Production yield is extremely important in all manufacturing plants. However, it is even more critical for contract manufacturers, such as US-based Steuben Foods, which assembled a loss improvement team to determine where product losses occur within its production facility. In order to achieve this, reliable data was required, and through a process of elimination, an Endress+Hauser Promass 83 F Coriolis flowmeter was employed.
Steuben Foods is a contract manufacturer of antiseptic products. Its range of products includes: organic milk, soymilk, soup broth, coffee concentrates and nutriceuticals. The facility has about 20 storage silos for a total inventory of 18 kilotonnes of product. With 15 production lines, product is constantly being moved in and out of silos. In addition, the problem is compounded by the fact that the specific gravity of each and every product differs.
The possibility of using a PLC to calculate the weight based on an estimated specific gravity was considered. However, this process was ruled out as it would have introduced more error. A modification to each silo by installing multiple sensors was also considered. However, the loss improvement team opted for a completely new approach.
By mounting an Endress+Hauser Promass 83 F Coriolis mass flowmeter on a wheeled cart, the content of each tank could be measured very accurately as the tanks were filled and later emptied. The solution was simple and cost-effective. An inventory schedule was established and the Promass was connected to a chart recorder to monitor flow rates and movement.
The first immediate result was the discovery that the truck scales used for incoming supply were inaccurate. The Promass meter was able to provide more consistent and repeatable measurement. The improvement team estimated the return on investment for the Promass flowmeter and the cart to be approximately one month.
Today, the cart is still in use and in addition to accurately measuring the transfer of product from storage to process, it also measures the transfer of product from process to filling and is used as a reference in calibration. Vortex meters are (for example) used to record and control CIP flow and these are calibrated on a regular schedule, using the Promass meter. Turbine water meters and sucrose meters are also checked using a similar method.
Hydrostatic level transmitters are also used on the milk silos, but their purpose is monitoring. As soon as media is transferred in or out, the Promass cart is used. In fact, to ensure accurate reporting of incoming products, Steuben Foods installed a second permanent Promass on the receiving line to verify the truck scales. As a simple and cost-effective solution, the Promass 83 F Coriolis mass flowmeter accurately measures the content of each tank on filling and emptying.
Flow measurement in mobile applications ifm - South Africa
Flow Measurement & Control
The SU Puresonic Mobile ultrasonic sensor from ifm is characterised by its displayless design and high temperature resistance. It is ideal for mobile applications and processes with permanent media temperatures of up to 120°C.
Read more...Optimising water quality in a building cooling system ifm - South Africa
Flow Measurement & Control
A leading company in industrial water management has installed water treatment systems that not only optimise water quality but also help customers to improve their processes, thanks to the new insights and actions that can be generated based on the process data collected.
Read more...Ensuring clean and safe water Endress+Hauser South Africa
Editor's Choice Analytical Instrumentation & Environmental Monitoring
Endress+Hauser’s comprehensive range of disinfection sensors is designed to monitor and control disinfectant levels in water treatment processes.
Read more...Enhancing gold leaching efficiency Endress+Hauser South Africa
Sensors & Transducers
Endress+Hauser offers a range of advanced technologies designed to enhance the stability and accuracy of pH and dissolved oxygen measurements on gold processing plants.
Read more...Elevating mining separation processes through precision instrumentation Endress+Hauser South Africa
Analytical Instrumentation & Environmental Monitoring
In mining operations, the quest for efficiency and productivity is key. There is an urgent need for innovative solutions to enhance the performance of extraction processes while balancing operational costs and environmental impact.
Read more...New uncompromisingly simple flowmeter line for processes Endress+Hauser South Africa
Flow Measurement & Control
The demand for simplicity in commissioning, operation and maintenance in industrial process plants has increased significantly in recent years. The new Proline 10 range of flowmeters from Endress+Hauser meets this requirement without compromise, because simplicity is the top priority.
Read more...Ensuring clean and safe water Endress+Hauser South Africa
Analytical Instrumentation & Environmental Monitoring
Endress+Hauser’s comprehensive range of disinfection sensors are designed to monitor and control disinfectant levels in water treatment processes.
Read more...Loop signature 29: Averaging or surge level control
Editor's Choice Flow Measurement & Control
There are many processes where it is undesirable for the load to suddenly change quickly, for example in the paper industry. Examples of level control have involved reasonably fast tuning. An example of a level loop tuned this way and responding to a step change in setpoint is given.
While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements and company contact details are published as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material.
printer friendly version