Newsletter with examples of resource conservation in food industry using instrumetnation

1. talkline
Promass S - reliable Managing Critical control of Endress+Hauser’s
solution for your wastewater and cheese vats local service
food and beverage minimizing Page 6 technicians are
products treatment fees in a dedicated to
Page 2 & 3 yogurt plant keep your plant
Page 4 running 24/7
Page 7
Make every drop count
How to make the most of your raw materials
and reduce waste
Issue 12 • Volume 9

2. Introducing the new Promass S
Coriolis mass flowmeters offer a reliable
solution for many flow applications due to their
excellent reproducibility and high accuracy. Now
Endress+Hauser has added an exceptional and
highly optimized sensor design to the innovative
Promass family with the introduction of Promass S.
• The most accurate single tube Coriolis meter
ever made - not just flow but density as well
• Reduced shear stress on your products
• Requires no inlet or outlet straight run piping
• Eases concerns of pressure loss with highly
viscous fluids - excels in slurries,
heavy solids, gels and pastes
Promass S provides assurance
that 3-A, EHEDG, and the
intent of FDA guidelines are
met. Promass S provides a
polished surface finish throughout
the entire measuring system, not
just the process connection. The entire wetted
surface area meets or exceeds Ra max.
0.8 um ensuring drainability and less energy used
during cleaning.
Ideal for:
• Sheer sensitive products
• Fruit mixes
• Meat slurries
• Chocolate
Patented Torsion Mode Balance
eliminates influence from Promass S
external vibration with stainless
steel housing

3. Profit or loss - managing production costs
With many raw material costs increasing to all time highs in combination
with rising energy costs and environmental pressures, food manufacturers
must look closely at every drop or ounce used in the process.
Coriolis mass flowmeters are often seen as an optional expense in the
design of a new system or upgrade. However, with today’s advancement
in performance and reductions in unit price, the Coriolis mass flowmeter
has a better return on investment than ever. Even when used on
relatively low cost raw materials, the returns can be significant.
Examples:
In a typical milk plant, mass balance is critical to account for yield and
identify shrinkage. If we do the math for a medium size dairy with a
daily capacity of 480,000 lbs/day, an improvement in the accuracy of
the mass balance control from 0.% to 0.1% could save over $30,000
USD per year. (800 lbs/min x 60 min x 10 hour x 6 day operation at a
milk cost of $0cwt [100 lbs]). This is achieved by simply using a Coriolis
mass flowmeter with 0.1% accuracy vs. a magnetic flowmeter with 0.%
accuracy.
Another application is the accurate dosing of flavors, coloring and
ingredients. Not only does the increased accuracy help the bottom line,
product quality and repeatability is enhanced.
The math is simple, the solution is simple - call Endress+Hauser for
your next Coriolis mass flowmeter, ask for the new Best-in-Class 0.05%
accuracy backed by guaranteed calibration, fully traceable to national
standard ISO-1705.
www.us.endress.com
Close to you
Endress+Hauser is a global supplier of process A network of skilled sales and service
automation solutions. The power of this personnel are located throughout the US
global company is realized by its local support and Canada, ready to provide the support
to you. This support starts with excellent required. Regional sales and service
manufacturing facilities located within the locations assure there is someone available,
US. ISO 9001-2000 certified manufacturing in your time zone, to support you.
facilities and ISO 17025 certified calibration
capability assure Endress+Hauser delivers highly
reliable measuring instruments to customers
throughout North and South America. 3

4. Case study: managing wastewater and minimizing
treatment fees
On-line BOD (Biochemical Oxygen
Demand) saves yogurt manufacturer money
by eliminating effluent surcharges and
identifying sources of shrinkage
A yogurt plant was faced with the challenge to
prevent BOD shocks to a local municipal treatment
plant. The wash water and accidental releases from
the yogurt plant are laden with organic matter such
as milk proteins, sugars, fats, fruit and flavoring
agents all yielding high BOD. The high BOD
loading had caused major upsets at the treatment
plant resulting in large fines and surcharges to
the company. When the yogurt plant added a new
production line it was concluded by the treatment
plant that the additional flow from the plant would
be acceptable but BOD shocks must be avoided.
BIOX1010
The plant’s existing BOD determination method
utilized a time profile of the plants effluent the changes in its dissolved oxygen requirements.
established by collecting and assaying samples every Unlike the 5-day test, the BIOX1010 is a real time,
two hours over a 4 hour period for several years. truly continuous BOD measurement, capable of
Additional samples were collected as composites detecting changes in dissolved BOD in as little as
and assayed providing the plant with a daily BOD 3 to 5 minutes. Additionally, unlike the 5 day test,
value. Since the standard laboratory method the biomass is populated with organisms found
requires five days1 to produce a BOD result, it was in the actual waste stream therefore emulating
impossible to identify and inform the treatment the actual conditions of the treatment plant. To
plant of a high BOD excursion in time for them protect the biomass from pH shocks, and optional
to make an informed decision to divert the high bi-directional pH adjustment is available to keep
strength stream. the waste stream neutral. To remove particles larger
than 500 um, a course particle sieve is incorporated
Several online monitoring technologies were into a unique, easy access fast by-pass loop is
explored to address the situation in real time. The available.
following online technologies were considered;
COD (Chemical Oxygen Demand), TOC (Total As a direct result of the real time information
Organic Carbon), optical (UV54) and BOD. After available to the plant from the BIOX1010
evaluation and weighing the pros and cons of each BOD monitor, the yogurt plant is now able to
technology and monitoring system, it was concluded provide early warning to the treatment plant of
that the continuous BOD measurement provided unintentional high strength excursions. But the
by the BIOX1010 was the best option. All of the greatest benefit to the yogurt plant is that they are
above mentioned technologies are available from now able to divert their high BOD flow to holding
Endress+Hauser. tanks and reintroduce the high BOD waste on a
timed schedule. By keeping the plant in constant
The Endress+Hauser BIOX 1010 employ the same compliance with their NPDES permit limit has
measurement principle as the 5-day BOD test. allowed the plant to eliminate surcharges. A second
The analyzer utilizes a live culture and measures benefit to the yogurt plant is because they can now
constantly monitor their BOD, they have been able
to identify and reduce the sources of accidental
spills which significantly contribute to product
shrinkage.
1.Biochemical oxygen demand 5210 B 5-day BOD test, Standard methods
for examination of water and wastewater 17th Edition 1989.
4

5. Reduce shrinkage and accidental spills
Hydrostatic level measurement continues to Water-tight All of the instrument Modular concept Clear polycarbonate
design survives info is laser-etched reduces your window - no danger
be the most commonly used principle for level washdowns onto the housing inventory costs of glass chips in the
measurement in the food beverage industry. - easy to clean and
always visible
production area
However, it is important to understand the
capabilities and limitations. Hydrostatic level
sensors work on the principle of measuring
the pressure exerted by the column of liquid
above the sensor membrane, usually expressed
in inches of water column (pressure = height x
density). Many times the influence of density
is forgotten leading to measurement errors or
overspill situations. Temperature fluctuations not
only cause density variations but can also result Large viewing
in zero point error of the level transmitter, which area offers
you optimum
is often seen after CIP when the sensor is heated observation
of process
up. For smaller balance tanks the temperature parameters
effects on the sensor can be very visible and lead
to overspills or cause air to be sucked into the
Material and
system if the transmitter is not capable of quickly design lend
compensating for rapid temperature swings. In themselves to
easy cleaning
large tanks and silos the temperature effect after
CIP usually prevents the use of the silo until the Easy-to-use on-site
sensor has cooled down and shows empty tank. operation saves time
If the transmitter zero point is adjusted while
hot, it will likely show empty tank while there
is still product in the tank, causing unnecessary
product loss. Many hydrostatic level sensors are
also damaged during manual cleaning of tanks
or due to mishandling during calibration; the
thin membrane is easily deformed or pierced.
The solution
Installing other technologies such as load cells,
capacitance, radar or other principles may
be an option but usually this involves major Reduce lifecycle costs with
changes to the tank. An easier way is to use
the Endress+Hauser Deltapilot S FMB70,
Deltapilot S FMB70
which has been developed specifically for these
• Watertight CONTITE™ measuring cell withstands harsh
applications. Utilizing a specially developed
wash down environments
sensor with advanced temperature compensation
• 316L stainless steel transmitter housing with dual
and extra thick membrane the FMB70 is
chambers rated NEMA 6P
suitable for balance tanks with measuring
• Alloy C 76 measuring membrane
span down to 4”HO and ranges up to 150
• High accuracy; 0.1% of span
psi for large silos and pressure applications.
• Reduced calibration frequency - long term stability
The FMB70 is available with all common
+/-0.05% per year
process connections including Tri-Clamp®
• Effective compensation of temperature effects
and Anderson style flush weld connections.
5

6. Critical control of cheese vats
Endress+Hauser temperature assemblies
ensure temperature control of cheese vats
with highest accuracy and redundancy.
The temperature measurement in a cheese
vat is considered a critical control point.
The curd is heated and cooled repeatedly
during the cheese making process and the
cheese quality and yield is highly dependent TMT 162
on accurate and reliable temperature
measurement. Traditionally, single RTDs
are used with little attention to accuracy The Endress+Hauser TMT16 transmitter comes
or back-up. For a minimal investment the standard with these functions and free software is
measurement can be upgraded to a dual provided allowing you to program the Callendar
RTD system with sensor matching for van Dusen coefficients for the sensor matching.
optimal accuracy and continuous monitoring A complete system consists of the TH 15 or
of sensor drift with alarm. The system is TH 13 dual RTD sensor and the TMT 16
configured to automatically switch over transmitter mounted directly to the sensor
to the back-up sensor in event of failure or remotely. Sensor failure or drift alarm is
– maintaining batch quality. clearly displayed on the backlit display and
The sensor matching can increase the TH 13 is transmitted via the 4 to 0mA HART®
accuracy up to 4 times, for example an output signal. The optional power supply
unmatched assembly can have an accuracy RN1N also serve as an alarm unit, converting
of +/- 0.44°F vs. +/- 0.11°F for a the HART alarm signal into a contact
matched system. RN221N output for additional operator visibility.
Solution for FDA proposed rule - MIG replacement
“The Food and Drug Administration (FDA) has MIGs to alternative TIDs. Although these TIDs remain out-of-compliance
issued a proposed rule which, if finalized, would until the proposal is finalized, FDA will consider, on a case-by-case basis,
benefit both consumers and the food industry exercising its enforcement discretion if the new devices are used in a manner
by enabling manufacturers of heat-processed consistent with the proposed rule. Processors who choose this option
low-acid canned foods to modernize their must comply with any revised requirements when the final rule becomes
equipment by using alternative temperature- effective.”1
indicating devices (TIDs). Under the proposal,
these devices, which are the state-of-the-art Endress+Hauser temperature assemblies provide the solution to
equipment for measuring and recording follow the intent of the FDA’s proposed rule.
temperatures, may be used instead of, or in A complete system consists of the TH 15 or TH 13 dual RTD sensor and the
addition to, conventional mercury-in-glass TMT 16 transmitter. Sensor failure or drift alarm is clearly displayed on the
thermometers (MIGs). backlit display and is transmitted via the 4 to 0mA HART output signal. The
power supply RN1N serve as an alarm unit, converting the Hart alarm
The agency will allow low-acid canned food signal into a contact output. The system can be configured to automatically
manufacturers who follow the proposed rule to switch over to the back-up sensor in event of failure – maintaining batch
change immediately from the currently required quality. The sensor matching increase the accuracy up to 4 times, for example
an unmatched assembly can have an accuracy of +/- 0.44°F vs. +/- 0.11°F
for a matched system.
Batch records are easily recorded and maintained with the Memograph M
information manager. Designed for use in accordance with 1CFR part 11
the Memograph M is easily configured for up to 20 individual channels.
Information collected is securely retrieved directly on the unit or via Ethernet
connection.
1. Excerpt from FDA news release P07-43, March 13, 007
6
Memograph M

7. Service from Endress+Hauser
Endress+Hauser’s Service department is dedicated to keeping your plant working efficiently seven days-a-
week, 24 hours-a-day. Technicians are located throughout the country to provide various levels of support
for you and your instruments.
Start-up service
Delays and production losses can far exceed the costs of
planned start-up! A high percentage of instrument problems
can be traced to start-up by unqualified personnel. These
can be prevented by scheduling a trained Endress+Hauser Maintenance / Verification
service technician to be on-site during start-up. In many processes, the function of flowmeters must be
periodically checked and tested due to internal or legal
Basic factory warranty is extended from 1 to 3 years when requirements. Fieldcheck™ is a test and simulation
start-up is purchased on your instrumentation order. Ask for device that permits regular on-site checking of your
start-up to be quoted with your new instruments. installed flowmeters without the need of removal or
www.us.endress.com/start-up process interruption.
Preventative Maintenance Agreements
Planned maintenance lowers costs
To ensure optimum performance and help extend the life
of your instruments, our skilled service engineers perform
periodic checks (including any necessary adjustments), and
issue a report confirming the instrument’s performance.
Additionally, we provide specific recommendations for
maintenance of the equipment under the agreement.
www.us.endress.com/agreements
FieldCheck (traceable test result) 7
7

8. Your local partner:
Alabama Florida Louisiana MRC Technologies Ohio Utah
TriNova, Inc. AMJ Equipment Corp. FOR MUNICIPAL Newbury Park, CA Forberg Scientific, Inc. Weidner Associates
Mobile, AL Lakeland, FL INDUSTRY 805-498-3811 Cleveland, OH Midvale, UT
51-378-7837 863-68-4500 Endress+Hauser 16-71-6600 801-565-9595
Houston, TX New Hampshire
TriNova, Inc. TriNova, Inc. 713-300-600 O‘Connor George E. Booth Vermont
Bessemer, AL Mobile, AL Senecal, Inc. Co., Inc. O‘Connor
05-46-0494 51-378-7837 Maine Sutton, MA Indianapolis, IN Senecal, Inc.
O‘Connor 508-865-5600 317-47-0100 Sutton, MA
Alaska Georgia Senecal, Inc. 508-865-5600
Artic Controls, Inc. AMJ Equipment Corp. Sutton, MA New Jersey Oklahoma
Anchorage, AK Savannah, GA 508-865-5600 Endress+Hauser M D Controls Virginia
907-77-7555 91-898-0388 Chalfont, PA Tulsa, OK Applied Engineering, Inc.
Maryland 15-8-4710 918-664-7511 Midlothian, VA
Arizona Hawaii Philip R. Walker 804-378-3550
Industrial Automation IPT Group Associates FOR MUNICIPAL Oregon
Services San Francisco, CA Cockeysville, MD INDUSTRY Tourangeau Nor Wes Philip R. Walker
Chandler, AZ 415-956-9005 410-666-14 Dave Heiner Tualatin, OR Associates
480-413-0899 Associates, Inc. 503-691-6100 Cockeysville, MD
Idaho Massachusetts Parsippany, NJ 410-666-14
Arkansas Tourangeau Nor Wes O‘Connor 973-99-9990 Pennsylvania
TriNova, Inc. Tualatin, OR Senecal, Inc. LH Boleky Washington
Mobile, AL 503-691-6100 Sutton, MA LRM Inc. Coraopolis, PA Tourangeau Nor Wes
51-378-7837 508-865-5600 Souderton, PA 41-64-079 Tualatin, OR
Weidner Associates 15-71-4840 503-691-6100
Endress+Hauser Midvale, UT Michigan Endress+Hauser
Houston, TX 801-565-9595 Durable Controls New Mexico Chalfont, PA Washington D.C.
713-300-600 Hartland, WI Beabout Company 15-8-4710 Philip R. Walker
Illinois 6-367-4900 Littleton, CO Associates
M D Controls Antel Corporation 303-795-1000 Forberg Scientific, Inc. Cockeysville, MD
Tulsa, OK Willowbrook, IL Forberg Scientific, Inc. Cleveland, OH 410-666-14
918-664-7511 630-887-8910 Troy, MI Industrial Automation 16-71-6600
48-88-5330 Services West Virginia
California George E. Booth Chandler, AZ FOR MUNICIPAL LH Boleky
IPT Group Co., Inc. Minnesota 480-413-0899 INDUSTRY Coraopolis, PA
San Francisco, CA Indianapolis, IN Engineered Sales LRM Inc. 41-64-079
415-84-3679 317-47-0100 Company Pan-Tech Controls Souderton, PA
Bloomington, MN Arlington, TX 15-71-4840 Wisconsin
Process Instruments Miller Mechanical 95-888-1131 817-640-33 Durable Controls
Controls, LLC Specialties, Inc. Rhode Island Hartland, WI
Bakersfield, CA Des Moines, IA Mississippi New York O‘Connor 6-367-4900
661-37-7000 515-43-487 TriNova, Inc. BurnsCascade Controls Senecal, Inc.
Mobile, AL Instrumentation Sutton, MA Engineered Sales Company
ProFlow Dynamics R.L. Weisheimer 51-378-7837 Syracuse, NY 508-865-5600 Bloomington, MN
Corona, CA Assoc. 315-4-061 95-888-1131
951-79-5500 Columbia, IL FOR MUNICIPAL South Carolina
618-81-4148 INDUSTRY Endress+Hauser Endress+Hauser Wyoming
Endress+Hauser Rieth Corporation Chalfont, PA Charlotte, NC Beabout Company
Brea, CA Indiana Gretna, LA 15-8-4710 704-969-7974 Littleton, CO
714-54-8391 George E. Booth 504-36-7604 303-795-1000
Co., Inc. FOR MUNICIPAL South Dakota
FOR MUNICIPAL Indianapolis, IN Missouri INDUSTRY Engineered Sales Weidner Associates
INDUSTRY 317-47-0100 Compass Controls and Burgh Schoenenberger Company Midvale, UT
MRC Technologies Instrumentation Pavillion, NY Bloomington, MN 801-565-9595
Newbury Park, CA Antel Corporation Shawnee, KS 585-584-3768 95-888-1131
805-498-3811 Willowbrook, IL 913-441-9779 Puerto Rico
630-887-8910 Dave Heiner Tennessee Engineered Parts
Colorado R.L. Weisheimer Associates, Inc. AMJ Equipment Corp. Services, Inc.
Beabout Company Iowa Assoc. Parsippany, NJ Greeneville, TN Vega Alta, PR
Littleton, CO Miller Mechanical Columbia, IL 973-99-9990 43-639-3800 787-883-8880
303-795-1000 Specialties, Inc. 618-81-4148
Des Moines, IA North Carolina TriNova, Inc.
Connecticut 515-43-487 Montana Endress+Hauser Memphis, TN
O‘Connor Brock Easley, LLC Charlotte, NC 901-684-7099
Senecal, Inc. Kansas Billings, MT 704-969-7974
Sutton, MA Compass Controls and 406-5-1515 Texas
508-865-5600 Instrumentation FOR MUNICIPAL Endress+Hauser
Shawnee, KS Nebraska INDUSTRY Houston, TX
Delaware 913-441-9779 Miller Mechanical Johnston, Inc. 713-300-600
Endress+Hauser Specialties, Inc. Indian Trail, NC
Chalfont, PA Kentucky Des Moines, IA 704-81-6777 M D Controls
15-8-4710 George E. Booth 515-43-487 Tulsa, OK
Co., Inc. North Dakota 918-664-7511
Philip R. Walker Indianapolis, IN Nevada Engineered Sales
Associates 317-47-0100 IPT Group Company Measurement Resources
Cockeysville, MD San Francisco, CA Bloomington, MN Corpus Christi, TX
410-666-14 LH Boleky 415-84-3679 95-888-1131 361-88-3444
Coraopolis, PA
FOR MUNICIPAL 41-64-079 Weidner Associates Pan-Tech Controls
INDUSTRY Midvale, UT Arlington, TX
LRM Inc. 801-565-9595 817-640-33
Souderton, PA
15-71-4840
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