Automation in the Food Industry

1 Introduction to food processing.- 1.1 Introduction.- 1.2 Raw materials handling and storage.- 1.2.1 Categories of materials.- 1.2.2 Identifying incoming materials.- 1.2.3 Control and information requirements.- 1.2.4 Example of tank farm.- 1.2.5 Example of flour blending.- 1.2.6 Example of milk reception and storage with CIP system.- 1.3 Primary processing.- 1.3.1 Batch versus continuous processes.- 1.3.2 Modularity.- 1.3.3 Mixing.- 1.3.4 Evaporators and heat exchangers.- 1.3.5 Vacuum and pressure cooking.- 1.3.6 Variable flowrates.- 1.3.7 Effluent.- 1.3.8 Dispensing and container handling.- 1.3.9 Shaping and forming.- 1.3.10 Example of a confectionery assortment.- 1.4 Secondary processing.- 1.4.1 Packaging systems.- 1.4.2 Machine control and coordination.- 1.4.3 Assembly automation.- 1.4.4 Example of confectionery assortment packing.- 1.4.5 Finished goods storage and despatch.- 1.5 Weighing and metering.- 1.5.1 Weighing.- 1.5.2 Metering.- 1.5.3 Example of a 'loss in weight' metering system.- 1.6 Summary 27 Further reading.- 2 Total systems.- 2.1 Introduction.- 2.2 Current systems concepts.- 2.3 General requirements.- 2.3.1 The pragmatic approach.- 2.3.2 Utilise existing technology.- 2.3.3 Identify measurable benefits.- 2.3.4 Commonality of use.- 2.3.5 Transfer of information.- 2.3.6 Utilise a modular platform.- 2.3.7 Resilience.- 2.3.8 Adaptability and expandibility.- 2.3.9 Use industry recognised vendors.- 2.3.10 Maintainability.- 2.3.11 Allow for external factors.- 2.4 Food processing industry issues.- 2.4.1 Conversion factors.- 2.4.2 Quality.- 2.4.3 Safety.- 2.4.4 Cost.- 2.4.5 Repeatability.- 2.5 Manufacturing process system.- 2.5.1 Pre-production issues.- 2.5.2 Production issues.- 2.5.3 Post-production issues.- 2.6 Total systems.- 2.6.1 Functional blocks.- 2.6.2 Method of implementation.- 2.6.3 Benefits of total systems.- 2.6.4 Engineering the facility.- 2.6.5 Training and education.- 2.7 Examples of total systems approach.- 2.7.1 Example 1: the design phase.- 2.7.2 Example 2: the planning phase.- 2.7.3 Example 3: the implementation phase.- 2.8 Summary 46 Further reading.- 3 Integrated factory systems.- 3.1 Introduction.- 3.2 Integration objectives.- 3.3 Integration phases.- 3.4 Process control and factory automation.- 3.5 Human interface.- 3.6 Summary 57 Further reading.- 4 Specification for success.- 4.1 Introduction.- 4.2 Control system concepts.- 4.3 Hardware requirements.- 4.4 Software requirements.- 4.5 Case studies.- 4.5.1 Soft drinks plant.- 4.5.2 Edible oil plant.- 4.6 Summary.- References.- 5 Computers in control.- 5.1 Introduction.- 5.2 Types of computer.- 5.2.1 Programmable controller.- 5.2.2 Personal computers.- 5.2.3 Mini- and mainframe computers.- 5.2.4 Summary of computer types.- 5.3 SCADA and DCS systems.- 5.3.1 SCADA system.- 5.3.2 DCS equipment.- 5.4 Stand-alone controllers.- 5.5 Three term control.- 5.5.1 The purpose of three term control.- 5.5.2 Algorithm based three term control.- 5.5.3 Auto tuning.- 5.6 Hardware configuration.- 5.6.1 Single system.- 5.6.2 Single controller with remote I/O.- 5.6.3 Hierarchical system.- 5.6.4 Intelligent field sensors.- 5.7 Secure system configurations.- 5.7.1 Dual processor single I/O.- 5.7.2 Dual channel.- 5.7.3 Triple (or more) channels.- 5.7.4 Single channel with non-computer back-up.- 5.7.5 Safety considerations.- 5.7.6 Reboot and auto synchronising.- 5.8 Operator interfaces and maintenance aids.- 5.8.1 Operator interfaces.- 5.8.2 Maintenance data.- 5.9 Summary.- 6 Operator interfaces.- 6.1 Introduction.- 6.2 Operator functions.- 6.2.1 Supervision and alarm handling.- 6.2.2 Process overview.- 6.2.3 Production control.- 6.2.4 Maintenance.- 6.2.5 Which system?.- 6.3 Serving the person behind the machine.- 6.3.1 Ergonomics.- 6.3.2 Picture hierarchy.- 6.3.3 The need to know and the need for speed.- 6.3.4 How much information?.- 6.3.5 Alternatives to keyboards.- 6.3.6 Control-room design.- 6.4 The right system on the right level.- 6.4.1 The local operator interfa... Mehr