Integrating process line controls with 'Link'

FMC FoodTech introduces a new solution - Link: a control systems technology that enables the line operator to control, aggregate, analyse and improve food production and line management

The old adage of "the left hand doesn't know what the right hand is doing," may seem true when working with old, antiquated production line systems.

You may have one set of controls for belt speed, another set for temperature control, and that's only the beginning.

Even worse, not all of these controls are on the same machines, and some machines are from different manufacturers.

This can lead to quality control problems and operating inefficiencies.

FMC FoodTech has the solution - Link.

Link is a control systems technology that enables the line operator to control, aggregate, analyse and improve production and information line management.

And recently, FMC FoodTech unveiled Link Process Analysis, the latest addition to Link.

The Link Process Analysis module is a total solution for data collection, storage and analysis to help processors improve yield, throughput and productivity while ensuring traceability and food safety.

"More and more customers are demanding a solution with a holistic view," said Thomas Lundqvist, product line manager for FMC FoodTech: "Link Process Analysis deciphers product and process data from entry point to execution, enabling companies to improve their processes to increase yield, throughput and productivity, while ensuring traceability and food safety".

Link Process Analysis allows the line processor to easily capture relevant process and product data in electronic format and securely store it at one central location, augmenting or replacing paper-based systems.

Process data may include machine parameters such as belt speed, oil temperature of fryer, infeed temperature of oven and stroke rate of a forming machine, while product data includes specific product characteristics such as lot number, raw temperature, discharge weight from an oven or freezer and product form.

Also, Link Process Analysis can incorporate existing databases and, most importantly, can be used with equipment from other suppliers.

Another component of Link Process Analysis is the report generator function, that analyses critical data points in process lines, identifies the causes of inconsistencies and problems, and tracks and controls product and process parameters.

Predefined queries and reports are included, and Link Process Analysis can incorporate information using any combination of parameters - time periods (personnel shifts), lines, product codes, lot numbers, recipes and operators, to name a few.

Customers can display reports in either real-time or historical format.

Real time reports provide instant operator feedback on actual values as compared to specification limits.

Likewise, management can access real-time reports on specific quality, throughput and yield information.

Historical reports give extended statistical process control capability.

These reports can be used for process optimisation and local traceability purposes.

"Gathering large amounts of data is great, but your reward only comes when and if you use the data to improve your process," said Lundqvist: "Link Process Analysis uses analytical and relational tools to mine data and make your information actionable".

Because Link Process Analysis can be configured for any equipment regardless of the manufacturer, each implementation is specific to the equipment used.

For general implementations, process data is first collected either manually, from programmable logic controllers (PLC) on the equipment or via handheld devices, and is then imported into a database.

Simultaneously, product data is collected manually or automatically (e.g weight scales communicating directly with the computer).

The software analyses the data instantaneously, creating reports based on applicable queries.

Process or product conditions are then graphically represented to show different scenarios, including warning, critical alarms or optimal performance.

Graphical presentations make it easier for personnel to be proactive, enabling line processors to react quickly to situations that might otherwise result in downtime or wasted product.

"Combining process and product data in real-time results in a previously unattainable degree of relevant detail.

Link Process Analysis provides, for the first time, the opportunity to fully optimise the process, allowing operators to work on hard, up-to-date and easily understandable information instead of individual experience and skills," said Lundqvist: "Link Process Analysis puts management in total control of the product and the process, enabling cause and effect to be rationalised with accuracy".

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