tighter control to achieve food saftey with process...

Standards

Certification

Education & Training

Publishing

Conferences & Exhibits

National Symposium on

Automation & Digital Transformation of

Food & Beverage Industry26th & 27th February 2016

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Wolfgang Felber,Group VP,ABB

AG,Switzerland,[email protected]

T R Ravishankar,VP,ABB Ltd,India,

[email protected]

Tighter Control to Achieve Food Saftey

with Process Control, Batch, and MES

Basics of Modern Industrial Automation

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Academic- MScEE (PowereElectronics & Biomedical Engineering), SwissFederal Insitute of

Technologies ETH, Zürich

- MBSc (Business Sciences) Swiss Federal Insitute of Technologies

- Post graduade Gene technologies, University of Zurich

Worked in:• ABB Ltd, 1997 to 2007, Process Automation Division, global head of Newspaper

production automation

• ABB Switzerland 1994 – 1997: Head of Project Management for Pharma and

Food automation

• ABB Switzerland 1991 – 1994: Sales and Project mgmt Automation for

Environmental industries.

• Roche Diagnostics 1988 – 1991: R&D project manager for DNA Diagnostics

Currently working with:

- ABB Ltd, Process Automation Division, Global Head of Systems for F&B, Pharma

and Specialty Chemicals Industries since 2008

Wolfgang Felber


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Academic- B. E. (Electronics Engineering), Bangalore University

Worked in:- Started Career in BARC Training Centre, Mumbai in 1980

- Worked in Rajasthan Atomic Power Station & Kalpakkam Atomic Power Station till

1985

- Working in Process Automation in ABB since 1985 in industries such as Sugar,

Dairy , Pharmaceuticals , Cement ,Primary Metals ,Industrial Boilers, and Chemical

Currently working with:- ABB process Automation ,Local BU manager for Control Technologies

Association:- Senior Member, International Society of Automation (ISA), Past President, ISA

Bangalore Section , Founder Member of ISA Bangalore

TR Ravishankar


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• Context Setting

• FSSAI Standards

• Technology

• ISA Manufacturing Model

• Definition of Batch

• MES for F&B applications

Agenda


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Context Setting

Maggi worth Rs 320 crore being destroyed: Nestle PTI | Jun 15, 2015, 06.04 PM IST NEW DELHI: Nestle India is in the process of destroying Maggi instant noodles worth Rs 320 crore after it was banned by central food safety regulator FSSAI due to presence of lead and taste enhancer monosodium glutamate (MSG) beyond permissible limits.

http://www.fssai.gov.in/

FSSAI demands pictorial and health warnings on junk food packetsFriday, January 29, 2016 - 08:33

New Delhi: Health experts on Thursday demanded pictorial and health

warnings on junk food packets in order to provide information to people

on health issues caused by them.

The demand was made by a panel of experts from the Food Safety

and Standards Authority of India (FSSAI), AIIMS, the Public Health

Foundation of India and the National Institute of Nutrition


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Standards

Equivalent of

USFDA 21 CFR

Supervisory Scada

& Historian ,MES

Process

Control,Batch

Training on

Automation

Solutions,Products


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© ABB Group

March 20, 2016 | Slide 7

Changes of paradigms

4th Industrial Revolution

Industry 1.0 – 1712First Steam Engine

Industry 2.0 – 1870First Assembly Line

Industry 3.0 – 1969Electronics- /

Software-based Control

Industry 4.0 – today and tomorrow

People

ServicesThings

Internet

of


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Models & Standards in Manufacturing

Level 4

IEC 61131

Fieldbus

ISA 88

(IEC 61512)

OPC

ISA 95

(IEC 62264)

Batch

Control

Discrete

Control

Continuous

Control

Levels

2,1,0

Equipment Control

Intelligent Devices

Equipment Control

Intelligent DevicesAutomation

ERP

MES

Manufacturing

Operations & ControlDispatching Production, Detailed Production

Scheduling, Reliability Assurance, ...

Level 3

Adapted from: ISA-95.00.01-2000

Business Planning & LogisticsPlant Production Scheduling,

Operational Management, etc


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Technology Enables Process Control at all Levels


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Definition of Batch Control

Some applications require that specific quantities of raw

materials be combined in specific ways for particular

duration to produce an intermediate or end result.

One example is the production of adhesives and glues,

which normally require the mixing of raw materials in a

heated vessel for a period of time to form a quantity of

end product. Other important examples are the

production of food, beverages and medicine. Batch

processes are generally used to produce a relatively low

to intermediate quantity of product per year (a few

kgs/litres to Thousands of kgs/litres).


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Definition of Batch Control

• Specific quantities >Recipe of raw materials

• Combined in specific ways >Sequence Logic Or Workflow dependent

on how-sequence/ Auto/ Manual, where-localised control ,Remote

control, Actual Control done locally ,Remote Control done Locally

• Particular duration to produce an intermediate or end result.

>Processed Food

Recipe

Noodle Meal

for 8 persons =

Ingredients

+

Processing

Steps

(Actual = Control)

Recipe

Noodle Meal for 6

persons


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Simple to Complex Batch Manufacturing

Local PID Controller

Dedicated Batch Controller

PLC with Scada

PLC with Scada & Batch Server DCS with HMI

DCS with HMI & Batch server

PLC/DCS System with MES As Batch Server

PLC/DCS System with ERP As Batch Server

Batch Algorithm

Human Interface

No Flexibility to alter productsFexibility to alter products

Fexibility to alter products as per other production /quality dataFexibility to alter products as per other production /quality & Market Demand data

No S88 Standards Compliance

Partial S88 Standards Compliance

Medium S88 Standards Compliance

Higher S88 & S95Standards Compliance

Full S88 & S95 Standards Compliance


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MES - Integrating business with plant floor

Synchronizing & integrating production

Production Order

BOM, Recipe

Routing, Operation

Material Classifications

Inventory Receipt/ Reservation

other ...

Production Yield Confirmation

Production Scrap Confirmations

Material consumption

Equipment Downtime

Equipment Utilization

Actual Labour Time

Inventory Return / Scrap

Product Characteristics

Quality Notification

other ...

Material

receptionMaterial storage

Material

preparationProcessing Dispensing Packaging Pallettizing

MES – Synchronizing and orchestrating flow across «the island of automation»Share information andexecuting timely and accurately. Vertical and horizontal integration

Enterprise Ressource Planning

(ERP)

Warehouse ScalesPLC/

SCADA / DCSHistorian CAPA LIMS

Documen

repository

Quality

management

system


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MES

Support production processes

Control of logistic flow

for materials

and products

Fulfill document

requirements

Improve traceability

for materials

and products

Improve production

performance

Customer expectationsReliable and safe manufacturing execution system

Food Safety RELEVANT


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5The MES Impact - Achieving competitive advantages

Operational Excellence powered by MES

IMPROVE RESSOURCE UTILIZATION, THROUGHPUT AND LEAD TIMES

• Machines and equipment utilization, downtime & interruptions in the context enables fast

interventions and systematic improvements

AGILE MANUFACTURING

• Ease of introducing new products and processes, integration with engineering and

design solutions, discovering and removing production constraints,

FACILITATE CONTINUOUS IMPROVEMENTS

• Systematic collection, visualization and analysis of downtimes, quality test records,

deviations and non conformances increase knowledge and enables intelligent decisions

IMPROVE QUALITY AND REDUCE VARIATIONS, ERRORS, AND WASTE

• Defined workflows, electronic work instructions & checklists, enforces processes and

specifications

REDUCE MATERIAL CONSUMPTION AND INVENTORY

• Real-time update and accurate overview of the material usage and inventories / WIP

eliminates the need for “just in case” inventories and reduces obsolete inventory

FULFILL REGULATORY COMPLIANCE

• Effectively deal with complex genealogy and traceability requirements, using

automated transactions

10-20% OEE IMPR

20-40% TPT

LINE EFFIECIENCY

ENABLED!

ENABLED!

50% SCRAP /

WASTE

2-10 % RM /WIP

INVENTORY

REDUCTION OF

HUMAN ERRORS

Examples


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Genealogy and all Quality supporting functionsFood Safety on Level 3

Reduced product

throughput time

& raw material

storage

Availability of real-time

information from the

entire process,

significantly improved

visibility in production

Full material and

product genealogy

on lot and batch

level Reduced errors &

impact from

bottlenecks in the

production

Improved

production

performance


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Human Factor Role in Food Safety

Role Based Access & User Interface Log-in to workplace

Role based displays

- Administrator

- Production

Management

- Operator

- other

Authentication

- keyboard

- touch screen

keyboard

- badge

- barcode scanner

- USB

- integrated Windows

security

Log-in to the

station/machine

- automatic to a defined

default

- manual selection from

the list of

stations/machines

National language

support (NLS)


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© ABB Group


Material Track & Trace

Genealogy

Providing comprehensive

track and traced capabilities

from raw material,

intermediates to finished

goods

Product genealogy allows

searching and analysis of

production data

Downstream and upstream

by equipment instance

person name

production period

produced and consumed lot


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© ABB Group


Quality assurance and quality control

Enforcement of quality and compliance measures

Proactive enforcement of quality

and compliance measures

Approved materials are used

Appropriate equipment and

locations are used

Support for sampling and

testing requirements

Manual or logic-based

material quality status /

characterics (e.g. expiration

date)

Real time laboratory

interaction with the production


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© ABB Group


Quality assurance and quality control

Non-conformity reporting

Deviation from the product, process,

procedure, or compliance

specifications.

Submitted on demand by the operator

Submitted automatically if

measurement out of tolerance

Reason, description, just for

information or need to abort product

and hand over problem to a

supervisor, information attached to

product

Configurable NCR reasons

Configurable NCR actions (abort,

resume, decide)


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© ABB Group


Quality Assurance & Quality ControlElectronic Signatures / Electronic Batch Report


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Shop-floor logistics - identification, picking, packing ...

Material Management

• WorkOrder (PO)

• BOM

• Configuration

• ….

ERP

Picking Station

a)

b)

Electronic PickList

(QCCard)

input/scan SerialNumber

confirm component

real-time validation

against BOM

comments entry, when

required

Picking Packing

http://www.google.ch/imgres?imgurl=http://www.clker.com/cliparts/2/1/f/f/1194983950939265703workstation_hash_0x89c79_01.svg.hi.png&imgrefurl=http://www.clker.com/clipart-1938.html&usg=___CEA5p9MvAVcQTlJD7LBtNCh2dA=&h=470&w=600&sz=38&hl=en&start=1&zoom=1&tbnid=4qJeDT2wdPH07M:&tbnh=106&tbnw=135&prev=/images?q=work+station+symbol&hl=en&gbv=2&tbs=isch:1&itbs=1

http://www.google.ch/imgres?imgurl=http://www.clker.com/cliparts/2/1/f/f/1194983950939265703workstation_hash_0x89c79_01.svg.hi.png&imgrefurl=http://www.clker.com/clipart-1938.html&usg=___CEA5p9MvAVcQTlJD7LBtNCh2dA=&h=470&w=600&sz=38&hl=en&start=1&zoom=1&tbnid=4qJeDT2wdPH07M:&tbnh=106&tbnw=135&prev=/images?q=work+station+symbol&hl=en&gbv=2&tbs=isch:1&itbs=1

http://www.advantecdesign.ca/images/bom1.jpg







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Transparency of Operations

Genealogy – Progress – Status - Performance

Product genealogy

PO Progress Overview

SN Status, WIP

Plant Performance

”Today we don’t have

a proper tool to

answer where actual

manufacturing order

is in the workshop an

dbe able to give an

order

acknowledgement for

a new order in time.”


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Batch Management – Boost effincency and flexibility

Effective batch automation according to S88

Batch and Operations

in one single user

interface

Flexible recipe

handling including

version control

Automatic arbitration

of resources in

runtime

Reduce process

variability, increase

process reliability and

yield

Interface to ERP


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ABB Food and Beverage software libraries

Boost efficiency and flexibility

Easy to use and operate

A complete industry

library of ready-made

objects for the food and

beverage industry

Assuring food safety and

quality 21 CFR Part

11 compliant

High engineering

efficiency – typically

reducing your

engineering cost up to

20%

ProBase library example


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Comprehensive MES functionalities -

from loading of raw material and order

preparation to packaging and quality

control of finished goods

Control from raw material to finished productABB’s MES-ECS

Out of the box connectivity with ERP

(SAP) and PLCs

PLC

Start

Order Preparation

Deconditioning

Mixer Loading

Mixing

Packaging

Finish


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Raw material intake and Order managementRecording, monitoring and analyzing data

Start

Order Preparation

ECS manages a list of warehouses and

inventory level of liquid and dry material,

adjust quantities and monitor material

locationECS generates pick lists

ECS covers workflow

and recipe management

with production order

flow definition and order

sequence

Calculating material lot

correction factors from

theoretical content of active

substance and humidity in raw

materials


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Weighing and scale management Optimization of material usage in mixer loading

Weighing

Mixer Loading

Managing weighing

orders for dry and liquid

material that are not

supplied in whole

packages

Listing bags to be loaded

to what mixer


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Full contrl mixing, quality sampling and packaging Automated and smooth processes

Equipment maintenance

management for cleaning

orders, scale calibration

and metal detectors orders

Mixing

Packaging

Finish

Check of calibration of

equipment used, batch id

verification to avoid errors

Integration to scales,

scanners and printers

along the production line

Packaging control and sample

sequence definition and

notification

Forward and backward

genealogy on lot and

batch level


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“We now have reliable and transparent real-time data from the entire process and are very pleased with the ECS-MES functionalities“

- Gilles Nodot, Chief Production Manager, DSM in Village Neuf, France

Voice of the customer

|

Sli

© ABB

Switzerland

Ltd, File_Ve

rsion-


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© ABB Group


Simple Batch :Flash Pasteurisation (HTST)

Dairy, Fruit juices and brewing

Control/Recording of Heat Exchanger exit

temperatures, flow and valve status

Heated to 72 - 75ºC for 15-30 sec

Cooled prior to packaging

Similar process for UHT but at higher

temperature for a shorter time

T

Cold Product

Hot Product

IP

Steam Inlet

Heat Exchanger


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© ABB Group


Customer Reference

Owner & Market Position

Amul is the largest food brand in India and world's Largest Pouched Milk Brand with an annual turnover of US $1050 million .

Managed by an apex cooperative organization GCMMF. Its milk processing capacity 10-12 millions liters per day.

ABB System800xA

Products

Includes milk powders, milk, butter, ghee, cheese, curd, chocolate, ice cream, cream, shrikhand, paneer, gulabjamuns, basundi, Nutramulbrand and others.


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Client: DSM Nutritional Products

Sites: Grenzach-Wyhlen, GermanyVillage-Neuf, FranceSisseln, SwitzerlandLalden, SwitzerlandDalry, Scotland

Application: Control system for a vitamin plant

Automation from ABB –over 20 years of serviceMES-ECS in VillageNeufSystem 800xA in VillageNeuf, Dalry, GrenzachMelody in LaldenSattline in Sisseln

DSM Nutritional ProductsCH, DE, FR & UK


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Wander AG

Switzerland

Client: Wander AG

Site: Neuenegg, Switzerland

The Ovomaltine manufacturer Wander

combines the production control with the

systems for controlling and planning.

The project put highest demands on all

contributors. There was only one solution that

could be considered in terms of assuring the

connection of complex data and processes

ranging from easy applications to existing

production control systems.

During the evaluation phase of different

providers, Wander AG chose the Enterprise

Connectivity Solution (ECS) from ABB.

MES in operation: Go live 2019. Upgrade

2014

For information: Matilda Steiner Arvidsson


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Client: Heineken Brewery.

Sites: Araraquara, Brazil

Application: Plant wide control systems

Automation from ABB: System 800xA SV 4.2

AC 800M controllers per brewery

Integrated Batch mgmt

Wide range of ABB drives

Why ABB: Reliable technology,

In operation: 2009

Heineken BreweryAraraquara Brazil


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Client: Royal Friesland Foods Via SI, Tetra Pak Processing Systems

Site: Leeuwarden, the Netherlands

Application: New Milk Plant

Automation from ABB: System 800xA SV3.1 comprised of:

o AC800M, PM864o System 800xA Operations: 5 clientso S800 I/O (about 1500)o Profibus DP/PA communicationo Integrated with PlantMaster from TetraPak

Why ABB: Probase Library & TetraPak as Global Solution Provider

In operation: February 2005

For information: Aad Fokker

Royal Friesland FoodsThe Netherlands


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ABB Control Technologies

Annual Partner Conference 2015 ● Sep 23-24 ● Berlin, Germany

Food & Beverage in ABB web site

http://www.abb.com/food&beverage


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tighter control to achieve food saftey with process...

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