Morgan Foods ensures quality and repeatability with automated batch processing.Page 2

Isfet sensors outperform traditional paracetic acid measurement systemsPage 4

The innovation continuesPage 6

talkline

Issue 5 • Volume 9

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

Creating process improvements with measurable resultsStrategic use of instrumentation in the food and beverage industry

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Morgan Foods realizes quick return on investment of instrumentation

Morgan Foods of Austin, Indiana was founded in 1899 and is now the third largest condensed soup maker in the world. With over 100 different canned products, Morgan Foods must be flexible with processing and labeling lines. To accommodate these lines, there are four different types of cooking operations. Morgan Foods can handle thirteen different can sizes and sixteen assorted case configurations with increased efficiency due to constant automation improvements.

In 2002, Morgan Foods contacted Endress+Hauser to help with a project to upgrade their retorts. The retorts, which were still running after more than 25 years of operation, required a lot of manual supervision. Replacing less reliable mechanical systems and indicating pressure gauges with new measuring technology including microwave radar for level measurement and new pressure transmitters gave the retorts a new lease on life. The automation of the retorts helped Morgan Foods to operate with less downtime and at optimal speed and temperature. This resulted in energy savings and also helped to ensure food safety. Although many canneries still rely on manually adding ingredients, Morgan Foods has recognized that in order to ensure quality and production repeatability, automated batching needs to be implemented eliminating the manual addition of ingredients where possible.

Pressure on retort steamRetorts

Automation of cook decks and retorts

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Automated systems are set up on several lines to control the ingredients and the amounts that are added to each batch of product. Employees follow specific instructions at each step of the process based on electronic batch sheets. Endress+Hauser Promass Coriolis mass flowmeters were used to automate the Chester Jensen cook decks.

Other instrumentation such as pressure and level switches help ensure stable operations. Today, a PLC based control system allows operators to focus on the addition of secondary ingredients such as paste and spice mixes. The bulk components such as oil, sugar, starch and water are all batched in through the mass flow meters.

An operator oversees the operation of the cook deck who now also has time for other duties due to increased productivity and throughput - as a result of automated process controls

Radar for mix tank level Promass batch process meters

Cory Lytle, Director of Engineering at Morgan Foods reports that since the cook deck was commissioned 18 months ago there has been no out-of-specification product and throughput has doubled without adding any staff.

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Increased plant utilization with new generation of non-glass pH measurement for CIP control

A bottling company located in North Carolina is responsible for five bottling plants in the Southeastern United States. In an attempt to improve production throughput, a decision was made to use paracetic acid (C2H4O3) on one of four bottling lines. The idea being that paracetic acid can be used at ambient temperatures to clean the line thereby eliminating cross-contamination of flavors in one to two hours. The normal hot wash using sodium hydroxide (NaOH) could then be conducted over the weekend in two to three hours (excluding preparation). As a result, the bottling plant would have at least 1.5 to six hours more daily production time, depending on the number of recipe changes or line sanitation cycles.

Isfet sensors outperform traditional conductivity systems for concentrations measurement of paracetic acid

ApplicationThe measuring task is to measure the CIP concentration with the purpose of controlling the addition of paracetic acid and determination of the change between water and chemical for rapid change over. Traditionally, conductivity sensors were used to determine the concentration of NaOH caustic soda. In the case of paracetic acid however, the baseline water values change between 100 to 350 �S/cm at any given time as there is no significant purification or pre-treatment of the plant water used for CIP makeup.

Proposed solutionIsfet (Ion specific field effect transistor) non-glass pH sensors as opposed to traditional glass sensors were chosen due to the following conditions:• Sanitary requirements and food safety• Periods of dry conditions leading to dehydration and breakage of brittle glass sensors• Changing of chemistry of the measuring surface due to evaporation/hardening of the gel layers unseen to the naked eye on glass membranes

Realized benefitsIn contrast to glass sensors, the overall response time to monitor the CIP process is improved because the non-glass Isfet sensor shows no change in impedance, and in addition:• Ability to use the transmitters current output for concentration measurement by building a simple table based on pH vs. percent of concentration of paracetic acid• Isfet sensor mounting allows for easy access• Ability to use a strong cleaner at ambient temperature providing for shorter recovery time between batches• With an average of four bottling lines per plant, this technology allows for an estimated savings of 20 to 120 hours production time per day

CPS471 non-glass pH sensor

Liquiline M 2-wire transmitter

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CIP optimizationFood producers consistently rate food safety as their highest priority; initiatives to enhance process cleaning are the next highest priority. A range of new CIP and plant cleaning detergents makes the cleaning task easier but it also comes with new challenges. Care has to be taken when selecting suitable components such as instrumentation; the newer detergents often contain strong surfactants that may attack or seep under gaskets and seals.

Endress+Hauser recognized this and investigated new ways to protect the instruments from damage, helping protect your investment. Examples are the Easytemp – TSM 470F self contained temperature sensor/transmitter and the Liquiphant FTL50H point level switch. Conventional ½” NPT cable seals are notorious to leaking. A good alternative is the use of quick disconnects cable connectors that not only simplifies installation but also keeps water out.

When designing CIP systems, the efficiency and cost of operation need to be considered. Basic

instrumentation, such as flow measurement on the supply header and temperature and conductivity measurement on the return header, is a must. This arrangement not only allows for optimizing the use of costly detergents but also helps conserve water and heating costs. Optimized water use also leads to savings on effluent treatment costs and municipal charges.

Endress + Hauser offers all the instrumentation you need to optimize your CIP systems:• Magnetic flowmeter – Promag 50H or alternative the Prowirl 72 vortex flowmeter• Conductivity – Several options including the CLS 54 or CLD 132 transmitter• pH sensors, both glass and non glass solutions depending on application• Temperature – Easytemp TSM 470F• Level measurement of detergent or make-up tanks - Capacitance, ultrasonic, guided or free space radar or classic hydrostatic pressure sensors for retrofit to existing nozzles• Recorders to capture CIP performance

Sanitizer solution

Overflow protectionwith Liquiphant M

Acid Caustic Water

Y Drain

CIP - Return flow 1

CIP - Return flow 2

Make-up water

To heatexchanger

CIP - line 1

CIP - line 2

• Flow - Promag 50H Magnetic flowmeter offers high turndown, is resistant to vibration and is comparable in price to vortex meters• Conductivity – optimize water/chemical usage• Temperature - water tight design and immune to vibration - TSM 470F• pH – keep up with new advanced detergents and sanitizers

• Level - best fit for every media and tank size with your choice of guided radar, capacitance or hydrostatic level measurement or overflow protection with Liquiphant M• Ecograph T - track CIP conditions with 6 channel, fully programmable display unit with recording, trending and alarm functions

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The innovation continues...For more than 50 years, Endress+Hauser has provided innovation to help customers meet their unique and changing needs. Here are some examples for our customers in the food industry.

Liquiline M - universal transmitter for pH and conductivity. Used in combination with Memosens technology (pictured at left sidebar), you no longer need to do pH calibrations in the plant. pH sensors can now be pre-calibrated in the laboratory under controlled conditions and installed into the process when needed. Patented inductive connectors eliminate problems with moisture or ground loops.

CLS 54 conductivity sensor - specially developed for CIP applications. PEEK construction ensures long life in demanding applications. Integrated temperature sensor provides fast temperature compensation.

Ecograph T - 6 channel, fully programmable display unit with recording, trending and alarm functions. Connects easily to plant network via Ethernet or RS232 connections. Overall depth of only 7” (18 cm) allows for installation in most panels. Keeps track of storage conditions, CIP systems or general process data.

Levelflex FMP41C - first guided radar level transmitter to meet 3-A sanitary standards. Use for tank levels up to 13 ft (2.2 m). Great solution for day tanks or for products with density or temperature changes.

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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 a start-up to be quoted with your new instruments.www.us.endress.com/start-up

Technology is changing rapidly. Are you and your staff keep-ing up with the changes? We can help with schools designed to teach fundamental, theoretical, and practical knowledge about instrumentation and application technology, with an emphasis on service and maintenance of the instrumentation.

Training, combined with hands-on experience, is a powerful combination that will help you better manage you life cycle costs. To contact us for training schedules or to obtain a quote for on-site sessions, call 800-642-8737 or visit us online.www.us.endress.com/training

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

The School of Instrument MaintenanceStart-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

Long-term maintenance offers more savingsThe Endress+Hauser Instrument Management Solu-tions (IMS) service provides a long-term plan to a more reliable operating plant, cost-effective maintenance, and gives a basis for complete life cycle management of your instrumentation.www.us.endress.com/IMS

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CP 010B/24/ae/10.05AE/INDD CS

USA

Endress+Hauser, Inc.2350 Endress PlaceGreenwood, IN 46143Tel. 317-535-7138Sales 888-ENDRESSService 800-642-8737Fax 317-535-8498inquiry@us.endress.comwww.us.endress.com

Canada

Endress+Hauser Canada1075 Sutton DriveBurlington, ON L7L 5Z8.Tel. 905-681-9292800-668-3199Fax 905-681-9444www.ca.endress.com

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Endress+Hauser Mexico, S.A. de C.V.Av. Gustavo Baz No. 43Fracc. Bosques de EchegarayNaucalpan de Juárez, C.P. 53310,Estado de MéxicoMéxicoPhone: (52) 55-5371-1110Fax: (52) 55-5371-1128E-mail: eh.mexico@mx.endress.com

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