The food and beverage industry faces ever-increasing demands for the highest quality, safety, and security. Manufacturers are constantly striving to reduce costs in order to enhance competitiveness. Yokogawa’s industrial IoT (IIoT) solutions enable day-to-day improvement cycles, eliminate defective products, and minimize manufacturing downtime.
Smart Factory
Transform a food and beverage factory into a smart factory using the IIoT to automate the entire facility, manage all information in a centralized manner, and reduce costs throughout.
Cost Reduction
Enable cost reductions through detailed cost variance analyses, which link information on production, sales, and inventory, while automatically collecting manufacturing statistics.
Traceability
Certify the results of error-free manufacturing and quickly respond to customer inquiries.
Quality Management
Improve the reliability and efficiency of QM through automatic data recording, paperless management, and standardized inspection procedures.
Food Defense
Ensure safety and security by preventing unauthorized personnel from entering the factory and foreign materials from entering production lines.
HACCP / FSSC22000
Satisfy HACCP requirements and regulations such as FSSC 22000 while discovering solutions to address food safety and sanitation management.
Equipment Maintenance
Detect equipment malfunctions, predict failures, and develop maintenance plans to optimize operations.
Energy Efficiency
Provide visualization of energy consumption, awareness of energy inefficiencies, and energy use-improving activities that can reduce costs.
Sensors for Food Factories
Support food and beverage safety and security by substantially expanding accurate measurements throughout the factory.
Smart Factory
What are smart factories?
Smart food and beverage factories manage all data on the movements of equipment, humans, and supplies in a centralized manner to promote factory automation and labor-saving.
A successful smart factory achieves three primary objectives:
- Improvement of quality and productivity
- Cost reduction by reducing manufacturing loss and indirect work
- Creation of an environment capable of focusing on work of higher value
To accomplish this, Yokogawa optimizes a factory by building infrastructure using the IIoT to connect equipment and data (as opposed to locally introducing automated equipment).
Why is a smart factory necessary?
Given recent global infection events , food and beverage manufacturers have seen their on-site workers subject to significant restrictions. Factories must now review existing work systems that require workers to be in close proximity to each other and establish new protocols that ensure the safety of all those involved in the manufacturing process.
It is important for food and beverage factories be flexible enough to not only to take measures against potential infection, but also to shift to high-mix, low-volume production to meet diversifying consumer needs and adapt to social changes such as a decrease in the working population.
Food and beverage manufacturers are required to build new manufacturing systems with marked improvements in quality and productivity, reduced costs, and standardized work processes that support remote operations with significantly fewer people physically on-site.
Effects:
- Reduction of production planning man hours through automated planning
- Cost reduction by cost visualization through the centralization of cost data
- Creation of a nonstop factory by reducing equipment downtime, the number of failures, and equipment restoration time through the construction of prediction and preventive maintenance infrastructure
- Reduction of stock loss by accurately controlling raw materials
- Prevention of wrong inputs and reduction of erroneous work-derived loss through double-checking with humans and systems
- Quick tracing
- Labor-saving through equipment automation
- Shorter time for quality analysis
- Detection and correction of wasteful energy use by double-checking energy consumption and energy flow for each unit of equipment
- Relief of bottlenecks and quality stabilization by collecting and analyzing operational data
Total solutions from Yokogawa
With an extensive history of providing industry-leading solutions and products, Yokogawa helps food and beverage manufacturing companies achieve a smart factory through comprehensive consultation and guidance.
What are Yokogawa’s total solutions for food and beverage manufacturers?
Yokogawa engineers partner with food and beverage manufacturing professionals to plan the measures that solve problems and achieve goals, and continue to assist throughout the life cycle of corporate activities, ranging from consultation to solution development to operation and maintenance.
Specific solutions from Yokogawa support environmental management aimed at reducing the environmental load of corporate activities, from the viewpoint of energy-saving. With a wide array of measurement instruments, field meters, production control systems, and other products closely related to production processes, Yokogawa backs up operations extensively at the on-site production level, as well as at the production management and corporate management levels.
Yokogawa also provides solutions for the visualization and centralized management of information by combining its manufacturing execution system (MES), production management system (PMS), enterprise resource planning (ERP) system, and more.
YOKOGAWA’s total solutions for food manufacturers
Solutions Map
Major package products for building a smart factory
| 【Production scheduling】 | Production scheduler ASTPLANNER FLEXCHE |
| 【Production, sales and cost management】 | Integrated production/cost management package mcframe |
| 【Equipment maintenance and management】 | Equipment maintenance system eServ |
| 【Failure prediction and management】 | Automatic device status analysis package DUCSOnEX Predictive detection |
| 【Manufacturing execution and management】 | Manufacturing management package CIMVisionLIBRA |
| 【Quality/inspection management】 | Laboratory information management system Lab-Aid |
| 【Logistics/warehouse management】 | Logistics management package MaterialStream |
| 【Process database】 | Realtime operational information management package PI System Plant information management system Exaquantum |
| 【Energy management】 | Factory energy operation supporting system Enerize E3 Energy Management |
| 【Procedural Automation】 | Operational efficiency supporting package Exapilot |
| 【Production process monitoring and control】 | CENTUM VP |
※Some of the products introduced may differ between the Japanese version HP and the English version HP.
Cost Reduction
Yokogawa helps food and beverage manufacturers reduce costs through planning assistance, data-derived cost management solutions, stock management, and reduction of error-related disposal loss.
Challenges:
- Production planning by hand requires time
- Cost-related calculations in profit analyses and cost variance analyses are complicated
- Accurate costs, results, and losses are difficult to identify
- There is a considerable amount of disposal loss during manufacturing
Solutions:
- Production planning in an automated manner in view of manpower and equipment capacity
- Identification of costs and losses by on-site collection and cost-calculation of accurate result data
- Appropriate stock management by strengthening control of the best-by dates of ingredients and reviewing sales and production plans
- Clarification of work instruction and guidance by introducing standard operating procedures
Effects:
- Considerable reduction of man-hour planning
- Setting of standard costs, identification of actual costs, and simplification of cost variance analysis
- Clarification of costs and losses to shorten time required for taking cost/loss reduction measures
- Reduction of stock loss through accurate stock management
- Reduction of disposal loss with a decrease in workers’ input errors
Major package products for cost reduction
- Production scheduler ASTPLANNER
- FLEXCHE
- Integrated production/cost management package mcframe
- Manufacturing management package CIMVisionLIBRA
- Operational efficiency supporting package Exapilot
※Some of the products introduced may differ between the Japanese version HP and the English version HP.
Traceability
There is an increasingly strong demand for food and beverage safety. As a manufacturer, it is imperative that efforts are made to build a safety chain for supplying safe and secure food and beverage products.
Yokogawa provides solutions that refine quality at these sites, thus ensuring that the ultimate end product is safe for consumption.
Environment surrounding food and beverage manufacturing
Not only must food and beverage manufacturers consider safety and security, so too must the other food-related businesses in the supply chain review and address the quality of their processes and products.
Crop growing environments (fertilizers, agricultural chemicals, livestock feed, etc.)
- Where did the crop come from?
- Which fertilizers and agricultural chemicals were used in its production?
Allergen issues
- What allergens are contained?
- How much of an allergen does each material/ingredient contain?
- Is there a possibility of allergen cross-contamination?
Cultural requirements compatibility
- Are only culturally-approved (halal, kosher, etc.) foodstuff used in production?
GMO issues
- Were any genetically modified ingredients used?
- Is there a possibility of cross-contamination with genetically modified ingredients?
BSE issues
- Were any ingredients of bovine origin used?
- What are the meat butchering/processing procedures?
- Where is the production located?
Challenges to food and beverage manufacturers
Quick response to market inquiries
(Development of an inquiry/complaint handling system)
Quick response to quality problems attributable to ingredients or process failures
(Development of a recall system)
Shortening life cycles of products
Varieties of foods processed in many ways
Management of vast amounts of information
Consistent management of information throughout the product development, manufacturing, and supply processes
Management of four M’s 【Man(Human), Machine, Material, and Method】at manufacturing sites responsible for food and beverage safety
Traceability solutions from YOKOGAWA
Manufacturing-related information (such as composition, methods, equipment, etc.) is integrated and managed using a manufacturing execution system (MES) and a product data management (PDM) system in order to support a work series of procurement, manufacturing, shipment, and distribution.
Yokogawa provides high quality management/assurance-supporting traceability solutions aimed at not only handling customer complaints and recalled products, but also refining quality that underlies food and beverage safety and security.
Major package products for building a traceability system
- Production scheduler ASTPLANNER
- FLEXSCHE
- Manufacturing management package CIMVisionLIBRA
- Operational efficiency supporting package Exapilot
- Quality information management supporting package Lab-Aid
- Realtime operational information management package PI System
- Plant information management system Exaquantum
- Paperless recorder
※Some of the products introduced may differ between the Japanese version HP and the English version HP.
Food Defense
Total defense that enhances factory security
Yokogawa provides preventative security-focused solutions and mechanisms that seek to head-off safety-related instances, as well as the ability to trace back through events and procedures to discover the root of potential violations.
- Premises entrance management: Prohibits a third party’s entrance onto the premises
- Factory entrance management: Prohibits a third party’s entrance into a factory and its manufacturing processes
- In-process monitoring: Video recording of work processes for material/product traceability
FSSC 22000 food safety management systems certification assistance
Food and beverage industry business partners regularly request and require safety and sanitation management certifications. Yokogawa helps manufacturers meet the requirements for food defense, biovigilance, and bioterrorism, as stated in Section 18 of ISO/TS 22002-1:2009, the prerequisite programs for building a food and beverage safety management system in conformity with FSSC 22000.
Food defense in manufacturing processes
| Video recording of work processes | In-process zoning management | Ingredient/chemical storage linking |
Video recording of work processes
A manufacturing execution system (CIMVIsionLIBRA) allows for video recording of work processes by adjusting webcam angle at the time of each input.
In-process zoning management
Entrance to and exit from each process are monitored to establish a system for preventing third parties from entering the process.
- Management of in-process staying time: A stay is judged as abnormal if it exceeds a preset duration.
- Anti-passback: This prevents an entrance or exit without the use of an individual’s ID card.
Ingredient/chemical storage linking
The removal of ingredients or chemicals from storage is monitored and video-recorded by image detection technology.
Major package products for food defense
- Manufacturing management package CIMVisionLIBRA
- Operational efficiency supporting package Exapilot
- Monitoring camera FIELDEYE
※Some of the products introduced may differ between the Japanese version HP and the English version HP.
HACCP / FSSC22000
Yokogawa provides solutions for sanitation management at food and beverage factories, including HACCP conformity, FSSC 22000 conformity, food quality management, and sanitary appliances.
HACCP and Comprehensive Sanitation Management and Production Process
The increase of BSE (bovine spongiform encephalopathy) and O-157-related incidents is raising consumers’ concerns about food and beverage safety.
Businesses are required to establish a safety chain over multiple categories, including suppliers, food manufacturers and distributors, and retailers, for such purposes as factory sanitation management.
To ensure food and beverage safety, it is important to:
- Comply with prerequisite programs
- Build a Food Safety Management System (FSMS) by introducing HACCP (Hazard Analysis and Critical Control Point) methods and obtaining the certification of ISO 22000, an international standard of quality assurance for food and beverage manufacturers
- Develop an environment for traceability
Major package products for ensuring food safety (building an FSMS)
- Manufacturing management package CIMVisionLIBRA
- Operational efficiency supporting package Exapilot
- Quality information management supporting package Lab-Aid
- Realtime operational information management package PI System
- Plant information management system Exaquantum
Sanitary sensors and analyzers
YOKOGAWA has sanitary sensors and analyzers available to food manufacturers to meet their challenging needs in sanitary aspects.
※Some of the products introduced may differ between the Japanese version HP and the English version HP.
Equipment Maintenance
Yokogawa improves the factory operating ratio through the proactive prevention of factory and machine breakdown.
Challenges:
- Waiting until after a breakdown occurs to take action results in lost production and profit
Solutions:
- Switch from breakdown maintenance to preventive maintenance
- Failure analysis on the dashboard
- Improvement of equipment maintenance standards
- Implementation of scheduled checks
Effects:
- Preventive maintenance performed instead of breakdown maintenance, leading to a significant decrease in equipment failures and an improvement in factory operating ratio
- Effective use of information on past failures
- Identify breakdown causes for the purposes of preventative maintenance
Cost advantages of a factory operating ratio improved by preventive maintenance
Major package products for equipment maintenance
- Computerized maintenance management system eServ
- Sushi Sensor
- Automatic device status analysis package DUCSOnEX
- Predictive detection
※Some of the products introduced may differ between the Japanese version HP and the English version HP.
Energy Efficiency
Yokogawa reduces fuel costs by optimizing the number of operating units in accordance with demanded steam flow.
Challenges:
- The number of operating units is unchanged while required steam flow fluctuates
Solutions:
- Identification of the ideal number of operating units through model simulation
Effects:
- Reduction of fuel consumption by adjusting the pattern of controlling the number of operating units
- Reduction of fuel costs by operating the minimum required number of units determined based on required steam flow
Major package products for promoting energy-saving
- Factory energy operation supporting system EnerizeE3
- Energy Management
- Production scheduler ASTPLANNER
- FLEXCHE
※Some of the products introduced may differ between the Japanese version HP and the English version HP.
Sensors for Food Factories
Challenges:
- Existing mass flowmeters produce an overrange result if air bubbles enter them
Solutions:
- Successful measurement of a fluid containing 10% or more air bubbles
Effects:
- Reduction of disposal loss through continuous measurement, which prevents the disposal of products with their composition unknown due to air bubble mixing
Major sensor products for food factories
※Some of the products introduced may differ between the Japanese version HP and the English version HP.
※Please note that the mounting port differs depending on the area and the standard.
Through extensive experience built on long-term relationships with IA industry leaders, Yokogawa offers the advanced products and custom solutions that food and beverage manufacturers need to create a quality product. Brewery operations and sugar manufacturing serve as two examples.
| Brewing Applications | Sugar Production Applications |
Brewing Applications
Malt Silo
- Raw Material Handling
Brew House
- Raw Material Handling
- Mashing
- Batch Management
- CIP (Cleaning In Place)
Fermentation/Lager
- Fermentation/Lager
- Racking
- Fermentation Management
- Yeast Management
- CIP (Cleaning In Place)
Filtering
- Filteration
- Beer Movement
- CIP (Cleaning In Place)
Bottling/Canning
- Packaging
- Warehousing
Inspection/Shipping
- Quality Control
Affiniated Sugar Melt
- Weighing Control
- Affination
Purification
- Carbonation
- Filter Machine Control
- Ionic Exchange Resin Control
- Decolourization
Concentrate and Crystallization
- Concentration
- Vacuum Pan Control
- Centrifuge Control
Centrifugal
- Drying Control
Packaging
- Packaging Management
Shree Renuka Sugars Limited (SRSL) is a global agribusiness and bio-energy corporation. The company is one of the world’s largest sugar producers and refiners.
- The new package software running on the CENTUM CS 3000 has enabled flexible configuration and data settings for greater productivity.
- The CENTUM CS 3000 features a standard long-term trend function that can store a year's worth of data on more than 200 tags that are sampled at 2 minute intervals.
- Yokogawa provided control solutions for expansion project in sugar and bio-energy plant.
- Consolidated central control room was designed for safe, comfortable, and efficient work environment.
Yokogawa Electric Corporation has completed a unique control system project in Arcadia, Florida, which is located in the heart of a beautiful citrus-growing region. Peace River Citrus Products has installed a Yokogawa CENTUM CS 1000 R3 control system to control a proprietary orange juice production process at its citrus processing plant.
- Integrated automation solutions for high reliability and availability system
- Reduced consumption of steam, bagasse, and bunker fuel oil with increased daily throughput of massecuite
- Achievement of 24-hour production schedule with increased output
- Higher level of reliability and security attained by adding emergency operation system
- Implementation of control system supported by global maintenance, service, engineering, and technical support capabilities
- Improved stability and safety of plant operation
S&B Sankyo uses the GX20 Paperless Recorder to monitor temperature and pressure in a food processing plant's sterilization process.
Rousselot Ghent won Belgium Factory of the Future Award. Yokogawa has supported Rousselot with automation systems since 1993.
Data of 20,000 tags gathered by Exaquantum helped to find the ideal production parameters.
The TC series of temperature controllers is perfect for controlling the heating temperature of sealing parts and the temperature of sealing rolls (pre-heating) in a variety of different wrapping machinery.
- For remote monitoring (of temperature, pressure, and flow volume), installing the SMARTDAC+ GM in the plant and the SMARTDAC+ GX in the office provides for a scalable, pc-free on-site data monitoring solution.
- You can centralize management of large quantities of data by automatically transferring acquired data to a FTP server.
Fish perform all their bodily functions in water. Because fish are totally dependent upon water to breathe, feed and grow, excrete wastes, maintain a salt balance, and reproduce, understanding the physical and chemical qualities of water is critical to successful aquaculture. To a great extent water determines the success or failure of an aquaculture operation.
SMARTDAC+ GX series records the clean room temperature, humidity, atmospheric pressure, door openings and closings, etc.
This introduces a system that uses Ethernet communications to acquire measured values, target values, and control output values from a controller installed on site into a PLC at high speed (ten units' worth within one second).
In semiconductor manufacturing processes, a deficient clean room environment can lead to defects and wasted resources, making a strictly controlled clean room indispensable. Maintaining the environment in the clean room requires control of air filters, HVAC systems, room temperature, humidity, airborne particles, and other factors.
Milk should be processed within 4 to 6 hours of production to make it fit for human consumption. Temperature is a very important parameter which has to be monitored at different stages of milk processing.
In the plants of food and beverage manufacturers, there are times when monitoring and recording of production equipment is necessary inside clean rooms. This is an introduction to monitoring and recording in clean rooms using paperless recorders.
With advances in process automation comes a greater need for level measurement and control. As pressure on at the bottom surface of a liquid is proportional to the height of the liquid's surface, you can measure pressure using a differential pressure transmitter to detect the level of the liquid, acquire the data on the UT75A Digital Indicating Controller, and use the measurements to control the tank level.
Yokogawa's ceramic liner can offer the customer superior resistance to thermal shock and the failure that can occur due to liner cracking. This is due to Yokogawa's use of 99.9% pure Al2O3 for the liner.
The paperless recorder DX series automatically calculate the Fo value from the heating temperature and are useful in managing the sterilization process by displaying and recording the value together with the heating temperature.
In the manufacturing process of Pharmaceutical, Chemical and Food & Beverage industries, the cleaning and sterilization of tanks and piping are done with various cleaning solutions, fresh or hot water and steam after manufacturing products. Clean-In-Place (CIP) is the system designed for automatic cleaning and disinfecting.
Reverse osmosis (RO) is a separation process that uses pressure to force a solution through a membrane that retains the solute on one side and allows the pure solvent to pass to the other side. More formally, it is the process of forcing a solvent from a region of high solute concentration through a membrane to a region of low solute concentration by applying a pressure in excess of the osmotic pressure.
One of the critical control points in the brewing process is the monitoring of the progress of the fermentation stage. The DM8 Vibration Type Liquid Density Meter offers high sensitivity and stability, realizes precise control, reduces workload, and reduces instrument costs.
Skim milk is what remains after cream is removed from raw milk. Cream is removed to bring the fat content of the skim milk as close as possible to the lower limit of a designated range. For this purpose, control of the fat content in the cream and the skim milk is essential. The fat content in the cream and the milk has a direct relationship to their density and is controlled by the measurement thereof.
In the food industry, the control of concentrations on the production line is critical to product quality, determining, among other things, how good the food tastes. One such procedure for doing this involves taking a sample from the production process and measuring its specific gravity (density) with a hydrometer.
The discharge of improperly treated industrial chemicals and fuel gas can have a major impact on the environment, posing a serious threat to public health. Concurrent with the global growth of manufacturing operations to keep pace with market trends, many countries are taking measures to deal with environmental problems.
By using the Multibatch function (an option added with SMARTDAC+), you can efficiently record data from multiple devices onto a single SMARTDAC+.
Using the custom display function that comes standard with DXAdvanced means that you can combine the recorders, displays, and switches used in various kinds of equipment.
Using the batch name + lot number system, past measured data can be recalled for reference by batch name.
- Universal inputs provide support for thermocouple, RTD, voltage, and a variety of other input signals.
- Lineup of models for up to 450 inputs.
Allows multipoint monitoring and recording on a single unit. - Easily enables network-based data management.
file transfers, Web monitoring, and alarm e-mail
By using the computation function of the SMARTDAC+ series Paperless recorder GX/GP, computation option computes the "F-value," or sterilizing value for the sterilization process, so that the computation results can be recorded in the form of data.
The sterilization temperature prior to the filling process is monitored in the field or office. The temperature data is recorded in an external storage medium.
Temperature plays a key role in storage of Molasses to maintain the chemical properties of molasses. When temperature rises over 40.5 degree C, destruction of structure in sugar occurs, which results in losing the feeding property of molasses. There is also a safety concern that a rise in temperature can lead to a rise in storage tank pressure leading to an explosion of the tank.
- Temperature monitoring at a tank farm
- Temperature and pressure monitoring in tank jungles, three vertical monitoring points.
After extraction from sugar cane or sugar beets, juice must be purified to remove the many other organics and minerals that accompany it. The processing to accomplish this is heavily dependent on reliable pH measurement and control as illustrated.
One of the primary applications for high purity water is for boiler feed water. The measurement of pure water pH can be one of the quickest indicators of process contamination in the production or distribution of pure water. Effective chemical treatment of the feed water is vital in maintaining the useful operating life and minimizing maintenance costs of the boiler.
To defray energy costs, many industrial plants have their own boilers to generate steam in order to produce a portion of their energy needs. In addition to generating power, the steam may also be used directly in plant processes or indirectly via heat exchangers or steam jacketed vessels.
Measurement and control of Heat Exchanger Leakage can help prevent costly maintenance, repair and downtime. The simple, essentially maintenance-free measurement of condensate conductivity will give the operator information necessary (or provide automatic control) to prevent severe damage to the boiler should a breakthrough of the heat exchanger occur.
Ion Exchange is a method for the exchange of ions between two electrolytes or between an electrolyte solution and a complex molecule. In most cases the term is used to denote the processes of purification, separation, and decontamination of aqueous and other ion-containing solutions with solid polymeric or mineralic ion exchangers.
This technical white paper will discuss Yokogawa's CENTUM VP DCS (Distributed Control System) product, hereafter referred to as "CENTUM VP", and the extent of its compliance with Part 11 of Title 21 of the Code of Federal Regulations, (21 CFR Part 11), the Electronic Records / Electronic Signatures Rule.
Sugar and alcohol market are increasing, due humanity needs to find alternatives for fossil fuels dependence. Brazil joins climactic and technologic features to place itself at the forefront of this industry.
The worlds of process automation and production management have been converging for some time. What once used to be islands of automation and production management functionality connected through highly proprietary integration schemes that were costly to maintain have developed into integrated platforms that provide seamless data exchange between the world of automation and the plant floor, the functions of production and operations management, and integration with business level systems.
The world of process automation is governed by procedures. While we like to refer to the process industries as being largely "continuous", this could not be further from the truth. Process manufacturing is constantly in flux.
This document describes the operation and data flow of the Yokogawa Print Wave software using the DX-P Reporter. It will provide a detailed explanation of the Advanced Alarm Reporter functions. The functions described in this paper were first released in Print Wave version 5.5.
Discovering your Baseline with OT Security Risk Assessment
Honeywell and Yokogawa have both been producing Distributed Control System (DCS) platforms for decades, and both are very active in this area. In 1975, Honeywell introduced its TDC2000 platform and Yokogawa brought out CENTUM. These two competing systems emerged from a similar place, oil refining and petrochemical industries, so they started out with similar basic concepts and use cases in mind.
- Optimizes the supply chain and operations by enabling plant personnel to work more efficiently -
- For improved agility in implementing control system projects -
- Ideal for construction of small-scale field wireless systems -
- Highly reliable and scalable -