digitalization in chemical operation an enabler for ...€¦ · manufacturing sites or working on...

News

According to a recent PWC study, adopt-

ing digitalization is expected to improve

profit margins by 5-9 percent. But how

is digitalization helping to put these im-

provements into practice?

Predictive maintenanceMaintenance of production devices in-

cluding production downtime and un-

planned stoppages for quick fixes is one

large cost block. Predictive maintenance

that is directly built into devices simplifies

maintenance activities and saves costs.

Data analytics With heightened customer expectations,

tight control of your processes and im-

proving response time makes the differ-

ence. The ability to gather, analyze and

access data is key – but doing this effi-

ciently still remains a challenge.

Modular production Modular production allows for the cre-

ation of standardized production units

giving flexibility to adjust capacity to

changes in market demands. A reliable

automation process and standardized

interfaces along with plug-and-play

principles help realize this concept.

Read on to see how your next invest-

ment in measurement technology can

help you to prepare for the future.

Chemical companies are challenged to continuously deliver profitable growth. Adopting

digitalization is one of the key levers to improve capacity utilization and reduce operating

costs. The right investments in sensor technology, interfaces and software pave the way

for new concepts in chemical operation.

Digitalization in Chemical OperationAn Enabler for Profitable Growth

9Industrial Weighing & Product Inspection

Chemicals

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Three Investments that Pave the Way for Digitalization

Within the chemical industry there is a lot of discussion about how to apply digital

concepts to daily operations. When it comes to measurement technology, some

basic principles are here to stay. This means that when you are upgrading existing

manufacturing sites or working on Greenfield projects, investing in the right

sensors, interfaces and process technologies will help you fully leverage the

potential of digitalization.

Investment #1: Digital sensors Sensors are the foundation of a digital world. To play this critical role, they must provide more than simple analog signals. Signal conversion built into sensors improves signal quality signifi-cantly, while monitoring environmental parameters such as temperature or sensor condition are the basis for predictive maintenance. Stored calibration data speeds up sensor installation and replacement.

Find more examples on page 4-5

Investment #2: Standardized interfaces With an increasing number of devices and sensors in production plants, data processing and transfer can be a painful process not only in automated systems but also when communicating to ERP systems. Innovative new interfaces hold the promise to make modularization possible and integration faster.

Compare different integration concepts on page 6-7

Investment #3: Smart softwareIncreased data volumes require smarter, faster selection and processing. Lags in making collected data

available can create production bottlenecks. New software can simplify information gathering and impro-

ve data-processing speeds. Data visualization supports process insights, cloud services ensure uptime

and data collection software increases production efficiencies.

Explore our software solutions on page 8-9

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METTLER TOLEDO Chemical News 9

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Reduce data collection

and reporting costs up to 70%

with ProdX and Collect+

Save up to 50% in

maintenance costs with POWERCELL®-based scales

Integrate your PLC up

to 10x faster with the

ACT350 transmitter


Industry 4.0 in chemical manufacturingThis eBook clarifies the basic concepts of Industry

4.0/IoT and provides ideas on how to leverage them

for weighing applications.

www.mt.com/ind-smart-manufacturing

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Next Generation SensorsAccuracy – Stability – Reliability

Sensors play a critical role in digital chemical production, providing more than

simple output signals. Learn how modern sensors are used and how they help

enable exceptional signal quality, predictive maintenance and easier integra-

tion.

5METTLER TOLEDO Chemical News 9

PBK9 and PFK9 high precision scalesWhen high precision and signal speed are critical, such as during

formulation or filling of valuable materials, our new EMFR sensors are up

to the challenge. Their direct and fast PLC connectivity, high update rates,

filtered values, internal calibration and signal conversion, as well as

on-board condition monitoring make them the choice for manual or auto-

mated precision weighing in industrial environments… even in Ex areas.

` www.mt.com/pbk9

Load cells with POWERCELL™ technologyPOWERCELL load cells take reliability to a new level through predictive

diagnostics that continuously inform you about your scale’s perfor-

mance. The load cell’s on-board microprocessor also provides the most

accurate weight possible by continually adapting to common factors

such as temperature, nonlinearity, hysteresis, voltage variation and

sensor creep. Look for POWERCELL® in our truck, tank and floor scales.

` www.mt.com/powercell

InPro 4800 family – pH sensor managementSensor management is under control with ISM sensor technology. ISM

provides real-time information on sensor conditions, helps to run pro-

duction at peak efficiency, reduces sensor lifecycle costs and simplifies

and improves the operation of process analytical systems. This helps to

improve sensor use from installation through ongoing maintenance, to

help you increase productivity and profitability.

` www.mt.com/InPro4800i

V2413 for high-performance vision inspectionAdvanced high-resolution camera technology combined with sophistica-

ted lighting arrays are at the core of V2413 Mosaic XL vision inspection

systems. Utilizing six cameras, sensors allow the V2413 to capture label

features from multiple angles for increased label inspection accuracy.

Systems can inspect round, un-oriented products, including those with

full wraparound labels.

` www.mt.com/vi-v2413

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Historically, equipment in production has been integrated into the plant IT infrastructure following the

automation pyramid (ISA95). In most cases, sensors provided only simple data. Today sensors can

provide more robust data, such as status monitoring, predictive diagnostics and calibration alerts. In-

tegration choices are driven by the kind of data required, the existing infrastructure and the type of data

network available. Sensor data is complemented by prioritized information such as alarms and condi-

tion data.

Moving toward Industrial Ethernet

Industrial Ethernet (IE) is the use of Ethernet (IEEE 802) in an industrial environment with protocols that

provide determinism and real-time control. Examples such as PROFINET, EtherNET/IP, EthernetTSN are

replacing classic fieldbuses and serial communication when connecting with automation systems be-

cause they provide more flexibility and are easier to install, troubleshoot and replace.

OPC-UA brings another level of standardization

OPC Unified Architecture (OPC UA) is a machine-to-machine communication protocol for industrial

automation developed by the OPC Foundation. It focuses on communicating with industrial equipment

and systems for data collection and control, is freely available without restrictions or fees, is not tied to

one operating system or programming language and is one of the leading standards for cloud connec-

tivity inside and outside the facility. Combined with IE, it becomes the basis for future industrial devices.

Learn how to reduce installation effort when connecting to PLC:

www.mt.com/ind-video-PLC-integration

Future Gateways to the Digital World Standardizing Industrial Connectivity

While an increasing number of devices and sensors are being used in production

plants, data processing and transfer in automated systems that must communicate

with ERP and MES systems can still be painful. Modern interfaces and open data stan-

dards hold the promise to make interoperability possible by extending the amount and

type of valuable data available.


Data protocol Industrial EthernetPROFINET, EtherNet/IP, EthernetTSN

OPC UA Server or Gateway OPC UA

Classical Data IntegrationRS232 (for PC systems)4-20mA (DCS, PLC)

Advantage Standardized robust network Standard for data transfer Installed base

Disadvantage Relative newness Requires a server Limited data availability

Control strategy Centralized/decentralized Centralized/decentralized Centralized

Layout Network Network Point-to-point

Transfer rate 1ms NA 100ms

Bandwidth High High Low

Determinism High High Low

Installation effort Medium Low Medium-high

Use in industry Growing Growing Stable

Component cost Low-to-medium Low Low

Use in hazardous areas

Through fiber optic or increased

protection

NA Use of 20ma, 4-20ma and

Profibus PA

Typical use Tank-weighing system; filling

machine integrated into plant

automation system

Scales connected to cloud system

for documentation and tracking pur-

poses, process inspection solutions

Traditional integration either to au-

tomation systems or data-collec-

tion systems

Example Transmitters with IE, ACT350 ` www.mt.com/ACT35

Gateway with OPC UA ` www.mt.com/pi-omac

Classic terminals ` www.mt.com/terminals

OPC UA RS232Industrial Ethernet

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e Smart Software SolutionsFaster Access to Process Data

Data visualization for process insights

Collect+ is a PC software designed to collect data from your production devices in a

central repository. You can view graphical representations of your data using an

integrated, web-based dashboard tool. Benefits include:

• Production data in one place

• Integrated dashboard visualizations

• Ability to view data anytime, anywhere

` www.mt.com/collectplus


Demands to optimize chemical manufacturing processes to further increase

uptime and efficiency will continue. Integrated analysis and use of data are key

capabilities for leveraging the full potential of digitalized production processes.

Smart algorithms analyze large amounts of data and create the visibility to

generate new insights, support decision making and react quickly.


Increasing product inspection efficiencyProdX data management software provides seamless integration of product

inspection devices to give you complete control of your entire product

inspection management process. Benefits of using ProdX software include:

• Live collection of product inspection data

• Remote transfer of settings for rapid equipment setup

• Regulation compliance and due diligence reporting

` www.mt.com/prodx

Ensure uptime with remote service

InTouch monitoring is a service that constantly evaluates the condition of connected

devices, allowing personnel to be immediately notified of critical equipment issues.

It provides:

• Real-time awareness of equipment health

• Planned service interventions

• Increased productivity

` www.mt.com/ind-intouch


Pharma Workflow

Improve Productivity and SafetyInnovative Weighing Solutions Across Your Processes

PowerDeck™ Floor ScalesPowerDeck™ digital floor scales offer many benefits, including real-time operator guid-ance, reduced maintenance cost – and more!

` www.mt.com/powerdeck

1 2Bench ScalesOur high precision compact scales with global Ex approvals provide safety and performance – where it matters most.

` www.mt.com/ICS466x


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Pharma Workflow

Improve Productivity and SafetyInnovative Weighing Solutions Across Your Processes

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Weigh ModulesPrevent costly bad batches and rework by monitoring the performance of your tank-weighing systems in real-time.

` www.mt.com/ind-powermount

Formulation SoftwareAutomating your process with formulation soft-ware eliminates the number one cause of quality issues – human error in manual work flows.

` www.mt.com/rms

5Weighing TerminalsOur user-friendly terminals help to reduce the overfilling of drums by up to 40% – and higher speeds increase efficiency.

` www.mt.com/IND570

POWERCELL® PDX® Load CellsReduce maintenance costs by up to 30% and avoid costly downtime with our POWERCELL® PDX® truck scales.

` www.mt.com/powercell


For more information

METTLER TOLEDO GroupIndustrial DivisionLocal contact: www.mt.com/contacts

Subject to technical changes©09/2018 METTLER TOLEDO. All rights reservedDocument No. 30403376MarCom Industrial

www.mt.com/chemical

`www.mt.com/hazardous-area

Check out the hazardous page

Weighing equipment in explosive areas must fulfill stringent regulatory requirements to ensure process safety – however, keeping up-to-date with regulatory requirements is a challenge.

Ex equipment catalogHelps select the right equipment and stay compliant `www.mt.com/ind-hazcat

Equipment marking poster Quick-and-easy identification of markings and protection methods `www.mt.com/ind-haz-poster

Competence guide Offers necessary know-how to ensure safety in critical areas `www.mt.com/ind-hazguide

Ex lifecycle eBookHelps manage equipment recommendations according to IECEX standards `www.mt.com/ind-ex-lifecycle

Hazardous area white paperHelps avoid explosion risks in dynamic checkweighing `www.mt.com/cw-atex

Upgrade Your Competence LevelWith 5 Key Hazardous Resources

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