Food & Beverage

Shree Renuka Sugars Limited (SRSL) is a global agribusiness and bio-energy corporation. The company is one of the world’s largest sugar producers and refiners.

NISSIN FOOD PRODUCTS selected Yokogawa as a partner to realize a next-generation smart factory.
An integrated MES solution helps fully automate the large-scale food factory in Japan.

• Yokogawa provided control solutions for expansion project in sugar and bio-energy plant.
• Consolidated central control room was designed for safe, comfortable, and efficient work environment.

Success Story:

CENTUM VP Cuts Clean-in-place (CIP) Time by 50% and Improves Productivity

S&B Sankyo uses the GX20 Paperless Recorder to monitor temperature and pressure in a food processing plant's sterilization process.

Rousselot Ghent won Belgium Factory of the Future Award. Yokogawa has supported Rousselot with automation systems since 1993.

Data of 20,000 tags gathered by Exaquantum helped to find the ideal production parameters.

The Pasteurized Milk Ordinance (PMO) is a set of standards and requirements that regulate aspects of dairy plants producing Grade “A” products. It is the “dairy bible” that dairy producers, manufacturers, and balancing plants must follow to verify food safety. Discover how Yokogawa recorders (PMO compliant) are helping Michigan milk producers.

Kyowa Hakko Bio monitors vibration trends with Yokogawa's Sushi Sensors to prevent unexpected equipment failures.
By using eServ, sensor data and maintenance information are shared with everyone involved in manufacturing.

Trappist monks, brewers of the infamous Trappist beer, leverage the precise and reliable measurement of the Rotamass TI Prime Mass Flow Meter.

The TC series of temperature controllers is perfect for controlling the heating temperature of sealing parts and the temperature of sealing rolls (pre-heating) in a variety of different wrapping machinery.

Accurate and reliable data acquisition of temperature is critical in the processing of fresh milk.

Temperature is essential to the pasteurization process in beer manufacturing. Yokogawa’s fiber optic temperature sensor DTSX provides precise temperature measurements throughout the tunnel, eliminating blind spots.

Yokogawa’s Touchscreen GX10 Paperless Recorder eliminates the cost and labor associated with paper-based data recording.

High-capacity memory, network, and part 11 compliant paperless data recorders greatly increase work efficiency while eliminating data recording errors.

• For remote monitoring (of temperature, pressure, and flow volume), installing the SMARTDAC+ GM in the plant and the SMARTDAC+ GX in the office provides for a scalable, pc-free on-site data monitoring solution.
• You can centralize management of large quantities of data by automatically transferring acquired data to a FTP server.

Challenge: The customer's existing measurement device was disturbed by vibration and could not be compensated or corrected by the product that was installed.

To meet state requirements for calibration checks, use Meter Verification (part of the Total Insight concept of the ADMAG TI - AXG) to verify the calibration and functionality of each meter. The reliable accuracy of the AXG magmeter results from Yokogawa’s proprietary, dual-frequency excitation method. It combines traditional high/low-frequency excitation methods to ensure greater stability and quicker response even if noise or other problems are present in the line. With EtherNet/IP, an operator can initiate a verification from the HMI to ensure the gallery is running optimally.

SMARTDAC+ GX series records the clean room temperature, humidity, atmospheric pressure, door openings and closings, etc.

Questionable flow and conductivity measurements during CIP could raise questions about food quality and safety.

Yokogawa's Paperless Recorder series offers a multi-point touch panel to improve intuitive operator control with predictive monitoring for early detection during sake production and managing brewery wastewater. 

Milk should be processed within 4 to 6 hours of production to make it fit for human consumption. Temperature is a very important parameter which has to be monitored at different stages of milk processing.

In the plants of food and beverage manufacturers, there are times when monitoring and recording of production equipment is necessary inside clean rooms. This is an introduction to monitoring and recording in clean rooms using paperless recorders.

The reliable accuracy of the AXG magmeter is a result of Yokogawa’s proprietary, dual-frequency excitation method, which combines traditional high/low-frequency excitation methods to ensure greater stability and quicker response even if noise or other problems are present in the line. The customer was very pleased with the result, as it allows him to automatically mix yogurt with cherries, which was previously impossible due to the measurement deviations.

Yokogawa's ceramic liner can offer the customer superior resistance to thermal shock and the failure that can occur due to liner cracking. This is due to Yokogawa's use of 99.9% pure Al2O3 for the liner.

Where and why are the pH Measurements important in a brewery? No one wants a skunky beer. pH measurements in the wort, during mashing/souring the malt, and in the yeast enzymes are critical.
 

The paperless recorder DX series automatically calculate the Fo value from the heating temperature and are useful in managing the sterilization process by displaying and recording the value together with the heating temperature.

In the food and beverage industry, government regulations for whisky production require compliance of distillation strengths to strict limits. Yokogawa’s ROTAMASS TI Coriolis mass flowmeter is well-matched for the application with its density calibration for ethanol or water percentage and a special calibration for maximum accuracy and stability. The mass flow meter’s dual bent tube technology and advanced software enabled the customer to measure the very small and sensitive range required. Yokogawa commissioned the mass flowmeter onsite to ensure the correct installation and commissioning from the outset, affording Total Insight through the entire product lifecycle. 

In the food industry, the control of concentrations on the production line is critical to product quality, determining, among other things, how good the food tastes. One such procedure for doing this involves taking a sample from the production process and measuring its specific gravity (density) with a hydrometer. 

By using the Multibatch function (an option added with SMARTDAC+), you can efficiently record data from multiple devices onto a single SMARTDAC+.

Using the custom display function that comes standard with DXAdvanced means that you can combine the recorders, displays, and switches used in various kinds of equipment.

Yokogawa’s EJA565E Hygienic and Sanitary pressure and level transmitter presents an ideal solution to improve production throughput in a convenient and easy-to-use package. Breweries can expect an excellent return on investment. With less fluctuation in the level measurement, brewers can confidently increase their setpoints without fear of overfilling their vessels. 

Using the batch name + lot number system, past measured data can be recalled for reference by batch name.

Tank level measurements must be simple and accurate in order to maintain the milk quality, reduce waste and clean-up costs, and enable facility profitability.

• Universal inputs provide support for thermocouple, RTD, voltage, and a variety of other input signals.
• Lineup of models for up to 450 inputs.
  Allows multipoint monitoring and recording on a single unit.
• Easily enables network-based data management. 
  file transfers, Web monitoring, and alarm e-mail

By using the computation function of the SMARTDAC+ series Paperless recorder GX/GP, computation option computes the "F-value," or sterilizing value for the sterilization process, so that the computation results can be recorded in the form of data.

In today’s tightening orange juice market, facilities must improve efficiency to deliver high-quality products. With that goal in mind, a leading U.S. juice and citrus processor uses or sells each part of the orange. Nothing goes to waste. In the drive to improve efficiency, the juice and citrus products producer needed a reliable partner to help determine ways to reduce maintenance costs and deliver high returns. The producer selected Yokogawa products such as the EJAC80E Diaphragm Seal System with DPharp sensor technology for level control and monitoring, ADMAG AXG magnetic flow meters (magmeters) for flow measurement, and FLXA402 analyzers for pH and conductivity monitoring. 

With industrial and economic development comes increasingly large and advanced power plants and factories. Nevertheless, we find many cases where the original cables, cable tunnels, and other components of the power infrastructure have languished under continuous operation.

The sterilization temperature prior to the filling process is monitored in the field or office. The temperature data is recorded in an external storage medium.

Fish are totally dependent upon water to breathe, feed, grow, maintain a salt balance, and reproduce. Water quality determines the success or failure of an aquaculture operation.

Difficulties in measurement and monitoring can arise, however, when the recycled milk from the pasteurization process is introduced to the balance tank.

• Temperature monitoring at a tank farm
• Temperature and pressure monitoring in tank jungles, three vertical monitoring points.

This introduces a system that uses Ethernet communications to acquire measured values, target values, and control output values from a controller installed on site into a PLC at high speed (ten units' worth within one second).

To defray energy costs, many industrial plants have their own boilers to generate steam to produce a portion of their energy needs. In addition to generating power, the steam may also be used directly in plant processes or indirectly via heat exchangers or steam jacketed vessels. 

A milk tanker is typically fitted with a pump and flowmeter that records the volume of milk loaded from each individual farm. Confirmation of the total volume of milk delivered to the dairy plant is performed either by weighing the tanker or via flowmeters in the tanker bays.

With advances in process automation comes a greater need for level measurement and control. As pressure on at the bottom surface of a liquid is proportional to the height of the liquid's surface, you can measure pressure using a differential pressure transmitter to detect the level of the liquid, acquire the data on the UT75A Digital Indicating Controller, and use the measurements to control the tank level.

Clean-in-place (CIP) is the system designed for automatic cleaning and disinfecting in the food & beverage, pharmaceutical, and chemical industries. Tanks and piping are cleaned and sterilized with various cleaning solutions, fresh or hot water, or steam after manufacturing products is completed.

Reverse osmosis (RO) is a separation process that uses pressure to force a solution through a membrane that retains the solute on one side and allows the pure solvent to pass to the other side. More formally, it is the process of forcing a solvent from a region of high solute concentration through a membrane to a region of low solute concentration by applying a pressure in excess of the osmotic pressure.

Conductivity measurement can be used as a reliable indicator of the real-time brine concentration. Using an online process analyzer removes the need for timely grab sample analysis. 

After extraction from sugar cane or sugar beets, the juice must be purified to remove the many other organics and minerals that accompany it. The processing to accomplish this is heavily dependent on reliable pH measurement and control as illustrated. 

Measurement of pH in high purity water presents many difficulties. Yokogawa's pH instrument's design success comes from addressing the unique challenges of the application.

The process consists of mixing meats, oils, and water to create a finished product, animal feed, using a PLC-based automation system.

Temperature plays a key role in storage of Molasses to maintain the chemical properties of molasses. When temperature rises over 40.5 degree C, destruction of structure in sugar occurs, which results in losing the feeding property of molasses. There is also a safety concern that a rise in temperature can lead to a rise in storage tank pressure leading to an explosion of the tank.

Heat exchangers are devices that provide the flow of thermal energy between two or more fluids at different temperatures. Heat exchangers are used in a wide variety of applications. These include power production; process, chemical and food industries; electronics; environmental engineering; waste heat recovery; manufacturing industry; and air-conditioning, refrigeration, and space applications.
 

Ion Exchange is a method for the exchange of ions between two electrolytes or between an electrolyte solution and a complex molecule. In most cases the term is used to denote the processes of purification, separation, and decontamination of aqueous and other ion-containing solutions with solid polymeric or mineralic ion exchangers.

Yokogawa's best-in-class panel mount paperless recorders are fully integrated data acquisition and display stations with secure, built-in data storage and network connectivity. Panel-mount solutions are NEMA compliant and integrate the data acquisition equipment into a control panel. Yokogawa's paperless recorder lineup meets rigorous industry standards such as PMO, HTST, and FDA 21 CFR Part 11.

Brewers recognized that correcting flowmeter inefficiencies in out-of-date technology would help them achieve the increased and consistent throughput they needed. 

Accurate measurement of the oil concentration would allow the heat/steam to be adjusted. Increases efficiency and saves money. 

There are many points in the processing of edible fats and oils that benefit from the use of analytical measurements. Inductive conductivity, contacting conductivity, gas density, and pH can be utilized to increase the quality of the end product, as well as protecting expensive processes.

Ingress of oxygen into a finished beverage container can affect the taste and shelf life of the product. The greater the concentration of oxygen in the container's headspace or dissolved in the solution itself, the greater the flavor degradation. The presence of oxygen causes negative quality characteristics in beverages such as beer and wine.

The condiment facility staff had success with Yokogawa’s ADMAG TI AXG magnetic flowmeters in other applications. When they learned EtherNet/IP communication was now offered on the ADMAG TI - AXG, they chose to use the Yokogawa magmeter solution on the mustard grinding lines.

Humidity is a good indicator of drying progress as it expresses the amount of vapor in the carrier gas stream. Humidity affects the dryness of the solids with which it comes into contact. Therefore, humidity control is crucial for final product quality in drying processes such as in food manufacturing, tobacco production, and malt drying. Challenges vary from too much drying, which can cause cracking, to too little drying, which results in poor taste and texture quality. 

Dairy wastewater is a mixture of organic compounds, suspended solids, fats, and bacteria that can produce a film or coating on equipment in the process. 

There are numerous industrial applications where measurements and/or control of a specific chemical strength of the process is critical for optimizing the production of the end product. These specific concentrations are obtained by mixing a full strength solution with water to achieve the desired percent concentration.

Optimizing four key factors will decrease pH sensor costs and optimize process control and overall plant efficiency.

Read this eBook to learn how to best leverage the latest measurement instrumentation to avoid incidents and improve productivity. You will also find valuable information about overcoming common CIP challenges and stories of success.

This eBook explains why implementing IIoT based digital operator monitoring solutions for autonomous anomaly detection enhances operations.

In this Yokogawa RAP Best Practices eBook, you’ll discover how our wealth of knowledge about Integrated Safe Systems and Control of Work is available to help you and your teams design and implement a system that best suits your needs.

This technical white paper will discuss Yokogawa's CENTUM VP DCS (Distributed Control System) product, hereafter referred to as "CENTUM VP", and the extent of its compliance with Part 11 of Title 21 of the Code of Federal Regulations, (21 CFR Part 11), the Electronic Records / Electronic Signatures Rule.

Sugar and alcohol market are increasing, due humanity needs to find alternatives for fossil fuels dependence. Brazil joins climactic and technologic features to place itself at the forefront of this industry.

Get Connected: Advancing Workers and Capabilities
In this whitepaper by Shahzad Khan, you will learn how to use collaborative, integrated, optimized, and autonomous operations to integrate your systems and emerging performance metrics.

By downloading this whitepaper you will learn how to:

• Connect operations, systems, processes, maintenance, and goals
• Empower employees digitally, to improve their decision-making skills
• Gain access to immediate improvements to production efficiency

The worlds of process automation and production management have been converging for some time. What once used to be islands of automation and production management functionality connected through highly proprietary integration schemes that were costly to maintain have developed into integrated platforms that provide seamless data exchange between the world of automation and the plant floor, the functions of production and operations management, and integration with business level systems.

The world of process automation is governed by procedures. While we like to refer to the process industries as being largely "continuous", this could not be further from the truth. Process manufacturing is constantly in flux.

This document describes the operation and data flow of the Yokogawa Print Wave software using the DX-P Reporter. It will provide a detailed explanation of the Advanced Alarm Reporter functions. The functions described in this paper were first released in Print Wave version 5.5.

The agnostic approach to cybersecurity and solution integration, built around the concept of modularity, offers a scalable and flexible way to reduce the risk of cyberattacks on OT networks.

The whitepaper discusses the importance of safety culture in achieving a smarter and safer working environment. It highlights statistics on work-related accidents and diseases, the cost of poor safety culture, and the need for a true safety culture achieved through company leadership.

On-site digital champions can drive your operation towards data integration and a more aligned way of working.

Digital twins are dynamic digital representations that enable companies to understand, predict and radically reorient their business processes.

Discovering your Baseline with OT Security Risk Assessment

Smart devices, like Yokogawa’s line of Total Insight transmitters and flowmeters contribute to Digital Transformation during operations and throughout the lifecycle of the instrument.

Honeywell and Yokogawa have both been producing Distributed Control System (DCS) platforms for decades, and both are very active in this area. In 1975, Honeywell introduced its TDC2000 platform and Yokogawa brought out CENTUM. These two competing systems emerged from a similar place, oil refining and petrochemical industries, so they started out with similar basic concepts and use cases in mind. 

Thanks to a two year upgrade project, Foster's Yatala brewery is now one of the country's most efficient integrated brewing and packaging operations. More than 1,100 measurement and control devices from instrument manufacturer Yokogawa Australia will help keep it that way.

This article discusses automation, autonomy, and the importance of an overall plan. We introduce a case study with the best practices.

Why should leaders act on Digital Transformation, Autonomous Operations, and Smart Manufacturing? - Food Processing - eHandbook March 2022

Wireless sensors and the network can reduce expenses

The lifetime of a pH sensor has a significant impact on the overall annual costs of a pH measuring loop. Optimizing four key factors will decrease these costs and optimize process control and overall plant efficiency.

Kind of. Calibration itself will not extend the life of a sensor, however, a sensor that is not calibrated properly can cause unreliable measurements - that are often misdiagnosed leading to unnecessary replacements.

Optimizing the maintenance cycle is not always straightforward. In some cases, cleaning once a week is sufficient and other processes may require every 8 hours.

Learning these four lessons will help you improve your engineering skills and most importantly extend the life of your pH sensors.

Select the correct pH glass and reference type to improve your pH sensor lifetime and you can limit or even eliminate the effects of temperature and pressure on especially the reference sensor.

ROTAMASS is the integral and remote type Coriolis Mass Flow Meter. Both types have highly refined digital signal processing electronics, so that accurate and stable mass flow measurement is achieved.

It is the most technologically advanced mass flow meter yet. By combining the superior design of the application specific flow sensor and transmitters with the Total Insight philosophy and functionality, the flexibility of the ROTAMASS to adapt to changing  requirements guarantees performance throughout the lifecycle of the process measurement.

Open up control. Open Process Automation (OPA) opens the door to expanded choices, leverage, and customization.

Create a scalable, sustainable architecture. Remove the restraints of proprietary systems. OPA enables you to leverage all available technologies to open up solutions. Explore the possibilities today.

This video describes the process of connecting the Yokogawa Magnetic Flow Meter ADMAG TI - AXG with EtherNet/IP to a webserver

This video explains how to open .eds files in Studio 5000. The Yokogawa Magnetic Flow Meter ADMAG TI - AXG with EtherNet/IP is used as an example.

This video covers the navigation and basic structure of the Yokogawa Magnetic Flow Meter ADMAG TI - AXG with EtherNet/IP webserver.

>  Video: How to Connect to Webserver

This video shows steps to bring the Studio 5000 Data Points into the FactoryTalk View Studio. The Yokogawa Magnetic Flow Meter ADMAG IT - AXG with EtherNet/IP is shown as an example.

In this webinar, we will:

• Share best practices for monitoring, recording, and transferring data 
• Challenges in data acquisition and how Yokogawa can help
• Demonstrate GA10 Data Logging Software capabilities

In this webinar, industry-leading experts will describe how OPAF is selecting standards that will achieve the vision of truly open systems, the status of its efforts, and what this exciting change to the process automation world means to you.

In this webinar, we will:

• Introduce Yokogawa AI, including Sushi Sensors
• Demonstrate GA10 AI Dashboard and simple setup
• Discuss applications and real-world examples

Discover how to achieve industrial autonomy step by step through one of the 75+ inspiring presentations.

This workshop provided by industry partners Yokogawa and ThreatConnect will show you a way to strategically manage cyber risk within an industrial environment. Learn how to transition from the “break/fix” model of industrial cybersecurity to a business risk management strategy through cyber risk quantification, return on investment (ROI) for industrial cybersecurity solutions calculations, and cyber risk identification.

DX value delivery at scale requires high-quality data to be accessible to the users and systems that rely on it.