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News15
Less Maintenance and Better Performancein Sugar and Ethanol ProductionThe more critical a pH measurement is, the more accurate and reliable
the pH measurement system has to be. METTLER TOLEDO offers intelligent,
high performance sensors with advanced diagnostic capabilities, that
predict their own maintenance requirement – the perfect solution for a
Brazilian group trying to reduce maintenance costs.
Brazilian sugar producerOur customer is one of the biggest sugar
and ethanol production groups in Brazil.
It has been producing sugar for almost
one century and ethanol for over three
decades. At peak production it produces
15,000 sacks of sugar per season.
ApplicationsTwo of the most critical applications in
sugar and ethanol production from cane,
are liming and fermentation.
In the first process, milk of lime (CaO
particles suspended in water) is pumped
into raw sugar juice for three reasons:
n to neutralize acids in the cane, there-
by preventing the sucrose from
turning into starch or other forms of
sugar
n to precipitate the organic acids into
salts for subsequent removal
n to keep foreign matter in suspension
until it can be removed by filtration.
pH measurement is used as an indicator
of the right amount of CaO to be added.
The measurement is challenging as the
lime tends to adhere to the electrode,
which therefore requires regular clean-
ing.
Anaerobic fermentation of the cane juice
produces ethanol, which is later separated
during a distillation process. Yeasts sup-
porting fermentation require tightly
controlled temperature and pH conditions
for maximum conversion of the natural
sugars into alcohol. For best results, the
pH value of the juice must be held within
INGOLD Leading Process Analytics
Sugar Starch & YeastPerspectives in Liquid Process Analytics
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2 METTLER TOLEDO Sugar News 15
Publisher / Production Mettler-Toledo AG
Process Analytics
Im Hackacker 15
CH-8902 Urdorf
Switzerland
IllustrationsMettler-Toledo AG
Marlee, Margouillat, Stormur, Imdan
| Dreamstime.com
Subject to technical changes.
© Mettler-Toledo AG 12/09
Printed in Switzerland.
3.0 – 3.5 during the fermentation pro-
cess.
Our customer is already a user of
METTLER TOLEDO pH systems in other
areas of the mill. Though very satisfied
with the equipment, with the new systems
the customer wanted a lower maintenance
burden and was looking for a solution to
the problem of signal degradation due to
the humid process conditions.
ISM delivers the main require-mentsTwo METTLER TOLEDO systems were
installed. For the liming process an
InPro 4800 i pH electrode was chosen for
its resistance to high temperatures and
alkali solutions. For the fermentation
process the InPro 3250 i was selected due
to its excellent measurement performance.
The M400 was installed as the transmitter
for both systems.
The electrodes were chosen not just for
their suitability to the processes. The “i”
suffix indicates that they are part of
METTLER TOLEDO’s Intelligent Sensor
Management (ISM) range of sensors, and
it is the ISM features that provide the vital
requirements the customer requested.
Microchips in the head of the electrodes
monitor the sensors for signs of stress or
degradation and transfer the information
to the transmitters. The advanced diag-
nostics features of ISM systems interpret
the sensor data to inform the user when
electrode cleaning or calibration is re-
quired. Thus maintenance can take place
only when it is needed, rather than wait-
ing until measurement performance from
the sensor is reduced, or conducting regu-
lar maintenance when it may not be
necessary.
Stay one step ahead of maintenance with ISM
Intelligent Sensor Maintenance reduces the installation, main-tenance and calibration effort for METTLER TOLEDO’s digital sensors to a minimum. This considerable improves process reliability, productivity and sys-tem availability.
Find out how ISM can help you, at:
Best Practice
www.mt.com/ISM
www.mt.com/InPro3250i
In an ISM system, communication be-
tween sensor and transmitter is via a
digital signal. Low-impedance digital
signals are unaffected by humid condi-
tions, even over long cable lengths, giving
the customer robust data at all times.
Satisfied customerThe combination of reliable signal, pre-
dictive maintenance and dependable,
accurate pH measurement is exactly what
our customer was looking for. Such is
their satisfaction that they are now con-
sidering upgrading their other METTLER
TOLEDO installations with ISM equip-
ment.
Discover more at:
Transmitter M400
pH electrodeInPro 3250 i
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Transmitter M420
METTLER TOLEDO Sugar News 15 3
Cond
uctiv
ity T
rans
mitt
ers
M420 2-wire transmitter, a reliable solution for hazardous area applications Designed for hazardous area operation,
the M420 2-wire transmitter is the perfect
solution for advanced process control. Key
features include the IP 67 rated enclosure
and options for additional functions e.g.
for extended logbook or a second output
signal. As the 2-wire transmitter with its 4
- 20 mA output signal provides HART
communication as standard, the M420
represents a future-proof investment for
integration into your process control sys-
tem.
Trouble-free Conductivity MeasurementA New Team of 2- and 4-Wire TransmittersMonitoring conductivity is an excellent way of ensuring product quality,
reducing product loss and optimizing processes. The latest editions to
our conductivity transmitter line feature Intelligent Sensor Management
(ISM) for even greater productivity.
Important measurementConductivity measurement with 2-e or 4-e
sensors is common for monitoring water
quality during water purification. For
concentration determination through
chemical processes, very often an induc-
tive conductivity measuring approach is
chosen.
M400 4-wire transmitter, a versatile solution for standard applications Thanks to its multi-parameter capabili-
ties, universal power supply, number of
current output signals and relays, the
M400 4-wire transmitter is a particularly
versatile instrument. The Intelligent
Sensor Management (ISM) Plug and
Measure function and Quick Setup routine
enables quick and simple commissioning;
while the display provides measurement
values from two sensors, and alarms for
out-of-spec conditions, plus warnings of
potential sensor failure.
ISM – the leading sensor technologyMETTLER TOLEDO’s new transmitters all
feature ISM technology for better process
and maintenance control of measurement
points, without compromising process
reliability. The mixed mode input feature
of the transmitters means that digital ISM
sensors or traditional analog sensors can
both be connected. The transmitters can
be used in combination with 2- or 4-elec-
trode sensors as well as inductive
conductivity sensors. The large backlit
display with its clearly structured menus
ensures intuitive and easy operation.
The METTLER TOLEDO solution METTLER TOLEDO is a total solution
provider with many years’ experience in
conductivity measurement. Our portfolio
covers various transmitter lines, analog
and innovative ISM technology digital
sensors, as well as housings for a wide
range of applications.
Discover more at:
www.mt.com/M400www.mt.com/M420
Transmitter M400
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4 METTLER TOLEDO Sugar News 15
Yeas
t Fer
men
tatio
n
n DO measurement system:
M400 transmitter in combination with
DO sensor InPro 6850 i.
The digital pH electrode InPro 3100 i fea-
tures special design elements that
effectively prevent clogging and fouling.
This makes it ideal for use in yeast fer-
mentation as contamination by bacteria
represents the greatest risk factor during
all stages of production. It is therefore
essential to maintain a slightly acidic pH
value and to sterilize the measuring
equipment and culture medium (molas-
ses) in order to prevent any bacterial
growth.
The same requirements can also be fully
met by the DO sensor InPro 6850 i, which
combines hygienic design (sterilizable or
autoclavable and hygienically polished
surface finish) with exceptional measure-
ment accuracy.
The use of these two measurement systems
from METTLER TOLEDO guarantees
accuracy and dependability of the mea-
surement values, as well as full process
reliability.
ResultsOver many tests of the process parameters,
precise pH and DO measurement values
were established. This enabled the consid-
erable improvement in production
efficiency and product quality that the
production engineers were looking for.
The tests showed that for optimal process
results, pH values should lie between 4.5
and 5 during preparation of the molasses,
and between 5 and 8 during the different
fermentation stages. It was also possible to
determine the precise amount of dissolved
oxygen required in relation to the amount
of substrate added during the course of the
reaction phase. Achieving this balance
would prevent formation of ethanol (and
other volatile dissolved substances) during
the transition from aerobic to anaerobic
fermentation.
Scale upThe pilot phase results made it possible to
extrapolate the values required for direct
application in large volume production
fermenters (10,000 liters and 15,000 liters).
Additional pH and DO measurement sys-
tems were purchased from METTLER
TOLEDO which are now being used to
monitor the different fermentation stages
for smooth running of full-scale produc-
tion.
To improve product yield and quality at
your facility, go to:
How Does Measuring pH and DO In-lineImprove Yeast Production?In-line measurement of pH and dissolved oxygen (DO) values is an
effective way of monitoring primary and secondary yeast fermentation,
with the added bonus of improving yield and quality.
Production of baker’s yeastA French group specializing in the pro-
duction of baker’s yeast was convinced
that they could achieve significantly im-
proved product yield and quality if they
could more precisely control the different
fermentation processes. In particular they
wanted to test the influence of pH and DO,
and to this end set up a 100 liter pilot
fermenter with the pure yeast strain
Saccharomyces cerevisiae together with
molasses (a by-product of sugar rich in
saccharose).
Measurement of pH and dissolved oxygenProduction engineers at the factory knew
that to optimize fermentation they would
need dependable, continuous and real-
time pH and DO measurement values.
This would allow rapid intervention in the
fermentation process and timely adjust-
ment of external parameters in the event
of out-of-spec conditions. They asked
METTLER TOLEDO for measurement so-
lutions that would best meet their
requirements.
The solutions provided by METTLER
TOLEDO consisted of:
n pH measurement system:
M400 transmitter, InPro 3100 i pH
electrode and static housing InFit 761
CIP for insertion of the electrode into
the fermenter.
www.mt.com/pro-pHwww.mt.com/DO
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METTLER TOLEDO Sugar News 15 5
InPro 6850 i DO sensorn Low maintenance and long lifetime
n Long lasting membranes
n Easy-to-replace membrane body
n ISM technology for easier installation,
maintenance and calibration
n Quick-disconnect interior body
n In situ fully autoclavable or steriliz-
able
InPro 3100 i pH electroden Low maintenance and long lifetime
n Gel electrolyte – no refilling required
n Resists fouling and clogging – less
cleaning required
n ISM technology for easier installation,
maintenance and calibration
n In situ fully autoclavable or steriliz-
able
n Watertight process connector for easy
connection
Be clever – with Intelligent Sensor Management (ISM)
Thanks to ISM technology, digi-tal sensors are able to monitor themselves in real time for possible defects, providing you with status information to pro-actively identify maintenance requirements.
Discover more at:
Best Practice
www.mt.com/ISM
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6 METTLER TOLEDO Sugar News 15
Cabl
eles
s So
lutio
n
tion. It is also the perfect answer for
remote monitoring tasks.
The W100 supports ISM sensors for pH, DO
as well as 4-E conductivity, which are
compatible with the advanced transmitter
line M400 or the value transmitter line
M300.
Additional benefits of the cableless solu-
tion include the long battery lifetime of up
to 6 months, and the communication
range of up to 150 meters.
Discover more at:
Tricky Sensor Installation Point?Go Cableless!Proper wiring between sensor and transmitter can be very costly, especially
in locations with limited access or where moving parts can be a hazard.
The cableless solution W100 gives you the option to solve expensive and
challenging installation conditions at a very reasonable cost.
No more cablesWith the W100, METTLER TOLEDO offers
an innovative solution for cost-intensive
measurement point installations. Based
on reliable and industry-proven wireless
technology (according to IEEE802.15.4),
the W100 replaces the cable between
METTLER TOLEDO Intelligent Sensor
Management (ISM) sensors and the
transmitter, and provides bi-directional
digital data transfer with full calibration
and diagnostics functionality.
Real-time monitoring of the measurement
value as well as auto-recognition of the
sensor is ensured. Additionally, the W100
convinces with its very simple one button
operation, which is also the basis for the
easy pairing between transmitter and
sensor. Thanks to the LED display, the
state of the W100 can be recognized at a
glance. Installation at existing ISM mea-
suring points is simple as there is no need
to change any transmitter settings.
For many applicationsSince there is no cable to be laid, the sys-
tem offers great advantages in applications
where high installation costs due to
physical barriers or contamination risks,
exist. Also, in applications where the
measuring point is needed only temporar-
ily, where the installation of the sensor
has to be changed several times, or where
the sensor is mounted on a moving part,
the W100 is a highly cost-efficient solu-
Stay one step ahead of maintenance with ISM
A METTLER TOLEDO ISM mea-suring system with the W100 will not just save on installation costs; ISM also reduces the maintenance and calibration effort to a mimimum. This con-siderably improves process reliability, productivity and sys-tem availability.
Find out how ISM can help you, at:
Best Practice
www.mt.com/ISM
www.mt.com/W100
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METTLER TOLEDO Sugar News 15 7
O 2 G
as M
easu
rem
ent
This technology, with a proven industrial
track record due to its simplicity and rug-
gedness, is ideally suited for the in-situ
measurement of gaseous oxygen.
METTLER TOLEDO offers a comprehen-
sive range of amperometric systems with
sensors for wide application coverage, re-
tractable housings for sensor extraction
without process interruption, and trans-
mitters for signal conversion and
connection to process control systems
using HART, FOUNDATION fieldbus or
PROFIBUS. Naturally, the complete mea-
surement system is available with ATEX
Zone 0 / FM Class 1 Div 1 approval if re-
quired.
Amperometric sensors can be maintained
in two minutes, with minimum impact on
your running process. All that is required
is to replace the membrane body and fill
it with fresh electrolyte solution.
Subsequent calibration can be performed
on site using air as a calibration gas.
Measure Oxygen Where it Really MattersDirectly in Your ProcessPerformance of gaseous oxygen measurement is now redefined with
METTLER TOLEDO’s amperometric systems. They not only allow reliable
and stable measurement, they are inexpensive to maintain and, what’s
more, do not require any gas sampling system.
Unwanted oxygenOxygen levels in industrial processes are
heavily controlled to contain the risk of
explosion of flammable liquids and dusts,
as well as to protect products against oxi-
dation. Not only is oxygen monitoring a
critical issue in transport systems, storage
tanks or centrifuges, it can also nega-
tively affect the yield of a chemical
reaction in a vessel.
Many solutions – which is best?When selecting a vendor for a measure-
ment system, technologies and solutions
abound, but in many cases a trade-off
exists between sufficient performance and
reliability, and reasonable maintenance
effort and system availability. In order to
function correctly, paramagnetic systems
need to protect the measurement cell from
heat, moisture and / or corrosive gases.
However, the more instruments there are
between the process and the sensor, the
longer the response time will be and the
higher the probability of system failure.
Amperometric: simple and reliableLooking at the field of dissolved oxygen
measurement however, membrane-based
amperometric sensors using the Clark
principle offer an alternative. For decades
they have demonstrated optimum perfor-
mance in a wide range of applications
ranging from fermentation processes in
breweries, in biopharmaceutical indus-
tries or in chemical process applications.
www.mt.com/O2-gas
Intelligent sensors for smart processesAll amperometric sensors from METTLER
TOLEDO are available in digital versions
equipped with Intelligent Sensor
Management (ISM) technology. With the
Plug and Measure feature, pre-calibrated
sensors can be immediately used in the
process, minimizing the time necessary
for maintenance and without the need for
specialist know-how. Additionally, ISM
sensors have built-in self-diagnostic
abilities in order to detect early signs of
failure such as low electrolyte levels, and
alert users before measurement quality or
process availability is impacted.
If you want to save costs on O2 measure-
ment at your facility, go to:
www.mt.com/ISM
Dissolved oxygen sensor InPro 6850 i
F O2
Paramagnetic system
N2 in
METTLER TOLEDO solution
The sample path through a The METTLER TOLEDO solution paramagentic system is long and slow. measures directly in the vessel – immediately.
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8 METTLER TOLEDO Sugar News 15
Com
preh
ensi
ve W
ebsi
te The Information you Want is at www.mt.com/pro
The METTLER TOLEDO Process Analytics web-site contains a vast amount of up-to-date information on all our products and services.
Content is localized for your country and tailored to suit your selections.
Simple layout allows you to quickly find the infor-mation and features you are looking for.
n Learn about our most recent product develop- ments
n Register for free webinars
n Request further information on products and services
n Obtain a quote quickly and easily
n Download our latest white papers
n Read case studies relevant to your industry
n Access buffer and electrolyte solution certificates
n and more...
A typical Product page: with Features
and Benefits and quick access to rele-
vant application information,
related products and downloads
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METTLER TOLEDO Sugar News 15 9
The Information you Want is at www.mt.com/pro
Search by Product or by Application n Read the latest product news
n Access our Newsletter archive
n Find out when our next Trade
Show or Exhibition is in your
area
n Register for free webinars
presented by our industry
experts
n Download our White PapersApplication pages help guide you to the
products that are right for your processes
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10 METTLER TOLEDO Sugar News 15
Plug and Measure
Inte
lligen
t Sen
sor M
anag
emen
t Intelligent Sensor Management Reduces Life Cycle Costs and Improves Process Safety
Intelligent Sensor Management (ISM)ISM reduces the installation, maintenance and calibration effort for METTLER TOLEDO’s digital sensors to a minimum. This considerably im-proves process reliability, productivity and system availability.
Reliable installationDigital communication between sensor and transmitter means signal is always reliable and unaffected by moisture.
Intelligence – starts in the headISM sensors are equipped with integrated elec-tronics in the sensor head that store all relevant sensor parameters and includes algorithms for enhanced sensor diagnostics.
Predictive maintenanceIntelligent diagnostics information is calculated and displayed on the sensor's transmitter and tells you if the sensor needs maintenance or replacement – no more downtimes due to sen-sor failure!
System integrationKey ISM parameters can be fully integrated in a process control system via PROFIBUS® PA or FOUNDATION Fieldbus™.
■ Sensors are immediately recognized when connected to the transmitter – eliminating difficult configuration procedures.
■ Operational availability of measurement point within seconds.
■ Wireless module available for transmission from sen-sor to transmitter – no need for costly cable installation.
■ Sensors can be pre-calibrated in the lab and stored for later use, saving time and increasing operational avail-ability.
METTLER TOLEDO’s ISM product range includes…
… a wide range of sensors for … advanced single- and multi-channel transmitters … software applications ■ pH ■ 4-wire ■ iSense Asset Suite ■ dissolved and gaseous O2 ■ 2-wire ■ pH data logger ■ conductivity ■ wireless module ■ turbidity
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METTLER TOLEDO Sugar News 15 11
Intelligent Sensor Management Reduces Life Cycle Costs and Improves Process Safety
Diagnostics Maximum Performance
■ Any sensor maintenance requirement is recognized at an early stage, reducing downtimes and minimizing plant operation costs.
■ Dynamic Lifetime Indicator estimates in real time the remaining lifetime of the sensor.
■ CIP / SIP cycles counted automatically.
■ Sensor spider diagram for fast troubleshooting.
■ iSense Asset Suite software offers you a unique means of optimizing the performance of ISM sensors for en-hanced reliability and process safety.
■ Key Performance Table enables you to evaluate the condition of an ISM sensor at a glance, without the need of a transmitter.
■ Documentation of every calibration as well as the entire sensor history – documentation requirements to regu-latory standards are easily met.
METTLER TOLEDO’s ISM product range includes…
… a wide range of sensors for … advanced single- and multi-channel transmitters … software applications ■ pH ■ 4-wire ■ iSense Asset Suite ■ dissolved and gaseous O2 ■ 2-wire ■ pH data logger ■ conductivity ■ wireless module ■ turbidity
Intelligence starts in the head
www.mt.com / ISM
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Visit for more informationwww.mt.com/pro
Accurate Phase Separation with Intelligent Conductivity SensorsProduct losses will be minimized and your yield maximized if you use a faster and more accurate phase separation monitoring solution. The new conductivity sensors from METTLER TOLEDO measure more quickly and more precisely – that means better phase separation control, increased yield and lower costs. Further, with built-in Intelligent Sensor Management (ISM) tech-nology, sensors carry their own up-to-date status data which is automatically uploaded to the transmitter, thus allowing fast and error-free start up.
When precise measurement and easy handling are important, think ISM conductivity sensors from METTLER TOLEDO.
www.mt.com/Cond
Get in-line with METTLER TOLEDO
Mettler-Toledo Ind. E Com. Ltda.Divisão ProcessoAlameda Araguaia, 451Alphaville - Barueri - SP - 06455-000Fone: (11) 4166-7444 (vendas) / 4166-7400 (pabx)Fax: (11) 4166-7401E-mail: [email protected]
Mettler-Toledo S.p.A. Via Vialba, 42 20096 Novate Milanese (MI) Phone: +39 02 333 321 Fax: +39 02 356 29 73 E-Mail: [email protected]
Mettler-Toledo AGProcess AnalyticsIm Hackacker 15, CH-8902 Urdorf, Switzerland