Food and Beverage Manufacturing – Improving Flexibility

1. Pre-wired systems 

Customers prefer to have everything set up in their system and ready to go so that they can change processes easily. You can request products tailored to the customer’s needs such as specific cable lengths.

Examples of pre-wired products:

• Pre-assembled beacons with M12 connection and plugs with male and female threads, universal and easy to install 
• Pre-assembled compact signal towers, with different cable lengths available on request

2. Error recognition and quality checking throughout the process

Address problems early in the process so you can meet demands for flexibility. Quality inspection can eliminate any human-related errors, and consistency can be achieved in elements like flavour, taste and texture. 

Some examples of products used for error recognition and quality checking include:

• Various machine vision cameras for food inspection to test geometrics, packaging and for foreign objects, and to analyse food quality and freshness
• Smart vision sensors and cameras to check whether the quality of an object is ‘good’ or ‘not’, displayed on a computer linked to the sensor 
• Smart vision sensors and cameras for quality control, identification and positioning. Their software guides the user step-by-step. This can be used, for example, to check that bottle caps are firmly secured

3. Traceability

By using automation, you can trace where production faults occurred and make appropriate alterations to prevent a product recall or low-quality product. 

The following are examples of products that help to monitor and change future processes and so increase flexibility:

• Smart vision sensors to check whether an object is ‘good’ or ‘not good’
• Image-based scanners for fast omni-directional barcode scanning during the barcode stage
• SWIR cameras combined with speciality lenses can be used for food inspection to check damage within food, for example bruises within an apple
• Various industrial protocols and networks such as IIOT and Ethernet-enabled products can be more effective than recognition by the human eye

4. Use components with quick turn-around and easy maintenance

Flexibility requires quick turn-around times and quick and easy maintenance products. Examples include:

• Easily pluggable connectors
• Products with IO-Link interface
• IIoT enabled products
• Motor drives with built-in Profinet and Ethernet/IP, easily interfaced with many PLC systems
• Motors and drives that work with many protocols

5. Increase safety for workers

Flexibility can mean that people do not have to undertake complex tasks that could put them in danger. By utilising automation and all its various functions, people also do not have to undertake often repetitive critical tasks where consistency is difficult to achieve.

Examples of safety products:

• Non-contact safety switches
• Solenoid interlock switches with IP69K
• Safety relays
• Slip rings
• IP69K beacons for alerting and notification

6. Quick hygiene and sanitation processes

It is critical to get hygiene and sanitation right in food and beverage manufacturing. 

The following ideas can help you maintain high hygiene levels during changes in the process, and without wasting time.

Washdown

Develop an easy washdown procedure with well-designed equipment made from stainless steel and IP-rated equipment.

IP-rated products include:

• Cable conduits and cable glands with IP68K
• IP69K push buttons
• Stainless steel motors and safety switches with IP69K
• FDA and Ecolab approved products such as cable entry systems are suitable for washdown 

CIP cleaning

CIP systems clean, rinse and sanitize pipes to remove any excess product. A twin-screw pump, for example, enables CIP cleaning and product handling within just one pump.

Twin-screw pumps ensure:

• An additional CIP pump is not necessary, saving costs and time
• High hygiene level
• Quick product handling and CIP cleaning

OEM Automatic process instrumentation, such as pigging valves, pressure gauges and turbidity sensors are suitable for CIP cleaning.

7. Reduce wastage

Flexibility means you can change production direction and switch functions without wasting too many resources. Reducing waste not only saves you resources but also improves the environmental image of your manufacturing process. 

An example of a product that helps reduce waste is a pigging system. Here a pig is pushed into the pipe to stop media getting through, thus enabling the pipe to be quickly scraped and cleaned.

A pigging system ensures:

• Less waste and less use of cleaning agent 
• Reduction in water consumption
• Lower energy consumption