Food Talkline Every Drop

Make every drop countHow to make the most of your raw materials and reduce waste

Promass S - reliable solution for your food and beverage productsPage 2 & 3

Managing wastewater and minimizing treatment fees in a yogurt plantPage 4

Critical control of cheese vats Page 6

talkline

Issue 12 • Volume 9

Endress+Hauser’s local service technicians are dedicated to keep your plant running 24/7Page 7

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.

Introducing the new Promass S

Promass S with stainlesssteel housing

Patented Torsion Mode Balance eliminates influence from external vibration

Ideal for:

• Sheer sensitive products • Fruit mixes• Meat slurries• Chocolate

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Close to you

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-170�5.

www.us.endress.com

Profit or loss - managing production costs

3

Endress+Hauser is a global supplier of process automation solutions. The power of this global company is realized by its local support to you. This support starts with excellent manufacturing facilities located within the US. ISO 9001-2000 certified manufacturing facilities and ISO 17025 certified calibration capability assure Endress+Hauser delivers highly reliable measuring instruments to customers throughout North and South America.

A network of skilled sales and service personnel are located throughout the US and Canada, ready to provide the support required. Regional sales and service locations assure there is someone available, in your time zone, to support you.

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.

The plant’s existing BOD determination method utilized a time profile of the plants effluent established by collecting and assaying samples every two hours over a �4 hour period for several years. Additional samples were collected as composites and assayed providing the plant with a daily BOD value. Since the standard laboratory method requires five days1 to produce a BOD result, it was impossible to identify and inform the treatment plant of a high BOD excursion in time for them to make an informed decision to divert the high strength stream.

Several online monitoring technologies were explored to address the situation in real time. The following online technologies were considered; COD (Chemical Oxygen Demand), TOC (Total Organic Carbon), optical (UV�54) and BOD. After evaluation and weighing the pros and cons of each technology and monitoring system, it was concluded that the continuous BOD measurement provided by the BIOX1010 was the best option. All of the above mentioned technologies are available from Endress+Hauser.

The Endress+Hauser BIOX 1010 employ the same measurement principle as the 5-day BOD test. The analyzer utilizes a live culture and measures

Case study: managing wastewater and minimizing treatment fees

the changes in its dissolved oxygen requirements. Unlike the 5-day test, the BIOX1010 is a real time, truly continuous BOD measurement, capable of detecting changes in dissolved BOD in as little as 3 to 5 minutes. Additionally, unlike the 5 day test, the biomass is populated with organisms found in the actual waste stream therefore emulating the actual conditions of the treatment plant. To protect the biomass from pH shocks, and optional bi-directional pH adjustment is available to keep the waste stream neutral. To remove particles larger than 500 um, a course particle sieve is incorporated into a unique, easy access fast by-pass loop is available.

As a direct result of the real time information available to the plant from the BIOX1010 BOD monitor, the yogurt plant is now able to provide early warning to the treatment plant of unintentional high strength excursions. But the greatest benefit to the yogurt plant is that they are now able to divert their high BOD flow to holding tanks and reintroduce the high BOD waste on a timed schedule. By keeping the plant in constant compliance with their NPDES permit limit has allowed the plant to eliminate surcharges. A second 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.

4

BIOX1010

1.Biochemical oxygen demand 5210 B 5-day BOD test, Standard methods for examination of water and wastewater 17th Edition 1989.

Reduce shrinkage and accidental spills

Hydrostatic level measurement continues to be the most commonly used principle for level measurement in the food & beverage industry. 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 in zero point error of the level transmitter, which is often seen after CIP when the sensor is heated up. For smaller balance tanks the temperature effects on the sensor can be very visible and lead to overspills or cause air to be sucked into the system if the transmitter is not capable of quickly compensating for rapid temperature swings. In large tanks and silos the temperature effect after CIP usually prevents the use of the silo until the sensor has cooled down and shows empty tank. 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 solutionInstalling other technologies such as load cells, capacitance, radar or other principles may be an option but usually this involves major changes to the tank. An easier way is to use the Endress+Hauser Deltapilot S FMB70, which has been developed specifically for these applications. Utilizing a specially developed sensor with advanced temperature compensation and extra thick membrane the FMB70 is suitable for balance tanks with measuring span down to 4”H�O and ranges up to 150 psi for large silos and pressure applications. The FMB70 is available with all common process connections including Tri-Clamp® and Anderson style flush weld connections.

Reduce lifecycle costs with Deltapilot S FMB70• Watertight CONTITE™ measuring cell withstands harsh wash down environments• 316L stainless steel transmitter housing with dual chambers rated NEMA 6P• Alloy C �76 measuring membrane• High accuracy; 0.1% of span• Reduced calibration frequency - long term stability +/-0.05% per year• Effective compensation of temperature effects

Large viewing area offers you optimum observation of process parameters

Clear polycarbonate window - no danger of glass chips in the production area

Modular concept reduces your inventory costs

All of the instrument info is laser-etched onto the housing - easy to clean and always visible

Water-tight design survives washdowns

Material and design lend themselves to easy cleaning

Easy-to-use on-site operation saves time

5

Critical control of cheese vatsEndress+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 on accurate and reliable temperature measurement. Traditionally, single RTDs are used with little attention to accuracy or back-up. For a minimal investment the measurement can be upgraded to a dual RTD system with sensor matching for optimal accuracy and continuous monitoring of sensor drift with alarm. The system is configured to automatically switch over to the back-up sensor in event of failure – maintaining batch quality. The sensor matching can 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.

The Endress+Hauser TMT16� transmitter comes standard with these functions and free software is provided allowing you to program the Callendar van Dusen coefficients for the sensor matching.A complete system consists of the TH 15 or TH 13 dual RTD sensor and the TMT 16� transmitter mounted directly to the sensor or remotely. Sensor failure or drift alarm is clearly displayed on the backlit display and is transmitted via the 4 to �0mA HART® output signal. The optional power supply RN��1N also serve as an alarm unit, converting the HART alarm signal into a contact output for additional operator visibility.

Solution for FDA proposed rule - MIG replacement

“The Food and Drug Administration (FDA) has issued a proposed rule which, if finalized, would benefit both consumers and the food industry by enabling manufacturers of heat-processed low-acid canned foods to modernize their equipment by using alternative temperature-indicating devices (TIDs). Under the proposal, these devices, which are the state-of-the-art equipment for measuring and recording temperatures, may be used instead of, or in addition to, conventional mercury-in-glass thermometers (MIGs).

The agency will allow low-acid canned food manufacturers who follow the proposed rule to change immediately from the currently required

MIGs to alternative TIDs. Although these TIDs remain out-of-compliance until the proposal is finalized, FDA will consider, on a case-by-case basis, exercising its enforcement discretion if the new devices are used in a manner consistent with the proposed rule. Processors who choose this option must comply with any revised requirements when the final rule becomes effective.”1

Endress+Hauser temperature assemblies provide the solution to follow the intent of the FDA’s proposed rule. A complete system consists of the TH 15 or TH 13 dual RTD sensor and the TMT 16� transmitter. Sensor failure or drift alarm is clearly displayed on the backlit display and is transmitted via the 4 to �0mA HART output signal. The power supply RN��1N serve as an alarm unit, converting the Hart alarm signal into a contact output. The system can be configured to automatically switch over to the back-up sensor in event of failure – maintaining batch 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, �0076

TH 13

RN221N

TMT 162

Memograph M

77

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 service technician to be on-site during start-up.

Basic factory warranty is extended from 1 to 3 years when start-up is purchased on your instrumentation order. Ask for start-up to be quoted with your new instruments.www.us.endress.com/start-up

In many processes, the function of flowmeters must be periodically checked and tested due to internal or legal requirements. Fieldcheck™ is a test and simulation device that permits regular on-site checking of your installed flowmeters without the need of removal or process interruption.

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.

Service from Endress+Hauser

Maintenance / Verification

Start-up service

Preventative Maintenance AgreementsPlanned maintenance lowers costsTo 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)

CP 0�6B/�4/ae/10.07AE/INDD CS�

USA

Endress+Hauser, Inc.�350 Endress PlaceGreenwood, IN 46143Tel. 317-535-7138Sales 888-ENDRESSService 800-64�-8737Fax [email protected]

Canada

Endress+Hauser Canada1075 Sutton DriveBurlington, ON L7L 5Z8.Tel. 905-681-9�9�800-668-3199Fax [email protected]

Mexico

Endress+Hauser México S.A. de C.V.Fernando Montes de Oca �1 Edificio A Piso 3Fracc. Industrial San Nicolás 54030. Tlalnepantla de BazEstado de MéxicoPhone: +5� 55 53�1 �080Fax: +5� 55 53�1 �[email protected]

10.07/SC USA

Your local partner:

AlabamaTriNova, Inc.Mobile, AL�51-378-7837

TriNova, Inc.Bessemer, AL�05-4�6-0494

AlaskaArtic Controls, Inc.Anchorage, AK907-�77-7555

ArizonaIndustrial Automation ServicesChandler, AZ480-413-0899

ArkansasTriNova, Inc.Mobile, AL�51-378-7837

Endress+HauserHouston, TX713-300-6�00

M & D ControlsTulsa, OK918-664-7511

CaliforniaIPT GroupSan Francisco, CA415-8�4-3679

Process Instruments & Controls, LLCBakersfield, CA661-3�7-7000

ProFlow DynamicsCorona, CA951-�79-5500

Endress+HauserBrea, CA714-5�4-8391

FOR MUNICIPAL INDUSTRYMRC TechnologiesNewbury Park, CA805-498-3811

ColoradoBeabout CompanyLittleton, CO303-795-1000

ConnecticutO‘Connor & Senecal, Inc.Sutton, MA508-865-5600

DelawareEndress+HauserChalfont, PA�15-8��-4710

Philip R. Walker & AssociatesCockeysville, MD410-666-�14�

FOR MUNICIPAL INDUSTRYLRM Inc.Souderton, PA�15-7�1-4840

FloridaAMJ Equipment Corp.Lakeland, FL863-68�-4500

TriNova, Inc.Mobile, AL�51-378-7837

GeorgiaAMJ Equipment Corp.Savannah, GA91�-898-0388

HawaiiIPT GroupSan Francisco, CA415-956-9005

IdahoTourangeau Nor WesTualatin, OR503-691-6100

Weidner & AssociatesMidvale, UT801-565-9595

IllinoisAntel CorporationWillowbrook, IL630-887-8910

George E. Booth Co., Inc.Indianapolis, IN317-�47-0100

Miller Mechanical Specialties, Inc.Des Moines, IA515-�43-4�87

R.L. Weisheimer & Assoc.Columbia, IL618-�81-4148

IndianaGeorge E. Booth Co., Inc.Indianapolis, IN317-�47-0100

Antel CorporationWillowbrook, IL630-887-8910

IowaMiller Mechanical Specialties, Inc.Des Moines, IA515-�43-4�87

KansasCompass Controls and InstrumentationShawnee, KS913-441-9779

KentuckyGeorge E. Booth Co., Inc.Indianapolis, IN317-�47-0100

LH BolekyCoraopolis, PA41�-�64-07�9

LouisianaFOR MUNICIPAL INDUSTRYEndress+HauserHouston, TX713-300-6�00

MaineO‘Connor & Senecal, Inc.Sutton, MA508-865-5600

MarylandPhilip R. Walker & AssociatesCockeysville, MD410-666-�14�

MassachusettsO‘Connor & Senecal, Inc.Sutton, MA508-865-5600

MichiganDurable ControlsHartland, WI�6�-367-4900

Forberg Scientific, Inc.Troy, MI�48-�88-5330

MinnesotaEngineered Sales CompanyBloomington, MN95�-888-1131

MississippiTriNova, Inc.Mobile, AL�51-378-7837

FOR MUNICIPAL INDUSTRYRieth CorporationGretna, LA504-36�-7604

MissouriCompass Controls andInstrumentationShawnee, KS913-441-9779

R.L. Weisheimer & Assoc.Columbia, IL618-�81-4148

MontanaBrock Easley, LLCBillings, MT406-�5�-1515

NebraskaMiller Mechanical Specialties, Inc.Des Moines, IA515-�43-4�87

NevadaIPT GroupSan Francisco, CA415-8�4-3679


MRC TechnologiesNewbury Park, CA805-498-3811

New HampshireO‘Connor & Senecal, Inc.Sutton, MA508-865-5600

New JerseyEndress+HauserChalfont, PA�15-8��-4710

FOR MUNICIPAL INDUSTRYDave HeinerAssociates, Inc.Parsippany, NJ973-�99-9990

LRM Inc.Souderton, PA�15-7�1-4840

New MexicoBeabout CompanyLittleton, CO303-795-1000 Industrial Automation ServicesChandler, AZ480-413-0899

Pan-Tech ControlsArlington, TX817-640-3�3�

New YorkBurnsCascade Controls & Instrumentation Syracuse, NY315-4��-0�61

Endress+HauserChalfont, PA�15-8��-4710

FOR MUNICIPAL INDUSTRYBurgh & SchoenenbergerPavillion, NY585-584-3768

Dave HeinerAssociates, Inc.Parsippany, NJ973-�99-9990

North CarolinaEndress+HauserCharlotte, NC704-969-7974

FOR MUNICIPAL INDUSTRYJohnston, Inc.Indian Trail, NC704-8�1-6777

North DakotaEngineered Sales CompanyBloomington, MN95�-888-1131

OhioForberg Scientific, Inc.Cleveland, OH�16-71�-6600

George E. Booth Co., Inc.Indianapolis, IN317-�47-0100

OklahomaM & D ControlsTulsa, OK918-664-7511

OregonTourangeau Nor WesTualatin, OR503-691-6100

PennsylvaniaLH BolekyCoraopolis, PA41�-�64-07�9

Endress+HauserChalfont, PA�15-8��-4710

Forberg Scientific, Inc.Cleveland, OH�16-71�-6600

FOR MUNICIPAL INDUSTRYLRM Inc.Souderton, PA�15-7�1-4840

Rhode IslandO‘Connor & Senecal, Inc.Sutton, MA508-865-5600

South CarolinaEndress+HauserCharlotte, NC704-969-7974

South DakotaEngineered Sales CompanyBloomington, MN95�-888-1131

TennesseeAMJ Equipment Corp.Greeneville, TN4�3-639-3800

TriNova, Inc.Memphis, TN901-684-7099

TexasEndress+HauserHouston, TX713-300-6�00

M & D ControlsTulsa, OK918-664-7511

Measurement ResourcesCorpus Christi, TX361-88�-3444

Pan-Tech ControlsArlington, TX817-640-3�3�

UtahWeidner & AssociatesMidvale, UT 801-565-9595

VermontO‘Connor & Senecal, Inc.Sutton, MA508-865-5600

VirginiaApplied Engineering, Inc.Midlothian, VA804-378-3550

Philip R. Walker & AssociatesCockeysville, MD410-666-�14�

WashingtonTourangeau Nor WesTualatin, OR503-691-6100

Washington D.C.Philip R. Walker & AssociatesCockeysville, MD410-666-�14�

West VirginiaLH BolekyCoraopolis, PA41�-�64-07�9

WisconsinDurable ControlsHartland, WI�6�-367-4900

Engineered Sales CompanyBloomington, MN95�-888-1131

WyomingBeabout CompanyLittleton, CO303-795-1000


Puerto RicoEngineered Parts & Services, Inc.Vega Alta, PR787-883-8880

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