PROCESO DE MILKSHAKE

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This document is an example of the output from a ControlDraw model, in this case the Milkshake plant demo.It has been produced entirely in the ControlDraw Print and Review software.

The model itself contains portions of text from the original EBF working group. The model has now been developedfollowing the developments in ControlDraw and in experience gained with it's deployment on many projects, althoughit is still under development in several respects.

The model is part of a suite of sample models that are anchored in a single reference model. These are not justdemonstrations, they are usable libraries of process automation objects.

The New Milkshake model

IntroductionWhen originally conceived, the intention was to illustrate a realistic process that 'challenged' S88 and then toshow how the standard can be interpreted to meet these challenges. These challenges are identified below.Further on this document describes where the milkshake plant shows examples of them.The ControlDraw model presented here provides workable solutions to a number of these issues. These arenot the only answers, but they are we think they are good ones.They are based on the work done by experts and represent typical good practise.The model also demonstrates many of the advanced features of ControlDraw.

The model is not yet complete

The challenges:The CIP issue

There is a common perception among CIP specialists that CIP does not 'fit' S88. This is illustrated in part bythe CIP process description that was provided by GEA for the originally EBF working Group.It is possible to view CIP processes as Servers to the Process Units, so that when a unit wants to be cleanedit can call on the CIP Common Resource to carry out the clean. However this seems unnatural - the cleanerwhen cleaning must be completely in charge of the equipment. What about a line clean, where is the unit inthat?

ControlDraw Ltd Milkshake S88 Model

Model: milkshake2.cnd524View Web Publish in comments.mdb

Print Date: 23/10/2003 Page: 1 of 129


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What is a Storage Tank?

Is it a Unit - or a Common Resource?This topic can cause a considerable amount of lively discussion in a group of batch specialists.

It's not a Unit because although Tanks can have a batch in them, they also often have a mix of batches. Ofcourse a proper S88 Unit never has a mix of batches in it, so this type is not a unit under the presentdefinitionArguably if it only stores one batch and does something to look after the batch (even just monitoring it) thensuch a tank could be a unit.

Cont inuo us processing equipm ent with the batch

Often there are parts of a batch process that are really continuous in operation

Handl ing of mater ial rout ing Equ ipment

Often this is a major challenge in plants especially where multiple routes are required.

Bou ndar ies between S88 objects

Often it is not clear where the boundaries, should these be placed, in fact sometimes there seem to bealternative boundaries depending what is happening , eg CIP or production.

Effic ient m odu lar isat ion

How best to split the process into modules and to make the modules re-usable

The Milkshake plantThis section briefly describes some feature of the plant that illustrate the above issues

CIPThis plant includes multiple CIP 'units', numerous line cleans and tank cleans. To further complicate theissue, the CIP 'unit' can run two cleans at once, and shares the Water, Acid and Caustic tanks

Storage Tanks

The milk silos operate on a continuous cycle whereby they are filled repeatedly during the day and thencleaned at night, when no milk deliveries are expected.A similar concept applies to the product tanks except here the rules are that different products shouldobviously not be mixed.





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Cont inuous process ing equipment

The homogenisers are examples of continuous 'units' in the process.

Material rout in g The milkshake plant, like many dairies, breweries and other liquid food processes uses valve manifolds

Dif ficul t Boun dar ies

For example in our milkshake plant units such as the Batch Vessels, have things around them (the inletvalves are a good example) that intuitively seem to belong to the units.However, the 4 port valves can carry both process fluids and cleaning fluids. Whilst they are under thecontrol of a cleaning program it seems equally reasonable that they should belong to the CIP system as to theUnit or line that is being cleaned.

The Milkshake Model Solutions

CIP

In the model, CIP is treated as the master - a Unit whose function is to clean a collection of 'dumb'equipment.

In fact the model contains two CIP units, each sharing the same collecion of

Storage Tanks

The milk silos operate on a continuous cycle whereby they are filled repeatedly during the day and thencleaned at night, when no milk deliveries are expected.A similar concept applies to the product tanks except here the rules are that different products shouldobviously not be mixed.

Cont inuous process ing equipment

The homogenisers are examples of continuous 'units' in the process.

Material rout in g

The milkshake plant, like many dairies, breweries and other liquid food processes uses valve manifolds forCIP and process routing.

Dif ficul t Boun dar ies

In our milkshake model, the Batch Mixing Unit and the silos contain 'shared' equipment modules. Takingthe example of the inlet valves, these are acquirable so that whilst they are taking part in the mixing unit

procedure they are under control of the Mixing Unit, however when running a CIP or a transfer then they arecommanded by the CIP





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However, the 4 port valves can carry both process fluids and cleaning fluids. Whilst they are under thecontrol of a cleaning program it seems equally reasonable that they should belong to the CIP system as to theUnit or line that is being cleaned.





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Table of Contents

Section PageCover 1Table of Contents 5

Project Description 7Project Information 8Project Details 9Diagrams 15

1 - Milkshake Plant Overview 15 2 - Liquids Processing Bldng 16 3 - Milk Silos 17 5 - Product Silos 18

7 - All CIP Recipes 19 8 - Material Reception Recipes 20 9 - Milk shakes 21

10 - un Milk/Product Silo 22 . . . Variant 1 - Product Silo 22

. . . Variant 2 - Milk Silo 23 11 - un Additive Storage Hopper 24

12 - un Batch Mixing 25 13 - un Homogeniser 26 14 - un Packaging Line 27 15 - un Solids Blending 28

16 - un Solids Preparation Line 29 19 - CIP Generation System 30 23 - CIP Unit 31

24 - crFreshWater 32 25 - Homogeniser Outlets manifold 33 26 - Milk Distribution Manifold 34 27 - Milk Supply manifold 35

28 - Product Homogenisation manifold 36 30 - Product to packaging manifold 37

31 - Recycled water 38 32 - Tank, LSL,LSH,Agit, TT 39

. . . Variant 1 - Caustic 1 39 . . . Variant 2 - Caustic 2 40

. . . Variant 3 - Acid 41 33 - Tanker unloading bay 42 34 - em Agitator 43 . . . Variant 1 - Fixed Speed 43 . . . Variant 2 - Variable Speed 44

35 - em CIP Drain 45 36 - em CIP Line Select 46

37 - em CIP Supply 47 38 - em Discharge 48

39 - em Generic Machine Interface 49 40 - em Heat/Cool Jacket 50

41 - em Homogeniser 51 42 - em Homogerniser in 52 43 - em Loss In Weight Feeder 53 44 - em Tanker Reception 54

45 - em Transfer in 56 . . . Variant 2 - Type 2 56 46 - em Transfer out 57

47 - em Water Feed 58

. . . Variant 1 - In-Line 58 48 - rcp Additive Preparation 59





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49 - rcp Batch Mixing 60 . . . Variant 1 - With Homogenising 61 . . . Variant 2 - No Homogenising 62 50 - rcp generic Vessel CIP 63

51 - rcp Receive Addiitive 64

52 - rcp Receive milk 65 53 - up Fill and Pack Procedure 66 57 - op Batch Mix and Homogenise 67

58 - op CIP Supply to Vessel Clean 68 59 - op Homogenising 69 60 - op Line Clean 71

61 - op Silo Deliver 72 62 - op Silo Receive 73 64 - op Unload Tanker 74 65 - op Vessel CIP 75

66 - ph Add Milk 76 67 - ph Add Milk and Solids 77 69 - ph Mix and Heat 78

70 - ph Vessel CIP 79 71 - Mixproof Valve 80 72 - On Off Valve 81 . . . Variant 3 - 2 Limit Switches 82

73 - Fixed Speed Motor 83 74 - Variable Speed motor 84 75 - cm Agitator Control 85 76 - cm CIP Status Control 86

78 - Standard PID Loop 87 79 - Control Valve 88 80 - Analog Input from Transmitter 89 81 - Weight measurement 90

82 - Alarm Switch Input 91

83 - Controller Status 92 84 - Interface 93

85 - CIP Routing diagram 94 86 - CIP Routing diagram snapshot 2 95 87 - Complete CIP Graphic 96 89 - Jacket Heat/Cool Type 1 98

Data Reports: 99 Alarm 99 Motor 108 Control System IOList 109

Equipment Parameter Real 122 Effector Analog 124Page Instance Count 125

Back Sheet 129





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Project Information

Item Value

Project Name:EBF WG3 Milkshake Plant

File: F:\cdArchive\milkshake2.cnd524Client: The World Batch ForumLast Author: Francis LoveringDate Edited: 23/10/2003 16:53:07Date Printed: 23/10/2003Issue 0DVersion: 524Version: Minor Issue - 0D Rev 520 - Issue for interim Web site publishiing ArchivePath: F:\cdArchiveBase Model Version: 149Reviewer View Name: Web Publish in F:\_CDReference\Samples\comments.mdb

Issue History

Date Issue Version Author Details23/10/2003 Minor Issue - 0D 520 Francis Lovering Issue for interim Web site publishiing

09/10/2003 Minor Issue - 0C 409 Francis Lovering

The model has now been developed

following developments inControlDraw and experience gained init's deployment on many projects.

The model contains portions of textfrom the original EBF working group,and is designed to address the issuesraised.

08/08/2003 Minor Issue - 0B 328 Francis Lovering Added CIP state and pulsing to silos13/05/2001 Issue Reset 0 Francis Lovering Cleared Model History





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Milkshake Process descr ipt ion Additive Deliveries

On arrival of a lorry at the Additives reception bay the pallets of additives are unloaded by fork lift truck and

taken to the Additive Warehouse.A procedure is required to register the arrival, which should match an expected delivery as scheduled in theMESAdditive Warehouse

The Additive Warehouse stores palettes of Flavour additives. Each pallet contains a number of sacks oradditives A system to control the location of materials and to ensure that they are used in an appropriateorder, such as first-in first out or according to use by dates will be required. This document does not explorethese areas of functionality.Solids Processing

Flavour additives materials are depalletised then the sacks are slit, the contents extracted and then pneumatically conveyed into the Additive Silo.Additives are then milled, sieved and then weighed into IBC'sThis is driven by the production campaign requirements so that the right additives in the right quantities are processed.Intermediate Product StoreThe Intermediate Product Store provides a buffer which is used to store IBC's which have been prepared inadvance of when they are needed or in case of a hold up in the liquids processing.Milk Reception

On arrival of a tanker at the mile reception bay the tanker is connected up to one of the three possibleunloading points. Milk is then pumped from the tanker into one of the 3 milk silosOn completion of the unloading of the tanker a clean is carried out of the tanker and the pipework whichroutes the milk from the tanker to the silos.The milk silos operate on a continuous cycle whereby they are filled repeatedly during the day and thencleaned at night, when no milk deliveries are expected.Only one tanker is unloaded at one time and generally to only one milk silo.However, operators can in exceptions unload into one silo until it is full and then the nextCIP Chemical Deliveries

On arrival of a lorry at the CIP chemicals reception bay the drums are unloaded by fork lift truck and takento the CIP Chemical Store.A procedure is required to register the arrival, which should match an expected delivery as scheduled in theMESCIP Chemical Store

The CIP Chemical Store stores drums of cleaning chemicals A system to control the location of the drums and to ensure that they are used in an appropriate order, suchas first-in first out or according to use by dates will be required. This document does not explore these areasof functionality.CIP Generation System

The Clean In Place system provides rinse water and also doses the cleaning chemicals into the water tomake cleaning liquidsThe system also takes the returned liquids and can store the final rinse water for use in subsequent firstrinsesLiquids Processing Building

Batch Mixing Processes are carried out to make batches of the various products. Certain products are then

homogenised on their way to the Product Silos.A typical mixing process comprises





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Add Milk Start qtyAdd Milk and AdditiveAdd Final Milk QtyMix

Mix and HeatTransfer Out

Packaging Building

In the packaging building liquid product from one of the product silo's is filled into bottles and then labelledand packed into pallets - further details are given below.The operation of the packaging lines is organised in terms of Work Orders.A Work Order is characterised by:

The number of bottles to be packedThe labelling on the bottle - one work order per label typeThe customer - a single customer per work order

A single work order may be made up from one or more Product SiloBottlesBottles are supplied to the filling line in boxes of pallets. A depalletising machine takes the boxes from each pallet, and the de-boxer takes bottles from the boxes. Bottles are then fed onto an accumulation conveyorwhich feeds into the filling machine.

Customers

Milko Ltd supplies to a large number of customers including the premium Supermarkets, Milko Ltds own brand and some others. Milko also has a strategy to be able to supply new customers in response to order placed over the phone or the Internet when the customers usual supplier is unable to meet the demand or hasa production problem. The pricing of such orders is a strategic decision made by Milko's senior management

- sometimes the cost will be high in order to make sure that the costs of the disruption to the schedule aremore than covered, however sometimes the work is done at cost or even at a loss if the new customer isconsidered strategically important enough.Rework

Just occasionally, and notwithstanding the highly effective scheduling system ,a batch is made which doesnot meet the critical quality standards of Milko Ltd.This can happen when there is an equipment failure - in general equipment failures can be tolerated by putting the process into hold, repairing the failed item, and then re-starting.However, sometimes there are failures which cannot be fixed in time to allow the batch to be completed.In these cases it is highly preferable to be able to re-use the batch if possible. This is far more acceptablethan disposing of the batch down the effluent system, and can be achieved by using small percentages of the

batch in subsequent batches of similar products provided this is done in time.This practise is accepted to a greater or lesser degree by the customers.The pipework in the plant makes it possible to divert a failed batch back into one of the milk silos forsubsequent rework.

A further issue with rework is that when a problem does occur and some rework is needed , it can becomenecessary to change the production schedule to make product which can use up the reclaimed batch. (It mayalso require that the current schedule is altered in order to free space in a Milk Silo to hold the batch. )

Recipes

The plant produces a large number of products, in a variety of packages.

There are three basic types of recipeSplodge Drinks





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These include Banana, Strawberry and other fruit based milkshakesFudge DrinksThese include Chocolate and other cocoa based drinksAlchoshake

These are the hot sellers, Milko Ltds latest introduction of milk shake alcoholic drinks have taken the clubdrinks market by storm since their introduction.

Recipe CharacteristicsEach type of products is made in a different way

Within each general recipe type there are a large number of specific recipes. The Premium Supermarkets,and Milko themselves each have their own recipes but the lower price customers all use exactly the samerecipe.

Rework is handled by a rework substitution algorithm - this is a set of recipe parameter which define how

much of a particular type of rework batch can be added. For example, small parts of banana milkshake can be added to all other product which also contain banana, no rework which contains alcohol can be used inany non-alcoholic products etc.PackagingThe product is packed in a variety of ways. Each customer has their own labels for the bottles or cartonswhich are use. Alcoshake is provided in bottles with child-proof caps. And each customer has their own barcoding standard.Homogenisation

Homogenisation is essentially a mixing process which ensures that the various constituents of a batch aredeeply mixed. The depth of the mix is determined by the physical properties of the batch and the pressureand flow through the homogeniser.

Homogenisation, if required, takes place in the process of transferring a batch from a Batch vessel to theProduct Silos.

The process of starting up a homogeniser is a complicated by the mechanical problems of raising the pressure, which can be very high and the fact that it is possible to physically damage the equipment byrunning it empty. hThe homogeniser supplier provides a control system specifically for this equipment and refuses to guaranteeit if this system is not used. Consequently Milko has bought the homogeniser and it's control system as acomplete package. The vendors system includes a serial interface so that all of the control parameters thatthe vendor considers relevant can be set from a supervising system.

GEA P.T. Automation Ltd.

Milkshake PlantCIP Process Descriptions

2 April, 1997

Table of Contents1. Introduction 3





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2. CIP Station P&ID 3

3. CIP Process Description 33.1. Line CIP 33.2. Tank CIP 43.3. CIP Tank Make-Up 4

4. CIP Recipe 55. The Physical Model 56. CIP Batch and CIP Batch Scheduling 5

7. CIP Batch Reports 6

1. Introduction

The CIP Station for the milk shake plant essentially consists of one Fresh Water Tank, one ReturnWater Tank, one Hot Caustic Tank, one Acid Tank and two feed and return lines.

The CIP station is used to clean the Milk Silos area, the Liquids Processing area and the ProductSilos. These are two types of CIP sequences, line CIP and tank CIP.

2. Download original document

3. CIP Process Description

3.1. L ine CIP

The normal sequence for a line CIP is as follows;

1 Pre-Rinse Return Water Tank to drain at CIP station via selected line2 Push Out Water with Caustic Caustic Tank to drain at CIP station via selected line3 Caustic Wash Caustic Tank to Caustic Tank via selected line4 Push Out Caustic with Water Fresh Water Tank to Caustic Tank via selected line5 Post Caustic Wash Fresh Water Tank to Return Water Tank via selected line6 Push Out Water with Acid Acid Tank to Return Water Tank via selected line7 Acid Wash Acid Tank to Acid Tank via selected line8 Push Out Acid with Water Fresh Water Tank to Acid Tank via selected line9 Final Rinse Fresh Water Tank to drain via selected line

3.2. Tank CIP

The normal sequence for a tank CIP is as follows;

1 Pre-Rinse Return Water Tank to drain at CIP station via selected line2 Empty Tank Empty Tank to drain at CIP station via selected line3 Push Out Water with Caustic Caustic Tank to drain at CIP station via selected line4 Caustic Wash Caustic Tank to Caustic Tank via selected line5 Empty Tank Empty Tank to Caustic Tank via selected line6 Push Out Caustic with Water Fresh Water Tank to Caustic Tank via selected line7 Post Caustic Wash Fresh Water Tank to Return Water Tank via selected line

8 Empty Tank Empty Tank to Return Water Tank via selected line9 Push Out Water with Acid Acid Tank to Return Water Tank via selected line





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10 Acid Wash Acid Tank to Acid Tank via selected line11 Empty Tank Empty Tank to Acid Tank via selected line12 Push Out Acid with Water Fresh Water Tank to Acid Tank via selected line13 Final Rinse Fresh Water Tank to drain via selected line14 Empty Tank Empty Tank to drain via selected line

The line and tank CIP's in the milkshake plant would usually only include the acid wash once aweek or once a fortnight. If the acid wash is not included then steps 7 through 12 are skipped.

The sequence for cleaning the Batch Mixing tanks will probably include some additional steps.During wash steps it would also be necessary to pulse sample valves etc..

Assuming that there are two feed and return lines then two CIP's can operate in parallel. Thismeans that one of the mix tanks could be cleaned at the same time as one of the tanker intakelines and that the liquid from one of the CIP tanks (e.g. acid) could be circulated through the intakeline and the mix tank at that time.

In the post caustic wash fresh water is recovered to the return water tank. This leaves thepossibility for cross contamination.

3.3. CIP Tan k Make-Up

The normal sequence for a CIP Tank Make-Up is as follows;

1 Dump Tank Contents Transfer contents of CIP tank to effluent plant2 Fill Tank with Water Fill Tank to High Level with Fresh Water 3 Dose Chemical Concentrate Empty Tank to drain at CIP station via selected line4 Heat Tank Caustic Tank to drain at CIP station via selected line

Fresh Water Tank requires only step 1.Cold Caustic and Acid Tank only require steps 1 and 2.Hot Caustic Tank requires steps 1, 2 and 3.

4. CIP Recipe

The recipe for a CIP will usually consist only of a set of times for each wash step and a singleon/off bit to decide whether to include an acid wash in the CIP sequence.

It is possible to include additional items such as pre-set values for watch dog timers for push outand emptying steps etc.. to allow the operator to tune the CIP's. It would also be possible to allowthe sequence of steps to be modified as part of the recipe but this is not really necessary.

Therefore a CIP recipe can essentially be reduced to the following

1 With Acid Y/N 1 / 02 Pre-Rinse 10 minutes3 Caustic Wash 20 minutes4 Post Caustic Wash 8 minutes5 Acid Wash 15 minutes6 Final Rinse 15 minutes





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5. The Physical ModelThe CIP station is not a process cell, it is not a unit, the individual CIP vessels are not units either

as they do not perform any batch processing (unless we consider the make-up process).If we look at the CIP station in terms of the CIP feed and return lines rather than in terms of the CIPvessels the CIP station can be viewed in a similar way to any other utility. The CIP feed linessupply the required liquids to the various units and transfer lines in the plant. Therefore the CIPStation is probably best viewed as shared resource even though the procedural control for cleaninga unit is associated with the CIP station rather than the unit in question.

The CIP station will be required to clean not only other units (such as the batch mixing vessels) butalso other vessels which might not even be defined as units. For example the CIP station will beused to clean a milk silo and neither the CIP station nor the

Note : If we assume that the CIP station for the Milkshake Plant was delivered with it's own controlsystem then it would require the above recipe to be downloaded from the MES (or SCADA) itwould carry out the sequencing through prerinse, caustic wash etc..and deliver the cleaning media to the various units.

6. CIP Batch and CIP Batch Scheduling

A CIP sequence is not a Batch as defined in S88.01.

A CIP batch could be included in the batch recipe for each product. In this case the CIP unitprocedure would form part of the procedure for producing "Spladge Drink".

In the Milkshake plant it would be necessary to schedule a CIP of a Batch Mixing Tank beforeproducing any "Splodge Drink" if the previous batch had been an "Alchoshake" batch, however ifthe previous batch had been a "Splodge Drink" batch no CIP would be required.

7. CIP Batch Reports

The milkshake plant owner would obviously require some reporting mechanism for the plant CIP.The CIP reports could be attached to batch report to show for example that a Batch Mixing Vesselhad been cleaned before use.





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Diagram Description 1 - Milkshake Plant Overview

RecipesAdditiveWarehouse

Stores the palettes

of Flavour additivesSolids Processing

Flavour additivesmaterials are depalletised

and weighed into IBC's

IntermediateStore

Milk Silos

3 silos filled duringday, cleaned at night

CIP ChemicalStore

CIP Generation System

3 silos filled during day, cleaned at

night

Liquids

Batch MixingProcesses

FLT2 FLT4

FLT5

PackagingBldng

PackagingStore

FLT3 FLT6

ProductSilos

3 silos

Milk shakes

QuarantineStore

Final ProductStore

Stores the palettes

of final product

Product

Additives

CIPChemicals

Packaging

Milk Tankers

Water Treatment PlantSteam

Resources

CIP Recipes

FLT1

Material Reception

Chemicals

Palettes

Milk

17

6

20

3

18 19

2 4

21

5

9

22

7

8





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Diagram Description 2 - Liquids Processing Bldng

This Process cell is where the batches of product are produced.Each batch mixing unit can be making a different product or being cleaned.PCS Design point

The corresponding graphic in the PCS will be animated with the states of the main areas.Sheet Version: 490 Class: Process Cell Sheet 2 of 89 PageID: 15

BV1

Batch MixingUnit

SH1 SH2

BV2

Batch MixingUnit

CIPSupply

HG2

Homogeniser

HG1

Homogeniser

CIPReturn

cr06

Product Homogenising pipework

cr07

Product Distribution manifold

PS1 PS2 PS3

CIPSupply2

CIP Return2

Controller 2

Product Silos

Additive Storage Hoppers

LocalDisplay

Parent Symbols:1 - Milkshake Plant Overview.... , Liquids

Milk ShakeCovers Banana,Strawberry and otherblends

Cross Reference

TagnameBV1

BV2

HG1

HG2

SH1SH2

Sheet262826282528292528

2966

cr08

Product Silo inlet manifold

12

11 11

12

1313

28

25

83

49

25





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Diagram Description 3 - Milk Silos

The milk silos store fresh milk and unused returned milk.In this model they are grouped into one process cellThis is because the batches in this area are not one to one related to other areas.

PCS Design pointThe corresponding graphic in the PCS will be animated with the states of the main areas.Sheet Version: 513 Class: Process Cell Sheet 3 of 89 PageID: 14

MS1

Milk Silo

MS2

Milk Silo

MS3

Milk Silo

cr04

Milk Supply manifold

cr05

Milk Distribution pipework

Milk Reception 1

Tanker UnloadingBay

Milk Reception 2

Tanker UnloadingBay

Milk Reception 3

Tanker UnloadingBay

CIP

Supply 1

CIP

Return 1

CIPSupply 2

CIP

Return 2

Controller 1

LocalDisplay

rp Receive Milk

Cross Reference

TagnameMS1

MS2

MS3

Sheet262729302627293026272930

10/2

10/210/2

27

26

33

33

33

83

52





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Diagram Description 5 - Product Silos

The product silos store the batches of product.In this model they are grouped into one process cellSheet Version: 474 Class: Process Cell Sheet 5 of 89 PageID: 16

PS1

Product

Silo

PS2

Product

Silo

PS3

Product

Silo

cr08

Product Distribution pipework

cr09

Product to Packaging pipework

Controller 3Local Display

10/1 10/1 10/1

25

30

83





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Diagram Description 7 - All CIP Recipes

This diagram will show all the CIP procedures (to be completed)Sheet Version: 513 Class: Recipe Sheet 7 of 89 PageID: 255

Line CIP Recipes Vessel CIP Recipes

rcCIPLine rcCIP MS1

rcCIP MS2

rcCIP MS3

rcCIP BV1

rcCIP BV2

rcCIP HG1

rcCIP HG2

X SH1

rcCIP SH2

rcCIP PS1

rcCIP PS2

rcCIP PS3

X Solids Prep Line 1

50

50

50

50

50

50

50

50

50

50

50





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Diagram Description 8 - Material Reception Recipes

This diagram shows the Recipe procedure icons for material receptionSheet Version: 515 Class: Recipe Sheet 8 of 89 PageID: 326

Receive Addiitive

Receive Chemical Drums

Receive Packing Pallets

Receive Milk

51

51

51

52





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Diagram Description 9 - Milk shakes

Covers Banana, Strawberry and other blendsSheet Version: 522 Class: Recipe Sheet 9 of 89 PageID: 325

FudgeDrink

Alchoshake

FudgeDrink

Banana Milk shakes

Alchoshake

Strawberry Milk shakes

Banana Additive Preparation

Strawberry Additive Preparation

48

49/2

49/1

49/1

49/148





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Diagram 10 - un Milk/Product SiloSheet Version: 513 Class: Unit Sheet 10 of 89 PageID: 18Variant 1 - Product Silo

Silo

LSL

Empty

LSH

LAH

LAL

CIP_V1Vessel CIP

ZSAZSO

Manway Switch

Line

From Line to

Silo Receive

Off Set ReceiveRoute

Set Deliver Route

States

Receive

Deliver

Drain

Silo Deliver

Silo CIP

LTSiloLevel

Variants

VariantMilk Silo

Product Silo

TagnameLTLSL

LALWIA

ExcludedXX

XX

VarTag SubVar

em transfer out

em

FeedLine

From Line to

em Discharge

CIP withReturn

Drain

Milk/Product Silo

Off

Set Deliver Route

Deliver

Set Receive Route

CIP with Return

CIP Drain

Receive

Drain

em Discharge

Off

Off

Transfer

Off

Transfer

Drain

Off

Drain

em Feed

Through

Through

Through

Through

Receive

Receive

Receive

Through

emAgitator

Run

Run

Run

Run

Run

Off

Run

Run

Line to

6

6

6

6

6

6

6

6

em transfer out

Through

Through

Send

Through

Send

Through

Through

Through

CIP Drain

emAgitator

op Receive Product82

82

65

82

62

61

58

80

46

45/2

38

34/1

59





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Diagram 10 - un Milk/Product SiloSheet Version: 513 Class: Unit Sheet 10 of 89 PageID: 18Variant 2 - Milk Silo

Silo

WIA

LSH

LAH

CIP_V1Vessel CIP

ZSAZSO

Manway Switch

Line

From Line to

Silo Receive

Off Set ReceiveRoute

Set Deliver Route

States

Receive

Deliver

Drain

Silo Deliver

Silo CIP

Variants

VariantMilk Silo

Product Silo

TagnameLTLSL

LALWIA

ExcludedXX

XX

VarTag SubVar

em transfer out

em

FeedLine

From Line to

em Discharge

CIP withReturn

Drain

Milk/Product Silo

Off

Set Deliver Route

Deliver

Set Receive Route

CIP with Return

CIP Drain

Receive

Drain

em Discharge

Off

Off

Transfer

Off

Transfer

Drain

Off

Drain

em Feed

Through

Through

Through

Through

Receive

Receive

Receive

Through

emAgitator

Run

Run

Run

Run

Run

Off

Run

Run

Line to

6

6

6

6

6

6

6

6

em transfer out

Through

Through

Send

Through

Send

Through

Through

Through

CIP Drain

emAgitator

op Receive Product

81

82

65

82

62

61

58

46

45/2

38

34/1

59





24/129

Diagram Description 11 - un Additive Storage Hopper

Not yet fully modularisedSheet Version: 511 Class: Unit Sheet 11 of 89 PageID: 23

StorageHopper

LSH

LSLEmpty

RV1

Parent Symbols:

2 - Liquids Processing Bldng.... , SH1, SH2

Idle

Feed

Additive Storage Hopper

Idle

Feed

Receive

RV1

Stop

Run

Stop

LSH

Disabled

Enabled

Enabled

LSL

Disabled

Enabled

Enabled

Receive

82

82

74





25/129

Diagram Description 12 - un Batch Mixing

The batch mixing Unit is split into a number of equipment modules, these are:em Temp Control Controls the vessel temperatureem Agitator Runs the Agitator

em Discharge Controls discharge to drain or to downstreamem Feed Controls feeds into the vesselem Transfer Out Controls Transfer out of the vesselNote that em Feed and em Transfer Out are not completely owned by the Unit, they can also be acquired by the CIPrecipes and transfer routes.

Sheet Version: 517 Class: Unit Sheet 12 of 89 PageID: 19

BatchVessel

States

em TempControl

WT1

WQ1

Loss-In-Weight Feeder

LSL

LSH

LAH

LAL

ShutDown

CIP

Receive MilkReceive

Additives andMilk

ReceiveAdditives

Hold

Transfer Out

Batch Mixing Unit

ShutDown

Receive Milk

Hold

Receive Additives

Receive Additives and Milk

Settle

Transfer Out

Heat Up

Cool Down

CIP

Drain

emAgitator

Off

Run

Run

Run

Run

Off

Run

Run

Run

Run

Off

em Temp Control

Idle

REG

REG

REG

REG

REG

REG

MH

MC

Idle

Idle

em Feed

Through

Receive

Through

Through

Receive

Through

Through

Through

Through

Receive

Through

em transfer out

Through

Through

Through

Through

Through

Through

Send

Through

Undefined

Send

Undefined

WQ1

Stop

Stop

Stop

Run

Run

Stop

Stop

Stop

Stop

Stop

Stop

LAL

Disable

Enable

Enable

Enable

Enable

Enable

Enable

Enable

Enable

Disable

Disable

LAH

Disable

Enable

Enable

Enable

Enable

Enable

Enable

Enable

Enable

Enable

Enable

Heat Up Cool Down

Drain

Animated

Diagram

Unit interface CM

em Agitator

em Feed

LineFrom

Line to

LineFrom

Line to

em Transfer Out

em Discharge

Settle

op Batch Mixing

op Homogenising

81

43

40

82

82

84

34/2

45/2

46

38

59

57





26/129

Diagram 13 - un Homogeniser Sheet Version: 413 Class: Unit Sheet 13 of 89 PageID: 35

emHomogeniser

Line 1

Line 2

Line 1

forwardLine 2

forward

Through

Run

IL01 Interlock

Review Status:Under Development

em Homogeniser

in

Line 2 Line to

CIP_H1

CIP for Homogeniser

em transfer out

http://www.gchahn.com/media/systematic_aeration_en_0103.pdf Double click to open

Line 2 Line to

60

41

42

46





27/129

Diagram Description 14 - un Packaging Line

The packaging area is a process cell containing two packaging lines.The packaging line is treated as a single nit .Each machine is an Equipment module

Sheet Version: 458 Class: Unit Sheet 14 of 89 PageID: 20

Bottles to line

Accumulation

Conveyor

Packing Conveyor

EM01

FillingMachine

EM02Palletiser

EM03Labeller

EM04

CartonFiller

EM05CartonShrinkWrapper

EM06Palletizer

Packing Procedure

Local

Display Text Display

Efficiency 39%MadeTargetShop Order 12313

Button on graphic to callup Shop Order Controls

Shop

Order

Parent Symbols:4 - Packaging Building.... , Packaging Line 1, Packaging Line 2

Shutdown

Running

39

39

39 39 39 39 39 39

53





28/129

Diagram Description 15 - un Solids Blending

Not yet fully modularisedSheet Version: 449 Class: Unit Sheet 15 of 89 PageID: 22

Blender

IBC2

Blender Drive

RV1

IBC1

LSLEmpty

LSH

LAH

LAL

IBC3

Prepared IBC of Additives

Blend to IBC

Prepare IBC of mixed

additivesOff

Receive

Deliver

73

73

82

82





29/129

Diagram Description 16 - un Solids Preparation Line

NOTE - this is not yet modularised in Equipment modulesSheet Version: 513 Class: Unit Sheet 16 of 89 PageID: 21

Sack Slitting Machine

RV1

Fan

AdditiveSilo

Depalletiser

Conveyor

RV2

Mill

Sieve

MetalDetector

IBC

SolidsBatch

IBC

Reject

IBC

Oversize

LSLEmpty

LSH

Prepare IBC

Prepare IBC of Additives

Parent Symbols:6 - Solids Processing Bldng.... , Solids Prep Line 1, Solids Prep Line 2

Off

Receive

Deliver

Solids Preparation Line

Off

Receive

Deliver

Receive andDeliver

Conveyor

Stop

Run

Stop

Run

Fan

Stop

Run

Stop

Run

MetalDetector

Off

Off

On

On

RV1

Stop

Run

Stop

Run

RV2

Stop

Stop

Run

Run

SackSlitting

Machine

Undefined

Undefined

Undefined

Undefined

LSH

Disabled

Enabled

Enabled

Enabled

LSL

Disabled

Enabled

Enabled

Enabled

Receive andDeliver

73

73

73

82

82





30/129

Diagram Description 19 - CIP Generation System

This diagram shows how there are Two CIP units that share the same collection of Water, Acid and Caustic tanks.Note that each CIP unit can supply either of the linesSheet Version: 523 Class: Cell Common Resource Sheet 19 of 89 PageID: 36

tk ColdCaustic

tk Acidtk Hot

Caustic

Water

Controller 6Local Display

tk ReturnWater

tk FreshWater

See also CompleteGraphic

CIP Unit1

CIPSupply/Return

CIP Unit2

CIPSupply/Return

See CIP RoutingDiagram

Line 1Routing

Line 2Routing

A

A

B

B

C

C

D

D

D

E

E

32/3 32/1 32/2

83

3124

87

23

23

85

85





31/129

Diagram Description 23 - CIP Unit

CIP Supply/ReturnSheet Version: 524 Class: Common Resource Sheet 23 of 89 PageID: 318

tk ColdCaustic

Line CleanVessel Clean

Feed A

tk Acidtk Hot

Caustic

Return A

FT2

tk ReturnWater

tk FreshWater

Equipmentor Line

QT2Conductivity TT02

Shutdown Supply AcidSupply Cold

CausticSupply Hot

Caustic

Rinse toRecycle

Acid RecycleCold Caustic

RecycleHot Caustic

Recycle

CIP Unit

Shutdown

Supply Acid

Acid Recycle

Supply ColdCausticCold CausticRecycleRinse toRecycleHot Caustic

RecycleSupply HotCaustic

KV005

Close

Close

Close

Close

Close

Close

Close

Close

CIP SupplyPump

0

0

0

0

0

0

0

0

tk Acid

0

0

0

0

0

0

0

0

tk ColdCaustic

0

0

0

0

0

0

0

0

tk FreshWater

Shutdown

Shutdown

Shutdown

Shutdown

Shutdown

Shutdown

Shutdown

Shutdown

tk HotCaustic

0

0

0

0

0

0

0

0

tk ReturnWater

0

0

0

0

0

0

0

0

Valve inManifold

Valve inManifold

Gravity

em CIPSupply

em CIPDrain

em CIP Line Select

6058

8080

32/132/3 32/23124

80

37

35

36





32/129

Diagram Description 24 - crFreshWater

Whilst having the class of Equipment Module, it is also an exclusive use Common Resource.Only one control recipe can put the module into the feed state at one time.The module has to be explicitely acquired and given it's route select parameter, then it can feed. Once it is released

another recipe canSheet Version: 458 Class: Common Resource Sheet 24 of 89 PageID: 271

FW1

Fresh

water

V02

V01

V03

Water

LSLEmpty

LSHFull

LSMMinimum

Line 2

Line 1

Supply On

Demand

V01 cmd

V02 cmd

EnableFilling

Set/Reset

V03 cmd

Shutdown

Supply 1

Supply 2

A

A

B

B

B

72/3

72/3

72/3

82

82

82





33/129

Diagram 25 - Homogeniser Outlets manifoldSheet Version: 523 Class: Common Resource Sheet 25 of 89 PageID: 33

HG2

Homogeniser

HG1

Homogeniser

V01

V02

Supply

HG1.em transfer out

[Sheet 2]

HG2.em transfer out

[Sheet 2]

V02

V01

Return

V04

72/3

72/346 46

71





34/129

Diagram 26 - Milk Distribution ManifoldSheet Version: 515 Class: Common Resource Sheet 26 of 89 PageID: 30

CIP Supply

MS1

Milk Silo

MS2

Milk Silo

MS3

Milk Silo

BV1BV2

CIPReturn

Animated Diagram

Put in Run Mode thenclick the valves

BV2.emFeed

[Sheet 2]

BV1.emFeed

[Sheet 2]

MS1.em transfer out

[Sheet 3]

MS2.em transfer out

[Sheet 3]

MS3.em transfer out

[Sheet 3]

V04

V03

V02

V01

19

12 12

45/245/246 46 46

72/3

72/3

72/3

72/3





35/129

Diagram 27 - Milk Supply manifoldSheet Version: 522 Class: Common Resource Sheet 27 of 89 PageID: 31

CIP Supply

V05

V09

CIPReturn

MS1

Milk Silo

MS2

Milk Silo

MS3

Milk Silo

FromHomogenisers/Batch

vessels

Milk Tanker

Line Control

Controls the

Setting of routes inthe lines

CIP_Check

Clean Status Monitor

Control Modules

V01

Line 1

Line 2

Animated Diagram

Put in Run Mode thenclick the valves

MS1.emFeed

[Sheet 3]

MS2.em

Feed

[Sheet 3]

MS3.em

Feed

[Sheet 3]

em Tanker Reception 1

Milk Tanker

Milk Tanker



72/3

72/3

72/3

10

77

76

45/2 45/2 45/2

44

44

44





36/129

Diagram 28 - Product Homogenisation manifoldSheet Version: 515 Class: Common Resource Sheet 28 of 89 PageID: 32

BV1.em

Transfer Out

[Sheet 2]

BV1 BV2

BV1.em

Transfer Out

[Sheet 2]

CIPSupply

CIP

Return

HG2

Homogeniser

HG1

Homogeniser

HG1.em

Homogeniser in

[Sheet 2]

HG1.em

Homogeniser in

[Sheet 2]

V06

V05

V02

V01

V03

V04

V01

46 46

12 12

19

1313

42 42

72/3

72/3

72/3

72/3

72/3

71





37/129

Diagram 30 - Product to packaging manifoldSheet Version: 474 Class: Common Resource Sheet 30 of 89 PageID: 34

PS1

ProductSilo

PS2

ProductSilo

PS3

ProductSilo

PS1.em transfer out

[Sheet 5]

CIPSupply

CIPReturn

V04

V03

V02

V01

PS2.em transfer out

[Sheet 5]

PS3.em transfer out

[Sheet 5]

5

19

72/3

72/3 46

72/3

72/346 46





38/129

Diagram 31 - Recycled water Sheet Version: 395 Class: Common Resource Sheet 31 of 89 PageID: 273

RW1

Return

water

V02

V04

V03

V01

LSL

Empty

LSH

LAH01

LAL02

72/3

71

72/3

71

82

82





39/129

Diagram 32 - Tank, LSL,LSH,Agit, TTSheet Version: 502 Class: Common Resource Sheet 32 of 89 PageID: 39Variant 1 - Caustic 1

em Water Feed

CIP Tank Agitator

LAL

LAH

TT

AG1

Water to Next

P3

Caustic

Supply CM

List of Variants

Acid

em Water Feed

to Next

1-Caustic 1

Caustic

/Var 1

2-Caustic 2

Caustic

/Var 2

{Excluded}

3-Acid

/Var 1

em transfer out

em Feed

82

82

73

73

46

45/2

47 /1





40/129

Diagram 32 - Tank, LSL,LSH,Agit, TTSheet Version: 502 Class: Common Resource Sheet 32 of 89 PageID: 39Variant 2 - Caustic 2

em Water Feed

CIP Tank Agitator

LAL

LAH

TT

AG1

Water

P3

Caustic

Supply CM

List of Variants

Acid

em Water Feed

to Next

1-Caustic 1

Caustic

/Var 1

2-Caustic 2

Caustic

/Var 2

{Excluded}

3-Acid

/Var 1

em transfer out

em Feed

82

82

73

73

46

45/2

47 /2





41/129

Diagram 32 - Tank, LSL,LSH,Agit, TTSheet Version: 502 Class: Common Resource Sheet 32 of 89 PageID: 39Variant 3 - Acid

em Water Feed

CIP Tank Agitator

LAL

LAH

TT

AG1

Water to Next

P3

Acid

Supply CM

List of Variants

Acid

em Water Feed

to Next

1-Caustic 1

Caustic

/Var 1

2-Caustic 2

Caustic

/Var 2

{Excluded}

3-Acid

/Var 1

em transfer out

em Feed

82

82

73

73

46

45/2

47 /1





42/129

Diagram 33 - Tanker unloading baySheet Version: 273 Class: Common Resource Sheet 33 of 89 PageID: 27

V12

Milk Supplymanifold

Milk Tanker

Pump

LSLLine Empty

LAL

Parent Symbols:

3 - Milk Silos

.... , Milk Reception 1,

Milk Supply

manifold

Off Set Route Deliver

States

Tanker Deliver Fred

Tanker unloading bay

Deliver

Off

Set Route

LAL

Enabled

Disabled

Enabled

Pump

Run

Stop

Stop

V12

Mix

Thru

Mix

Milk Tanker

10

0

10

73

27

82

72/3

64





43/129

Diagram 34 - em Agitator Sheet Version: 2 Class: Equipment Module Sheet 34 of 89 PageID: 261Variant 1 - Fixed Speed

LT001

Agitation CM

FM01

Vessel

Off

Run

States

epStart_Level

epStop_Level

epOn_Time

epOff_Time

em Fixed Speed Agitator

Off

Run

Agitation CM

Off

On

FM01

Stop

Start

75

73





44/129

Diagram 34 - em Agitator Sheet Version: 2 Class: Equipment Module Sheet 34 of 89 PageID: 261Variant 2 - Variable Speed

LT001

VSD AgitationCM

Vessel

Off

Run

States

epStart_Level

epStop_Level

epOn_Time

epOff_Time

VM01

epSpeed

SIA

Select

Remote

em Fixed Speed Agitator

Off

Run

VSD Agitation

CMOff

On

VM01

Stop

Start

75

74

78





45/129

Diagram Description 35 - em CIP Drain

This incomplete module enables the routing of CIP returns to drainSheet Version: 513 Class: Equipment Module Sheet 35 of 89 PageID: 328

KV005

Drain2

72/3





46/129

Diagram Description 36 - em CIP Line Select

This incomplete module switches a CIP Supply and return between one or other linesSheet Version: 515 Class: Equipment Module Sheet 36 of 89 PageID: 329

XV02

XV01 Line 1Routing

Line 1Routing

A

A

BB

C

C

DD

72/3

72/3

85

85





47/129

Diagram Description 37 - em CIP Supply

This incomplete module controls the supply of CIP into the CIP linesSheet Version: 513 Class: Equipment Module Sheet 37 of 89 PageID: 327

CIP SupplyPump

Feed A

CV

Condensate

Steam

TT01

TIC01

CIPFeed 1

CIP Line

73

79

80

78





48/129

Diagram 38 - em DischargeSheet Version: 395 Class: Equipment Module Sheet 38 of 89 PageID: 263

V02

Pump

Drain

V01

Next

Off

Transfer

IL01 Pump cannot run if valve not open

Drain

em Discharge

Off

Transfer

Drain

Pump

Stop

Run

Stop

V5

Closed

Open

Open

V6

Closed

Closed

Open

72/3

73

72/3





49/129

Diagram 39 - em Generic Machine InterfaceSheet Version: 514 Class: Equipment Module Sheet 39 of 89 PageID: 234

Starved

Alarm code

Machine Status

Machine Supertag

SCADA Tag Points

Machine States

Machine Alarm 1

Machine Alarm 2

Producing

Waiting.

Stopped

Failed

Machine Alarm 3

Machine Alarm 4

Machine Alarm 5

Machine Alarm 6

Machine Alarm 7

Machine Alarm 8

Machine In Count

Machine Out Count

8 SpecificAlarms

Machine Speed

Alarm Code for allalarms

Machine Status as instates

0 to 4

Counter Reset

Integer Value

Discrete Value

Real Value

Key

Reset from new order

Machine Alarm Group

Machine Mimic

Each machine has a mimicdiagram showing all current

machine data.





50/129

Diagram 40 - em Heat/Cool JacketSheet Version: 517 Class: Equipment Module Sheet 40 of 89 PageID: 86

Batch Vessel

TT1

V12

V10

V09

V11

Coolant Supply

Coolant Return

Steam Supply

Temperature ControlEquip phase

Condensate

Parent Symbols:12 - un Batch Mixing.... , em Temp

Control

SMH

Set MaxHeating

MH

Max Heating

MC

Max Cooling

SMC

Set Max

Cooling

StopIdle

REG

Regulating

SREG

Set

Regulating

72/3

72/3

72/3

72/3

89





51/129

Diagram 41 - em Homogeniser Sheet Version: 413 Class: Equipment Module Sheet 41 of 89 PageID: 313

PT01

PT02

HS03

HS04

XA01

XA02

XA03

XA04

XA05

XA06

PBO01

PBO02

PAHH

PAL

HS02

I/O and AlarmsThis shows small PLC controlling the homogeniser that also reports via alarms and some

process measurments.

PLC

Machine Controller

PLCFailPLC Failure

Includes comms failures

SI

Homogeniser

CWS CWR

PD Pump

Material

Material

73





52/129

Diagram 42 - em Homogerniser inSheet Version: 490 Class: Equipment Module Sheet 42 of 89 PageID: 306

V01

V02

Line 1

Line 2

Line 1forward

Line 2forward

Homogeniser

Route Select

V01 cmdEquals1

V02 cmdEquals2

Off

Homogenise

72/3

71





53/129

Diagram 43 - em Loss In Weight Feeder Sheet Version: 517 Class: Equipment Module Sheet 43 of 89 PageID: 46

Hopper

WT

Screw Feeder

Controller 7

SI

81





54/129

Diagram 44 - em Tanker ReceptionSheet Version: 457 Class: Equipment Module Sheet 44 of 89 PageID: 314

Milk Tanker

PumpLAL

Line Empty

XV10

Material

Material

Idle

Feed

Ready

33





55/129

Diagram Description 45 - em Transfer in

Variant 2 - Type 2

This module can be acquired by the batch manager. This also sends a Route number to the module.The unit then sets the module to the Through or Feed State





56/129

Diagram 45 - em Transfer in

Sheet Version: 458 Class: Equipment Module Sheet 45 of 89 PageID: 264

V03

V04

Line 1

Line 2

Line 1forward

Line 2forward

Unit

Through

Receive

Route Select

V01 cmdEquals1

V02 cmdEquals2

IF Transfer in

V06

CIP V04 cmd

CIP Pulse

A

A

A

72/3

71

84

72/3





57/129

Diagram Description 46 - em Transfer out

This module can also be acquired by the CIP recipes and transfer routes.

Sheet Version: 517 Class: Equipment Module Sheet 46 of 89 PageID: 266

Line 1

Line 2

Line 1forward

Line 2forward

Unit

V08

V07

Through Send

Route SelectFrom Recipe Procedure

V01 cmdEquals1

V02 cmdEquals2

A

A

A

72

71





58/129

Diagram Description 47 - em Water Feed

Variant 1 - In-Line

This module fills the vessel with water - when the level drops below the low level switch filling starts and it stops onhigh level.

Note that the value of ep Timer SP in the Low level switch modules should be greater then the time taken to allow thewater to increase the level. Also that ep Fill Time SP should be long enough to allow the level to rise enough, but to below the High level switch,since that would trigger a High level alarm.If a third switch just below the LAH were provided then that could be used instead of the timer.Sheet Version: 510 Class: Equipment Module Sheet 47 of 89 PageID: 324

Water

V05

to Next

List of Variants

to Next

V05

V05

1-In-Line

{Excluded}

2-EndLine{Excluded}

{Excluded}

Idle

Feed

LAH.blnVal

[Sheet 32]

EnableFilling

Set/Reset

V05.AutoCmd

[Sheet 47]

LAL.blnVal

[Sheet 32]

em Water Feed

Idle

Feed

Enable Filling

False

True

Timer

ep Fill TimeSP

A

A

72/3





59/129

Diagram Description 48 - rcp Additive Preparation

Makes up a batch in an IBC for use in next cellSheet Version: 509 Class: Recipe Procedure Sheet 48 of 89 PageID: 267

UP 0

UP 1

Release

Release

Acquire

Acquire

To be defined





60/129

Diagram 49 - rcp Batch MixingSheet Version: 515 Class: Recipe Procedure Sheet 49 of 89 PageID: 56

Parent Symbols:

2 - Liquids Processing Bldng

.... , Milk Shake

9 - Milk shakes

.... , Alchoshake/1, Banana

Acquire MixingUnit

op Deliver Milk

Acquire Milk Silo

Release Milk Silo

BV1

Mixing Unit

HG1

Homogeniser

PS1

Milk Silo

Acquire

Homogeniser

Release Mixing

Unit

Release

Homogeniser

op Batch Mixing

OP 2 Homogenising

Acquire Storage

Silo

op Receive

Release Storage

Silo

CIP Not Required CIP Required

Prompt to CIP Unit

61 57

59

62





61/129

Diagram 49 - rcp Batch MixingSheet Version: 515 Class: Recipe Procedure Sheet 49 of 89 PageID: 56Variant 1 - With Homogenising

Parent Symbols:

2 - Liquids Processing Bldng.... , Milk Shake

9 - Milk shakes


Acquire MixingUnit

op Deliver Milk

Acquire Milk Silo

Release Milk Silo

BV1

Mixing Unit

HG1

Homogeniser

PS1

Milk Silo

AcquireHomogeniser

Release MixingUnit

ReleaseHomogeniser

op Batch Mixing

OP 2 Homogenising

Acquire StorageSilo

op Receive

Release StorageSilo

CIP Not RequiredCIP Required

Prompt to CIP Unit

61 57

59

62





62/129

Diagram 49 - rcp Batch MixingSheet Version: 515 Class: Recipe Procedure Sheet 49 of 89 PageID: 56Variant 2 - No Homogenising

Parent Symbols:

2 - Liquids Processing Bldng.... , Milk Shake

9 - Milk shakes


Acquire MixingUnit

op Deliver Milk

Acquire Milk Silo

Release Milk Silo

BV1

Mixing Unit

HG1

Homogeniser

PS1

Milk Silo

Release MixingUnit

op Batch Mixing

op Mix and Heat

Acquire StorageSilo

op Receive

Release StorageSilo

CIP Not RequiredCIP Required

Prompt to CIP Unit

61 57

59

62





63/129

Diagram 50 - rcp generic Vessel CIPSheet Version: 515 Class: Recipe Procedure Sheet 50 of 89 PageID: 257

Takes place in theUnit vessel being

cleaned

Takes place in CIP Unit

ph Vessel CIP

Acquire CIP Unit

op CIP Supply toVessel Clean

Release CIP Unit

Note - this is a 'Virtual unit'

Acquire Route Acquire Vessel

Release Route Release Vessel

ph Set Route

7058





64/129

Diagram 51 - rcp Receive AddiitiveSheet Version: 513 Class: Recipe Procedure Sheet 51 of 89 PageID: 243

Truck Deliver

This is purely manual

Warehouse Receive

This is purely manual

PrepareCheck delivery note againstorders, sample, tell ERP etc

Acquire WarehouseSlot

Move Truck

To acquired bay

Acquire deliverybay

Parent Symbols:8 - Material Reception Recipes

.... , Receive Addiitive, Receive Chemical Drums, Receive Packing Pallets

Release WarehouseSlot

Release deliverybay





65/129

Diagram 52 - rcp Receive milkSheet Version: 488 Class: Recipe Procedure Sheet 52 of 89 PageID: 244

Tanker Deliver SynchOut

Silo ReceiveSynchIn

PrepareCheck delivery note against

orders, sample, tell ERP etc

Acquire SiloMove Tanker

To acquired bay

Acquire deliverybay

Parent Symbols:

3 - Milk Silos

.... , rp Receive Milk

8 - Material ReceptionRecipes

.... , Receive Milk

64

62





66/129

Diagram 53 - up Fill and Pack ProcedureSheet Version: 513 Class: Unit Procedure Sheet 53 of 89 PageID: 55

Start Cartonfiller

Start box filler

Start Stacker

Start ShrinkWrap

Fill and pack

Stop Carton filler

Stop box filler

Stop Stacker

Stop ShrinkWrap

Start up the line

Run Fill/Pack operation

Shut down the line





67/129

Diagram 57 - op Batch Mix and HomogeniseSheet Version: 369 Class: Operation Sheet 57 of 89 PageID: 310

Add MilkStart Qty

Mix andHeat

Add Milkand Solids

Sample

Add MilkFinal Qty

66

69

67

66





68/129

Diagram 58 - op CIP Supply to Vessel CleanSheet Version: 457 Class: Operation Sheet 58 of 89 PageID: 68

Pre-RinseSet to hState

'Return Water Tank to drain at CIPstation via selected line

True

Push Out Water with Caustic

Caustic Tank to drain at CIP stationvia selected line

Conductivity

Caustic Wash

Caustic Tank to Caustic Tank viaselected line

Timer1

Push Out Caustic with Water

Fresh Water Tank to Caustic Tank viaselected line

Conductivity

Post Caustic Wash

Fresh Water Tank to Return Water Tank via selected line

Timer2

Push Out Water with Acid

Acid Tank to Return Water Tank viaselected line

Conductivity

Acid Wash

Acid Tank to Acid Tank via selectedline

Timer3

Push Out Acid with Water

Fresh Water Tank to Acid Tank viaselected line

Conductivity

True

Empty Tank

Empty Tank to drain at CIP station viaselected line.

Tank Empty LevelSw

Empty Tank


Tank Empty LevelSw

Empty Tank


Tank Empty LevelSw

Empty Tank


Tank Empty LevelSw

Parent Symbols:10 - un Milk/Product Silo.... , Silo CIP23 - CIP Unit.... , Vessel Clean50 - rcp generic Vessel CIP.... , op CIP Supply to VesselClean

A

A





69/129

Diagram 59 - op HomogenisingSheet Version: 509 Class: Operation Sheet 59 of 89 PageID: 312

Mix andHeat

HomogenisingTransfer Out 69 68





70/129

Diagram Description 60 - op Line Clean

Generic Line Clean





71/129

Diagram 60 - op Line Clean

Sheet Version: 457 Class: Operation Sheet 60 of 89 PageID: 69

Pre-Rinse

Return Water Tank to drain at CIP station viaselected line

True

Push Out Water with Caustic

Caustic Tank to drain at CIP station viaselected line

Conductivity

Caustic Wash

Caustic Tank to Caustic Tank via selected line

Timer1

Push Out Causticwith Water

Fresh Water Tank to Caustic Tank viaselected line

Conductivity

Post Caustic Wash

Fresh Water Tank to Return Water Tank viaselected line

Timer2

Push Out Water with Acid

Acid Tank to Return Water Tank via selectedline

Conductivity

Acid Wash

Acid Tank to Acid Tank via selected line

Timer3

Push Out Acid with Water

Fresh Water Tank to Acid Tank via selectedline

Conductivity

True





72/129


73/129

Diagram 62 - op Silo ReceiveSheet Version: 513 Class: Operation Sheet 62 of 89 PageID: 247

T

Route Set

LSH or Source LSL

Route Set

Parent Symbols:

10 - un Milk/Product Silo.... , Silo Receive

To Add - Ready check and

set step and transition for the

interface with the sendingunit

S1

Set to Set Receive

Route

Set State

Set to Receive

Set State

Set to Off





74/129

Diagram 64 - op Unload Tanker Sheet Version: 455 Class: Operation Sheet 64 of 89 PageID: 245

Parent Symbols:33 - Tanker unloading bay

.... , Tanker Deliver 55 - up Receive Milk

.... , Transfer Milk

T

Route Set

LSH or Source LSL

Route Set

S1

Set to Set Route

Set State

Set to Deliver

Set State

Set to Off





75/129

Diagram 65 - op Vessel CIPSheet Version: 397 Class: Operation Sheet 65 of 89 PageID: 259

epVesselEmptyLevel

S04_Clean / Drain

Init

S05_CIP

Set to CIP Vessel

T04_Source ActiveSource "Active" signal Set

Destination (Z unit) "Ready" signal Set

T05_Source Flush Reset

Source "Flush" signal Reset

T09_Source Ready Reset

Source "Ready" signal Reset

End

T02_Source Ready Set

Source "Ready" signal Set

S02_Ready to CIP

Set to Ready to CIP Vessel

S07_CIP Drain

Set to CIP Vessel Drain

T10_States Confirm

EM States confirmed

T03_States ConfirmEM States confirmed

S03_Set ReadyDestination "Ready" signal Set

Source "Ready" signal Set

Parent Symbols:

10 - un Milk/ProductSilo

.... , CIP_V1

S06_CIP Drain

Set to CIP Vessel Drain

T06_Source Flush Set

Source "Flush" signal Set

T08_Source Flush Reset

Source "Flush" signal Reset

T07_Source Flush Set

Source "Flush" signal Set

S08_Reset Ready

Destination "Ready" signal Reset

Source "Ready" signal Reset

T11_True

T01_UnitRun

S01_Initialised Stop 'Storage_Timer'

A

A





76/129

Diagram 66 - ph Add MilkSheet Version: 454 Class: Phase Sheet 66 of 89 PageID: 59

Start

T 01 Start

S01 Stabilise

Set to Settle

T 02 StableWeight stable for xseconds

S02 Store Tare Wt

Store the weight for use in batchcalcs

T 03 TrueDummy

S03 Receive

Set to Receive Milk Add milk a full rate.

T 04 WT > WTSPWeight greater thanTarget Weight

S04 Stabilise

Set to SettleWait for the weight to be steady

T 05 Time + WT.StandsstillWeight stable for x seconds

S05 Store Final Wt

Calculate the weight added.Calculate the Inflight weight.

T 06 TrueDummy

WTSP

Target Weight

WTPV Actual Weight

Parent Instances

Set State MatrixBatch Mixing Unit





77/129

Diagram 67 - ph Add Milk and SolidsSheet Version: 298 Class: Phase Sheet 67 of 89 PageID: 58

Start

T 01 Start

S01 Stabilise

Set to Settle

T 02 Stable

Weight stable for xsecondsS02 Store Tare Wt

Store the weight for use in batch

calcs

T 03 True

Dummy

S03 Receive

Set to Receive Additives and Milk

T 04 WT > WTSP

Weight greater than

Target Weight

S04 Stabilise

Set to Settle

Wait for the weight to be steady

T 05 Time + WT.Standsstill

Weight stable for x seconds

S05 Store Final Wt

Calculate the weight added.

Calculate the Inflight weight.

T 06 True

Dummy

WTSP

Target Weight

WTPV

Actual Weight





78/129

Diagram 69 - ph Mix and HeatSheet Version: 456 Class: Phase Sheet 69 of 89 PageID: 63

T_Start

Mix and heat

Set to Heat Up

Time

Time = Mixtmie

jhhoiooiooi

MixTemp

Target Temperature

Mixtime

Time for mixing

Start





79/129

Diagram Description 70 - ph Vessel CIP

This diagram is the procedure for a vessel that is being cleaned. Note that all vessels must have CIP and Drainstates.Basically the vessel is extremely ignorant of what is happening, the CIP unit is in charge

Sheet Version: 455 Class: Phase Sheet 70 of 89 PageID: 311

T01

S 0Set to Drain

T0

S 0

Set to CIP

T0





80/129

Diagram 71 - Mixproof ValveSheet Version: 0 Class: Valve Sheet 71 of 89 PageID: 242

FailOpenInst: Boolean

TypeInst: Text

MixOpen =

Signed

ThruClose =Clean

Upper

CleanLower

Flip Group handling

Clean Upper when the value from the CIP station = Valve Flip group 1Clean Lower when the value from the CIP station = Valve Flip group 2

Can Not Clean Upper and Lower at the same time. (Upper takes preference)Can Not Clean when in Mix position

States

Stroke Count - Upper

can be ResetStroke Count Lower

can be Reset

AutoCmd Auto CommandFrom control logic

ManualManual Command0 = close, 1 = OpenOperator set Valve Driver

Standard Auto/Manual.

Travel is timed in eachdirection. Timeout causesFail to Open or Fail to Close Alarm.The same Travel Time valueis used in the case of 2 limitswitches

Sov

DIClosed

Interlock ConditionSet false by interlock logic if required todeenergize output

OVRCOverride Open - set true to ignore limit switch

efSov

ZSCClosed Limit Switch

TMRMaximum Travel Time

Stroke Count

can be ResetHold

From Unit Hold

Hold Action

Determines whether to open, close, becontrolled or stay put if in Hold. Default toClose (for Fail closed valves) Valve status Log

can be Enabled / Disabled

Auto / Manual Auto/Manual0 = manual, 1 = Auto

Status Open / Close

FTOFail to Open Alarm

FTCFail to Close Alarm

Mixproof Valve

Thru

Mix

Clean Lower

Clean Upper

Sov

Off

On

Off

Off

SovL

Off

Off

On

Off

SovU

Off

Off

Off

On

DOSovUpper

SovU

DOSovLower

SovL

OVRO

Override Open - set true to ignore limit switch

DIOpen

ZSOOpen Limit Switch





81/129

Diagram 72 - On Off ValveSheet Version: 144 Class: Valve Sheet 72 of 89 PageID: 231

A/M Auto/Manual

0 = manual, 1 = AutoSet by Unit Manual

AutoCmd Auto Command

From control logic

MANManual Command

0 = close, 1 = OpenOperator set

Valve Driver


Travel is timed in eachdirection. Timeout

causes Fail to Open orFail to Close Alarm.

Individual times for eachdirection must beprovided.

FTOFail to Open Alarm

FTCFail to Close Alarm

TMRCMaximum Close Travel

Time

DOSovDIClosed

DIOpen

InterlockCondition

OVROOverride Open = If setto 1 the Open limit

switch is ignored

OVRCOverride Closed - If set

to 1 the Open limitswitch is ignored

Valve status

Sov

ZSOOpen limit switch


TMROMaximum Open Travel

Time

Stroke Count

List of Variants

DIClosedDIOpen

FTCFTO

OVRCOVROTMRC

TMROZSCZSO

1-Open LS{Excluded}

{Excluded}

{Excluded}OVR{Excluded}

TMR{Excluded}

2-Closed LS

{Excluded}

{Excluded}

OVR{Excluded}TMR

{Excluded}

{Excluded}

3-2 Limit Switches

Signed

FailOpen

Inst: Boolean

TypeInst: Text





82/129

Diagram 72 - On Off ValveSheet Version: 144 Class: Valve Sheet 72 of 89 PageID: 231Variant 3 - 2 Limit Switches

A/M Auto/Manual0 = manual, 1 = AutoSet by Unit Manual

AutoCmd Auto CommandFrom control logic

MANManual Command

0 = close, 1 = OpenOperator set

Valve Driver


Travel is timed in each

direction. Timeoutcauses Fail to Open orFail to Close Alarm.

Individual times for eachdirection must be

provided.

FTO

Fail to Open Alarm

FTC

Fail to Close Alarm

TMRCMaximum Close TravelTime

DOSovDIClosed

DIOpen

InterlockCondition

OVROOverride Open = If set

to 1 the Open limitswitch is ignored

OVRCOverride Closed - If setto 1 the Open limitswitch is ignored

Valve status

Sov

ZSO

Open limit switch


TMROMaximum Open Travel

Time

Stroke Count

List of Variants DIClosed

DIOpenFTC

FTOOVRCOVRO

TMRCTMROZSC

ZSO

1-Open LS{Excluded}

{Excluded}

{Excluded}OVR

{Excluded}TMR{Excluded}

2-Closed LS

{Excluded}

{Excluded}OVR{Excluded}

TMR{Excluded}

{Excluded}

3-2 Limit Switches

Documents

PROCESO DE MILKSHAKE