Industrial Technology and automation's research project
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Transcript of Industrial Technology and automation's research project
industrial technology and automation’s research project
Company: LAIVE
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26 DE SEPTIEMBRE DE 2013memberS:
ADANAQUE GUERRERO, DIANA GRACE - 201012428 Kumagai human, javier kenta - 201212301 DURAND
YUCRA , SARA - 20UNIVERSIDAD PERUANA DE CIENCIAS APLICADAS
EXECUTIVE SUMMARY
The objective we pose is provide valuable information on the application of the core
concepts of process technology and industrial automation. The specific objective is
centered on a real processand the necessary control loops for the automation of that
process.
Suggesting improvements in industrial automation is not only relatively complex
because of the number of solutions possible, but also, and above all, because of the
variety of applications. Ironically, these in turn are responsible for the multitude of
solutions available. If the analysis of the basic needs is relatively standard, as they will
always involve connecting sensors, actuators, and field controllers with each other, the
options in architecture are numerous and can impose the need for certain services.
The required performances expected fundamentally depend on the applications.
This paper traces the aplication and develop in an organization. The principal stages of
development are mentioned, from the initial requirement specifications to the current
state of standardization. The diverse technical solutions are then analyzed and
classified. In particular, we study the general aspects, the medium access control
protocols, and application relationships.
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INDEXEXECUTIVE SUMMARY.................................................................................................................1
1. INTRODUCTION....................................................................................................................3
2. GENERAL DESCRIPTION........................................................................................................4
MISSION...................................................................................................................................4
VISION......................................................................................................................................4
DISTRIBUTION PLANT...............................................................................................................4
3. DESCRIPTION OF THE PROCESS TO BE AUTOMATED............................................................6
I. Pasteurization:..................................................................................................................7
4. ANALYSIS CONTROL OF LOOPS, MEASURES AND MANIPULATES VARIABLES.......................8
5. PROCESS AND INSTRUMENTS DIAGRAMAS (ISA S5.1)........................................................10
6. SELECTION OF AUTOMATIC CONTROL COMPONENTS (Sensors, controllers, actuators). . .12
7. COST ANALYSIS...................................................................................................................14
8. CONCLUSIONS AND RECOMMENDATIONS.........................................................................19
9. SOURCES OF INFORMATION...............................................................................................19
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1. INTRODUCTION
Nowadays because of the technology and commercial advancement, we confirm
that we are facing a highly competitive and demanding market, which requires
varied products to increasingly smaller cycles, that is why companies are looking up
to expand their market share by adopting various measures which make them
more competitive. These organizations have discovered that industrial automation
plays a key rolle in industrial plants, so the implementation of automated systems
contributes to an increase in efficiency, effectiveness, quality and safety in facilities
in the whole organization.
The subject of Industrial Technology y Automation allows to develop concrete
improvement plants for the industrial sector, applying new technologies, especially
industrial automated systems that integrate and contribute to the competitiveness
of the whole organization.
For this reason, we will use these concepts to make a decision regarding the
analysis of a real process and the necessary control loops for the automation of
that process.
The company is Laive S.A., their commitment is to offer high quality products at
low prices. So, we're going to improve their dairy processes to make the company
more competitive.
In the following paragraphs, we will present the progress of the research project
applying the basic concepts of the course in the company and the context in which
it is located.
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2. GENERAL DESCRIPTION
Company’s name: LAIVE S.A.
R.U.C.: 20100095450
Sector: Dairy processing.
Location: Av. Nicolás de Piérola 601
Laive is an efficient and innovative dairy company, which offers products with
guaranteed quality and recognized brand contributing a proper nutrition to their
costumers.
This company is committed to be the best strategic agent to their costumers and
suppliers; and an excellent oportunity of profitability to the shareholders.
At the same time, Laive is committed to contribute to the growth of their
employees and the welfare of the community operating with social responsibility.
Laive wants to be recognized as a leading food company in innovation, technology
with consumer-oriented products of assured quality.
MISSION
Be innovative, efficient and socially responsible company, composed of
committed people to produce and sell guaranteed food through trusted brands
contributing to healthy food for costumers.
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VISION
Be the leader in innovation of healthy dairy products.
BLOCK DIAGRAM
DOP
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DISTRIBUTION PLANT
The facilities of the yogurt processing plant are divided into five zones,
separated by walls with spaces that allow free communication between areas:
Zone 1 which adjusts content of pretreated milk solids.
Zone 2: there occurs homogenization and pasteurization.
Zone 3 is the area of inoculum preparation, fermentation and cooling.
Zone 4: in this area is carried out the addition of flavors, colors and stabilizers.
Zone 5: where is packaged and cooled in yogurt in their respective containers.
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3.DESCRIPTION OF THE PROCESS TO BE AUTOMATED
YOGHURT MANUFACTURING FLOWCHART:
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Source: Personal compilation
Here we will have a general description of the process. Firstly, the company verifies
that the milk is clean, then strain the milk in a sieve with care. Secondly, the
company prepares the ingredients, flavoring and coloring, soon starts the
pasteurisation which mean bringing the milk at high temperature and the lowering
the temperature quickly. Next, we mantain a stable temperature during
fermentación. The product quality depends on, fermentation time. Gel formation
process takes place together with viscosity changes. Later, homogenisation
prevents the formation of cream and improves flavor and consistency. It is done
sharply to prevent further acidification yogurt. Finally, we sweeteners, stabilizers,
and fruit juices are added, according to product and close the airtight container to
maintain the safety. It is important to remember that conservation of the cold
chain ensures healthy quality after the products leaves the production site.
I. Pasteurization:
Pasteurization of the yoghurt base has two purposes: to reduce the initial bacterial
population to ensure a controlled fermentation after inoculation of the starter cultures
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and to inactivate and denature some enzymes such as lipases, whose actions affect the
stability of the base.
Pasteurization is performed in three stages: heating, holding and cooling. In the case of
yogurt, the treatment involves rapid heating - 9 s - to a temperature of 85 ° C sustained
for a minute, followed by cooling to 45 ° C which is the temperature of fermentation.
HTST pasteurization takes place in heat exchangers, plate or double-tube, which are
configured to integrate the heat fluxes, using the heat of the base leaving the support
stage and to be cooled to
preheat incoming base
exchanger. Thus it is possible
to save energy advantage
about 90% of the energy
transferred to the base.
IDEAL PASTEURIZATION CYCLE
ACTUAL PASTEURIZATION CYCLE
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4. ANALYSIS CONTROL OF LOOPS, MEASURES AND MANIPULATES VARIABLES
a) There is one control loop (0303) on the given diagram that consists on the valve
(actuator) that is between the heat exchanger and the deodorizer. This a
cascade control because we only have one manipulated variable (by the pump)
and more than one manipulates variables (base product flow and
temperature). Based in the base product temperature the flow that will go to
the deodorizer will be manipulated. This control analyzes the quality (pH and
concentration of lactic acid) of the base product obtained by the pasteurization
process of the heat exchangers that will regulate the base product that will go
directly to the fermentation tanks or that will be send back as a reflux to the
deodorizer.
Measured Values: the process is controlled by following the pH and the
concentration of lactic acid
Manipulated variables:
- Base product flow
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- Fermentation tank level
- Base product temperature
b) Another control loop is placed in the homogenization tank that consists in
another cascade control. Based in the flow of the base product after
pasteurization the temperature will be regulated in the heat exchanger and will
determine if there will be a return to the pasteurization process. The controller
will determine if the base product temperature is between the parameters
needed to the homogenization. In case it doesn’t have the established
temperature, the base product will be send back to the heat exchangers.
Measured values: Base product temperature
Manipulated variables:
- Base product flow in pasteurization
- Pressure in homogenization tank (homogenizator)
- Temperature in heat exchangers
- Level in homogenization tank
C) Has been added a new control loop (0301) on the beginning, regulating the
feed of pretreated milk. It now has a weight meter at the beginning that will weigh
the milk entering to the system and a pump that will send the milk though the
pipes. The relay will activate the pump depending of the signal send by the weigh
meter that will also activate the entering line valve.
- Manipulated variable: weight of pretreated milk entering to the line
- Flow of mixed milk, cream and sugar to the deodorizer
D) Like the last added control loop, has been added another (0308) but to the
cream feed of the system.
- Manipulated variable: flow of cream entering to the system
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E) Control loop 0301 A/B is a feed forward control that flow of mixed milk, sugar and
cream entering to the heat exchangers that will begin the fermentation process. This is
a feed forward control.
5. PROCESS AND INSTRUMENTS DIAGRAMAS (ISA S5.1)
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6. SELECTION OF AUTOMATIC CONTROL COMPONENTS (Sensors, controllers, actuators)
Among the many choices of precision measuring devices in the market, we decided to
propose a comprehensive action which consists in an implementation for future
automation. In the next lines, it shows the principal elements that support our proposal:
I. Sensors:
Temperature Transmitter: A temperature
transmitter is an electrical instrument that
interfaces a temperature sensor (e.g.
thermocouple, RTD, or thermistor) to a
measurement or control device (e.g. PLC, DCS, PC,
loop controller, data logger, display, recorder,
etc.). Typically, temperature transmitters isolate,
amplify, filter noise, linearize, and convert the input signal from the sensor then
send (transmit) a standardized output signal to the control device.
Pressure Transmitter: A pressure
sensor measures pressure, typically
of gases or liquids. Pressure is an expression of
the force required to stop a fluid from
expanding, and is usually stated in terms of
force per unit area. A pressure sensor usually
acts as a transducer; it generates a signal as
a function of the pressure imposed. For the
purposes of this article, such a signal is
electrical.
II. Controllers:
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Temperature controller: Temperature Controllers Analog / Digital (PID), offer a
quick adjustment and provide precise temperature management and control well
for a variety of applications to provide the best price, design and easy operation.
They will be the ultimate choice for your successful control in any temperature
application.
Pressure controller: Is a primary element connected to the pressure to be
controlled, transforms through a mechanical-pneumatic tire on a control signal.
This signal is amplified in flow and pressure for a
driver that produces the output signal.
III. Actuators:
Solenoid Valves: To open and close the valves
that allow the output to the valve inputs.
Centrifugal pump: For the transportation of
inputs
7. COST ANALYSIS
TRIBLENDER
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Machine Cost ($) 8500
Maintenance Cost (c/3meses) ($) 80Setup Fee (3 Technicians) ($) 220Training Cost (2 operators - 2 Days) ($) 70Hours Cost - Men (2 operators) ($) 0Energy Cost ($) 7Total Cost ($) 8877
DESODORIZADORMachine Cost ($) 15000
Maintenance Cost (c/3meses) ($) 100Setup Fee (3 Technicians) ($) 330Training Cost (2 operators - 2 Days) ($) 70Hours Cost - Men (2 operators) ($) 0Energy Cost ($) 9Total Cost ($) 15509
INTERCAMBIADOR DE CALOR
Machine Cost ($)12000
Maintenance Cost (c/3meses) ($)90
Setup Fee (3 Technicians) ($) 450Training Cost (2 operators - 2 Days) ($) 0Hours Cost - Men (2 operators) ($) 0Energy Cost ($) 3Total Cost ($) 12543
BOMBA DOSIFICADORAMachine Cost ($) 450
10
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Maintenance Cost (c/3meses) ($)Setup Fee (3 Technicians) ($) 1Training Cost (2 operators - 2 Days) ($) 0Hours Cost - Men (2 operators) ($) 0Energy Cost ($) 2Total Cost ($) 463
PURCHASE OF EQUIPMENT AND MACHINES
To purchase the above machines, application must be made to list each one so that the
vendor give us the specifications of each team and the terms of purchase. Then, we
perform an analysis to gauge the feasibility of implementing these machines, this will be
done by IRR and NPV analysis. For the above analysis, it was developed the company's
balance sheet. We must also coordinate with the supplier to reach an agreement that
specified and determined by what means and how it can be delivered the product
(machinery and equipment) and what is the medium that suits us.
Below is the balance sheet of the company:
Balance Sheet
Expressed in soles
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TANQUE DE FERMENTACIONMachine Cost ($) 4000
Maintenance Cost (c/3meses) ($)12
Setup Fee (3 Technicians) ($) 5Training Cost (2 operators - 2 Days) ($) 13Hours Cost - Men (4 operators) ($) 7Energy Cost ($) 6Total Cost ($) 4043
Activo corriente Pasivo CorrienteCaja Banco S/. 70,000.00 Proveedores S/. 30,000.00Clientes S/. 250,000.00 Remuneraciones S/. 30,500.00Mercadería S/. 500,000.00 Impuestos por pagar S/. 10,000.00Envases y embalajes S/. 200,000.00 T. Pasivo Corriente S/. 70,500.00
Pasivo no corrienteT. Activo Corriente S/.
1020,000.00Deuda largo plazo S/. 6
000,000.00Intereses y comisiones S/. 10,150.00
Activo no corriente T. Pasivo no corriente S/. 610,150.00Edificios e instalaciones S/. 1
000,000.00Vehículos S/.
1500,000.00Total Pasivo S/. 680,650.00
Herramientas y equipos S/. 50,000.00Terrenos PatrimonioMobiliario S/. 700,000.00 Capital S/.
3580,350.00Reservas
T. Activo no corriente S/. 3250,000.00
Resultados acumulados
T. Patrimonio S/. 3580,350.00
Total Activo S/. 4270,000.00
Total pasivo y patrimonio S/. 4270,000.00
Below is an analysis of the costs that will be incurred for the purchase of machinery and
equipment important and necessary to be implemented in the company.
SIGNIFICANT COSTSMachine Cost ($) 27950Maintenance Cost (c/3meses) ($) 292Setup Fee (3 Technicians) ($) 450Training Cost (2 operators - 2 Days) ($) 100Hours Cost - Men - Month (2 operators) ($) 500
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Energy Cost - Month ($) 163Total Cost ($) 29455
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CÁLCULO DEL TIR Y EL VANAños Hoy 0 1 2 3 4Inversión -40983
Costo (S/.) 4 4 4 4 4.16 4.16Producción promedio a la semana 200,000 200,000 210000 220500 231525 243101.25
Ingresos 800000 800000 840000 882000 963144 1011301.2
Costos mensuales 98,650 98650 103582.5 108761.625 114199.706 119909.692Depreciación -8196.6 -8196.6 -8196.6 -8196.6 -8196.6
Margen Bruto 701350 693153.4 728220.9765041.775
840747.694
883194.908
Gastos Administrativos y Ventas 35200 35200 36960 38808 40748.4 42785.82Utilidades antes de Impuestos 666150 657953.4 691260.9 726233.775 799999.294 840409.088
Impuesto a la Renta (30%) 199845 197386.02 207378.27 217870.133 239999.788 252122.727
Utilidad Neta 466305 460567.38 483882.63508363.643
559999.506
588286.362
Depreciación (+) 8196.6 8196.6 8196.6 8196.6 8196.6
Flujo de caja 466305 468763.98 492079.23516560.243
568196.106
596482.962
Tasa de descuento 0.1 0.1 0.1 0.1 0.1 0.1Flujo de descuento -40983 426149.073 406677.05 388099.356 388085.585 370368.99VAN 193839.053
-1938397.053 468764.08 492079.33 516560.343 568196.206 596483.062TIR 11%
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8. CONCLUSIONS AND RECOMMENDATIONS
The automation's proposal of the production process of the company LAIVE,
generates an investment of S/ 40,983, which is accesible to the company.
The production size and profitability will sustain such investment
The possibility to automate the processes can eliminate the employees's
limitations in their operations, as well as the delays.
But, most important, reduces human error in the processes by using
standardized process that allows have disponibility and diversity of production,
and reach the costumer satisfaction.
The implementation save manpower and allows greater efficiency and
accuracy.
9. SOURCES OF INFORMATION
http://laiveesvida.com/ http://www.qo.fcen.uba.ar/Cursos/TecnoII/guia.pdf http://www.sisman.utm.edu.ec/libros/FACULTAD%20DE%20CIENCIAS%20MATEM
%C3%81TICAS%20F%C3%8DSICAS%20Y%20QU%C3%8DMICAS/INGENIER%C3%8DA%20INDUSTRIAL/03/PROCESAMIENTO%20%20LATEOS/YOGURT.pdf
Slides’s course.