Combined flow and temperature sensors optimise dairy processes

ACHIEVING PROCESS optimisation while controlling (cutting) costs is a constant challenge for all manufacturers, especially in the food and beverage sector. 

A good example of this is at Homann, part of the Müller Group, manufacturers' of a wide range of products including mayonnaise and salad dressings. Baumer helped Homann in achieving its goal of maximising process optimisation in production processes, thanks to the features and benefits of the sensing and instrumentation specialist's CleverLevel, CombiPress and CombiLyz sensors.

Level detection in storage, mixing and buffer tanks

Maintaining precise and reproducible switching of operations is vital to Homann, even in apparently simple tasks such as level detection. In storage tanks, conventional capacitive level switches, commonly known as 'micro wave switches', provide only limited reliability.

Whilst they only require medium / specific configuration, outside these thresholds the low dielectric constant of some media like edible oil (DK Ɛ>10) can cause measuring errors if a film of lye has remained on the sensing tip after cleaning. For Homann, this was one of the considerations for choosing Baumer's CleverLevel, the configurable universal level controller.

Operating on frequency sweep technology, CleverLevel sensors are designed as a single sensor solution, reliably detecting the level of any media including liquids, solids and powders. 

Depending on the recipes and dielectric properties of the ingredients in mixing tanks, Homann previously used product combinations of capacitive limit switches and vibrating forks. However, depending on the media, response times ranged from very slow, to highly sensitive, resulting in impaired process efficiency. 

Homann decided to replace its conventional solution with Baumer's CleverLevel sensors, which provide extremely fast response times of 0.1 seconds.  This has helped Homann to determine the optimum configuration which is conveniently changed and visualised via the FDT/DTM-based FlexProgram software.

Once the mayonnaise, salad cream or dressing is fully emulsified and dispersed it is pumped into buffer tanks until it is added to the salad in a later production step. Here, medium specific viscosity and adhesion play an important role. Conventional vibrating forks and capacitive limit switches were prone to measuring errors caused by adhering media, whereas CleverLevel is maintenance-free and not affected by media adhesion.

Measuring hydrostatic pressure in tanks 

Homann's Bottrop location uses a large outdoor vinegar tank and for consistent level monitoring they were looking for a precise, reliable, yet easy and convenient outdoor capable solution. The company decided on Baumer’s CombiPress pressure transmitter. Thanks to 0.1% (MEW) accuracy and active temperature compensation, it provides unambiguous measured results, independent of media and ambient temperature.

Easy configuration via the large touchscreen eliminates the need for an additional operating unit, while the robust housing with high IP67 rating reliably endures harsh outdoor conditions.

Capable of detecting medium-specific density and filling levels, Homann also installed CombiPress in glucose containers and horizontal tanks of edible oil. Here CombiPress excels with its integrated linearisation function and it also offers matching adaptors for optimum process connection.  

Conductivity measurement in CIP processes

Every cycle in salad dressing or mayonnaise production requires CIP (Cleaning in Place). This reproducible process must precisely define detergent dosing, regardless of pressure and or temperature variations. At Homanns' CIP installations in Bottrop, dosing needed to be improved and Baumer's new CombiLyz conductivity sensor was the solution.

Thanks to fast response time it ensures precise measured results at a maximum deviation of < 1%. The measuring connection of the inductive sensing element provides a 6.6 mm wide channel which will tolerate fabric or solid-containing media and this has helped Homann to optimise detergent dosing and reduce raw material costs

Andrew Moran, senior product manager at Baumer UK.

For more information: 

www.baumer.com

Tel: 01793 783839