BUMACON - Control system for butter and spreads manufacture
Control systems for continuous churns are out of date considering today's demands. Although the D.C. motors and hydraulic drives of the eighties have been replaced by three phase A.C. motors with vlt's, the existing control units no longer meet customers requirements in ergonomics and efficiency terms.
At the instigation of customers WAL Mess- und Regelsysteme GmbH developed BUMACON, a control system that corresponds with the already existing H2OMCON, the moisture measuring and control unit. These units may be integrated if desired and are not only used for existing churns - new plants, using this control unit are technologically on the highest level.
The systems are being delivered as a completely mounted unit, integrated in a high-grade steel control cabinet.
BUMACON is based on the following main components:
- A plc (programmable logic control unit) for the machine level, based on a Mitsubishi- or Siemens-S7 control systems.
- A bus-coupled input and output system for the force control unit.
- A microprocessor system for the moisture measurement and control of dosing.
- A visualisation and operating platform (based on InTouch) on a standard computer with WindowsNT/2000ã and a 17"/15" TFT-colour-display with touch screen. Therefore, user input is as simple as touching the display screen.
- Window "Display Screen"
In addition to the up-to-date operating requirements, BUMACON offers the following specific advantages:
- The recovery of fat is being maximised.
- The required specifications, especially moisture are achieved.
- The consistency of the finished product is improved.
- The attendance of the operator during the normal production and cleaning is minimised.
- The cleaning processes are optimised and verifiable.
- A quality assurance system has been introduced.
- Standard hardware and software tools are being used in order to guarantee the operating security and spare-part procurement.
The following extensions and modifications of existing plants provide production improvements:
SPEED CONTROL
Each speed drive in the machine is controlled by vlt's (frequency converters). The required revolutions per minute are not only checked and re-adjusted by the slip compensation of the converters but also by scanning the particular drive.
RECIPE HANDLING
Each desired and set point value of the machine and metering plant are being administrated in an internal database and can be stored under the respective product name. A start up or product change can be carried out faster.
QUALITY ASSURANCE
To meet the quality assurance recommendations, each measured value, number of revolutions per minute, etc. are displayed as a digital value as well as graphically on the monitor. The values are being stored on the hard disc of the computer and can be retrieved up to 6 months later.
CLEANING (CIP)
The entire CIP-process has been revised and optimised. This leads to better cleaning efficiency and longer production runs.
AMOUNT OF CREAM CONTROL UNIT (OPTION: XOPTBUMRME)
The speed control of the cream supply pump depends on the quantity of cream as measured with a magnetic inductive flow meter or a mass flow meter.
MASS FLOW METER AND DENSITY MEASUREMENT (OPTION: XOPTBUMMAP)
The quantity of cream can be measured in kg/h with a mass flow meter (after the Coriolis-principle) with a statistical accuracy of < 0,1%. The density of the cream is also measured.
CREAM HEATING (OPTION: XOPTBUMRAW)
The pre-heating of the cream, prior to churning, takes place in the existing cream heater, with some modification to improve control. The PID-parameters are adapted depending on the flow rate of cream. The use of a cascade control unit for operating the steam valve provides a standard deviation of cream temperature compared to the desired value of about 0.02 K. Therefore, a more consistent grain and minimum base moisture.
BUTTER PRESSURE (OPTION: XOPTBUMBPU)
The pressure at the end of the working section is being measured by means of an electronic pressure transmitter. This facilitates automatic adjustment of the butter pump revolutions per minute and is more microbiologically secure than before.
VACUUM CONTROL (OPTION: XOPTBUMVAK)
The control unit for stabilising the vacuum has been changed completely. The desired value of vacuum is being displayed and an electronic pressure transmitter continuously checks and maintains this by mean of a diaphragm valve regulated with a PID-controller. Thus, the desired vacuum value remains constant within a range of 0.02 bar. It is being measured as absolute value in order to minimise variation in the residual air content of butter.
VIDEO CAMERA (OPTION: XOPTBUMVID)
With up to three colour video cameras the actual fill status of the machine and the grain characteristic are being monitored. The colour pictures are integrated in the visualisation system.
MOISTURE MEASUREMENT + CONTROLLING (OPTION: H2OMCON)
Through the integration of our continuously updating online moisture measuring unit, the operation and storage of measured values takes place within the same menu as the controlling process of the churn. In addition, the complete metering control process for culture, salt and water is also being carried out by the system. The monitoring of all metering pumps can be enhanced out with magnetic-inductive flow or mass flow meters.
PRODUCTION DATA ACQUISITION (OPTION: XOPTH2OBDE)
Statistical values, such as the amount of cream supplied per shift, the amount of produced butter, the average moisture, the standard deviation of the moisture and the minimum and maximum cream temperature are displayed on screen and printed out as a hard copy if required.
CONDUCTIVITY MEASUREMENT (OPTION: XOPTBUMLF1)
During the cleaning, the conductivity and circuit temperature are constantly being observed and recorded. After each cleaning process a record can be obtained for Q.A. verification.
AUTOMATIC CIP - METERING (OPTION: XOPTBUMLF2)
During the conductivity measurement, the detergent supply can be carried out automatically by means of a metering pump for detergent.
OPERATING PLATFORM
Further advantage: The BUMACON control system has a menu-driven operating platform. It reduces the time for training operatives and product changes significantly.
TELESERVICE (OPTION: XOPTBUMLLW + LS7)
When using a modem, it is possible to monitor not only the PC but also the plc from WAL and to carry out a malfunction analysis. Which means, possible down-times and service costs are reduced and a software updates may be made.
TECHNICAL DATA
| control cabinet: | high-grade steel control cabinet 1.4301, matt finish type of protection IP65 1500 mm x 1170 mm x 600 mm (w x h x d) |
| power supply: | 230 V AC / 50-60 Hz / max. 2000 W |
| PC: | standard PC, IBM compatible INTEL processor of the latest generation operating system MS-Windows® |
| screen: | TFT-colour-display resolution: 1024 x 768 pixel 15" (equivalent to 17" CRT monitor) 5-wire resistive touch screen |
| keyboard: | front panel mounting keyboard type A6 IBM XT/AT and MF 2 compatible |
| plc: | Siemens S7-300 with professional bus-DP or Mitsubishi Q2A with mini-net |