CIP Automation & Monitoring for Breweriesconvention2016.ibdasiapac.com.au/wp-content/... · •...
Transcript of CIP Automation & Monitoring for Breweriesconvention2016.ibdasiapac.com.au/wp-content/... · •...
CIP Automation & Monitoring for Breweries
March 17, 2016
Adam Friedler
Agenda
• Automation Opportunities
• Automation for CIP monitoring & optimisation
• Case Histories
• Questions
GOAL OF AUTOMATION IS UNCOVERING OPPORTUNITIES
CELLAR
BREWHOUSE
BOTTLING HALL
Bottle washer
Pasteurizer
Filler
Filter
Crate washer
Filtration
UTILITIES
for CIP
OngoingOperational
Pressures
TroubleshootingQuality Issues
LaborAvailability
Balancing &Prioritizing
Activities
DataOverload
StandardizingProcesses
BREWERIES ARE IN CONSTANT MOTION
CIP SIGNIFICANTLY IMPACTS OPERATIONS AND IS DIRECTLY RELATED TO CORPORATE DRIVERS
BRAND PROTECTIONProduct Safety & Quality
OPERATIONAL EFFICIENCYCleaning TimeOptimization
SUSTAINABILITYWater Savings
Energy ReductionWater Treatment
COMPLIANCE WITH REGULATIONS
Validation Support
PRODUCT INNOVATIONNew ProductC&S Support
Next step on our CIP evolution
1957
First CIP single use
1973
First spray ball
80s – 90s
Sanitizer innovation (Peracids)
2013
3DT CIP
CIP LEADERSHIP JOURNEY
WHAT IS 3D TRASARTM CIP?
PlantInstruments
Advanced Sensors
Proprietary Chemistry
Ecolab CIP Experts
Process Visibility & Action
3D TRASAR CIP is a constant CIP optimization program that uses advanced sensors that monitor traced chemistry providing process visibility with actionable data supported by Ecolab service and
industry leading expertise.
Secure analytical and reporting portal
Secure web access to customized monitoring and analysis portal
HOW DOES IT WORK?
OPC ServerHistorian Database
I/O and MESChemistry
Sensors Valves/Pumps Analog
Signals
Meters/SensorsDigital Signals
Local Server(SmartBox)
PLC Network
for CIP
WHAT ARE THE OUTCOMES?
Monitors CIP systems 24/7/365, safeguarding CIP quality, total cost and process optimization by:
Establishingconsistent CIPsfor eachobject/circuit
Tracking each CIPagainst itsoptimal CIPprofile
Flagging deviationsthat may impactproduct qualityand efficiencies
Identifyingoptimizationfor quality & cost
Providing benchmarkperformance toSOP’s & betweensystems
for CIP
WHAT DOES THE OUTPUT LOOK LIKE?
Resource Consumption1
for CIP
Resource Consumption1 Change to last 7 or last 28 daysView a different
facility
View 10-day trends for each resource
Electricity consumption in last 24 hours
Electricity consumption vs. the previous 24 hours
WHAT DOES THE OUTPUT LOOK LIKE?
WHAT DOES THE OUTPUT LOOK LIKE?
Top Consuming Washes2
Drill down to understand why cost is so high
What equipment is using the most thermal resources?
Quick links to view CIP run report and chart
WHAT DOES THE OUTPUT LOOK LIKE?
Top Consuming Washes2
Wash Summary and Identifying Deviations3
WHAT DOES THE OUTPUT LOOK LIKE?
Drill down for Detail on the Deviation
What Deviation is occurring?
Quick links to view CIP run report and chart
Do I Need to Know Immediately?
Wash Summary and Identifying Deviations3
WHAT DOES THE OUTPUT LOOK LIKE?
European Brewer Case Study
CIP automation helped a brewer achieve exceptional hygiene procedures while realisingsignificant operational savings.
Ecolab’s 3D TRASAR CIP Technology provided a major European brewer with the technology it needed to achieve its “Golden Hygiene Plan” while reducing costs and driving continuous improvement.
REDUCED ENERGY USAGE
SAVINGSSAVEDSAVED
OPERATIONAL EFFICIENCY
approx.
$4,900
pa
Over
$110K
REDUCED WATER CONSUMPTION FOR
STERILIZATION
TOTAL ECONOMIC
BENEFIT
approx.
$42,700
pa
(After Two Months)
for CIP
CASE STUDIES
High Temperatures
Situation:• 3DTRASAR for CIP shows that temperatures for caustic and
sterilization cycles consistently exceed the stated set points• Caustic: feed temp 85C, return temp 75C• Sterilization: feed temp 92C, return temp 80C
Opportunity:
• Reduce temperatures to optimal range
Solution:
• Optimized temperature programming to save energy
• Established tighter range for exception reports to monitor the change
Caustic cycle showing a return temperature of 90.70C should be no more than 750C
Sterilisation cycle showing a return temperature of 94.70C should be no more than 800C
3D TRASAR™ CIP Analysis: • Sanitizer pump fired, but no
sanitiser signal detected indicating several possible scenarios (empty drum, sensor not working, cracked tubing etc)
• This occurred for a number of washes before resolution
• 2nd chart demonstrates 3D TRASAR™ sanitiser signal verified
• Ability to set sanitizer concentration Exceptions and Notifications
No Sanitiser Signal
3DT Sanitiser Signal Verification
Pumpsignal activated
No traced sanitiser signal
Pumpsignal activated
Traced sanitisersignal
CASE STUDIES
Hot Water not Recirculated
SITUATION:
OPPORTUNITY:
• During sterilization of yeast storage vessels, 3D TRASAR for CIP found that hot water was pumped to drain and not recirculated
• 141 hl per wash sent to drain
• Recirculate hot water to capture savings
• Recommended improvements to water management in the vessel to ensure correct flow rates achieved
• Improvements enabled the hot water to be recirculated around the vessel
• Alternative solution: replace hot water with PAA
SOLUTION:
Estimated annual savings:
$30,714
$46,750Assuming 48 cleans/week
CASE STUDIES
Safety & Energy Cost Avoidance
SITUATION:
OPPORTUNITY:
• High start-up temperatures during all CIP cycles
• Avoid early equipment replacement
• Save energy
• Prevent scalding incident
• Account Manager confirmed high temperatures at source
• Plant to replace leaking valve
• On going notification to prevent future incident
SOLUTION:Supply Temperature
CIP Inactive CIP Active
Return Temperature
Fact Summary:
$7,000
$14,000
$15,000
Total: $36,000
CASE STUDIES
Product Quality issue IDENTIFIED
SITUATION:
OPPORTUNITY:
• Investigation of wash water consumption deviation found operator skipped the pre-rinse on the wash of Tank 8.
• Carry over of heavy soils into wash will prevent effective wash
• SSOP Compliance
• Supervisor trained Sunday operator with Wash Summaries.
• New Exception for extended rinse phase AND low volume could indicate improper CIP connections.
SOLUTION:
Training
‘"Rinse" Phase, between steps 3 and 5 for this object was less than 4 minutes or under 400 gallons…’3D TRASARTM for CIP Diagnostics System Notification
3D TRASAR(TM) for CIP Diagnostics System Notification:
CASE STUDIES
3 Burst Rinses Skipped
Proper Rinsing
CASE STUDIES
CIP automation helped dairy achieve
consistent Clean-in-Place performance
— and consistently high quality product
REDUCED WATER CONSUMPTION FOR
CLEANING
REDUCED CLEANING TIME
SAVEDCONSERVED
963,750
gallons 1,295
hours
REDUCED CHEMISTRY FOR
CLEANING
CONSERVED
3,000
gallons
• Generally 10 to 20% reductions in CIP operating costs seen.
• Results vary based on current state of CIP system and SSOP compliance.
CASE STUDIES
Identify equipment malfunctions; protect
assets from unneeded wear; direct PM
resources to problem areas
Real-timevisibility to plant
SSOP conformance; automatically track
improvement over time; reduced risk of
quality incidents
Real-time visibility of consumption metrics;
trending reports over time; identification
of largest resource drains
SustainabilityCorporateQuality
Engineering & Maintenance
Plant QualityAssurance
Production &Operations
Manage and reduce CIP time; reduce risk
of product loss due to improper CIP;
data driven projects to reduce costs
Visibility to leadingindicators of product
quality; manage exceptionsto SSOP; faster root
cause analysis
CONSISTENCY & OPTIMAL SYSTEM PERFORMANCE
SUMMARY
Thank You.
Questions?