distributed control systems in food processing

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ISSN No: 2456

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Distributed Control Systems

Lecturer (Senior Grade), Sri Krishna Polytechnic College,

ABSTRACT The Objective of this study is to address the need for automation in the domestic food processing sector and to study its impact. This study investigates the challenges arising out due to the dependencythe modern human for processing of food. Throughthe medium of this study a pressing need for development of an automatic cooking machine is proposed. The impact of the development of this product has also been profoundly discussed. The advantages offered by the distributed control system(DCS) so far enjoyed by large, continuous process plants are now available to smallbatch processing industries. Examples of DCS applications in the food industry are described. KEY WORDS: Automation, distributed control system, Automation, Food Processing, Impact Economy, Processing Individual. I. INTRODUCTION Automating the food processing industry is becomingCritical in today’s rapidly changing environment. Several factors are pushing the industry towards automation, which may range from simple controls highly sophisticated controls using advanced capable of measuring intangible properties such asflavor, taste, smell, etc. These factors include: 1. Increasing competition from globalization and

mergers, 2. The consumer demand for higher quality goods,3. Higher emphasis on cleanliness and hygiene,4. Safety factors and the high costs of insurance and

compensation, and 5. Flexibility in manufacturing for more diversified

Product lines.

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ISSN No: 2456 - 6470 | Volume - 3 | Issue – 1 | Nov

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Control Systems in Food Processing

E. Sankaran. ME , Department of Instrumentation and Control Engineering,lytechnic College, Coimbatore, Tamil Nadu, India

The Objective of this study is to address the critical for automation in the domestic food processing

study investigates the dependency of

food. Through the medium of this study a pressing need for the

of an automatic cooking machine is impact of the development of this

discussed.

The advantages offered by the distributed control system(DCS) so far enjoyed by large, continuous

to small users and to batch processing industries. Examples of DCS

food industry are described.

distributed control Automation, Food Processing, Impact on

Automating the food processing industry is becoming Critical in today’s rapidly changing environment. Several factors are pushing the industry towards using

, which may range from simple controls to rols using advanced sensors

of measuring intangible properties such

globalization and

for higher quality goods, cleanliness and hygiene,

costs of insurance and

in manufacturing for more diversified

For example, in today’s competitive uncommon for manufacturers processing conditions or formulation ‘new and improved’ version of their products. This requires a control system the chemist or process engineer can easily recipe. To remain competitive, the industry min manufacturing flexibility, allowing for greater product diversity and manufacturing yield, better quality control to satisfy customer requirements and tighter material flow control to contain product cost. Automating plant operations is one of thindustry can respond to these challenges (see Figure I).Because of these new requirements

Fig: 1, Food and Consumer design II. PROCESSING OF FOODFood Processing is a technique to convert raw ingredients into consumable food form (by the modern human). It typically activities such as mincing, maceratingemulsification, pickling, canning, etc. Presently, the

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n Food Processing

nd Control Engineering, India

competitive market, it is not uncommon for manufacturers to change the processing conditions or formulation to provide a ‘new and improved’ version of their own existing products. This requires a control system with which the chemist or process engineer can easily modify the

remain competitive, the industry must build flexibility, allowing for greater and manufacturing yield, better

quality control to satisfy customer requirements and flow control to contain product cost.

Automating plant operations is one of the ways the respond to these challenges (see Figure

.Because of these new requirements.

Fig: 1, Food and Consumer design

PROCESSING OF FOOD Food Processing is a technique to convert raw

consumable food form (by the involves operations and

mincing, macerating, boiling, emulsification, pickling, canning, etc. Presently, the

International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456


processing of food mainly takes place processing stages i.e. at the industry and at domestic level. The agricultural produce provides the basic raw ingredients that undergo processing in the subsequent levels as shown in Fig. 2. Industrial food processing includes the production ofMarketable food (purchased by consumers) from rawIngredients provided by agricultural produce. It includes a variety of operations such as the addition of chemical ingredients, filtering, packaging, etc.conventional times, the primary rationale industrial processing of food was to preserve the food for a longer duration and ensure its supply round the year. Various methods such use of additives, salt, cold storage, etc. were employed to preserve the food

Fig: 2, Stages of food processing III. CONTROL SYSTEMS FOR THE FOOD

INDUSTRY The level of automation in the food industry variesConsiderably between companies, as well as plants within the same company. Most food processing plants have evolved from small operations with a rather conservative, gradual approach to technological changes. In the food industautomation began with the application of programmable controllers and single boardon manufacturing equipment, and very systems. These devices, particularly programmablecontrollers, were widely accepted by foodbecause they were simple to operate andThey were limited in what they could replace relays, timers and counters (Marien

Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456


processing of food mainly takes place at two major processing stages i.e. at the industry and at the

agricultural produce provides the that undergo processing in the

Industrial food processing includes the production of arketable food (purchased by consumers) from raw

provided by agricultural produce. It variety of operations such as the addition of

, filtering, packaging, etc. In conventional times, the primary rationale behind

processing of food was to preserve the food r duration and ensure its supply round the

methods such use of additives, salt, cold etc. were employed to preserve the food.

Fig: 2, Stages of food processing

CONTROL SYSTEMS FOR THE FOOD

the food industry varies Considerably between companies, as well as between

within the same company. Most food have evolved from small operations

, gradual approach to . In the food industry,

application of single board computers

simple control particularly programmable

by food processors operate and maintain.

They were limited in what they could do: usually replace relays, timers and counters (Marien, 1988).

Due to increased competition, however, the need forProduction flexibility, frequent changes in the manufacturing process and small engineering staffs, food processors can benefit from using flexible, easilyconfigured control and process management systems. Today food processors have a choice of upgrading their programmable logic controllers (PLCs) or installing distributed control systems (DCS). They can build upon their existing PLCs (Marien,1988) to achieve fully integrated control systems performing various functions such as process control, raw material management, sales order processing, financial management and architecture has performed thesecontinuous processes. The DCSis now available small continuousoperations at a competitive price.this paper describes the distribute its advantages. IV. DISTRIBUTED CONTROL SYSTEM

(DCS) FOR THE FOOD INDUSTRYDistributed control systems have evolved in the last ten years. From large systems tailored to the needs of continuous industries, such as refineries,DCSs can now respond to the batch-oriented processes and can address a variety automation projects. Many subsystems of the DCS. Figureconfiguration of the DCS.

Fig: 3, Distributed control sys

The philosophy of distributed control is to break downa large application into smaller subsystems and bring the level of control down to the unit level whenAppropriate to decrease overall system response time.This makes it possible to exchange between the different control units and allows integrated decision making at the product line or level.

Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470

Dec 2018 Page: 28

Due to increased competition, however, the need for flexibility, frequent changes in the

ocess and small engineering staffs, can benefit from using flexible, easily

configured control and process management systems.

Today food processors have a choice of upgrading logic controllers (PLCs) or

control systems (DCS). They can their existing PLCs (Marien,1988) to

control systems performing various functions such as process control, raw material management, sales order processing,

reporting. DCS-based performed these functions for large

DCS with all these benefits small continuous and batch

operations at a competitive price. The remainder of paper describes the distribute control system and

DISTRIBUTED CONTROL SYSTEM FOR THE FOOD INDUSTRY

Distributed control systems have evolved significantly the last ten years. From large systems tailored to

of continuous industries, such as refineries, DCSs can now respond to the requirements of small

oriented processes and can address a variety of elements make up the

Figure 2 shows a hardware

Fig: 3, Distributed control system

The philosophy of distributed control is to break downa large application into smaller subsystems and

level of control down to the unit level when Appropriate to decrease overall system response time. This makes it possible to exchange information

the different control units and allows for decision making at the product line or plant



Fig: 4, Control system hierarchy The next level of hierarchy, labelled as the level, improves control by integrating the control independent process parameters. For example, if theProduct quality is out of specification, then setProfiles or the recipe may have to be modified online. To perform on-line modification of set points orrecipes, a model of the process is requiredcan be a set of heuristic rules, a mathematical description of the process, or a combination of the two. DCS and other automation systems provide a user programming facility for such intelligent control of the process. For batch processes, vendorscurrently offering preconfigured software modules. Quality of Food The nutrient density is typically an indicator of proportion of nutrients present in a food item and can be selected as a measure of the quality of food. The nutrient content composition changes in food items depend upon the particular nutrient, the commodity, post-harvest handling, storage and home cooking conditions [7]. The time between the harvest and the final consumption also significantly affectsof food.

Fig: 5, Effect of food processing



Fig: 4, Control system hierarchy

as the tactical , improves control by integrating the control of

process parameters. For example, if the Product quality is out of specification, then set-point Profiles or the recipe may have to be modified on-

line modification of set points or model of the process is required. The model

be a set of heuristic rules, a mathematical description of the process, or a combination of the

and other automation systems provide a user programming facility for such intelligent control

batch processes, vendors are software modules.

The nutrient density is typically an indicator of the of nutrients present in a food item and can as a measure of the quality of food. The

composition changes in food items nutrient, the commodity,

and home cooking harvest and the

significantly affects the quality

5, Effect of food processing

V. BENEFITS OF THE DCSThe distributed control systems provide the benefits. Firstly, there are smaller logical incremental programming and easy fault isolation and maintenance. advantage of distributed control is to allow software program to be broken down into logical pieces, independent of system hardware. makes system design more efficient and simple modify. Software programs enable efficient management, accurate recording and analyzing production data, and statistical process and control functions. Secondly, there is a graceful degradation The distributed nature of the overall enough autonomy to the subparts sofailure of the system is unlikely. This is a direct digital control strategy based on computer controlling the entire process. A third benefit is that islands of automation removed via an integrated system. The control systems enable communication across different subunits of the manufacturing process, providing easy coordination of overall production rather than isolated islands of automation based on single controllers. VI. CHECKLIST FOR AUTOMATION IN

THE FOOD INDUSTRYA successful automation strategy hinges on:A. Defining a future vision of the company and

operations. B. Developing alternative automation scenarios.C. Defining criteria to evaluate each scenario

as: need for production flexibilitproducts on a single line, frequent changeover);need for system expandability to meet increasing automationfuture; requirements for open architecture (ability to integrate with existing equipment and/or plant host computer);ease of operator and engineer interaction with the system; availabilityfrom vendor (training, applicationmaintenance);range of advanced, proven technologies offered by the vendor (commitment to continuous evolution)


Dec 2018 Page: 29

BENEFITS OF THE DCS The distributed control systems provide the following

Firstly, there are smaller logical blocks involving incremental programming and checkout, together with easy fault isolation and maintenance. A direct advantage of distributed control is to allow the

program to be broken down into smaller pieces, independent of system hardware. This system design more efficient and simple to . Software programs enable efficient recipe

, accurate recording and analyzing of data, and statistical process and quality

Secondly, there is a graceful degradation from failure. The distributed nature of the overall system provides enough autonomy to the subparts so that massive failure of the system is unlikely. This is in contrast to a direct digital control strategy based on a single computer controlling the entire process.

A third benefit is that islands of automation are via an integrated system. The distributed

systems enable communication across the subunits of the manufacturing process,

providing easy coordination of overall production isolated islands of automation based on

CHECKLIST FOR AUTOMATION IN FOOD INDUSTRY

A successful automation strategy hinges on: Defining a future vision of the company and its

Developing alternative automation scenarios. Defining criteria to evaluate each scenario such

need for production flexibility (multiple on a single line, frequent recipe );need for system expandability to

increasing automation requirements in the for open architecture (ability

with existing equipment and/or with puter);ease of operator and engineer

system; availability of support training, application expertise,

maintenance);range of advanced, proven the vendor (commitment



VII. CONCLUSIONS The increase in dependency for processing food prove to be fatal for the modern human beings i.e. Homosapiens and hence an independent automated system needs to be developed to process the food at the domestic level. This in turn shall eliminate thedependency on processing individuals. Moreneeds to be done regarding automation at thelevel. One has to look beyond individual automationunits and incorporate a holistic approach. REFERENCES 1. C. S. Elton, Animal Ecology, Sidgwick and

Jackson, London, 1927.

2. S. Allesin, D. Alonso, M. Pascal, “A general model for food web structure,” Science, vol. 320, pp 658–661.



The increase in dependency for processing food could to be fatal for the modern human beings i.e.

Homosapiens and hence an independent automated to be developed to process the food at

. This in turn shall eliminate the individuals. More research

at the domestic individual automation

units and incorporate a holistic approach.

C. S. Elton, Animal Ecology, Sidgwick and

S. Allesin, D. Alonso, M. Pascal, “A general ,” Science, vol. 320,

3. F.N. Egerton, “Understanding food chains and food webs, 1700-1970,” Bulletin of the Ecological Society of America, vol. 88, 2007,pp 50

4. P. J. Fellows, Food processing technology: principles and practice, Elsevier, 2009.

5. S. Gunasekara, “Automation of Food Processing,” Food Engineering, vol. IV, 2011.

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7. D. M. Barrett, “Maximizing the nutritional value of fruits &vegetables,” Food technology, 2007.

8. M. C. Nicoli, M. Anese, and M. Parpinel, “Influence of processing onproperties of fruit and vegetables,” Trends in FoodScience & Technology, vol. 10, 1999, pp. 94


Dec 2018 Page: 30

F.N. Egerton, “Understanding food chains and 1970,” Bulletin of the Ecological

88, 2007,pp 50–69.

J. Fellows, Food processing technology: Elsevier, 2009.

S. Gunasekara, “Automation of Food Processing,” IV, 2011.

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Berlin Heidelberg, pp. 1041-1059, 2009.

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M. C. Nicoli, M. Anese, and M. Parpinel, “Influence of processing on the antioxidant properties of fruit and vegetables,” Trends in Food Science & Technology, vol. 10, 1999, pp. 94-100.

distributed control systems in food processing

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