-8737 Fax: 317-535-8498 inquiry@us.endress.com www.us.endress.com Getting Started The first step is to evaluate all the lab measurements and determine what can be replaced or supplemented with inline instrumentation. The goal is to help the lab focus on the final and critical food safety and quality measurements, while the instrumentation is used for real-time operations. Considerations here include: • How much time is being spent taking manual grab samples? • How much time is being spent running lab analyses? • How many workers are needed for these tasks? • How quickly does manual sampling detect process changes? • How much does the delay in obtaining manual results affect product costs? The hydro cooker application discussed above is a good example of a plant that saved worker’s time by eliminating two grab samples per hour, and then saved on disinfectant chemical costs with timelier inline analysis. The next step is asking: Which of the inline measurements would benefit a particular process? For example, dissolved oxygen measurements in brewing, wine and juice production minimize oxidation of the product. Measuring the Brix of tomato paste can help control the amount of paste to be added during cutting. Viscosity measurements can improve the product consistency of batter coating for beans, onions, meat, poultry and other products. Inline process analyzers cannot replace all the functions of a modern lab in a food plant, as certain measurements can’t yet be reliably made by inline analyzers and instruments. However, modern inline process analyzers and instruments can reliably replace or supplement many of the measurements traditionally made in a lab. Moving from offline to inline measurements cuts labor costs by eliminating manual sampling and analysis, and it adds consistency by automating the measurement process. Inline measurement delivers results in real-time, allowing automation systems to continually adjust process parameters to optimize quality and increase throughput. Ola Wesstrom began his career with Endress+Hauser in 1992 at the Singapore facility, serving as the Product Manager for Level and Pressure. Since 2000, Ola has served as the Senior Industry Manager for the Food and Beverage Industry. With a degree in Process Measurement and Automation from Sweden’s National Pulp and Paper Institute, Ola started his professional career with a process signal conditioning manufacturer in Sweden.