Challenges and Expectations in Adopting Automation And Rolling...

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Certification

Education & Training

Publishing

Conferences & Exhibits

National Symposium on

Automation & Digital Transformation of

Food & Beverage Industry26th & 27th February 2016

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ARJUN KUMAR SAHUManager- Quality Assurance

Hindustan Coca-Cola Beverages Pvt Limited

[email protected]

Challenges and Expectations in Adopting

Automation

And Rolling out Digital Technologies in

Beverage Industries

Basics of Modern Industrial Automation

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Academic

- Post Graduate in Chemistry from Sambalpur University

Worked in:

- Hindustan Unilever Limited at Himachal Pradesh in Quality Assurance

- Asian Paints (I) Limited in Industrial Paint Operation at Hyderabad

Currently working with:

- Hindustan Coca-Cola Beverages Pvt Limited at Khurda and NE for 8

years in Quality Assurance

Arjun Kumar Sahu


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• Need of Automation

• Process Flow in Beverage Industry

• Automation systems in process Areas

• Automation in Cleaning & Sanitation Practices

• Advanced Technologies in Beverage Manufacturing

• Technology Solutions in Secondary Packaging

• Automation System in Warehousing

• Technology automation in Analysis

• Automation in Environment Monitoring

• Challenges with Automations

Agenda


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AUTOMATION…Need of the Hour..

Restriction to Manual interference

Reduction of workforce

Demand of High Productivity & Yields

Ensure Hygiene by Design

Control on monitoring

High adherence to compliance

Less dependency on individual skill

Waste reduction

Safety adherence in workplace


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PROCESS FLOW IN BEVERAGE INDUSTRY

AlkalinityReduction & Coagulation

DisinfectionCarbon

Purification

PolishingFiltration

EnhancedFiltration

TOPRODUCTION

SourceWater

MULTIPLE BARRIER WATER PURIFICATION SYSTEM

UV Treatment

HOT CARBON TREATMENT FOR SUGAR PURIFICATION

Receiving and Storageof Raw Materials

HC Treatment and Filtration of Sugar Syrup

Mixing & Blending ofConcentrate Base


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PROCESS FLOW IN BEVERAGE INDUSTRY

ContainerWashing

ContainerInspection

Beverage Proportioning

Filling & Capping

Coding & Labelling

Palletization

Warehousing Dispatch to

Market


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AUTOMATION IN WATER TREATEMENT PLANT- Coagulation System to Advanced Technologies

(RO/UF)

Effective purification of Water

Enhanced control on Quality measures

Reduced consumption of Chemical for

treatment

No generation of solid waste as process

output

High productivity of water


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AUTOMATION IN WATER TREATEMENT PLANT- Online Monitoring Of Water Quality

Continuous Monitoring of

pH/TDS/Chlorine concentration like

parameters

Can design effective control with

interlocks/alarms

Ease for workforce to address

multiple activities


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EVOLUTION FROM BATCH TREATEMENT OF SUGAR TO

CONTINUOUS SUGAR DISOLVING SYSTEM

Hygienically designed

High in productivity

No use of paper

Low solid waste generation

Operated by single workman

FILTER PRESS TO VERTICAL

FILTERS


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AUTOMATION IN PROCESS QUALITY MONITORING- Online Monitoring Of Sugar Syrup Quality

Continuous Monitoring of sugar

content

Eliminates the differences of analyst

error


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AUTOMATION IN PROCESS- Programmed Syrup Batch Preparation

PLC operated Batch Preparation

Value measurement through level

transmitter, online refractometer

Auto valve operation

Single manpower in place


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2AUTOMATION IN READY SYRUP PROCESSING

- Valve Clusters and Remove operation on Display

panel

Complete automation of processes,

change overs etc

Operated by single associate

through PLC

Multiple activities can be performed

at same time like tank change over

and CIP


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3AUTOMATION IN CLEANING AND SANITATION PRACTICES

- Closed Loop CIP With SCADA

Complete close loop cleaning

SCADA monitoring with remote

access

No manual intervention improves

safety

Flow/Temp/Concentration can be

monitored continuously


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AUTOMATION IN CLEANING AND SANITATION PRACTICES- Automated Hygiene Station

Sensor based cleaning &

drying of hands at hygiene

stations

Easy to place at all entrances


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AUTOMATION IN CLEANING AND SANITATION PRACTICES

- Integrated COP at Filler

Enhances Exterior cleaning

efficiency

Saves time for cleaning

Effective in cleaning hard to

reach corners


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AUTOMATION IN CLEANING AND SANITATION PRACTICES

- CLEANING TOOLS

Effective Cleaning

Less Manpower

Easy to clean and faster


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AUTOMATION IN PROCESS & FILLING

- COMBI Line with Blower & Filler In Same Ambience

Protection from

surrounding

contaminations

Hygienically designed

Blower & filler operated

by single manpower

Provides interlocking for

critical quality

parameters

Have inbuilt inspection

system for packing

materails


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AUTOMATION IN PROCESS & FILLING- TETRAPACK FILLING

State of the art

manufacturing

Sterile environment of

filling

Complete interlock to

ensure compliance

High performance in

productivity and quality


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9AUTOMATION IN PROCESS & FILLING

-Evolution From Manual Inspection To

ASEBI/FBI

High reliability in removing foreign

matters

No requirement of visual inspection

Reduces manpower employment

Increases productivity

Reduced Consumer Complaints

All Surface Electronic Bottle Inspection


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- Online COBRIX Analyzer For Beverage Quality Monitoring

Continuous monitoring of

Quality

Easy process capability study

Interlocks to control non

conforming product generation

Alert alarms for deviations


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- Complete Auto Set Up With SCADA Controlled

Pasteurization System In Juice Manufacturing

Reduces the risk of

contamination

Provides remote operation

Historic data can be exported

for analysis

Alarms for any process

disturbance


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AUTOMATION IN PROCESS & FILLING- CONTINUOUS OZONE MONITORING AND

CONTROL IN PDW MANUFACTURING

Continuous display of Ozone in

water

Highly reliable

Controls the non conformity

generation through interlocks

Alerts the high/low trend

Provides high assurance of

food safety


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AUTOMATION IN PROCESS & FILLING- Continuous Monitoring Of Line Efficiency

Monitors the output on hourly

frequency

Alerts all management

through SMS

Collects historic data for

review

Displays trends on screen

Helps analysis of break

downs


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4AUTOMATION IN PACKAGING LINE

-Uncaser/Casepacker In Packaging Line

Increase in productivity

Operated by single

manpower

Safety features are inbuilt


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AUTOMATION IN PACKAGING LINE

-Tray Packing In Tetrapack Packaging

No labour required

High in productivity

Safety ensured

Good quality of

packaging


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6AUTOMATION IN PACKAGING LINE

- Shrink Wrapping And Stretch Wrapping

Operated by single operator

Safety is highly adhered

Pallet formation and warehousing has

improved

Visibility of product in secondary packaging is

effective

Reduced spillage of product for rain or high

moisture environment.


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7AUTOMATION IN WAREHOUSING

- Auto Loading Docks

BEFORE- PALLEETIZED

VEHICLE LODED BY

FORLIFT

AFTER – AUTO LOADING DOCK- LODING

DIRECT FROM WATERHOUSE TO TRUCK

0

10

20

30

Before After

30

10

OUTPUT

LOADING TIME


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AUTOMATION IN WAREHOUSING

- Auto Stacking In Racks

Improves productivity

Better space management

Less use of forklifts/ less fuel

consumption

Increases safety at

workplace

Enhances life of palletized

FG


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AUTOMATION IN LABORATORY

- Rapid Micro Analysis For Juices

No media preparation

No generation of Bio waste

Immediate result output

Saves historic data

Avoids personal contamination risks

Evolution from filtration/spread

method of analysis to inject and

count microbes


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AUTOMATION IN LABORATORY

- Gas Volume and Sugar Content Analysis

High level accuracy in results

Ease to do analysis

Stores historic data

Eliminates analyst error

Takes less time for result


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AUTOMATION IN Environment Monitoring

- Online Monitoring at ETP

High compliance to statutory

norms

Alerts destabilization of quality

Stores Historic data for

analysis

Eliminates analyst error


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CHALLENGES WITH AUTOMATION

Complexity in the Operation

Adequate infrastructural requirement(Dust free ambience ,

continuous utility supply)

Skilled manpower to operate & trouble shoot

High mass nonconformity generation for failure of automation

Increased inventory management

Higher cost of maintenance

Increased capital investment

Increased Energy requirement


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….THANK YOU

Challenges and Expectations in Adopting Automation And Rolling...

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