application 241 en - krohne

Equipping an inline blending system with measurement technology

•Controllingandmonitoringtheinlineblendingprocesses•Highdemandsplacedonmeasurementtechnologyused•Completesolutionwithstandarddevicesfromtheonesource

1. Background KHSAGisoneoftheworld'sleadingmanufacturersoffillingandpackagingmachinesaswellasprocesscontrolsystemsforthefoodandbeverageindustry.Inadditiontocomponentsusedtofill,cleanandpackageliquids,KHSalsosuppliestheentirerangeofprocesstechnology,includingsystemsforblendingsyrup.

TheKHSInnoproParamixCisanewlydeveloped,fully-automatedblendingsystemfeaturinghorizontal,two-stagevacuumdeaeration.Itisaflexiblesystemsuitedtotheproductionoffruitjuices,nectarsandthecarbonationofmineralwater.Theblendingsystemconsistsofthreecomponentsandcanbeexpandedtoincludeafourthorfifthcomponentifneeded.Softdrinkscanbeblendedorre-dilutedinalargerange.Asanoption,finishedbeveragescanbesupplied,carbonatedand/orchilled.Likewise,beercoolerscanalsobeblendedand/orchilled.

Thefinished,carbonatedbeverageisstoredfortheinteriminabuffertankinjectedwithCO2.Fornon-carbonatedproducts,nitrogenorsterileairisusedoptionallyforsuperposition.ThefinishedproductisthensuppliedtothefillingmachineandbottledinPETorglassbottlesordrinkcans.

TheKHSInnoproParamixCbelongstothelatestgenerationofblendingsystems.Thepurposeofdevelopingthisnewgenerationwastoachieveshorterproductchangeoverswhilemaintainingminimalproductloss.

Increasedautomationandareductioninthespacerequiredalsoplayedarole.Thankstoitscompactdimensions,thesystemcanbeputinastandardmarinecontainerandsenttothecustomer.Itsblendingcapacityisbetween6,000l/hand72,000l/h.

APPLICATION REPORT Food & Beverage

Application 241 EN.indd 1 05.05.2010 12:02:13 Uhr

2. Measurement requirements

Toensureahighdegreeofsystemautomation,theflowratesofthecomponentsintroducedmustbemeasuredatvariouspoints.Theseinclude:

• Mass flow measurement of syrup concentrate Themeasurementofsyrupisthemostimportantflowmeasurementperformedintheblendingsystem.Ontheonehand,syrupisthemostexpensivebeverageelementusedinproduction;ontheotherhand,ithasasignificantimpactontheflavouroftheendproduct.Inthepast,itwascommontomeasuresyrupusinganelectromagnetic(volume)devicebutthatmethodshouldbereplacedbymassflowmeasurement.Massflowmeasurementprovidesgreatermeasuringaccuracywhendeterminingtheflowrateanditalsodeterminesthesyrupconcentrationin°Brix.

• Volume flow measurement of non-carbonated mixed product Thequantityofthenon-carbonatedblendedproductshouldbedeterminedpriortocarbonation.Thismeasuringpointfeaturesasufficientlylong,straightinletdistancetoenabletheuseofdifferenttypesofmeasuringdevices.

• MassflowmeasurementofCO2tocarbonatetheblendedproduct ThismeasurementhelpstoensureaconsistentinputofCO2intotheliquid.Ameasuringprinciplethatprovideshighaccuracyregardlessofthepressureandtemperatureofthegaswasrequired.

• Visual monitoring of the minimum throughput by way of measuring the CO2 content Asanoption,KHSoffersCO2andBrixdeterminationintheblendedproductasameasurementofquality.However,thismeasurementrequiresaminimumflowthroughtheanalysisunitused.Theflowisthendisplayedonameasuringdevice.

Thereliablefunctioningofthemeasurementtechnologyintheblendingsystemshouldbeguaranteedineachprocessphase.Particularlyduringstart-upandshut-downofthesystem,thecorrectmixingratiomustbepreciselymaintainedinordertokeepsyrupandwaterlosstoaminimum.Thismeansthatthedevicesusedmustmeetavarietyofrequirementsincludingeasydrainageandalargeturndownratio.

Becauseofitscompactsize,thesystemgenerallycontainsnolongstraightinletdistances.Thispresentsanadditionalchallengeforthemeasurementtechnologyused.KHSwaslookingforanappropriatecustomisedsolutionfromtheonesourceifpossible.

3. KROHNE solution

KROHNEisthestandardsupplierofmeasuringdevicesforKHSandwonthecontracttoequiptheinlineblendingsystemwithmeasurementtechnology.Thediagramdepictsthedesignofthesystemwiththemeasuringdevicesinstalled.Thelevelmeasurementdepictedinthesyruptankandinthebuffertankisoptionalandisnottakenintoaccounthere.Thefillingequipmentisforillustrativepurposesonly;itisnotpartoftheblendingsystemandisalsonotconsideredinthiscase.

APPLICATION REPORT


Set-upoftheinlineblendingsystemconnectedtofillingmachine

1 2 3 3

A CB D

Filling machineMixing station

E

The measuring tasks in the inline blending system were tackled as follows:

3.1 Flow measurement of syrup concentrate

AnOPTIMASS7300Coriolismassflowmeterisusedtomeasurethehighlyviscoussyrup.

APPLICATION REPORT

Production stages

A DegassingofthewaterBMixingpumpC CarbonationDFinishedbeverageE Filling

Supplied components

1 Water2 Syrupconcentrate3 CO2


3.2 Volume flow measurement of the blended product

Thenon-carbonatedblendedproductismeasuredusinganOPTIFLUX6300electromagneticmeasuringdevicepriortocarbonation.

3.3 Mass flow measurement of CO2

ThequantityofCO2usedtocarbonatetheblendedproductismeasuredusinganOPTIMASS8300Coriolismassflowmeter.

3.4 Monitoring the quantity of CO2 in circulation

Asanoption,KHSoffersCO2andBrixdeterminationintheblendedproductasaqualitymeasurement.Theanalysisunitusedrequiresaminimumthroughputofliquid.AH250variableareaflowmeterisusedtovisuallychecktheminimumflowrateofapprox.300l/h.

APPLICATION REPORT


4. Customer benefits

KROHNEmetKHSrequirementswithstandardmeasuringdevices.InadditiontothebasicdemandssuchasCIP/SIPcapability,theselectionwasmadeonthebasisoftheadvantagesfortheindividualmeasuringpoints.Theyinclude

• Mass flow measurement of syrup concentrate TheOPTIMASS7300usedfeaturesintegratedmeasurementofBrixconcentration.Thismakesitpossibletoadjustthemassflowandprecisesyrupconcentrationpriortodosing.Dilutedsyrupphaseswhichmayoccurduringproductchangeovercannowbealmostcompletelyutilized.Thereisnownoneedtodiscardthewater/syrupmixingphases.Instead,theycanbeblendedintothefinisheddrinkusingtheKHSminBrix™controlunit.Thisresultsinareductioninsyruplossandannualsavingsinexcessof2,200litresofsyrupforthissystem.

Themeasuringdevicefeaturesasinglestraightmeasuringtubewithoutaflowsplitter.Thatmeansitiseasytoclean,thereisveryminimalpressurelossandiseasytodrain.Thisisarequirementsothesystemcanbeofferedtoendcustomerswhowanttofrequentlychangetheirproducts.

• Volume flow measurement of non-carbonated blended product TheasepticsealingconceptwascrucialinselectingtheOPTIFLUX6300.ThereisanEPDMsealbetweentheasepticprocessconnectionandtheflowmeter.Itisdesignedsothatwhenfacedwithanincreasedtemperature,itdoesnotexpandintothemeasuringtubebutratheritexpandsbackwardsintoanexpansionspace.Thismeansthatnodepositscanbuildupontheseal,endangeringthequalityoftheblendedproduct.Usingthissealpreventsalmostalltransferofaromafromproducttoproductfollowingachangeover.

Fortheenduserofthesystem(beverageproducer),theOPTIFLUX6300canalsotakeontheroleofcheckingthequalityoftheblendedproduct.Thedevicefeaturesanapplicationanddevicediagnosticsfunctionasstandard,enablingit,forexample,todisplaytheconductivityofthemediumandtooutputitviathecurrentoutputsorbus.Thebeverageproduceristhennotifiedwhenthereisadeviationfromtheaverageconductivityexpected.

Afurthercriteriumwastheavailabilityoflargernominalsizes:TheOPTIFLUXisavailableinthenominalsizesDN2.5toDN150withallindustry-specificasepticconnections.ThismeansthatevenwithlargenominalsizeslikeDN125andDN150,asepticmeasuringdevicescanbeusedandtheblendingsystemcanbeequippedwithalargerversionofthesamemeasuringdevicewithouthavingtoswitchsuppliers.

Ifendcustomersrequireevenhigheraccuracy,KHShasensuredthatKROHNEalsohasanalternativefortheseapplicationsintheformofamassflowmeter.

• MassflowmeasurementoftheCO2suppliedtocarbonatetheblendedproduct Atthismeasuringpoint,agasflowmeterthatcanreliablymeasureverylowgasquantitiesisrequired.Inthepast,thermalmassmeasuringdeviceswereusedbuttheycouldnotreliablymeasureiftheendcustomerwasusingmoistgas.Forthisreason,theywerereplacedbyOPTIMASS8300massflowmeters.

Thedevicefeaturestwobentmeasuringtubeswithflowsplitters(twintubeloop).Thankstothereductioninthecrosssectionandtheresultingincreaseintheflowvelocityofthegas,itcanevenmeasuresmallmassflowsofgas.

• Visual monitoring of the minimum throughput by way of measuring the CO2 content Areliablyfunctioningflowindicatorwasrequiredforthismeasuringtask.TheH250variableareaflowmeterusedmeasurestheflowpurelymechanicallywithoutapowersupplyandfeaturesaneasytoreaddisplay.Thisallowsfora"fleeting"visualchecktoascertainwhethertheCO2dosagecontainstherightamountofgas.

APPLICATION REPORT


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5. Products used

OPTIMASS 7300 C• Coriolismassflowmeterforliquidsandgases• Singlestraightmeasuringtube,easytoclean• Negligiblepressureloss• CertifiedtoEHEDGand3A

OPTIMASS 8300 C• Coriolismassflowmeterforliquidsandgases• Twoparallelbentmeasuringtubeswithflowsplitter

OPTIFLUX 6300 C• Electromagneticflowmeterforconductiveliquids• Specialsealingconceptpreventsproductbuild-uponsealingring• FDA-conformingmaterials• CertifiedtoEHEDGand3A

H250• Variableareaflowmeterforliquidsandgases• Alsoavailablewithstainlesssteelhousingforhygienicapplications

APPLICATION REPORT

Contact

PleasevisitourwebsiteforacurrentlistofallKROHNEcontactsandaddresses.


application 241 en - krohne

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