automatic control of coconut milk production

Automatic Control Of Coconut Milk Production

Laura Duque Vélez - [email protected] Miguel González Botero – [email protected]

Martin Llano Botero - [email protected] Luis Miguel Mesa Ruiz - [email protected]

David Russi Botero - [email protected] and Camilo Villegas Jiménez – [email protected]

I. INTRODUCTION

Tropical Milk is a company dedicated to the production

of coconut milk in glass containers. Our product is aimed

at lactose intolerant families, who have a taste for natural

drinks, with no artificial flavor and that can be served straight

to the table. Raw coconut enters our production line, goes

through certain automated steps, and leaves as a tasty bottle

of coconut milk. Our company produces (200?) bottles of

1000 mL, daily (on average). Tropical Milk is the first

Colombian company that has a 100 percent automated plant

in all its processes with the help of seven operators, of

which one supervises the machines compared to the other

companies where you might have more than 20 people

actively working on the production line.

Problems that come along with an automated plant, in-

clude mistiming of conveyor belts, coordination between sub-

processes, failure in detection when it is required, amongst

others. The objective when creating this automated plant,

is to overcome these problems and deliver a highly precise

production line with minimal waste of time and great effec-

tiveness. This will be done through the study of the process

and the implementation of several Programable Logic Con-

trollers (PLC) all throughout it, severe testing and correction

of each of the automated subprocesses, and constant control

in order to receive feedback regarding production times and

effectiveness in case any corrections or improvements need

to take place.

Every step throughout the entire process will be auto-

mated, starting when the raw coconuts are place at the

beginning of the line. This includes the cutting of the pulp,

the cleaning, grinding, crushing, squeezing, pasteurizing,

bottling, labeling, and finally, packing of the final product.

The intention is to increase productivity regarding the pro-

duction of coconut milk. It is very common to see plants that

might be too “handmade”. With an automated plant, one can

increase its daily production, meaning one can increase daily

profits. With the implementation of sensors, actuators, DACs,

and PLCs (all discussed later in the report), the so desired

automated coconut milk production plant will come to life.

Up next, you will find a clear breakdown of the entire

plan to make this plant a reality. Different sections in this

report include the description of our general and specific

processes, the instrumentation used, and our entire protocol

for the plant.

.

II. PROCESS DESCRIPTION

A. Flowchart

B. Layout

C. Productive Process

The production process consists of the following steps:

Coconut endosperm (pulp) reaches the plant in bags. Using

a forklift, they get off the truck and are placed in a hopper,

which unloads the raw material into a band that leads to a

refrigerator. Thisis meantto keep the pulp refrigerated while

production is notoperating. Once they leave the refrigerator,

an operator is responsible for unpacking the pieces of pulp

from the bags and releasing them on a conveyor belt.

The pulp is washed withperaceticacid and also in a steam

cleaning machine. Once cleaned and disinfected, it enters a

crushing machine and then a grinder. Consequently, it enters

a compression extractor of the grindedpulp, with coconut

milk and bagasse being separated. Then they enter a tank

where mineral water, sugar and preservatives are added. The

milk goes through a filtering process, in which the bagasse

and milk are separated again with their ingredients, the

bagasse is stored and the milk enters a tank with a specific

amount of bagasse. The remaining bagasse after filtering is

stored in a container and then sold as raw material for other

food products. Thenthe milkenters the last filtering process,

in which we finish with the coconut milk as such, which

enters the pasteurization process to eliminate the pollutants

and continues towards a storage tank at8 degrees Celsius.

Finally, the product enters the bottling and labeling process.

After this, the product ispacked and ready for distribution

and consumption.

D. Subprocesses

1. Fridge: Pulp bags are stored here.

2. Automatic washing with peracetic acid: Bath in per-

acetic acid to eliminate bacteria.

3. Steam cleaning machine: Inlays dirt present in the pulp.

4. Coconut crushing machine: Splits the pulp into small

pieces.

5. Grinding machine: Turns the pulp pieces into shred.

6. Compression extracting machine: Presses the pulp

shred, turning it into bagasse and coconut milk.

7. Bagasse storage: After the compression extracting ma-

chine, the bagasse and the milk are separated and the bagasse

goes to a storage tank.

8. Mixing tank: Exact cuantity of Bagasse, coconut milk,

mineral water, sweetener and preservatives, begin a homog-

enization process.

9. Filtering: Separate milk from bagasse.

10. Used bagasse storage: After filtering, the used bagasse

goes to a tank that store it for another use.

11. Pasteurization: The milk is heated to 80 degrees celsius

and rapidly cooled to eliminate microorganisms present.

12. Chiller tanks: milk is stored at 8 degrees celsius.

13. Bottling: Finished milk is bottled.

14. Labeling: Bottles filled with coconut milk are labeled

and ready.

15. Stacking: bottles are piled up in specific quantities.

16. Packing: the bottles after being piled up are packaged.

17. Final storage: the bottles are ready to go.

E. Location argument

The way the plant is arranged was designed in order

to fulfill requirements such as saving space, follow the

specific order to the production of the coconut milk, and

allow controlling operators to access machines in case of an

eventuality. If we take a look at the plant layout above, it is

clear that all the machines are confined in a not so massive

space, which means the costs of construction for the building

will be lowered and the monitoring times will be reduced.

Below, we can see a 3D reference image of the entire plant.

F. Processes and Subprocesses Illustration

III. INSTRUMENTATION

A. SCADA Diagram

B. Actuators and Sensors Flowchart

C. PLCs

The number of PLC selected for the entirety of the

production line, is four. Reason being, the selected type of

PLC (FX3GE – 40 MR/ES) has a vast amount of digital

inputs and outputs. Each of the PLC’s used, can have up to

24 digital inputs and 16 digital outputs. This benefits us in

the sense that once combined, we dispose of 96 inputs and

64 outputs. We are able to control quite a good amount of

our process through each of these 4 PLC’s, making it pretty

segmented for us.

D. Actuators and Sensors Chart

E. DAC and ADC Converters

The 4 PLCs are specified with their intended use and

its digital input variables, the ADC systems are used to

convert the analog signals into digital, what subprocesses

are programmed in which PLC and what are the outputs.

F. Graphics

IV. PROTOCOL

A. Protocol Description and Steps

1. Hopper – Fridge: It is a fridge with a pulp reception

hopper on top. This unit has 4 actuators: A hatch for the

entry of coconuts into the refrigerator, another hatch for the

exit of coconuts to the conveyor belt, a light that indicates

when the refrigerator is full and a motor that turns on the

cooling system. For the input signals there are 6 sensors:

The presence sensor in the hopper that indicates when there

are coconuts in it to open the refrigerator’s inlet gate, the

maximum level sensor that turns on the light that tells the

operator that the refrigerator is full and that it should not

empty more coconuts, the maximum cooling temperature

sensor that tells the engine to start so that it reaches the ideal

temperature which is indicated by the minimum temperature

sensor, the start signal that tells the output gate to open so

that coconuts enter the conveyor belt 1 to start the process

and the stop signal that tells the exit gate to close.

2. Conveyor Belt 1: There is a presence sensor which tells

the engine to start.

3. Peracetic Acid Bath: It is a peracetic acid irrigation

system that has 3 actuators: An acid spraying solenoid valve,

a motor that moves the pump to increase the acid pressure

in the system fed from a tank and a tank level warning light.

This is a circulatory system. It has 5 sensors which are:

Presence to indicate to the solenoid valve to open to wash

the coconuts, some maximum and minimum pressure sensors

that tell the engine to maintain a certain flow of acid in the

pipe and some sensors of minimum level and maximum level

of acid in the reserve tank that indicate activates a warning

light if it is necessary to fill the reserve tank.



5. Steam Cleaning: In the steam washing system there

are 3 actuators: An electric heater to heat the water and

transform it into steam, a water filling valve and a steam

outlet valve. For the input of information there are 6 sensors:

The presence that indicates when the coconuts enter the

chamber to open the steam solenoid valve, the maximum and

minimum pressure sensors indicate the resistance whether it

has to turn on to generate steam, the minimum temperature

sensor indicates the resistance the minimum temperature it

must maintain in order to turn the water into steam, and the

sensors of maximum level and minimum level of water tell

the filling valve to open or close.



7. Crusher: There is a presence sensor which tells the

engine to start.

8. Grinder: There is a presence sensor which tells the

engine to start.



10. Compression Extractor: There is a presence sensor

which tells the engine to start.

11. Pipeline 1: The milk is transported through a pipe that

is driven by a motor pump, it turns on when the presence

sensor indicates it and turns off when the maximum pressure

sensor activates.

12. Conveyor Belt 5: There is a presence sensor which

tells the engine to start.

13. Bagasse Storage 1: It has a maximum level sensor that

turns on a light informing that it is filled.




sensor activates

15. Mixing tank: In the milk mixing system there are 7

actuators that are: The motor, the ingredients input solenoid

valves, and the mixture outlet solenoid valve. For this unit

there are 2 sensors that are: Minimum level that indicate

that they can open the ingredients input solenoid valves,

the maximum level sensor that indicates that these solenoid

valves are closed and that the engine is turned on, and it

receives a signal from a timer so that it turns off after a

certain time and the mixing outlet solenoid valve is opened.




sensor activates.

17. Filtering: The mixture falls into a strainer which has

a maximum bagasse weight sensor that tells the engine to

move the mechanism to empty it in bagasse storage 2.



19.Bagasse Storage 2: The bagasse arrives through con-

veyor belt 8, a presence sensor informs the pneumatic

solenoid valve 1 to activate the passage of compressed air

to the hydraulic piston of gate 1 to enable the entry of the

bagasse for storage.




sensor activates.

21. Pasteurization: It has 3 actuators: a filling valve, an

output valve and an electric resistance. These are operated

under the information of 5 signals that are: minimum level

that indicates that the tank is filled, a maximum level

that indicates that the filling is stopped, one of minimum

temperature that indicates that the resistance should turn on

and one of maximum temperature that indicates that the

resistance should turn off, and a timer that indicates that

the outlet solenoid valve is opened.




sensor activates.

23. Chiller Tank: There are 3 actuators: A filling valve,

and exit valve, and an engine of a cooling system, which is

operated under the information of 5 signals that are: mini-

mum level that indicates that the tank is filled, a maximum

level that indicates to stop filling the tank, one of minimum

temperature that indicates that the engine is turned off and

one of maximum temperature that indicates that the cooling

engine is turned on and a timer that indicates that the outlet

solenoid valve is opened.




sensor activates.

25. Bottling Process: There is a pipe that maintains a

maximum pressure, when the pressure sensor detects a bottle,

it tells the filling solenoid valve to open, therefore the

pressure decreases when the minimum pressure is activated,

the motor pump starts and turns off when it arrives at

maximum pressure.



27. Labeling Process: There is a presence sensor which

tells the engine to move a mechanism that prints the label

on the package.



29. Pile Up: There is a mechanism that is moved by a

motor that is activated with a presence sensor.



31. Packing: There is a mechanism that is mobilized by

an engine which is activated with the presence sensor.



33. Final Storage – Fridge: It is a fridge. In this unit there

are 3 actuators: A gate to enter the refrigerator, a light that

indicates when the refrigerator is full and an engine that

turns on the cooling system. For the input signals there are

3 sensors: The maximum level sensor that turns on the light

that indicates that it is already at its maximum capacity, the

maximum cooling temperature sensor that tells the engine

to turn on so that it reaches the ideal temperature which is

indicated by the minimum temperature sensor.

B. Function Blocks

C. MEFs

D. Undefined Variables

E. Notation

The ¡ symbol is used to indicate that the variable is to

be negated. The + and * signs indicate disjunction and

copulative conjunctions.

V. IMPLEMENTATION

A. MEFs Implementation in the PLCs

B. PLC Folder Guide

In the Coconut Milk MEFs folder, you will find the

different programs for the operation of each machine in its

respective PLC. When you enter the GX-WORKS Software,

the project button is selected and you go directly to the

Global where all the general variables that enter and leave the

Function Blocks are written, similar to a black box. Inside

the POU folder, there is an option called “program”, in which

the created function blocks are added. Each Function Block

has its inputs and outputs.

If you want to see what makes up the programming of

each Function Block, go to the User Library module, where

the PLC’s are distributed, in which each Function Block will

be located, that is, each machine it represents. When PLC1 is

selected, the “Program” part and Local Labels are displayed.

The Program section describes the internal programming of

each function block and each machine. In the “Local Label”

part, the input and output variables, and the states that make

up each function block and each variable that is described

in the program were entered.

C. Screenshots

Conveyot Belt

Pipieline

Steam Cleaning

Crusher

Grinder

Compression Extractor

Bagasse Storage

Chiller Tank

Pile Up

D. IHM

VI. CONCLUSIONS

After completing this progress report, one realizes the

great magnitude of research that had to be performed in

order to have a clear image of the entirety of the general

process and each subprocess. Each unit may differ from one

another and having a precise idea of how each one works,

may allow the programmers and controlling personnel to

identify problems (if any) in an effective manner.

Furthermore, after analyzing our production line proposal,

it can be inferred the idea has great potential for becoming

a real business. The area covered by the entire line is not

too big, the employees required are few, our product is in-

line with today’s tendencies, and the raw material needed is

achievable. This means costs will not be too high.

Finally, it is certain there is room for improvement along

the production line proposal. But then again, we are under-

going a learning process which will help us figure this out.

REFERENCES

[1] Production process video:https://www.youtube.com/watch?v=W8YqTMmFUc

[2] Lewin, Jo. “¿Cuáles Son Las Bondades De La Leche De Coco?” BBC NewsMundo, BBC, 7 Dec. 2014,

www.bbc.com/mundo/noticias/2014/12/141202bondadeslechecocof indedv[3] “Datos Técnicos .” Datos Técnicos - Mitsubishi Electric Factory Automation

- Spain,es3a.mitsubishielectric.com/fa/es/shared/img/producttables/2PLCmainunit

FX3GFX3GEFX3GC.

[4] Sensores Fotoeléctricos. www.fegaut.com/es/productos/sensores-de-presencia-sensores-fotoelectricos/2-9/.

[5] Electrovalvulas. ph.parker.com/co/es/solenoid-valves.[6] Pressure Transmitters. www.te.com/usa-en/products/sensors/pressure-

sensors/pressure-transducers.html?tab=pgp-story.[7] Temperature Sensors. www.smith-systems-inc.com/products/temperature-

sensors/.[8] Indicator Lights. www.xindali.com/a/il/.[9] “Motores Eléctricos De Corriente Alterna AC.” Motores Electricos y Mo-

torreductores Moverica, www.moverica.com/motores-electricos/corriente-alterna.

[10] “Exportando Un Gráfico o Tabla De LabVIEW a UnArchivo De Imagen.” Exportando Un Gráfico o Tabla DeLabVIEW a Un Archivo De Imagen - National Instruments,knowledge.ni.com/KnowledgeArticleDetails?id=kA00Z0000019SPLSA2l=es-CO.

VII. ANNEXES

In the leche-coco folder there is a file called A.1, which

contains all the attachments for the realization of this report.

automatic control of coconut milk production

Documents