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CHEMICAL SAVINGS DURING CIP

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CIP-cleaning in the food processing industry

CIP-cleaning facilities are primarily used in those installations wherever supreme necessities are demanded for hygiene and product safety, such as dairies, breweries and in food production. Throughout this process the complete production facility, including tanks and conducts, are purged and rinsed with cleaning agents and water in several cycles.  The aim of Cleaning-in-Place (CIP) is to remove product residues and microorganisms from all wetted surfaces inside tanks, pipework and filling machines while not disassembling the plant. To warrant optimum and economical cleaning, all parts in direct contact with the product must be made according to the principles of hygienic design.  Anderson-Negele’s motto “Hygienic by Design” is an expression of commitment that sensors fulfill this superior demand of the food processing industry in an exemplary manner.

Sequences of a CIP-cleaning within the example of a dairy

The CIP cleaning process takes place in several coordinated process steps. In the first step remains of the product in the installation are extruded and adhering particles removed in the pre-rinsing process. In the next steps, organic traces are eliminated with caustic and mineral deposits by use of acid. Subsequently, the facility is rinsed with fresh water and thus prepared for the next production step.

  1. Pre-rinsing (water)
  2. Cleaning (caustic)
  3. Mid-cycle rinse (water)
  4. Cleaning (acid)
  5. Rinsing (freshwater)

 

Optimization of the CIP Process

A CIP cleaning process in commonplace applications lasts between 60 and 90 minutes. The operator of a production facility consequently suffers from downtime in production capacity leading to a loss of products, and from increased cost for the consumption of water, energy and chemicals.

The hygienic design of the complete production facility and automatized processes are key factors for a reduction of the cleaning cycle times and for an increase in the efficiency and productivity of the process itself. Being an experienced specialist for sensor technology in hygienic environments, the sensors and process connections from Anderson-Negele are perfectly adapted to the requirements of the food industry and ensure the safe and economical cleaning of the facility and installations.

Why Morton Controls together with Anderson-Negele’s ILM-4 could help you

 The analysis of the return media is one of the most important steps for an environmentally friendly and cost-efficient process. The ILM-4 inductive conductivity meter plays a central role in precisely determining the phase separation: during the discharge of the liquids at each cleaning stage the media are differentiated with cost-saving accuracy.  Re-usable cleaning agent that flows off after cleaning can thus be returned to the tank to the maximum possible degree. In a separate, internal circulation and for permanent optimum cleaning result, its concentration is adapted to the specified ideal value by re-dosing with detergent and fresh water in the cleaning agent tank. The ILM-4 conductivity meter also ensures the highly precise measurement of conductivity and temperature required here.

Inductive Conductivity Meter ILM-4

The ILM-4 is designed for hygienic applications in food-, beverage- and pharmaceutical industries and controlling of CIP processes (e. g. phase separation detergents/water). The ILM-4 is currently equipped with the IO-Link in parallel.  IO-Link offers important benefits over analog technology when it comes to reliably controlling the entire process technology with a variety of measuring points, control and operating elements.

FEATURES/ADVANTAGES

  • CIP/SIP cleaning up to 150 °C/maximum 60 minutes
  • Wear-free, inductive measurement
  • In contrast to conductive measurement procedures, no problems with electrode deterioration or polarization.
  • Accurate measurement through compensation of temperature influences.
  • High reproducibility of ≤ 1 % of the measurement value.
  • Analog outputs for conductivity and temperature are a standard feature.

    Anderson-Negele’s ILM-4 with IO-Link

  • Analog outputs for conductivity, temperature or concentration are freely adjustable.
  • Rapid temperature response time T90 15…60 s
  • Installation in tube diameters from DN 40

 

For more information please contact the Morton Controls team:  0861 000 393, sales@mortoncontrols.co.za, www.mortoncontrols.co.za

 

Anderson-Negele’s NCS-M Capacitive Level Sensor with the MPI-300 programming adapter

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In combination with theMPI-300 USB programming adapter, the NCS-M sensor can be individually adapted to the application used by the customer. In addition to setting the device to the appropriate medium, switching threshold, hysteresis and time delay can also be individually configured.

 

Application examples of the capacitive level sensor:

  • Limit detection in vessels or pipes
  • Product monitoring in pipes
  • Pump/dry running protection
  • Detection of syrup and fruit concentrate

 

 

 

 MPI-300 USB programming adapter in combination with the NCS-M sensor

  1. NCS-M-12:
  • Version with enhanced measurement range for critical media (e.g. Oil, Fat)
  • No adjustment necessary
  • The switching threshold, hysteresis and time delay parameters can be set for the sensor for complex applications
  • Insensitive to foam and adherence
  • Very short response time (< 100 ms)
  • IP 69K

2. The MPI-300:

Adapter for the universal programming of the NCS-M capacitive level sensor family. Level detection even for media with a low or no water content such as syrup, fruit concentrate, alcohols and oils with a dielectric constant εr (Dk) ≥ 2.

The switching threshold, hysteresis and time delay parameters can be set for the sensor.

Anderson Negele’s ILM-4 conductivity sensor with IO-Link

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Conductivity sensor with IO-Link

The ILM-4 conductivity sensor with IO-Link is a big step to industry 4.0 in hygienic process technology.

Proven industry standard now also for hygienic and aseptic applications

IO-Link offers advantages in process control and monitoring. The ILM-4 conductivity sensor, the first of a whole range of measuring instruments to be equipped with an additional IO-Link interface, is a well-known and proven conductivity sensor on the market. This will be followed in due course by the sensors ITM-51 for turbidity, NSL-F for level, L3 for pressure and D3 for differential pressure and volume, all based on the modular platform with fail-safe plug-and-play technology with standard cable for time-and-cost-saving installation and set-up.

The (R)evolution of conductivity measurement

IO-Link offers significant advantages over analogue technology when it comes to reliably controlling the entire process technology with many measuring points, control and operating elements. Set-up and installation are easy and cost-effective. A three-pole standard cable is sufficient for the signal transmission and power supply itself. In practice, point-to-point connections are made at field level from various sensors to collection points, so-called IO-Link masters, and from there via Fieldbus system to the control centre.

 

Simple data transfer becomes intelligent communication

With IO-Link, data streams in the opposite direction towards the sensors are now also possible. In this way, the status of the sensor can be checked and specifically queried at any time. This makes it possible to detect potential faults, signs of wear or an increased risk of failure at an early stage and helps to avoid production downtimes.

“Plug-and-play” takes on a whole new meaning

Sensor replacement of the ILM-4 with IO-Link becomes easier and safer than ever before and can be carried out independently, at any time and by any employee without any programming effort. The device configuration of each connected sensor can be stored in the IO-Link Master. Immediately when plugged in, the new sensor is automatically recognized, configured and parameterized by the IO-Link Master.

The new dimension in hygienic measuring technology is digital and analogue, compact or remote. It is: modular

ILM-4 conductivity transmitter with IO-Link creates planning security and flexibility for status control and sensor diagnostics for preventative maintenance avoids production downtime.  The combination with the modular platform, with the separation of sensor and electronic unit in the optional remote version, creates a unique constellation of hardware and software that is unparalleled in flexibility, simplicity and system compatibility.

ANDERSON-NEGELE’S NEW P41 PRESSURE SENSOR

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Morton Controls introduces Anderson-Negele’s new P41 pressure sensor with temperature compensation providing a quality, robust and cost-effective pressure and level measurement solution.

Pressure sensors for levAnderson-Negele P41 Pressure Sensor el measurement

Anderson-Negele’s new P41 pressure sensor compliments the range of pressure sensors from Anderson-Negele being the D3, L3, LAR, DAN-HH, PFS and P41. With our comprehensive range of sensors based on various measuring methods, you can be assured of a measuring instrument, for process pressure and level measurement, that is precisely tailored to your application.

Robust, needs-based, cost-effective

Despite its compact appearance, Anderson-Negele’s new P41 pressure sensor is designed to meet the high demand of process requirements: Pressure up to 40 bar, overpressure resistant up to 100 bar, vacuum resistant. The measuring range can be individually adapted to the desired process pressures and a choice can be made between absolute and relative measuring cells. Compound measurement is also possible, that means that the relative measuring cell can also be used to measure the vacuum range.

The P41 is robust when it comes to temperatures: up to 125 °C as standard, up to 150 °C / 60 min for CIP/SIP cleaning, and even up to 250 °C permanently with optional cooling section. The entire sensor, including the diaphragm, is made of stainless steel for excellent cleanability and durability. The P41 is versatile in terms of process connections and offers, in addition to the hygienic thread “G1” with CLEANadapt, further connections according to DIN 3852 in “G1/2” and “G1”, as well as Tri-Clamp and Varivent.

The complete rugged process sensor system from a single source

Morton Controls in conjunction with Anderson-Negele offer an extensive range of sensors to make all fluid processing application efficient and reliable.  With temperature, pressure, filling level, limit level, flow measurement and monitoring along with conductivity and turbidity. Measuring methods are adapted to the special requirements for the demands of process industry, due to their innovative products that are specifically designed for sanitary and hygienic sensitive areas. Solutions based and customer-oriented approach, Anderson-Negele has become synonymous with quality and efficiency in the food, beverage and life sciences industries.

We are pleased to bring Anderson-Negele’s new P41 pressure sensor to our clients.

Contact us today if you would like to find out more.

 

PETROCHEMISTRY: CHLORINE-ALKALI ELECTROLYSIS

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PETROCHEMISTRY 

 CHLORINE-ALKALI ELECTROLYSIS

The chlorine-alkali electrolysis is an important procedure in the chemical industry. The products chlorine, hydrogen, hydrochloric acid and caustic soda are generated from sodium chloride. There are three manufacturing methods: the diaphragm, the membrane and the amalgam process.

The LiquiSonic® analyzer provides an advantageous utilization in the varied process steps of the three methods. Foremost, the customer gains the advantages of a reduction in raw material and energy consumption, as well as an increase in the yield.

 

LiquiSonic® measuring points in the processes of the diaphragm method of the chlorine-alkali electrolysis

 

Preparation of end products

1.1  Caustic soda concentration

The market ready caustic soda (NaOH) typically has a concentration between 45 wt% and 50 wt%. Since NaOH gained from electrolyzer cells only yields a concentration range between 12 wt% and 33 wt%, it is concentrated in cascade evaporators.

If together with NaOH the solution contains NaCl (diaphragm method), the excess salt in the caustic soda precipitates in a crystal form during the evaporation. This way, the NaOH-concentration is elevated to 45 wt% and 50 wt%.

The LiquiSonic® analyzer continuously determines the concentration of caustic soda at any time after evaporation. A subsequent dilution of the caustic soda to a customer specific product concentration, can also be monitored.

ADVANTAGES:

  • Continuous concentration monitoring of the caustic soda
  • Reduction in the energy costs during the evaporation process

1.2 Chlorine gas drying

Water content needs to be removed from the chlorine gas before it is further processed as its corrosives elevate at a moisture content of over 30 ppm. For the drying, the chlorine gas is routed into the absorption towers, where the water content in the chlorine gas is absorbed with highly concentrated sulfuric acid (80 – 99 wt% H2SO4).

The effectiveness of this drying process significantly influences the productivity and quality of the gas. Therefore, a reliable measurement of the H2SO4 concentration is vital. The LiquiSonic® analyzer offers a continuous and safe monitoring of the H2SO4-concentration, in opposition to conductivity and density measurement.

ADVANTAGES:

  • Elimination of labour intensive sampling
  • Continuous monitoring of H2SO4-concentration
  • Clear concentration determination signal between 80 wt% and 100 wt% H2SO4
  • Ensuring the desired Cl2 dryness to avoid corrosion in the system

1.3  Hydrochloric acid production

The chlorine gas that is generated on the anode of the electrolyzer with the added hydrogen form the base materials for the synthesis of hydrochloric acid. Both gases are fed into a burner and react to form hydrogen chloride. Subsequently, the formed HCI-gas streams from the burning chamber into the integrated isothermic falling-film-absorber. Here, the gas is absorbed with the help of water or diluted acid, whereby concentrated hydrochloric acid (37 wt% HCI) is formed.

Using the LiquiSonic® analyzer, a continuous monitoring of the hydrochloric acid concentration is possible. This allows for deviations to be recognized from the target concentration and to react accordingly.

ADVANTAGES:

  • Continuous concentration monitoring of hydrochloric acid (20-40 wt% HCl)
  • Ensuring an extremely precise target concentration

Advantage of sonic velocity as compared to conductivity and density

 

 

suspended solid sensors

SUSPENDED SOLID SENSORS – GET BETTER CONTROL

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For better control over your suspended solids, we recommend Quadbeam’s S-range of suspended solid sensors, both for hygienic and immersion capabilities.

In addition, you will realise cost savings, a reduction in losses, and higher concentration control, in a repeated and accurate manner.

 

THE MAIN FEATURES OF THE S-RANGE SUSPENDED SOLID SENSORS

  1. Because of the 4-beam self-compensating sensor, drifting is eliminated and therefore electronics aging and contamination is done away with
  2. You have one-piece piece casing and therefore no leakage in the lenses – completely glass-free
  3. These sensors are reliable, repeatable and accurate

Quadbeam offers a number of models in their suspended solid sensors, namely:

Under Hygienic –

– S10-3HY

– S10HT-3HY

– S10-2HY

– S20-3HY

– S40-3HY

And, under Immersion:

– S10-IMM

– S20 -IMM

– S40-IMM

And, under Variline:

– S20-VN

– S40-VN

 

The measurement range of the S-range sensors are impressive:

– 0 – 25g/L in normal activated sludge (immersion)

– 0 – 40% milk fat (hygienic)

All dependent on the media and particle size

 

THE VARIOUS APPLICATIONS:

Quadbeam’s S range covers a wide area of applications, namely, mining, waste water, pulp and paper, dairy, and food and beverage.

For industrial applications, they are able to deal with the activated sludge measurement for return and waste. In the food, beverage and dairy arena, the monitoring of high levels of suspended solids is a popular application.

 

For hygienic applications:

– the product to water interface

– monitoring on fruit pulp

– concentration control of solids

– concentration of milk fat

 

For immersion applications:

– digested and thickened sludge to clarifiers

– measurements of waste and return sludge

– filter, gravity and centrifugal

 

Should you be wanting to explore these range of sensors, we urge you to make contact with us and we will arrange a demo at your convenience.

sensors

Precise Measurement with Sensotech’s Liquisonic Sensors

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For a more precise and quicker measurement of concentration and density, look no further than the Sensotech Liquisonic Sensors.

 

In particular Sensotech have had much success in the many sectors from chemical to the  brewing industry. While they use a standard system, there is also fine-tuning to customise the solution to the specific food industry specifications and hygienic requirements.

 

INSTALL AND FORGET

It is rare in an industry, where keeping tabs is the norm, to find a company that promotes walking away and letting the system manage the process alone. And that really is the case here! Sensotech’s Liquisonic sensors are that in tune, that once they have been set up correctly, they will monitor continuously.

 

Multiple signals are sent out every second and combined into one compensated signal. The temperature of the medium and the drifts are taken into account during single measurements. No matter what is happening with the conductivity and colour of the medium, the measurements continue. They are also resistant to pressure shocks.

 

The Liquisonic sensors are manufactured to be maintenance and drift-free for a period of 15-20 years. If you were concerned about drift in measurement before, no need to with SenorTech.

 

WHAT IS THE UNIQUE CONCEPT BEHIND THESE SENSORS?

sensors

The fast reaction time of these sensors using absolute sonic velocity as a well-defined and retraceable physical value means phase separation is quicker than before, with more accuracy. You are getting a reproducible physical signal that is quite unique handling temperature rangers of  up to 180 °C or 200 °C and can be use in explosion areas as well.  Solid rugged sensors for a precise and fast density and concentration measurement using absolute sonic velocity as a well-defined and retraceable physical value.

The positioning of the Liquisonic sensors is key in the application, be it in the main vessel or piping. The sensors are available to suit your process connections, such as tri-clamps, varivents or flanged.

The electronics can be housed inside a enclosures form polyester to stainless steel casing (IP 69) or in an existing cabinet.

 

THE STORAGE OF DATA

 

The Sensotech  controller can have up to four sensors connected for management of up to 32 (optional 99) products with an output of concentration and temperature, trend chart for a fast process course overview with  simple parameterization, e.g. of periphery analog and digital outputs, fieldbus, and Ethernet. It has a automatic self-monitoring function with a simple installation und intuitive operation for recording of events, e.g. exceeding of thresholds or change of product plus long-term memory of measuring results and user management with authorization levels. Remote operation via browser (PC, tablet, etc.)standard is to provide data storage that is situated internally as well as a card slot this way you can store the measurements for longer periods of time.

 

LET’S TALK APPLICATIONS

 

There are many variations and applications where the Liquisonic sensors can be applied. Namely:

 

Phase Interface Detection

Gas Scrubber Control

Concentration & Density Measurement

Refrigeration Cycle Monitoring

Evaporator

Neutralization

Incoming Goods Control

Bath Monitoring

Polymerization Monitoring

Solids control in pulp and paper (green, red and black liquor)

 

D3_1-Remote-Flush-Mount-Short_F-Trans

D3 Differential Pressure & Level Transmittor

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Focusing on the Food, Beverage, Dairy and Life Sciences industry, we bring you Anderson-Negele’s D3 Differential Pressure and Level Transmittor.

Using the Modular Platform of Anderson-Negele sensors and the technology of L3 it has a parallel display of differential pressure and head or system pressure in the display and two mA output interfaces. The electronics using digital signalling to avoid negative impact of temperature changes reduces the effects of process and ambient temperature changes quite significantly. One of the elements we like about the D3 is that it comes ready to use out-of-the-box and the simple setup and programming is just that – simple.  You can mount the D3 transmittor display direct or you can mount the two sensors remotely and insuring a reliable remote wire cabling.

Take a look at some of the applications where this transmittor has worked well.

THE RANGE OF APPLICATIONS FOR THE D3 DIFFERENTIAL PRESSURE AND LEVEL TRANSMITTOR

 

  • In yoghurt culture vessels for Level monitoring
  • In fermentation vessels for Level monitoring
  • In Mashtuns for grain bed monitoring
  • Across membranes for pressure drop measurement

WHAT ARE THE MAIN FEATURES?

 

As mentioned, the setup couldn’t be easier with the user interface display.  You are provided with two analogue outputs, the top or bottom pressure and the differential pressure output.  In addition, the temperature compensation which will minimise any errors in extreme temperature changing applications plus simple and reliable remote wire cable avoid frequent recalibration

 

Should there be a need to replace or repair components, this can be done in the field with ease and no interruption to the work process as there are no capillary issues!  On inputting the product and tank information, you will receive accurate mass and volume output due to the integrated tank tables.  The patented dual o-ring seals give you IP69K ingress protection and you can look forward to the dual loop output provided by the Hart 7.0 graphical and communication LCD display.

 

WHAT IS THE MEASURING PRINCIPAL OF THE D3 DIFFERENTIAL PRESSURE AND LEVEL TRANSMITTOR

 

In the D3 system, each sensor uses an internal piezo-electric signal converter and a temperature sensor to measure the pressure and temperature of the capillary fill.  The electrical signal of the pressure converter and the resistance of the temperature sensor are measured and converted to a compensated pressure value in the pressure fitting. Both signals are transferred digitally to the head. They are then output in a standardized 4…20 mA and HART 7.0 signal for the differential pressure and in a 4…20 mA signal for the top or total pressure.

 

Where you have level applications that have pressure and/or vacuum conditions, we highly recommend the D3 Differential Pressure and Level Transmittor from Anderson-Negele.

UWT T30

THE T30 PROCESS TURBIDITY SENSORS FROM QUADBEAM

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Quadbeam Technologies has two models available, the Immersion T30-IMM and the Hygienic T30-3HY.

 

Utilising Quadbeam’s four beam ratio-metric technology, with the 90 degrees Scattered and the Attenuated NIR, meeting ISO7027 standards, making it a truly unique turbidity sensor proving its reliability, repeatable ability and accurate measurement in many situations.

 

The measurement range is between 0 and 50 through to 0 to 1000NTU.  Note that these measuring ranges will change dependent on the media and particle size. The simple user interface is easy to calibrate, and you will find you will have much better control over many processes.

 

Both Immersion and Sanitary configurations are available with Hygienic 3A certified and Immersion Styles Airjet Cleaner of Immersion Style approved.

 

SOME COMMON APPLICATIONS WITH THIS TURBIDITY METER

 

  • Clarifier overflow weir monitoring
  • Steam condensate and cooling water returns
  • Surface water monitoring
  • Solids that are loaded in streams and rivers
  • Condensation water monitoring
  • Filtration control and monitoring
  • Measuring percentage solids in vegetables and fruit
  • On plate heat exchangers – product breakthrough control
  • From DAF plants, final outlet of effluent measurement
  • Dairy plant loss control

 

 

MORE ON THE T30

 

There are two emitters and two detectors, which are set at 90 degrees to each other.  As they pulse in sequence, two detector currents are produced, one from the detector at 90 degrees to the emitter (scattered light) and one from the detector opposite the emitter (attenuation). A Ratio-metric four beam signal processing compensates for changes in optical properties of emitters and detectors due to ageing and surface coating.

 

A standard built-in cleaner is available with the T30 submersible turbidity sensor from Quadbeam.  The recommended cleaning method is with high pressure air with an optional biocide included. To protect the sensor fingers from impact, stainless steel support rods are designed to lift and protect the sensor fingers in rugged applications.

 

For more info on the T30 Turbidity Sensor from Quadbeam, reach out to Morton Controls today.

rn3004-rotonivo-rotary-paddle-switch-for-point-level-limit-measurement-horizontal-tube-extension

Product Focus – The Rotary Paddle switch Rotonivo® RN 3004

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The Rotary Paddle switch Rotonivo® RN 3004

with horizontal tube extension for point level measurement

 

In the rubber industry the applications are very demanding and UWT can offer custom made level control solutions as per each client’s requirements.   For easy maintenance, durable ruggedness and reliable quality, the Rotary Paddle Switch Rotonivo® RN 3004 is perfect.

 

WHAT COULD THE CHALLENGE BE?

 

The environment could be extremely dusty, which is normal in the rubber factories, and an automated fill level measurement is required in a few carbon black storage silos.

What can UWT recommend?

 

WHAT IS THE SOLUTION?

 

The Rotary Paddle Switch Rotonivo® RN 3004 is perfect for such extreme environments and requirements.  The special bearing and sealing in the tube is suitable for dusty situations.

Let us take a closer look at this switch.

 

Here are the technical specs –

 rotovino specs

WHAT ARE THE FEATURES? 

  • The switch is perfect for most bulk solids
  • Easy maintenance
  • Easy to operate
  • Reliable
  • Not affected by caking, electrostatic charging and dust
  • A compact installation process
  • The die-cast aluminium housing is very robust
  • With a wide range of supply voltages and process connections, you are spoilt for choice
  • RoHS compliant
  • The boom is durable and rugged, including a protective tube
  • The switch has received international approval to be used in high explosive environments, such as where dust exists

 

Measuring Vanes Available

 rotovino vanes

Should you have similar needs in your rubber factory, contact Morton Controls today.