Lösung Kampfmeyer gb6neu · control and instrumentation level to the higher-level ERP system...

Automated Mixer Feeding for Pre-Mixes and Specialty Ingredients:Ready for the future

S O L U T I O N

Lösung Kampfmeyer_gb6neu.qxd 19.03.2008 14:35 Uhr Seite 1

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Ingredient systems for the baking industry

Günter Ellmann (General Manager - Production & Engineering) and Karl Heinz Driller (Managing Director), KAMPFFMEYER Food Innovation, Hamburg, Germany

»Today, technology innovations require speciality ingredientsbased on our natural raw materials for the food industry.We were looking for a business partner who could provideus with state-of-the-art technology and process IT, onewho could offer us flexibility and long term future security,which were needed for our production processes. Onewho would assist us with an experienced person on siteand who would fit in with our integrated approach to quality philosophy.«

The Customer

KAMPFFMEYER Food InnovationGmbH is a joint venture betweenEurope's largest mill group – VKMühlen AG, Hamburg, and one ofthe world's leading producers ofemulsifiers and unique ingredients,PALSGAARD A/S from Denmark.KAMPFFMEYER Food InnovationGmbH is a company within theKAMPFFMEYER Group and specializes in the refinement of rawvegetables. It is a European leaderin the development, production andmarketing of innovative ingredients,compounds and ready-to-useblends (pre-mixes).

In addition to functional flours; customized compounds, texturedproteins and functional food productsare produced for the baking industrysuch as OMEGA-3 bread®, GLYXbread®, CULT rolls® etc. at thenewly built plant in Hamburg.

Currently, cereal products are refined by means of cold sprayingcrystallisation or a variety of mixingtechnology. KAMPFFMEYER FoodInnovation GmbH also developsunique ingredients and conceptsfor top consumer brands from the KAMPFFMEYER Group, suchas Aurora® and Müller's Mühle®.

In the future, new products willinclude baking additives and ingredients, expanded cereals, fatpowders, function food (nutrientconcentrates for the baking andfood industries), functional milledgrain products, grain specialities,health ingredients, organicallygrown products such as lecithincompounds, special flours/concen-trates, standard milled grain pro-ducts, flour-based texturizing andbinding systems "PURAFARIN®“and other ingredients.

Concept with maximum flexibility and future security:A case study of mixer feeding systems from the market leader


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Cereal protein coatingfor the bakery industry

PURAFIN®, the flour thickening system

Task definition

• Plan the complete productionplant as a graduated conceptincluding the areas of packaging,filling, extruding, mixing, drying,grinding, screening and the automated handling of bulk and liquid ingredients.

• Include all control systems forthe plant in a central location and integrate the existing plantareas:- manage and update master

and production data- process production jobs- control automatic and

manual weighing machines- identify ingredients by

computer assisted systems- identify intermediate products

and weighing operationsthroughout the entire process

- monitor weighing processesand document all exceptions

- perform all documentation and reporting processes

- exchange data with customerhost (AS400)

Requirements

• Fully automated process chain:integrate all value-added chainsfrom ingredient delivery tosilo/bin filling, and mixing, drying,extruding, screening and grinding;reduce manual intervention to aminimum

• Seamless batch tracking incompliance with EU Directive178

• Flexibility: Produce batches of upto 20 ingredients quickly withoutany major cleaning at product

change; freely select the type offilling receptacle: bags, big bagsor tankers; automatically feedingthe in-house produced refinedcereal products via silos to themixer line

• Clear line allocation for mixingand extrusion lines

Cost Savings

• Increase profitability

• Optimise product quality

• Reduce production costs

»Our objective is to plan an overall processwithout adding to ourexisting engineeringcapacities and implement the project in phases to prepare us for future production«

Karl Heinz Driller, Managing Director KAMPFFMEYER Food Innovation GmbH


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The AZO solution:Intelligent process control

Outdoor silos Side mounted pressure relief Silo drying capability

Feeding three lines

The fully automated plant fromKAMPFFMEYER Food InnovationGmbH feeds a high-performancemixer, two single-shaft mixers andthe succeeding extrusion lines.The mixtures are conveyed via allmetal separators and screeningmachines to big bag and bag fillingequipment. The process then continues via a dryer, grinder andscreener to the finished product

silos, and then to the all-metalseparators/screeners. The finalmixes are filled in bags or bigbags. In addition, both the high-performance mixer line and theextrusion mixer line can feed tankers.

Bulk Ingredients delivered

by tanker

For bulk ingredients, aluminumoutdoor silos are used, each witha diameter of 3500 mm and acapacity of 108 cubic meters. The silos for cereal starches andgranulated sugars are equippedwith pressure relief fittings. This is not necessary with final productsand flours. All external silos areloaded by a central coupling station. A sample is automatically

taken from all delivered materialsand analyzed in the on-site labora-tory. Only when the results showthat the delivered raw materialsmeet the specifications, they arereleased to production. All silos areequipped with a dryer to preventthe formation of condensation.The products are transported bydependable vibrating bottomdischargers and rotary feeders.


5Sampling on delivery Discharged into the vacuum weighing system

Vacuum weighing systems –

ideal for large ingredients

From the flour silos, the productcan be transported to the centralscales or to the scales via theextrusion lines. The product is distributed by means of a diverter.The cleanliness of the frame skirts is proof that the vacuum conveying system is the ideal way to transport ingredients inpneumatic conveying systems.Large quantities are transported

to a central weighing station. This allows the conveyor scales to prepare the recipe automaticallyvia a vacuum weighing system.When the batch is complete, it is discharged to a vessel andtransported to the large conveyorscales via the high-performanceprecision mixer. To achieve thegreatest possible flexibility in theproduction process, raw material

silos can also be filled with semifinished products before

they are conveyed to the nextrefinement process.

»By combiningvibration bottomdischargers withan AZO vacuumconveyor, weachieve clean siloframe skirts.«

Günter Ellmann, General ManagerProduction & Engineering KAMPFFMEYER Food Innovation GmbH


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Raw material delivery in bags

A feeding hopper is provided todischarge ingredients from bagsthat are difficult to convey or containhighly fatty products. When theoperator opens the lid, an aspirationsystem transfers powder productsto the closed systems for a dust-freeenvironment. A barcode reader onthe feeding hopper ensures thatthe specified ingredients in therecipe are discharged. At thematerial supply level, conveyorscales can be charged in free fallfrom feeding hoppers with products

that are difficult to convey. They are then transferred to theextrusion lines.

Automated bag discharge

The bag discharge equipment isfully automated and opens preciselycoded raw material batches anddischarges the bags. The productis then transported via a pneumaticpressure conveying system fittedwith a barcode monitor and storedin indoor silos. For this purpose, thebags are picked from the storage

Feeding hopper for discharging bags into the closed system Storage in internal silos

Dust-proof docking and discharge

Extremely flexible ingredient dosing

area, placed on a conveyor upstreamof the bag discharge machine andrecorded by barcode. With the helpof the automated bag dischargeequipment, both the indoor silosand the three mixer lines can befed by pneumatic conveyingsystems.

Raw material delivery in big bags

The big bags are delivered fromthe high rack storage area, dockedin a dust-proof area on the big bagdischarge station, and conveyed

through the pneumatic conveyingsystem to the indoor silos.In addition, the three mixer linescales can be fed from the bigbags and the silos: extreme flexibility is also the key factor in big bag handling!

Indoor Silo Storage

Raw materials are stored in indoorsilos and filled pneumatically forthe purpose of automated access.


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Accurate Batch tracking

KASTOR, the integrated processcontrol system linked to an AS400, guarantees reliable producttracking from ingredient dischargeto the finished product. This can beachieved by barcode identification,e.g. barcode type EAN128:

• Product labels with plaintext and barcode ID are generated atcustomer's material income.

• Barcode data is separated intoseveral partial barcodes in accordance with the EAN128Standard.

In addition to barcode indetification,another security is the direct dataexchange with the host system viaa database interface. This allowsreliable ingredient identification withreal-time verification and releaseto production.

In addition, the general conditionsare retrieved continuously, e.g.minimum shelf life, article allocationand batch status.

Process control system

»Within ten minuteswe had all the data from the rawmaterials to thefinal product. That is accurateand dependablebatch tracking.«

Combined product discharge – extremely flexible

BigBag-Station&

Feeding hopper

FillingExternal silosInternal silosMixer lines

Silos

Mixer line

DosiBoxInstallation

for production

DosiBoxIntermediate

storage

FillingDosiBox

Big-Bag-Station&

Feeding hopper

Big-Bag


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Unique requirements – unique solutions

Transfer from bags and big bags to DosiBoxes

Fully automated weighing with the DOSINENTER® for minor or micro ingredients

Operator-guided weighing of very small quantities using ManDos Discharge bags into a feeding hopper

The DosiBox® – efficient

automation of frequently

used, small quantities

A DOSINENTER® system is availablefor minor or micro ingredients, e.g.salts, that are accessed frequently.The DosiBoxes® are dischargedfrom bags or big bags in productionplanning and provided with bar-codes. These ingredients can then be supplied to the mixer line automatically and weighed to theexact gram.

ManDos station: dosing very

small quantities without error

and with high precision

Very small ingredients are fed intoan operator-guided system by thecomputer-assisted ManDos dosingstation. Two different processes can be applied here:

Preproduction –

setting the premixer

• Preproduction for the mixing line• Preparing a mixture consisting

of manual additions (barcodeidentification via externalsystem)

• Data exchange with externalsystem, feedback with outputdata to the AS400

• Intermediate storage in a premix silo

Preproduction –

manual weighing

• Preproduction for the mixer line• Weighing small quantities on

a scale• Identifying raw materials by

barcode (EAN128)• Storing weighing data including

batch numbers, assign mixing job

»With the operator-guided weighing

stations, we are surethat even very small

quantities are batched, weighed and documented

without error andwith a high degree

of accuracy.«


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IT Process:Networking all added-value processes

Production overview

Data flow tracking

Accuracy from raw materials to

packaging

The process IT of the AZO subsidiaryhsh-systems for process IT controlsand documents the entire addedvalue process and provides accu-rate tracking from raw material topackaging. All production areas areviewed in Intouch, so that the cus-tomer has an overview of the enti-re process at all times. The dis-plays of material and data flowsand the continuous availability ofkey real-time data allow operatorsand managers to make quick deci-sions and take the correct actionin critical situations. One require-ment is the seamless integrationof actuators and sensors via thecontrol and instrumentation levelto the higher-level ERP system

Kastor – batch-based process

control system for automated

feeding systems

By combining the innovative Kastorprocess control system with avisualisation system based onstandard tools, the result is a centralprocess control and visualisationsystem that permits several workflow controls and checks.This central system also providesthe seemless documentation of production processes (active factory), e.g. batch logs, efficiency calculations and a long-term archive for all the data collected. It guarantees customized accesscontrol, system security and validation capability in accordancewith GAMP 4 and FDA regulations.The process control system also hasa master data management systemthat is based on the specifications of the S88 specifications. Kastor isalso connected to the high-levelcustomer system (AS400) to storerecipe and order data.

Other features of Kastor:

• Recording raw materials, deliveries, storage, storageremoval, filling, transferring,identifying (read, write, barcodecapability (39, 128, EAN), RFID,PDA and WLAN capability.

• Info points with display of production states (job progress),alarms, required action, e.g. silo refilling due to shortage of materials, truck loading andunloading operations, etc.

• Transfer to packaging machines.• Filling and discharging big bags,

containers, pallets etc. (returncontainers, identifying/labelling

with barcode (39, 128, EAN),transponders, RFID).

• Multistage production processeswith tracking of raw materials,order and batch overlaps.

• Combinable with concurrent andnoncurrent manual weighing.

• Calculating active ingredients,water content and productionfactors.

• Handling scale tolerances byselection dependent on orderrecipe specifications, ingredientspecifications or scale parametersand weighing ranges.

• Cleaning inspection.

Incoming goods, filling silos

Incoming goods,filling silos

Incoming goods,small containers

Batchdocumentation

Incoming goods,return containers

Packagingdata

Tracking through

productionplant


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AZO dosing and weighing

systems: a precise solution

All scales in the KAMPFFMEYERplant are capable of transportingby vacuum or pressure conveying.Over 20 ingredients can be transported in the conveyor scalesvia the high-performance mixer inmix line 3. An automated weighingprocess with coarse/fine dosingsystem helps to achieve accurateweighing and dosing at very high

Central weighing:

maximum capacity with

greatest possible flexibility

The central weighing system provides a flexible, high volumebridge to span long conveyingroutes. All raw materials can betransported on each of the threemixer lines and each mixture canbe filled in any required packagingform.

conveying speeds. In addition, fats and liquids can be added tothe mixing process via a specialliquid preparation system. Theconveyor scales in mix lines 1 and2 help to feed differential dosingscales that feed the cooking extruders. It is also possible to feedliquid ingredients to the extrusionprocess after precision weighing.

AZO dosing and weighing systemsensure that all ingredients feedingthe mixing and extrusion processare precisely weighed and documented. All processes andfunctions in the mixing and extrusion lines are integrated in the central control system.

Central weighing system

Feeding a horizontal mixer above cooking extruder

Feeding a single-shaft mixer Continuous batching

Vacuum weighing systems for dust-free feeding of mixing and extrusion lines:


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Integration of all added value phases into the closed automatic process

The grinding process

In the grinding section, a multiplesystem is used for dry grinding. It includes a very fine grindingmachine for grains under 50 μmand produces granulate up to 2.5mm in closely toleranced grainbandwidths. To feed the mills,gentle AZO vacuum conveyingsystems ensure that the millsreceive a consistent product flow.

Special conveying system

to dryer

A totally new type of special conveying system is used to feedhighly sensitive materials to thedrying process by means of apneumatic conveying system. An innovative principle applied inthe separator creates a pressurelessstate where the extrudates areseparated with extreme care andfed to the drying process.

Value added – screening

Screens are fed after the grindingprocess. They separate the productprecisely into coarse and finematerials, which are conveyedpneumatically to the final productand semifinished product silos.

Ingredient screening and separation

Automatic feeding of grinding processes

Filling indoor silos by vacuum

conveying

Vacuum conveying systems areused to convey the screened products to the final product and semifinished product silos.Before delivery to the filling process, the ingredients are safety screened and separated as a precaution.

Intermediate storage in indoor silos


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Filling bags and big bags

The final products coming fromthe individual production lines canbe handled by a fully automatedbag filling system. It also labelsand prints the bags prior to placingthem on pallets. The subsequentmultiline palletising system, whichis also fully automated, meets thetop customer and transportationrequirements. After the palletisingsection, each pallet is automaticallyprovided with a unique EAN 128

Fully automated metal separation

Safety screening and metal separation of product prior to filling bags, big bags and tankers

Safety Screening to meet HACCP standards

Feeding tankers

A high pressure conveying systemis used to feed tankers or outdoorsilos with final products and semi-finished products. The conveyingsystem ensures the greatest possible flexibility. These processesare also documented in the automated tracking system.

code. The fully automated tracking system provides full visibility andrapid retrieval. The EAN identificationsystem is also connected to thebig bag filling machine on eachline.

Automatic big-bag feeding with precise accuracy

»Open bulk materials handlingis a thing of thepast. We now benefit from dust-free mixer feeding and cleanseparationbetween the various stories.«

Safety screening and metal

separation

All final products and semifinishedproducts from all production linesare fed through highly efficientand highly sensitive screenersbefore they are filled in bags, bigbags, tankers or silos as semifinished products. The networkedprocess control system displaysinformation and documents theinspection points in real time inthe HACCP concept fromKAMPFFMEYER.


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Flexible and future-proof The control concept

Packaging flow diagram

Packaging control

The packaging control systemtransfers the packaging order data, e.g. order number and order description, to the packaging lines.The system then sends informationto the AS400 comprising batch data,the number of containers, and thestatus of the packaging job.

Connection to various control

systems

Various control systems are linkedvia Ethernet in case of large datavolumes, e.g. order data and packaging jobs. Profibus is usedfor low data volumes, status andcontrol data. Only dry contacts arefitted for status and control data.Of course, commercially availablesystems are used for the entirecontrol system in the plant.

Integrated overall control

concept

The overall control concept is optimally matched to customerrequirements for flexibility andprocess accuracy:

• Interfaces are easy to adapt to new requirements.

• The plant is easily expandable.• Seamless tracking of raw

materials throughout the entire plant.

• Subsystems are integratable to form an overall system.

• Data reception and return to the production planning andstock management system.

• Continuous expansion to thepresent solution.

Plant overview of control components Process control and visualisation system

Mix Line 1

Packaging line 1

Big-Bag

Bags

Packaging line 2

Bags

Tanker

Packaging line 3

Bags

Big-Bag

Mix Line 3

Mix Line 2

Extruder 2

Extruder 1 Final product silos

AS 400

SPS S 7-400

Host link

Manual weighingMaster data

OPC OPC OPC

Filling and refilling processes

Visualisation(Intouch)

Automaticproduction controlProduction server


AZO GmbH + Co. KGD-74706 Osterburken Tel. +49 6291 92-0Fax +49 6291 [email protected], www.azo.de

1506

003

8 E

Conclusion:»The technical consultation was excellent – both from the AZO field engineers on site and with our contacts at AZO. This was the only intelligent way to link and integrate all the added value chains to the interfaces.The production processes in our company becameincreasingly clear for customers, employees and our corporate management. Optimal communication duringthe installation phase between the project engineers atAZO and KAMPFFMEYER Food Innovation resulted intimely completion of the project. The problems thatalways crop up with such an enormous investment werediscussed jointly and practical solutions were found. We are proud of the design quality and functionality of the AZO system and we are positive that we foundthe right partners to secure and direct future.«

Günter Ellmann (General Manager – Production & Engineering) and Karl Heinz Driller (Managing Director), our contacts at KAMPFFMEYER Food Innovation in Hamburg


Lösung Kampfmeyer gb6neu · control and instrumentation level to the higher-level ERP system...

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