Process control for butter - why, where and how

In the above example, a sensor is installed at the outlet of the churn. Variations in moisture (down to 0.02) are monitored through measurements every few seconds. The result data is fed to a PLC system where it is used to automatically control dosing pumps. The process can now react to process changes in real time and variation in moisture is reduced by as much as 50%.

How it works and what you need to know

The following illustrates a typical set-up for control of moisture in butter production.

1. The sensor
2. The ProFoss™ 2 analyser unit. The solid metal casing houses a near infrared analyser which is highly robust and insensitive to vibration, heat and humidity.
3. As part of the installation, the unit is connected to the plant’s PLC system in a closed integration with no compromise to data security
4. A benchtop NIR analyser
5. A number of connectivity and software services making it simple to run the system and monitor the performance of the sensor and analyser

High performance infrared sensor and analyser unit

Measurements are made using near infrared transmittance. This form of analytical technology penetrates deep into the sample and in so doing, avoids interference from moisture that can form on the surface of butter.

The sample interface is positioned directly in the process pipe with a patented 3rd generation FOSS lateral transmittance probe. The probe gives a unique high-resolution signal for unprecedented accuracy. At the same time, the consistency of measurements ensures that all units can be relied on to always give the same high-quality measurements. Several units can be installed in different production lines and the consistency of measurements across units ensures that each line produces according to the same specifications.

Robust ANN calibration ensures rapid start-up

The stable performance of the probe and analyser lays the ground for another essential element of any process control solution – the calibrations (also known as analytics packages). These are based on a large pool of reference data which covers a very wide variety of sample types. The calibrations are made using a technique called artificial neural networking (ANN) that is ideal for handling the large volume of data.

This combination of stable hardware, comprehensive calibration data and ANN ensures that the calibration supplied with your process control solution will be straightforward to implement.  Only minor adjustments using local data will be required to ‘tune in’ the system to your particular production. What’s more the stability of measurements across units makes it simple to install multiple units across different production lines. If updates to calibrations are required, for example, in response to changing raw material characteristics, this does not require a lot of work to roll-out.

Secure integration to PLC

An interface is provided with the analyser for integration to local control systems, enabling automatic regulation. The interfaces are Ethernet 4-20 mA and Profibus (no OPC). The interface is secure in that no data from the local control system is shared with the analysis unit. The analysis unit is monitored and managed online via a separate system with no interference or connection to the local control system.

Performance monitoring made simple

Performance validation allows you to validate ProFoss™ 2 predictions using a FOSS benchtop analyser such as FoodScan 2 or NIRS™ DS3 as reference, without any manual entry of data.

Samples are measured and registered by the ProFoss™ 2 and benchtop analyser respectively to eliminate the risk of error and secure optimal performance. Using integration, connectivity and automation the results matched are saved via cloud and are ready for evaluation and reporting using digital services.

Online support and ongoing service

The same connectivity features that enable the online performance monitoring also provide a foundation for a complete range of services that make owning and running the ProFoss 2 solution simple and worry free. Uptime is safe-guarded and trouble-shooting alleviated, setting you free to do your job in pursuit of improved yield and profit from your butter production.