INDUSTRY FOCUS FOOD & BEVERAGE


Mark Lilley, field segment manager, Hygienic - Food and Beverage for Bürkert Fluid Control Systems, looks at the best way for SMEs to implement an automation project


M


ost large scale food processing plants have already grasped the


advantages of improved automation, but some medium and smaller scale businesses, although appreciative of the benefits, remain reticent about the process of implementation and how the latest technology will combine with an existing installation. One of the common misconceptions about introducing automation is that the entire manufacturing process has to be revised at once. This has some financial implications and when added to the cost of lost production during the installation, makes the concept non-viable. However, one of the most fundamental


principles of automation is scalability – with sufficient planning during the initial stages of an automation project, it is possible to develop a plan that can be deployed in one area and then gradually rolled out to include other processes in due course. In this way, business owners can set aside smaller budgets and also see the improvements in productivity. Developing the most appropriate automation plan for a business requires an understanding of what is possible and a detailed knowledge of what is already in place. It is at this point, when the initial planning is taking place, that businesses can benefit most from expert advice. The term automation covers a wide


AUTOMATION IS BREWING FOR SMEs


Ultimately, introducing automation can be a daunting prospect for those who have no experience of it, but with the proper foundations it is possible to create a process control system that can deliver both the needs of the business now and those in 10 years time


spectrum of technology; and for most, the solution will be positioned in the middle ground, with a possible eye for additional development in the future. One of the first steps to improving the automation of any process is to agree on the control infrastructure for the business so that it is able to accommodate future expansion. In some cases this may be governed by an existing system, while in others, a clean sheet allows a number of options to be considered. The modular nature of many automation


solutions makes it possible to expand on a pre-existing installation. Provided the communication protocols are maintained it is fairly easy to install standalone control systems based on a centralised control concept that contains all of the necessary components to operate valves, including a PLC, I/O systems and valve islands. For those looking to start from scratch,


the possibilities are only really constrained by the size of the business and the extent of the processes to be automated. One good example of a small business


THE LOGICAL CONTROL CHOICE FOR HAND-CRAFTED BEER


Hand-crafted beer, produced by a growing number of micro-breweries across the UK, is rapidly gaining popularity with drinkers. Dave Bailey, founder of the Hardknott micro-brewery in Cumbria, has been brewing ales such as ‘Azimuth‘ and ‘Intergalactic Space Hopper’ since 2005, and, along with his small team, has continued to develop, invest, innovate and drive forward craft beer production. Now, with the help of LOGO, an intelligent logic module from Siemens, he is tackling a vital part of the


brewing process – control of the fermentation process – so that it is more efficient and reliable. He explained: “Control of the fermentation temperature helps to considerably improve the quality and


consistency of beer. It takes place over several days and on a practical basis the process cannot be watched continually. Temperature control systems can be expensive and complex to set up and micro-breweries tend to use fairly rudimentary on/off controls, or even manual ones, which by definition are not overly accurate. However, some sort of automatic temperature monitoring and control system is essential in my view.” Temperature control of fermentation is a challenge, with tight control to a stability of around 0.1˚ being the


desired target. Utilising the LOGO module, which offers a logging facility and trend display courtesy of a HMI screen, provides a more intuitive set-up, as well as generating better information on which to base internal analysis of the controls and assess how stable the process actually is. Bailey said: “The specification of LOGO to control this central element of our brewing process has already proved to be beneficial as it offers cost-effectiveness, flexibility, scalability and the potential to be seamlessly networked with other Siemens technology.”


www.siemens.com


looking to expand using automation might be a craft brewery. In such cases, planning the structure of the automation system is the equivalent of laying foundations and allowing the project to grow over time. Initially, the focus of such a project


would be on the fermenters, where a precisely controlled process enables repeatability, which is essential for producing high quality beer. Accurate temperature control is essential in avoiding spoiled batches. This initial foray into automation can then be followed by a similar installation in the Brewhouse, where temperature control of the mash tuns ensures the perfect conditions for the enzymes to work. With precision control of hot and cold water supplies it is possible to achieve repeatability for every batch, making the business more productive. In the brewing industry there comes a


point where the use of electrical heating elements for each process becomes inefficient and the business needs to convert to steam brewing. At this point it is essential to know when expert assistance is required and where to find it. Steam can be extremely dangerous and Bürkert engineers have been involved with the design and installation of steam control systems for many years. As the scale of any business grows and


the level of automation increases, it should be possible to ‘bolt-on’ a new module without interfering with the existing installation. In craft brewing, it is not possible for the brewmaster to be on site 24 hours a day, but he would still want to know of an anomaly in the process, if one should occur. Again, adding an Ethernet module allows access to the process control system from remote locations and if necessary the ability to change parameters.


Bürkert Fluid Control Systems www.burkert.co.uk


28 MAY 2017 | PROCESS & CONTROL / PROCESS&CONTROL


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