TS06- Case Study Batching Plants - Challenges and ... · PDF fileCase Study Batching Plants - Challenges and Innovations ... ANSI / ISA 88 Standards ... TS06- Case Study Batching Plants

Copyright 2012 Rockwell Automation, Inc. All rights reserved.
Case Study Batching Plants - Challenges and Innovations
Ramkumar R S
Director Marketing Autosys Engineering (P) Ltd.
[email protected] ; [email protected] www.ael-india.com
11th Feb 2015

Copyright 2012 Rockwell Automation, Inc. All rights reserved. 2
Agenda
80-120 material batching
Speed vs Accuracy vs Consistency
Recipe diversity
Silo vs Silo less
Design inputs
Low cost Batcing for SMEs
ANSI / ISA 88 Standards overview

Design Inputs
Plant capacity / output per shift or per hour Total and product wise.
No. of products / varieties that the plant needs to produce in a given month
or year
No. of products / varieties that the plant needs to changeover within a
given shift and the changeover time expected.
Minimum and Maximum no of raw materials to be used for any given
product
No. of major materials that have to be automated
3

Design inputs
No. of minor ingredients to be added semi-automatically / manually
No. of micro ingredients to be added manually.
Green field project or Retrofitting in an existing plant
Roof height limitations & Plant floor space available
Can the raw materials be sourced just in time or do they have to be
sourced and stored in advance. Stores / Gowdown area available.
Can all the raw materials be sourced in 1 ton jumbo bags or is it available
in small bags like 25, 50 and 100 Kg.
Labour dependability & availability4

Silo vs Silo Less
Show sample drawing of silo based batching plant layout
Show sample drawing of silo-less batching plant layout
5

Recipe Diversity Sample case
6
Product: 010
Batch Size: 1000 kg
Ingredient Per batch
Major Minerals
Calcium Carbonate 3.80 kg
DCP Inorganic 500.00 kg
Dicalcium Phosphate Udaipur 327.00 kg
Trace Minerals
Cobalt Sulphate 0.72 kg
Copper Sulphate 4.72 kg
Potassium Iodide 0.43 kg
Dried Ferrous Sulphate 5.00 kg
Magnesium Sulphate 61.00 kg
Manganese Sulphate 6.10 kg
Sodium Selenite 0.022 kg
Sodium Thio Sulphate 20.00 kg
Zinc Sulphate (26%) 58.56 kg
ADEK VitaminVitamin AD3 Premix (10:2) 0.70 kg
Vitamin E-50% 0.50 kg
B Complex
VitaminsNiacinamide 1.00 kg
D.L. Methionine 1.93 kg
L. Lysine 4.40 kg
ProbioticsLactic Acid Bacillus 25 B/CFU 0.12 kg
Yeast Culture (Sacharomyces
Cerevisiae)
1.50 kg
This is a Animal Nutrient

Recipe Diversity Sample Plant
7

Speed vs Accuracy vs Consistency
Speed : No of batches per hour and No of kgs per batch : Feed speed
Accuracy : Difference between weighing accuracy and control accuracy
Consistency : Difference between accuracy and consistency
Achieving higher feed speed without compromising on accuracy and
consistency
Gravity vs two speed vs variable speed feeders Mechanical innovations
Example cases of difficult to flow materials and how they were handled
Recron fibre (Belt feeder with fingers!) Fibrous composites (Screw feeder that can stop @ +/- 1 gram)
8

80-120 material batching
Roof and shop floor space limitation
Silos and auto feeders are not economically viable
Poke Yoke and Traceability is more important.
Optimum automation in the Indian context
9

80-120 material batching - sample
10

Low cost Batching for SMEs
11

ANSI / ISA 88 Standards - Overview
American National Standard - Instrumentation systems and
Automation Society
Procedural control/equipment mapping to achieve process
functionality
Recipe types, Recipe procedures and transportability
Control recipe procedure/equipment control relationships
Production / Batch information, history and reports
Procedural states and exception handling
Batch control activities and functions12

ISA 88 Standards - Overview
Data models, data structures and guidelines for languages
Site recipe models and representation
Site independent and equipment independent recipe management models
Batch production records object models, event models, data models and
representations
Total 4 Parts : 392 Pages.
13

ANSI/ISA 95 - Overview
Enterprise - Control System Integration
Object Models and their attributes
Activity models of Manufacturing Operations Management
3 Parts : 350 Pages
14

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TS06- Case Study Batching Plants - Challenges and ... · PDF fileCase Study Batching Plants - Challenges and Innovations ... ANSI / ISA 88 Standards ... TS06- Case Study Batching Plants