Newslettter with varaity of applications for process enhancements using instrumentation in food industry

1. talkline
Morgan Foods Isfet sensors The innovation Endress+Hauser’s
ensures quality and outperform continues local service
repeatability with traditional Page 6 technicians are
automated batch paracetic acid dedicated to
processing. measurement keeping your plant
Page 2 systems running 24/7
Page 4 Page 7
Creating process improvements
with measurable results
Strategic use of instrumentation in the
food and beverage industry
Issue 5 • Volume 9

2. Automation of cook decks
and retorts
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.
Retorts Pressure on retort steam
2

3. 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
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.
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.
Radar for mix tank level Promass batch process meters
3

4. Increased plant utilization with new
generation of non-glass pH measurement
for CIP control
Isfet sensors outperform traditional conductivity systems
for concentrations measurement of paracetic acid
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.
Application
The 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
Liquiline M
over. Traditionally, conductivity sensors were used to 2-wire transmitter
determine the concentration of NaOH caustic soda. In
the case of paracetic acid however, the baseline water CPS471 non-glass
values change between 100 to 350 �S/cm at any given pH sensor
time as there is no significant purification or pre-
treatment of the plant water used for CIP makeup.
Proposed solution Realized benefits
Isfet (Ion specific field effect transistor) non-glass pH In contrast to glass sensors, the overall response time
sensors as opposed to traditional glass sensors were to monitor the CIP process is improved because the
chosen due to the following conditions: non-glass Isfet sensor shows no change in impedance,
• Sanitary requirements and food safety and in addition:
• Periods of dry conditions leading to dehydration and • Ability to use the transmitters current output for
breakage of brittle glass sensors concentration measurement by building a simple
• Changing of chemistry of the measuring surface due table based on pH vs. percent of concentration of
to evaporation/hardening of the gel layers unseen to paracetic acid
the naked eye on glass membranes • 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
4

5. CIP optimization
Food producers consistently rate food safety as their instrumentation, such as flow measurement on the
highest priority; initiatives to enhance process cleaning supply header and temperature and conductivity
are the next highest priority. A range of new CIP and measurement on the return header, is a must. This
plant cleaning detergents makes the cleaning task arrangement not only allows for optimizing the use
easier but it also comes with new challenges. of costly detergents but also helps conserve water
Care has to be taken when selecting suitable and heating costs. Optimized water use also leads
components such as instrumentation; the newer to savings on effluent treatment costs and municipal
detergents often contain strong surfactants that may charges.
attack or seep under gaskets and seals.
Endress + Hauser offers all the instrumentation you
Endress+Hauser recognized this and investigated new need to optimize your CIP systems:
ways to protect the instruments from damage, helping • Magnetic flowmeter – Promag 50H or alternative
protect your investment. Examples are the Easytemp the Prowirl 72 vortex flowmeter
– TSM 470F self contained temperature sensor/ • Conductivity – Several options including the
transmitter and the Liquiphant FTL50H point level CLS 54 or CLD 132 transmitter
switch. Conventional ½” NPT cable seals are notorious • pH sensors, both glass and non glass solutions
to leaking. A good alternative is the use of quick depending on application
disconnects cable connectors that not only simplifies • Temperature – Easytemp TSM 470F
installation but also keeps water out. • Level measurement of detergent or make-up tanks
- Capacitance, ultrasonic, guided or free space
When designing CIP systems, the efficiency and radar or classic hydrostatic pressure sensors for
cost of operation need to be considered. Basic retrofit to existing nozzles
• Recorders to capture CIP performance
CIP - Return flow 1
CIP - Return flow 2
Y Drain
Make-up water
Overflow protection
with Liquiphant M
CIP - line 1
Acid Caustic Water To heat
CIP - line 2
exchanger
Sanitizer solution
• Flow - Promag 50H Magnetic flowmeter offers high • Level - best fit for every media and tank size with
turndown, is resistant to vibration and is your choice of guided radar, capacitance or
comparable in price to vortex meters hydrostatic level measurement or overflow
• Conductivity – optimize water/chemical usage protection with Liquiphant M
• Temperature - water tight design and immune to • Ecograph T - track CIP conditions with 6 channel,
vibration - TSM 470F fully programmable display unit with recording,
• pH – keep up with new advanced detergents trending and alarm functions
and sanitizers
5

6. 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.
6

7. Service from Endress+Hauser
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.
Start-up service The School of Instrument Maintenance
Delays and production losses can far exceed the costs of Technology is changing rapidly. Are you and your staff keep-
planned start-up! A high percentage of instrument problems ing up with the changes? We can help with schools designed
can be traced to start-up by unqualified personnel. These to teach fundamental, theoretical, and practical knowledge
can be prevented by scheduling a trained Endress+Hauser about instrumentation and application technology, with an
service technician to be on-site during start-up. emphasis on service and maintenance of the instrumentation.
Basic factory warranty is extended from 1 to 3 years when Training, combined with hands-on experience, is a powerful
start-up is purchased on your instrumentation order. Ask for combination that will help you better manage you life cycle
a start-up to be quoted with your new instruments. costs. To contact us for training schedules or to obtain a quote
www.us.endress.com/start-up for on-site sessions, call 800-642-8737 or visit us online.
www.us.endress.com/training
Preventative Maintenance Agreements
Planned maintenance lowers costs Long-term maintenance offers more savings
To ensure optimum performance and help extend the life The Endress+Hauser Instrument Management Solu-
of your instruments, our skilled service engineers perform tions (IMS) service provides a long-term plan to a more
periodic checks (including any necessary adjustments), and reliable operating plant, cost-effective maintenance,
issue a report confirming the instrument’s performance. and gives a basis for complete life cycle management of
Additionally, we provide specific recommendations for your instrumentation.
maintenance of the equipment under the agreement. www.us.endress.com/IMS
www.us.endress.com/agreements 7
7

8. Your local partner:
Alabama Florida Maine New Hampshire Oregon Utah
TriNova, Inc. Instruments South Corp. O‘Connor & O‘Connor & Tourangeau Nor Wes Weidner & Associates
Mobile, AL Lakeland, FL Senecal, Inc. Senecal, Inc. Tualatin, OR Midvale, UT
251-378-7837 863-499-0146 Sutton, MA Sutton, MA 503-691-6100 801-565-9595
508-865-5600 508-865-5600
TriNova, Inc. Georgia Pennsylvania Vermont
Bessemer, AL Instruments South Corp. Maryland New Jersey LH Boleky O‘Connor &
205-426-0494 Savannah, GA Philip R. Walker Endress+Hauser Pittsburgh, PA Senecal, Inc.
912-898-0388 & Associates Chalfont, PA 412-931-5053 Sutton, MA
Alaska Cockeysville, MD 215-712-9050 508-865-5600
North Coast Electric Co. Hawaii 410-666-2142 Endress+Hauser
Anchorage, AK IPT Sales Company FOR MUNICIPAL Chalfont, PA Virginia
907-563-5229 San Francisco, CA Massachusetts INDUSTRY 215-712-9050 Applied Engineering, Inc.
415-956-9005 O‘Connor & Dave Heiner Midlothian, VA
Arizona Senecal, Inc. Associates, Inc. McStay Engineered 804-378-3550
Industrial Automation Idaho Sutton, MA Parsippany, NJ Products
Services Tourangeau Nor Wes 508-865-5600 973-299-9990 Cleveland, OH Philip R. Walker
Chandler, AZ Tualatin, OR 440-439-7208 & Associates
480-413-0899 503-691-6100 Michigan LRM Inc. Cockeysville, MD
Durable Controls Souderton, PA FOR MUNICIPAL 410-666-2142
Arkansas Weidner & Associates Hartland, WI 215-721-4840 INDUSTRY
TriNova, Inc. Midvale, UT 262-367-4900 LRM Inc. Washington
Mobile, AL 801-565-9595 New Mexico Souderton, PA Tourangeau Nor Wes
251-378-7837 Endress+Hauser Industrial Automation 215-721-4840 Tualatin, OR
Illinois Shelby Township, MI Services 503-691-6100
Endress+Hauser Antel Corporation 586-254-4920 Chandler, AZ Rhode Island
Louisiana Willowbrook, IL 480-413-0899 O‘Connor & Tourangeau Nor Wes
985-652-3265 630-887-8910 Minnesota Senecal, Inc. Snohomish, WA
Engineered Sales Pan-Tech Controls Sutton, MA 425-338-4477
M & D Controls R.L. Weisheimer Company Arlington, TX 508-865-5600
Tulsa, OK & Assoc. Bloomington, MN 817-640-3232 Washington D.C.
918-664-7511 Columbia, IL 952-888-1131 South Carolina Philip R. Walker
618-281-4148 New York Endress+Hauser & Associates
California Mississippi Control Equipment Charlotte, NC Cockeysville, MD
IPT Sales Company George E. Booth TriNova, Inc. Corporation 704-969-7974 410-666-2142
San Francisco, CA Co., Inc. Mobile, AL Cazenovia, NY
415-824-3679 Indianapolis, IN 251-378-7837 315-655-9700 South Dakota West Virginia
317-247-0100 Engineered Sales Cavcon, Inc.
Process Instruments FOR MUNICIPAL Endress+Hauser Company Charleston, WV
& Controls, LLC Indiana INDUSTRY Chalfont, PA Bloomington, MN 304-342-0385
Bakersfield, CA George E. Booth Rieth Corporation 215-712-9050 952-888-1131
661-327-7000 Co., Inc. Gretna, LA Wisconsin
Indianapolis, IN 504-362-7604 FOR MUNICIPAL Tennessee Durable Controls
Endress+Hauser 317-247-0100 INDUSTRY Instruments South Corp. Hartland, WI
Brea, CA Missouri Burgh & Schoenenberger Greeneville, TN 262-367-4900
714-529-1925 Antel Corporation Compass Controls and Pavillion, NY 423-639-3800
Willowbrook, IL Instrumentation 585-584-3768 Engineered Sales Company
FOR MUNICIPAL 630-887-8910 Shawnee, KS TriNova, Inc. Bloomington, MN
INDUSTRY 913-441-9779 Dave Heiner Mobile, AL 952-888-1131
Kube Engineering Iowa Associates, Inc. 251-378-7837
Riverside, CA Miller Mechanical R.L. Weisheimer Parsippany, NJ Wyoming
909-328-0343 Specialties, Inc. & Assoc. 973-299-9990 TriNova, Inc. Beabout Company
Des Moines, IA Columbia, IL Memphis, TN Littleton, CO
Colorado 515-243-4287 618-281-4148 North Carolina 901-684-7099 303-795-1000
Beabout Company Endress+Hauser
Littleton, CO Kansas Montana Charlotte, NC Texas Weidner & Associates
303-795-1000 Compass Controls and Brock Easley, LLC 704-969-7974 Endress+Hauser Midvale, UT
Instrumentation Edgewood, CO Houston, TX 801-565-9595
Connecticut Shawnee, KS 231-223-8794 North Dakota 713-300-6268
O‘Connor & 913-441-9779 Engineered Sales Puerto Rico
Senecal, Inc. Nebraska Company M & D Controls Parker Sales & Engineering
Sutton, MA Kentucky Miller Mechanical Bloomington, MN Tulsa, OK Santurce, PR
508-865-5600 George E. Booth Specialties, Inc. 952-888-1131 918-664-7511 787-722-3061
Co., Inc. Des Moines, IA
Delaware Indianapolis, IN 515-243-4287 Ohio Measurement Resources
Endress+Hauser 317-247-0100 George E. Booth Corpus Christi, TX
Chalfont, PA Nevada Co., Inc. 361-882-3444
215-712-9050 Louisiana IPT Sales Company Indianapolis, IN
Endress+Hauser San Francisco, CA 317-247-0100 Pan-Tech Controls
Philip R. Walker & Louisiana 415-824-3679 Arlington, TX
Associates 985-652-3265 McStay Engineered 817-640-3232
Cockeysville, MD Weidner & Associates Products
410-666-2142 FOR MUNICIPAL Midvale, UT Cleveland, OH Endress+Hauser
INDUSTRY 801-565-9595 440-439-7208 Louisiana
FOR MUNICIPAL Rieth Corporation 985-652-3265
INDUSTRY Gretna, LA Oklahoma
LRM Inc. 504-362-7604 M & D Controls
Souderton, PA Tulsa, OK
215-721-4840 918-664-7511
08.04/SC USA
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