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        <title>[PCN Europe] Editor's choice</title>
        <description><![CDATA[[PCN Europe] Editor's choice]]></description>
        <link>http://www.pcne.eu/content/editors-choice/index.html</link>
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            <title>[PCN Europe] Editor's choice</title>
            <link>[PCN Europe] Editor's choice</link>
            <description><![CDATA[[PCN Europe] Editor's choice]]></description>
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            <title>Transparent consumption, better electricity tarifs</title>
            <link>http://www.pcne.eu/content/editors-choice/pcn/transparent-consumption/index.html</link>
            <description><![CDATA[In the overall cost analysis of a chemical additives company from northern Germany, energy costs were a major cost factor at almost 40%. Combined with an anticipated annual price increase of about 5%, it was time to act. 
The world is facing a turning point in the energy policy. Since the industrialization 150 years ago, the industry depends on basic commodities, such as oil and gas. Reversing this dependence is the greatest and most difficult task that science&nbsp; and politics face in the future. Utilities reassure the industrialized countries with the promise: The supply of oil and gas is still secure for at least another 50 years. At the same time, the debate concerning nuclear energy is experiencing a renaissance. However, uranium cannot break down indefinitely. According to current projections, the deposits will be exhausted in approximately 35 years. Moreover, the safe storage of highly radioactive waste is still unclear to this day.
Renewable energies, such as photovoltaics, solar-thermal energy conversion, geothermal prospecting, biogas and wind provide hope. However, these do not have the efficiency needed to compete with the cheaper basic raw materials at this time. If renewable energy should become a serious alternative, energy consumption has to be dramatically reduced. Should this effort succeed, it would have an immediate dual effect: Lower energy requirement makes renewable energy affordable for the consumer, and every measure by itself reduces CO2 emissions.
Typical energy costs in chemical plantsHowever, until alternative energy sources are economically viable, conventionally produced energy will initially become more expensive, since an increasingly greater expense is necessary for the extraction and production. A lecture at the VDI / GMA Conference in Baden-Baden last year, stated: The average energy of a chemical production facility amounts to an average of 37% of the total cost. The energy costs, as determined in the overall cost analysis of a medium-sized chemical company, are therefore a typical value at up to 40%, rather than an isolated case.
Measurements create Transparency&quot;In the beginning was the measurement.&quot; This old phrase from the process automation is still valid. In order to understand and interpret processes, a possibly accurate and continuous monitoring of product flows is required. Known measuring methods, such as pressure, filling level, temperature, flow and analysis measuring transducers are enlisted. In order to be able to reduce energy costs in production, measurements are also required to make the energy consumption transparent. However, before the energy consumption can be affected, the energy flows must first be analyzed in detail. It was therefore important for the medium-sized chemical company in northern Germany to precisely capture the power consumption of vulnerable areas. It searched for a solution that can easily be integrated and pay for itself within a manageable framework. The choice fell on the Wago-I/O-SYSTEM. It has convinced the company, because, apart from the control functionality, is contains a variety of components, including one for energy monitoring. ((Figure 1))
The 3-phase power measurement module 750-493 was therefore an argument for the Wago I/O-SYSTEM. It allows a detailed measurement of electrical volumes in a three-phase supply network. The voltage of the three phases and zero can be measured at the terminal by directly wiring the individual lines.
However, it records the current and voltage values of all three phases by six analog / digital converters within a time frame of 16 microseconds. The currents are delivered by a simple current transformer for a current measurement. The measured current and voltage values are shown in root-mean-square values by the terminal and calculates the effective power (P), the energy consumption (W) and the power factor (cos &#966;) for each phase. The apparent power (S) and the phase shift (&#966;) can be derived from these values. In addition to these energy data, it also records the energy peaks occurring over a definable period and internally sums up the energy consumption. Various operating modes, or shifted peak times can therefore be already assessed after one production cycle. ((Figure 2))
Using these components, small intelligent &quot;I/O measurement nodes&quot; developed in selected areas in the northern German chemical plant, which capture the consumption with this power measurement terminal. Each node is provided in the field with an Ethernet controller, which is networked with other controllers. The power consumption of each node is also visible via the network from the intranet.
Measurements result in MeasuresConcrete actions followed, after the energy consumption was recorded and an analysis of the measurements was determined and the cost per consumer and time period were calculated. First, the chemical company negotiated with local suppliers. They laid down electricity rates for various time periods during the day and at night. In order to use the electricity rates optimally, the intelligent measurement nodes also had to assume turning the plant components on and off. This not only depends on favorable electricity rates, but also on the feasibility of the operation. However, there were actually pumps and compressors that were not operated continuously around the clock. Here, the optimization depending on the electricity rates and time was possible. This function was realized by decem-energy controlling. It assumes overriding management functions and can therefore objectively activate or deactivate or plant parts.
SummaryOnly an accurate recording of the power consumption and the determination of the timeframe brought clarity of the situation. Energy guzzlers could thereby be identified. &quot;I / O-measurement nodes, linked by an Ethernet network and some equipped with small on-site panels, were able to precisely analyze the energy flow. The energy controlling tool of the Berlin firm Dezem assumed the monitoring, analysis, billing and issuance of control commands of the plant. Based on the calculated values, the company negotiated the best rate with the energy supplier. The entire energy requirement was reduced by actively activating and deactivating the consumers in reference to the rates. This represents a reduction of energy costs to below 25% in the total cost analysis. The investments in this project therefore paid back over a period of approximately two years.]]></description>
            <pubDate>Tue, 01 Jun 2010 17:10:34 +0100</pubDate>
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            <title>Leak-free pump handles corrosive liquids</title>
            <link>http://www.pcne.eu/content/editors-choice/pcn/leak-free-pump/index.html</link>
            <description><![CDATA[The DB22 model plastic magnet-drive centrifugal pump handles capacities up to 50m3/h at maximum differential heads up to 45m. These robust, leak-free pumps are suited for the challenging liquids transfer applications occurring in corrosive and challenging environments. The non-metallic materials used for both the housing and all the key wetted components makes them suitable for pumping corrosive liquids manufacturing and processing or wherever hazardous liquids need to be transferred. A close-coupled design configuration allows for optimum magnet alignment and extended dry-running capability when specified with a carbon bushing.]]></description>
            <pubDate>Mon, 12 Apr 2010 14:57:35 +0100</pubDate>
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            <title>High-Tech Dairy Production Meets Strong Craftsmanship Professional dairy staff and innovative ...</title>
            <link>http://www.pcne.eu/content/editors-choice/pcn/high-tech-dairy-production-meets-strong-craftsmanship/index.html</link>
            <description><![CDATA[Professional dairy staff and innovative process technology join forces at the Løgismose micro-dairy, Denmark. The entire plant is connected via an EtherNet/IP network to manage all processes and safety functions from a few centrally-located touch screens.&nbsp;

Perfection is more important than profits at the Løgismose micro-dairy in Tivoli Gardens. Here, in one of Copenhagen’s most attractive locations, the Danish dairy industry has a unique showcase both for its proud craftsmanship traditions and for its groundbreaking production technology. The micro-dairy is an integrated part of the magnificent NIMB complex, one of the oldest and most beautiful buildings in Tivoli Gardens. NIMB has been transformed into a connoisseur’s paradise in recent years, and now comprises an exclusive hotel, a gourmet restaurant, a chocolate factory, a delicatessen and its own production of organic dairy products. 
Everything at NIMB has been handpicked to be the best: the furniture, the service concept and even the packaging. Of course, the dairy’s production equipment is no exception and the Løgismose dairy specialists have every imaginable monitoring and control technology at their disposal as they work with the delicate organic milk products. Despite its small size and limited production capacity, the dairy supplies Tivoli’s guests at the hotel, restaurant and delicatessen with a full range of dairy products. Milk, cheese, butter, yoghurt, sour cream and chocolate milk are all produced in just one plant – something that places great demands on production processes. 
The high-tech plant consists of 10 production tanks, a standardization tank, homogenization and pasteurization tanks, and three cleansing tanks. All supplied by APV in strategic cooperation with among others Rockwell Automation, who provided the overall control system, and Endress+ Hauser, who provided the process instruments. The entire plant is connected via an EtherNet/IP network that allows dairy specialists to manage all processes and safety functions from a few centrally-located touch screens. 
Dairy staff control each and every pump and mixer equipped with a PowerFlex drive connected to the EtherNet/IP network. This solution gives dairy specialists complete control of pump speeds, mixing frequencies, air mixtures and other factors that affect milk and dairy end products. 
“Quality is a fundamental principle for us – and this requires monitoring, control and precision. The Rockwell Automation solution gives us the same control of raw materials as dairies used to have using old-fashioned, manual methods. At the same time, we comply to all the food safety requirements that modern food processing companies must meet and that legislation requires,” says Kim Ernstsen, Dairy Manager at Løgismose MicroDairy:NIMB. 
The network provides dairy specialists instant access to all data collected in the production plant. All processes are registered in order to create a reliable basis for quality control and quick action if products do not meet the dairy’s exacting demands. Should electricity fail, a centrally placed UPS (Uninterrupted Power Supply) provides complete data backup. Process data also play a key role in the dairy’s day-to-day production and in product development. 
“Process data provide a treasure chest of information and give us a high-quality, empirical foundation for what we do. For example, if we make a really delicious butter product, we can dig into the data to see what the pasteurisation temperature was and determine exactly what we did to the cream to achieve just that taste. We do not make standard products where productivity is the main priority – we keep our focus on quality. In our constant search for the very best, data is a key parameter so it is a great advantage for us that everything is recorded and can easily be retrieved by our dairy specialists,” says Kim Ernstsen. 
Machine safety is also managed through CIP Safety over the EtherNet/IP network and an Allen-Bradley GuardLogix controller that combines automation and safety control into one. With the use of I/O blocks on EtherNet/IP for both automation and safety data, the dairy is not locked into a hard-wired solution and achieves great flexibility when it comes to changing the production set-up without installing new cables. Everything is controlled on screen, so dairy staff can easily transfer control from one safety zone to another and define which tanks and pumps stop when tank doors are opened. The solution provides more than just flexibility: it reduces the possibility of mistakes and safety breaches, and also makes it easier to keep the dairy clean since the number of cables is greatly reduced. 
“This is a state of the art solution that meets all directives for machine and product safety. The interaction between the modern dairy plant and its high-tech control system is a perfect demonstration of both APV’s and Rockwell Automation’s global competencies in the dairy industry,” says Morten Kiil Rasmussen, APV’s business development manager. “All programming was carried out abroad, and the development process has been quite flexible, and is a good example of Rockwell Automation’s global support.” 
Løgismose MicroDairy:NIMB has two key tasks: to demonstrate the very best Danish dairy production and to develop new gourmet products based on organic milk. Rockwell Automation has supplied an integrated EtherNet/IP solution that provides dairy staff with full control of all processes and safety aspects. The flexible, userfriendly solution can rapidly be reconfigured to produce all types of products in just one plant.]]></description>
            <pubDate>Mon, 12 Apr 2010 14:57:35 +0100</pubDate>
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            <title>Rotary disc valve for abrasive, corrosive or coarse substances</title>
            <link>http://www.pcne.eu/content/editors-choice/pcn/rotary-disc-valve/index.html</link>
            <description><![CDATA[The LRD rotary disc valve suits applications that involve abrasive or corrosive slurries, powders or coarse substances. It finds the users in mining and metal industries, mineral processing, power generation, sand and gravel, chemical &amp; pulp and paper industriesor in water and wastewater treatment. The design allows the valve to cycle in heavy scaling slurries without sticking or leaking and with minimum wear. It is available with pressure ratings up to 100 bar. The valve is designed for leak tight shut off slurries and liquids within a pipeline, to be operated only in the fully open or fully closed position. As the actuator is opened or closed, the disc is allowed to rotate. The wedge gate support has a cutaway behind the disc clearing debris away and thus, ensuring the disc closes and seals every time. The body and bonnet are made of cast steel and can be made out of different materials. The bonnet houses the rotating disc when open and seals around the spindle. The valves are produced with manual, manual gear, pneumatic, hydraulic and electromechanical actuators.&nbsp;]]></description>
            <pubDate>Mon, 12 Apr 2010 14:57:35 +0100</pubDate>
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            <title>Rotary Valve Design for Throttling Performance</title>
            <link>http://www.pcne.eu/content/editors-choice/pcn/rotary-valve-design-for/index.html</link>
            <description><![CDATA[The Control-Disk valve offers high throttling performance and suits applications that involve fast processes and varying pressure drops, such as in the hydrocarbon, refining, chemical, pulp and paper, and metals and mining industries. The valve’s wide control range is twice that of traditional butterfly valves for better adherence to set point. This improved capability allows control closer to the target set point, regardless of process disturbances, which results in a reduction in process variability. 
With a contoured edge on one side, the patented disk creates a flow clearance to give the Control-Disk valve an inherent equal percentage characteristic. Computational fluid dynamics (CFD), verified by flow testing, show the Control-Disk valve’s ability to reduce dynamic torque. 
The Control-Disk’s equal percentage flow characteristic provides an improved throttling range that allows control in the 15 to 70 percent valve travel range. It replaces poor performing butterfly valves that typically have a narrow 30 to 50 percent valve travel range. With its improved capability, the valve allows to control closer to the ideal set point with less chance of set point overshoot, so quality on spec and output on target can be kept. 
The valve is reliable and has low maintenance requirements for high plant availability, especially when it is paired with a Fisher spring-and-diaphragm actuator and digital valve controller. This assembly can capture and deliver diagnostic data to AMS ValveLink software, providing an accurate picture of valve, actuator, and digital valve controller performance. This makes it a core component of PlantWeb digital plant architecture. 
As a direct replacement valve, existing piping can be used. The valve meets API, ASME and EN standards, making it suitable for use in all world areas. The valve body meets PN 10 through PN 40, CL150, and CL300 ratings. Face-to-face and raised-face dimensions meet EN 593, API 609, and MSS-SP68 standards. Line centring clips provide for versatility to mount and align the same wafer style valve body in different piping configurations (ASME and EN ratings).]]></description>
            <pubDate>Mon, 12 Apr 2010 14:57:35 +0100</pubDate>
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            <title>Ultrasonic Measurement of Overflash Mass Flow In the BP Oil Refinery Emsland in Lingen, ...</title>
            <link>http://www.pcne.eu/content/editors-choice/pcn/ultrasonic-measurement-of-overflash-mass-flow/index.html</link>
            <description><![CDATA[The many processes running in a refinery form a highly complex system of material and energy flows which can only be managed by means of a dense network of measuring points continuously recording all relevant parameters. In days of rising costs for energy and resources, measurement and control technology is more than simply ensuring that a plant fulfils its function: a constant optimisation of the plant’s processes is required. Global competition makes it increasingly important to recognise and utilise all potential for minimizing the required energy and maximizing the yield. In the field of crude oil distillation, an important indicator for an efficient column operation is the overflash volume. The properties of the medium – a heavy and highly viscous gasoil – and the process conditions (low flow velocity and high temperatures around 380°C) make it very difficult to measure this quantity. 
The BP Oil Refinery Emsland processes approx. 4.4 million tonnes of crude oil annually. Most of it is comes from the north-west oil pipeline, which also supplies refineries in the Ruhr and the Rhineland with imported oil unloaded from oil tanker ships at the harbour of Wilhelmshaven. But not all crude oil is equal. Its composition, and thus the percentages of light and heavy hydrocarbons it contains, varies depending on its origin. The process control has to respond flexibly to these differences in order to achieve the highest possible yield of desired products. 
Usually, refinery plants almost exclusively use orifice flow meters because of the high temperatures. In Lingen, the overflash volume is conveyed in a 6” pipe located on the outside of the column. There, the overflash flows one column section downwards, driven only by gravity. Measurements using the differential pressure method are made particularly difficult by the low volume flow of 10t/h at the most. In the small overflash return line, this means the flow velocity is never higher than 0.15m/s. For orifice flowmeters, this means that an orifice plate with a very small diameter has to be used to obtain satisfactory precision. This accordingly results in a high pressure loss which cannot be compensated with the available hydrostatic height. After a test measurement had demonstrated the suitability of non-invasive ultrasonic technology for this application, a FLUXUS meter with WaveInjector mounting fixture was installed at the measuring point. The meter uses the transit time difference principle to measure the volume flow. Since the physical conditions at the measuring point are virtually constant, it is easy to calculate the mass flow without recording the pressure and temperature. The recorded measuring values are fed into the process control system and are used for automatic control tasks. 
The clamp-on WaveInjector extends the possible application range of non-invasive ultrasonic measurements to temperatures up to 400°C. Its functional principle is simple: The patented system consists of two coupling plates, each connecting a transducer with the pipe, yet keeping both of them a certain distance apart. The surface of these plates radiates enough heat to keep the temperature at the mounting point of the transducers within the permissible range. Simultaneously, the coupling plates ensure the acoustical contact between pipe and transducer. The mechanically robust mounting fixture maintains a high contact pressure. Specially designed metal foils replace the coupling gel and insure contact and long-term stability. 
As the WaveInjector is a purely mechanical arrangement, it can also be used in explosive atmospheres, together with transducers that have been tested and certified for explosion protection. It is not necessary to cut into any pipes to install the transducers. They can also be retrofitted - without downtimes or complicated approval procedures. The other advantages of clamp-on measurement – such as not being dependent on pressure or media, no wear caused by the medium, high measuring dynamics – of course still apply. 
The oil refinery in Lingen, which started operation in 1953, was one of the industrial motors behind the economic development of the previously backward Emsland region. With around 600 employees and 75 apprentices, it is one of the most important employers in the region. However, compared to other national plants, and in particular to international ones, it is rather small. This makes it even more important for the people of the Emsland to optimally use the available capacity. Their success is visible in the figures: In 2007, BP Oil Refinery Emsland achieved a plant availability of 98%, the capacity utilisation amounted to 90%. Especially as far as plant availability is concerned, the ideal solution would be using non-invasive measuring methods. The measuring unit for determining the overflash volume was installed without interrupting the production process. The measuring point is located in a potentially explosive atmosphere. Therefore the explosion-protected FLUXUS ADM 8027 is used as transmitter. 
In addition to unlimited availability of the system components and full utilisation of their capacity, the optimisation of systems and processes is becoming increasingly important. In Lingen, a software for advanced control has been implemented for this purpose. It varies the process parameters based on mathematical models and the data from the process control system, and optimises the process using iterative learning control. An important measuring value for this purpose is provided by the high-temperature ultrasonic measurement at the overflash return line. As reliable data is now available on the quantities that return as a function of the various types of crude oil and of the way the column is being run, thae process can be optimised to achieve more energy efficiency and yield.]]></description>
            <pubDate>Mon, 12 Apr 2010 14:57:35 +0100</pubDate>
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            <title>Image Sensor for Factory Floor Use The iVu Series TG Image Sensor, combines the simplicity of a ...</title>
            <link>http://www.pcne.eu/content/editors-choice/pcn/image-sensor-for-factory-floor-use/index.html</link>
            <description><![CDATA[The iVu Series TG Image Sensor, combines the simplicity of a photoelectric sensor and the intelligence of a vision sensor to deliver advanced and affordable inspection capabilities. It features a Touch screen with intuitive, 9-language interface and requires no PC for device setup making it suitable for factory floor use. It offers three advanced sensor types in one compact, rugged package, making it possible to solve a wide variety of complex applications with just one sensor. An inspection wizard guides the first time user through the procedure for choosing the correct sensor type: Match, Area or Area with Motion. Typical applications include: label inspection, date/lot code inspection, vial cap inspection, packaging verification, blister pack inspection, feeder bowl inspection, electronic marking verification and many more. The sensor features integrated lighting (red, blue, green or infrared options) but is available with an external too. The 2.7&quot; LCD touch screen display and the 752 x 480 CMOS imager are housed in a rugged IP67 housing. 
The device offers user-friendliness through nine onboard selectable languages with extensive help functions, Remote TEACH function and an onboard USB port for upload/download to/from USB drive. Further characteristics include adjustable focus lenses, an inspection/system logging for rapid analysis and a software emulator to program the iVu offline and load parameters via USB drive.]]></description>
            <pubDate>Mon, 12 Apr 2010 14:57:34 +0100</pubDate>
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            <title>Loading Bay Doors Keep Brewery Cool To support its naturally cooled ‘eco-cellar’ Otter Brewery, ...</title>
            <link>http://www.pcne.eu/content/editors-choice/pcn/loading-bay-doors-keep-brewery-cool/index.html</link>
            <description><![CDATA[In an attempt to drastically cut its energy consumption, Otter Brewery has built an ‘eco-cellar’, which uses low carbon insulation and natural cooling to obviate the requirement for electrical cooling systems. To maintain the controlled environment in the cellar, the brewery needed to install a suitable protective door system. A fail safe sequential two-door system that ensures the cellar is never exposed to the outside environment satisfied this requirement. 
Otter Brewery is a family run business that has been established for nearly 20- years. It is one of the most high tech small breweries in the UK, and produces a whole range of award winning beers and ales. The brewery is located in the Blackdown Hills, which is classed as an area of outstanding natural beauty and of specific scientific interest. As a result, Otter Brewery takes its environmental responsibilities extremely seriously and has recently built an ‘eco-cellar’ that is naturally cooled. 
In recent years the brewery has enjoyed significant expansion. With the brewery’s previous layout, up to nine separate chillers were needed to chill all of the beer that was produced in various buildings and chambers. This was prohibitively expensive and counter productive to the brewery’s environmental goals. The solution was found in the new ‘eco-cellar,’ which is built partly underground, with a living ‘sedum’ roof and low carbon clay honeycomb block walls that provide state-of-the-art insulation. 
The new cellar has been so successful that the correct room temperature is maintained without the use of any electric chillers using the natural temperature of the ground. However, in order to maintain the temperature in the cellar, Otter needed to find a door system that wouldn’t expose the cellar to the outside environment. Inefficient door systems are notoriously damaging to controlled environments, especially when there are no air conditioning systems in place. A door system was needed that could be in frequent use without affecting the insulation of the cellar. 
A solution was designed and installed tailored to Otter’s needs. The designed two door sequential locking system ensures one of the doors is always closed. Two doors from the Sprint range of high speed loading bay doors were used for the application. 
David McCaig, MD of Otter Brewery, commented: “The customer service provided by sara was exemplary. Paul Rudge, the Sales Engineer listened to our needs, and came up with a door system that matched all of our demands. The energy savings from the cellar that these doors have helped to achieve has meant that the doors will pay for themselves in a matter of years.” 
A Sprint 3000 was selected for the external door of the cellar. The door has galvanised steel frames and a curtain of individual aluminium profiles, which can be easily replaced if damaged. The door is designed for low maintenance, even after long term heavy use, utilising a Disc Drive mechanism which limits noise and wear vibration. The door reaches operating speeds of 2.5 m/s using the MCC Vector control system, which is fully programmable to each application’s needs. 
For the internal door the Sprint 355 was recommended, a high speed roller door, with a transparent curtain which provides visibility for safety in high tech areas. Curtain tensioning provides smooth and steady movement with an in-line motor available for applications where side clearance is restricted. MCC Vector control is available as an option, which allows users to programme a dual height opening function.
The Sprint 3000 is available between 1220-7000mm wide and 2500-5000mm high. Between each profi le there is a flexible rubber weather seal which provides protection from the elements. The door is wind resistant to EN 12424, class 3; which will protect against hurricane force winds. The Sprint 355 is available between 1000-4000mm wide and 1500-4200mm high. The high visibility transparent PVC curtain comes as standard and is wind resistant against high winds to EN12424, class 2 standard. 
Both doors were supplied with a ‘non-contact’ safety beam, this continuously scans ahead of the door curtain to act as a fail safe security system. If the beam is broken, the door stops, preventing the risk of damaging equipment or, more importantly, of injuring personnel standing beneath the closing door. While similar safety systems exist on the market, this one offers the advantage of not needing an accompanying spiral cable; as these stretch over time and become vulnerable to snagging.]]></description>
            <pubDate>Mon, 12 Apr 2010 14:57:34 +0100</pubDate>
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            <title>MESH Control Network for the Beverage Industry</title>
            <link>http://www.pcne.eu/content/editors-choice/pcn/mesh-control-network/index.html</link>
            <description><![CDATA[At Asia Pacific Breweries Singapore (APBS) a MESH control network has been successfully implemented. The automation solution upgrades and replaces copper-based communication networks and increases APBS’ overall computing processing capacity. Including the operating system upgrades and optimization for batch control processes, the entire project was brought online with nearly zero productionline downtime. 
APBS is the first brewery in Southeast Asia to use this technology to substantially improve their automated production speed and efficiencies while improving their ability to control and monitor more simultaneous processes. 
For many forward-looking producers such as APBS, MESH networks provide whole new levels of automating and controlling production and quality processes,” said Mr. Tony Ho, vice president of sales for Invensys Process Systems (IPS), Asia Pacific. “MESH networks bring high availability and fault tolerance to production lines. Their inherent configurability and adaptability allow APBS to bring to market new beer products faster, while maintaining high quality and consistent taste standards.” 
The MESH control network has greatly improved the network process communication loading compared with the previous copper cabled Ethernet network. This is achieved with a Foxboro Field Control Processor and a Field Device System Integrator Module, 10/100 MBPS Ethernet, Single. The installation of the distributed and field-mounted controller that performs and monitors process control according to the user-defined strategy provides an additional 25% spare blocks and 40% more CPU loading. Coupled with module, this provides Ethernet modbus communication that is many times faster than the previous serial modbus. This allows for quicker response and provides APBS the flexibility to add on more I/O points in AB PLC side when required. 
“APBS is glad to work with IPS in the upgrade and replacement of our legacy systems and to take the lead in implementing the region’s first MESH control network,” said Mr. Juan Candau, technical manager, APBS. “The increased capabilities and operation improvement powered by IPS systems are in line with APBS’ modern product processes and methodology that deliver consistent, high-quality beverages to customers all over the world.”]]></description>
            <pubDate>Mon, 12 Apr 2010 14:57:34 +0100</pubDate>
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            <title>Electric vibrators with up to 30,000kg centrifugal force</title>
            <link>http://www.pcne.eu/content/editors-choice/pcn/electric-vibrators/index.html</link>
            <description><![CDATA[The MVSI product range of electric vibrators has been extended with a model capable of creating as much as 30,000kg of centrifugal force. This introduction is geared towards extending the use of electric vibrators in new sectors and fields of application. The electric vibrator is offered with 6, 8, 10 and 12 pole options with electrical and mechanical over-sizing to allow it to be used in application srequiring increased starting and peak torque. The specially designed and oversized mechanical and electrical parts ensure that the vibrator can withstand the typical heavy wear and tear. To aid eccentric massregulation operations, the latest model has been equipped with two standard split covers with ring seals, ensuring the same IP66 protective strength as traditional seals. Also available to be used in potentially explosive Dust and Gas environments.]]></description>
            <pubDate>Mon, 12 Apr 2010 14:57:34 +0100</pubDate>
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            <title>In Hazardous Dust Areas... One Spark Might Be Enough</title>
            <link>http://www.pcne.eu/content/editors-choice/pcn/in-hazardous-dust-areas/index.html</link>
            <description><![CDATA[The standards that apply to electrical production equipment used in hazardous dust areas are changing rapidly. For those equipment owners and manufacturers that do not keep a breast of these changes, there can be serious consequences, warns Gordon Low of Cooper Crouse-Hinds.
“The standards governing electrical equipment for use in hazardous dust areas are changing so rapidly that buyers and users of electrical production equipment are finding it difficult to keep up,” says Gordon Low, OEM sales engineer at Cooper Crouse-Hinds (UK) Ltd. “However, if they do not keep a breast of the changes,they run the risk of a dust explosion occurring in their plant due to inadequately protected equipment. The risk of non-compliance or negligence is simply too high.”The risk of a dust or powder explosion occurring in a manufacturing plant should not be underestimated. Around 2,000 dust explosions occur in Europe every year, affecting all types of companies, including manufacturers of sugar, coal, cocoa, flour-based goods, milk powder, tea, grain, fodder and tobacco, as well as wood and metal processing companies. Any environment in which dust or powder is allowed to gather on hot surfaces or that could be ignited by a spark from electrical equipment is a potential risk.The cost, in terms of lives lost and damage to plant, as a result of a dust explosion can be enormous. In February 2008, a catastrophic dust explosion occurred at the Imperial Sugar Refinery in Port Wentworth, USA. The dust explosion killed 13 people and injured many more.Owners of new electrical equipment are governed by the compulsory European directive 1999/92/EC. From 2006, this directive also includes ‘old’ as well as ‘new’ equipment. Owners of electrical equipment are required to identify the risks of explosion; implement explosion protection measures such as avoiding sources of ignition (secondary explosion protection); define zones in areas at risk from dust explosions; create an explosion protection document; use suitable production equipment;and to create a test plan.For electrical equipment in areas at risk from dust explosions, a new series of stricter standards,EN61241, have been introduced, which came into effect from the 1st October 2008. The standards supersede the existing standardEN 50 281. Within EN61241, one of the main protection types for electrical equipment atrisk from dust explosions in accordance with ATEX Directive 94/9/EC, is the protection by enclosures type “tD”. This protection type is where the electrical equipment is protected by an enclosure to prevent dust penetration and where measures have been taken to limit the surface temperature.The main changes to this standard are concerned with impact energy – high demand on impact energy as in Zone 1; electrostatics– electrostatic conductance of the enclosure;and ageing resistance – high demand on the ageing resistance of the plastic enclosure. “It is imperative that production equipment owners are aware of these changes in standards when sourcing or upgrading electrical production equipment for hazardous dust areas,” says Low.The goal of the current European Directives is to protect manufacturing plants from dust explosions and to prevent damage or personal injury. As Low points out: “A recent reportfrom the HSE [Health &amp; Safety Executive] stated that on average there are 70 to 100 incidents each year in the UK that involve explosive atmospheres. In one particular year, the HSE investigated five fatal accidents involving explosive atmospheres and 16 major accidents. It’s not something companies can afford to ignore.”In addition, there are further pressures to comply, as Low warns: “On the 6th April2008, the Corporate Manslaughter and Corporate Homicide Act was introduced in theUK. This means that companies found guilty of negligence or non-compliance could face severe fines and/or imprisonment. This means that companies’ internal control of health and safety is a business risk that senior managers can no longer regard as a minor matter. Directors must act immediately in order to raise the status of health and safety so that it assumes the same level of boardroom importance as other business risks,” advises Low.Companies looking to reduce costs at the expense of health and safety should think again,says Low. According to the HSE, total compliance costs to UK industry are estimated at £350 million (€413 million) over the ten years from 2002-03, almost all of which is attributableto action that should be taken inany case under existing regulation. Against this cost, the total losses associated with incidents involving dangerous substances are valued at just over £800 million (€944 million)over ten years.For owner operators that need technical advice and guidance on explosion-protected electrical installations and the relevant EU Directives and standards, Cooper Crouse-Hinds provides a comprehensive range of explosion protected electrical equipment, including fluorescent light fittings, emergency lighting,switches, terminal boxes, control stations,portable lamps, connectors and plugs.]]></description>
            <pubDate>Mon, 12 Apr 2010 14:57:34 +0100</pubDate>
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            <title>VALVE SERIES designed for less complex tasks</title>
            <link>http://www.pcne.eu/content/editors-choice/pcn/valve-series/index.html</link>
            <description><![CDATA[The T-smart valve series is designed for basic functions; it is favorably priced and designed for less complex tasks. The series includes butterfly, single-seat, divert and mixproof valves. It is characterized by standardized products, while still offering the necessary variations (e.g. body combinations, seals, feedback options). Clearly assigned item numbers simplify the selection and ordering process. The valves offer a small, compact design. The resulting low weight enables easy handling and operation of the valve. The bayonet lock and the component concept allow for ease of maintenance. Seals can be replaced fast without special tools. The bayonet lock enables the valve to be dismantled easily without control air. The seat valves are manufactured in sizes DN25-100 and 1“-4“OD. The butterfly valve series is a cost-effective shut-off device in valve blocks and panels for product and CIP operation. It offers hygienic design, ease of maintenance, reduced cleaning cycles, installation and maintenance - achieving overall an economical production in the process plant. They are available in sizes DN25-150 and 1“-4“OD.]]></description>
            <pubDate>Mon, 12 Apr 2010 14:57:34 +0100</pubDate>
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            <title>Tablet Production &amp; Handling with Vacuum Technologies Compressed tablets are still the most ...</title>
            <link>http://www.pcne.eu/content/editors-choice/pcn/tablet-production-handling-with-vacuum-technologies/index.html</link>
            <description><![CDATA[The potential for growth in tablet manufacturing is high. However, several challenges and trends are threatening the profit potential. Today, pharmaceutical manufacturers are challenged to evolve their production processes in order to survive and excel in an increasingly competitive industry. While product quality has always been of paramount importance, strenuous economic times and continually inflating drug prices are heightening consumer demand for lower-priced prescriptions. Tablet manufacturers are more than ever seeking new ways to automate their lines to speed and streamline production, and vacuum conveying technologies are providing an answer. 
By automating the conveying process, vacuum technologies can improve productivity and enhance quality. In addition, selecting a vacuum technology that is maintenance-free and energy-efficient can provide further benefits to tablet manufacturers. These benefits allow companies to cut costs and meet challenging consumer demands for quality pharmaceuticals and lower prices. 
Offering a safer environment In general, reducing manual labor through automated vacuum conveying can improve working conditions by reducing heavy lifting. In addition, American manufacturers must abide by Safety, Health and Environment (SHE) regulations enforced by the US Department of Occupational Safety &amp; Health Administration. In Europe, the European Foundation for the Improvement of Living and Working conditions (EUROFOUNDA) oversees the improvement of industrial working conditions. 
Heat, dust and noise are all pollutants in the working environment that detract from worker safety and the stringent sanitation demands for pharmaceutical and chemical production. Tablet manufacturers can greatly reduce manual labor and diminish exposure to environmental irritants with the installation of a vacuum conveying solution that moves dry powder products through dedicated pipe systems. These systems fully contain the powders to minimize dust and also generate less heat. 
To ensure the highest standard of worker safety, the conveyors should also have few moving parts, and be easily assembled and disassembled to reduce worker strain. 
In one example of the benefits of vacuum conveying technology, Surepharm Services Ltd, a UK contract manufacturer specializing in tablet production, improved its working environment by reducing the amount of heavy lifting and manual labor performed by its employees. The company replaced its manual loading operation with three C-Series vacuum conveyors to transfer powder products to blending and tableting machinery. As a result, the company saved up to 30 hours of labor per week and reduced dust significantly. Additionally, the lightweight conveying equipment quickened the cleaning process by reducing the physical demand on the workers. 
Increasing uptime Given the 24/7 production runs in pharmaceutical manufacturing, automation technologies must be highly reliably. In today’s competitive pharmaceutical industry, there is simply no time for line stoppages or ongoing maintenance. Additionally, changeover can add significant costs and downtime to the production process. A vacuum conveyor must easily facilitate changeover or risk negating the gains realized through automation. 
Simple solutions can effectively combat the erosion of productivity caused by line stoppages, maintenance or changeover. Vacuum technologies with few moving parts are not only safer; they are maintenance-free and can reduce downtime. Conveyors that are easily handled by workers are more quickly assembled and disassembled, reducing the time it takes for equipment adjustments between batches and during cleanings. Machines containing fewer components also help minimize part mix-ups and help to prevent line stoppages. 
In one instance, Rottendorf Pharma, one of Germany’s leading contract manufacturers of solid dosage form drugs, replaced its traditional vacuum conveying machines with C2100-64 compact compressedair conveyors. The PIAB conveyors were lighter in weight and contained fewer parts. This made them easier and faster for workers to assemble and disassemble. As a result, the company reduced cleaning time from 7,200 hours to 6,600 hours yearly. The hours saved from cleaning were recycled back into manufacturing time and Rottendorf has improved productivity by 15 million tablets since the installation.
Cost-effective, easy cleaning In addition to aiming to reduce changeover time, tablet manufacturers must also prevent cross-contamination of the product. A vacuum conveyor that is easily disassembled for quick clean-up is a cost-efficient way of averting cross contamination. In Rottendorf’s example, the light-weight conveyors that replaced its older equipment offered&nbsp;a way to quicken the cleaning process and maximize uptime. 
Clean-in-place systems are effective but costly solutions to meeting strict FDA regulations on sanitary conditions. Additionally, the systems can add unnecessary bulk to existing equipment.
Energy-saving solutions As energy costs soar, the reduction of energy usage is a strategic step to trim expenses from pharmaceutical manufacturing operations. In addition, reducing energy consumption is good for sustainability efforts. However, in terms of energy consumption, not all vacuum solutions are created equal. 
Conveying systems powered by decentralized vacuum technologies are more energy-efficient than their centralized counterparts. While a centralized vacuum system puts more distance between the source of the power and the point of use, a decentralized vacuum system uses multistage ejector technology to apply the vacuum where needed. This way, no additional energy is expended to compensate for the extra distance. 
Optimizing automation Automating the tablet-handling process affords many advantages and conveniences to pharmaceutical manufacturers, including increased productivity and reduced staff injury. However, poorly designed automated conveying systems can cause segregation and tablet breakage. Simple precautions can be taken to avoid incurring the costs of product waste as a result of either event. 
Preventing Segregation Particle separation prior to tablet compression, known as segregation, can threaten the integrity of drug dosages and jeopardize the uniformity of a batch. Segregation can occur during tablet production as a result of gravity and particle characteristics as well as due to external factors such as air flow and vibration.
When implementing vacuum conveying, segregation risk can be significantly reduced by handling the material at a controlled speed to ensure that the materials stay blended. 
Preventing Tablet Breakage Tablets can also break due to exposure to friction and shock during or after the manufacturing process. A broken tablet is susceptible to contamination, rendering it useless. As a result, product waste can accumulate and cause production delays. 
To prevent breakage, tablet manufacturers can employ an accommodating vacuum conveying system. To start, the conveying system should have an adaptable feed rate to enable the system to be sped up or slowed depending on the size or volume of the tablets being handled. 
Also, the vacuum conveyor’s tubing and piping specifications along with couplings can be specifically designed to reduce speed and avoid product damage. The tubing and piping should have soft curves to avoid tablet breakage. 
Conclusion Vacuum automation technologies can play a key roll in streamlining tablet production. By taking the right precautions in installing a reliable, efficient vacuum conveying system, manufacturers can increase their productivity, reduce energy usage and improve their work environments. As companies harness vacuum technology to advance tablet production, more efficient conveying systems will translate into cost savings, helping tablet manufacturers stay competitive by enabling them to produce more affordable prescriptions. 
By Häla El Sheemy Washbrook, Business Unit Manager, Pharma &amp; Chem, PIAB ]]></description>
            <pubDate>Mon, 12 Apr 2010 14:57:34 +0100</pubDate>
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            <title>Radar sensors temperature range up to 450°C</title>
            <link>http://www.pcne.eu/content/editors-choice/pcn/radar-sensors/index.html</link>
            <description><![CDATA[More than 200,000 Vegapuls radar sensors are installed and operate all over the world. The Vegapuls plicsplus represents the next generation of the tried pulse radar technology. Through the extension of the temperature range to 450°C and the higher chemical resistance of the antennas, the sensor has a much wider application spectrum. It features additional housing versions, an optimised connection concept and simplified operation thanks to clear adjustment parameters allowing for easy setup and commissioning. Its microprocessors provide power for the signal analysis and enable complex processing algorithms. The electronic components allow for fast signal evaluation and a differentiation between product level and vessel installations enabeling the sensors to follow quick level changes. This accommodates the recent market trend of implementing smaller vessels with shorter filling and emptying cycles.]]></description>
            <pubDate>Mon, 12 Apr 2010 14:57:34 +0100</pubDate>
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            <title>Potato Processor Implements Automatic Defect Removal System Norwegian potato processor Hoff ...</title>
            <link>http://www.pcne.eu/content/editors-choice/pcn/potato-processor-implements-automatic-defect-removal-system/index.html</link>
            <description><![CDATA[Norwegian potato processor Hoff Norske Potetindustrier installed an automatic defect removal system on their primary processing line for French fries, improving yield and product quality. 

When the largest potato processor in Norway, Hoff Norske Potetindustrier, began searching for a new sorter for their French fry line last year, they considered several options and selected an Automatic Defect Removal (ADR) system, instead of a traditional sorter, to remove defects from the primary processing line. This application, called ADRFirst, increases yields and improves product quality simultaneously. 
“We heard that our competitor had been using Key Technology’s ADR for several years to remove defects on the sorter’s reject stream to recover the good product. Our problem, however, was that we didn’t have the space to install an ADR on the reject stream of a sorter,” noted Ole Solberg, Assistant Technical Manager at Hoff’s Gjøvik plant. 
Hoff analyzed the costs and benefits of three options – upgrading the existing sorter, installing a new sorter, and replacing the old sorter with the ADRFirst solution. Despite the higher capital cost, the ADRFirst solution offered the best return on investment due to a dramatic increase in yields. A six-month payback was projected based on installing ADR4 on Hoff’s two-ton per hour production line. 
“Having used ADR for about nine months now, we’ve found the maximum performance of the system far exceeds our expectations,” said Solberg. “In the past, we had to push our sorter to the limit to achieve our quality objectives. With ADR, we exactly match our required end-quality specifications and we’ve improved our yields while doing so.” 
ADR 4 uses a belt conveyor, LED light source, Vis/IR (visible infrared) cameras, a patented rotary cutter with air-actuated knives, and Iso-Flo vibratory conveyor to align, singulate, inspect, and trim defects from peeled and peel-on French fries and remove the defects from the product stream. Unlike traditional sorters, which remove the entire potato strip when defects are identified, ADR cuts the strip and removes only the defect. 
French fry lines using traditional sorters lose product to the sorter’s reject stream. If an ADR is located on the sorter’s reject stream to recover good product, seasonal overloading often compromises quality and reduces yields or necessitates a reduction in production rates. The ADRFirst solution addresses these common problems. But, due to space limitations, Hoff had been operating their old sorter without an ADR on the reject stream, causing them to lose high-value potato strips to low value waste destined for alcohol production. 
At Hoff, the increase in yields drives the quick payback on the ADRFirst solution, but improved product quality is another important benefit. Compared to traditional lines that feature a sorter with an ADR system on the sorter’s reject stream, which tend to remove 65 to 75 percent of the defects, the ADRFirst solution removes more than 90 percent of the defects without reducing yields. This allows processors to match high quality specifications while increasing yields. 
“Another important advantage of the ADR system comes from its Smart Cutting feature. When we’re producing single serve packages of 130 grams, the ADR is programmed to cut longer potato strips into shorter pieces to fit into the smaller bags,” said Solberg. “We used to have problems sealing bags when fries that were too long for the bag reached the packaging station. Now, we rely on ADR to match our desired length profile for each particular package.” 
By preprogramming the ADR for various products, Hoff can easily match the length and quality that is specified by each customer. Changeovers are achieved in less than one minute on the ADR system via the color touchscreen user interface. No change parts or mechanical adjustments are required. 
“It’s easy to produce near-perfect product with Key’s ADR,” concluded Solberg. “At Hoff, we devote a great deal of attention in the field and in the plant to making perfect potatoes. Installing the ADRFirst solution is just one example of our dedication to quality.”]]></description>
            <pubDate>Mon, 12 Apr 2010 14:49:30 +0100</pubDate>
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