Distributed Control Systems in Food Processing

1. International Journal of Trend in International Open International Open Access Journal | www.ijtsrd.com International Journal of Trend in Scientific Research and Development (IJTSRD) Research and Development (IJTSRD) www.ijtsrd.com ISSN No: 2456 ISSN No: 2456 - 6470 | Volume - 3 | Issue – 1 | Nov Nov – Dec 2018 Distributed Control Systems Control Systems in Food Processing n Food Processing E. Sankaran. ME Department of Instrumentation and Control Engineering, lytechnic College, Coimbatore,Tamil Nadu, India Lecturer (Senior Grade), Sri Krishna Polytechnic College, nd Control Engineering, India 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 dependency the modern human for processing of food. Through the 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 small batch 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 becoming Critical 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. 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 m in 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 th industry can respond to these challenges (see Figure I).Because of these new requirements .Because of these new requirements. The Objective of this study is to address the critical for automation in the domestic food processing 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 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 Fig: 1, Food and Consumer design Fig: 1, Food and Consumer design II. Food Processing is a technique to convert raw ingredients into consumable food form (by the modern human). It typically activities such as mincing, macerating emulsification, pickling, canning, etc. Presently, the emulsification, pickling, canning, etc. Presently, the for higher quality goods, cleanliness and hygiene, costs of insurance and PROCESSING OF FOOD PROCESSING OF FOOD Food Processing is a technique to convert raw consumable food form (by the involves operations and mincing, macerating, boiling, in manufacturing for more diversified @ IJTSRD | Available Online @ www.ijtsrd.com www.ijtsrd.com | Volume – 3 | Issue – 1 | Nov-Dec Dec 2018 Page: 27

2. International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456 Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456 Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470 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 of Marketable food (purchased by consumers) from raw Ingredients 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 etc. were employed to preserve the food. 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 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. Due to increased competition, however, the need for Production flexibility, frequent changes in the manufacturing process and small engineering staffs, food processors can benefit from using flexible, easily configured 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 financial management and architecture has performed these continuous processes. The DCS is now available small continuous operations at a competitive price. this paper describes the distribute its advantages. IV. DISTRIBUTED (DCS) FOR THE FOOD INDUSTRY Distributed 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. Figure configuration of the DCS. 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 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 order processing, 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 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 CONTROL CONTROL SYSTEM SYSTEM elements make up the Figure 2 shows a hardware Fig: 2, Stages of food processing Fig: 2, Stages of food processing III. CONTROL SYSTEMS FOR THE FOOD INDUSTRY The level of automation in the food industry varies Considerably 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 indust automation began with programmable controllers and single board on manufacturing equipment, and very systems. These devices, particularly programmable controllers, were widely accepted by food because they were simple to operate and They were limited in what they could replace relays, timers and counters (Marien replace relays, timers and counters (Marien, 1988). 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, Fig: 3, Distributed control sys Fig: 3, Distributed control system the single board computers simple control particularly programmable by food processors operate and maintain. application application of of 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 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 when Appropriate 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. They were limited in what they could do: usually @ IJTSRD | Available Online @ www.ijtsrd.com www.ijtsrd.com | Volume – 3 | Issue – 1 | Nov-Dec Dec 2018 Page: 28

3. International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456 Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456 Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470 V. The 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 so failure 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 INDUSTRY A 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 flexibilit products on a single line, frequent changeover);need for system expandability to meet increasing automation future; requirements for open architecture (ability to integrate with existing equipment and/or plant host computer);ease of operator and engineer interaction with the system; availability from vendor (training, application maintenance);range of technologies offered by the vendor (commitment to continuous evolution) BENEFITS OF THE DCS 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 Fig: 4, Control system hierarchy Fig: 4, Control system hierarchy 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. The next level of hierarchy, labelled as the level, improves control by integrating the control independent process parameters. For example, if the Product quality is out of specification, then set Profiles or the recipe may have to be modified on line. To perform on-line modification of set points or recipes, a model of the process is required can 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, vendors currently 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 affects of food. 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 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 software modules. CHECKLIST FOR AUTOMATION IN FOOD INDUSTRY A successful automation strategy hinges on: Defining a future vision of the company and its 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 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 nutrient, the commodity, and home cooking harvest and the significantly affects the quality advanced, advanced, the vendor (commitment proven proven Fig: 5, Effect of food processing 5, Effect of food processing @ IJTSRD | Available Online @ www.ijtsrd.com www.ijtsrd.com | Volume – 3 | Issue – 1 | Nov-Dec Dec 2018 Page: 29

4. International Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456 Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456 Journal of Trend in Scientific Research and Development (IJTSRD) ISSN: 2456-6470 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. 6.D. G. Caldwell, “Automation in food processing,” Springer Handbook of Automation, Springer Berlin Heidelberg, pp. 1041 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 on properties of fruit and vegetables,” Trends in Food Science & Technology, vol. 10, 1999, pp. 94 Science & Technology, vol. 10, 1999, pp. 94-100. VII. 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 the dependency on processing individuals. More needs to be done regarding automation at the level. One has to look beyond individual automation units 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. CONCLUSIONS 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 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. at the domestic individual automation D. G. Caldwell, “Automation in food processing,” ook of Automation, Springer Berlin Heidelberg, pp. 1041-1059, 2009. units and incorporate a holistic approach. D. M. Barrett, “Maximizing the nutritional value of fruits &vegetables,” Food technology, 2007. C. S. Elton, Animal Ecology, Sidgwick and M. C. Nicoli, M. Anese, and M. Parpinel, “Influence of processing on the antioxidant properties of fruit and vegetables,” Trends in Food S. Allesin, D. Alonso, M. Pascal, “A general ,” Science, vol. 320, @ IJTSRD | Available Online @ www.ijtsrd.com www.ijtsrd.com | Volume – 3 | Issue – 1 | Nov-Dec Dec 2018 Page: 30