CENTUM VP Cuts Clean-in-place (CIP) Time 50% and Improves Productivity

Plant Manufacturing Applications

Industry: Food & Beverage

 

Executive Summary

Each month a major food factory plant produces 700 tons of margarine and 150 tons of shortening from palm oil and other ingredients. This plant manufactures many different products for its customers and has over 150 specifications of production (SOP). The SOP include all detailed specifications and production conditions. Detailed recipes are stored on and downloaded from a production management computer that runs SAP. The new package software running on the CENTUM VP has enabled flexible configuration and data settings for greater productivity.

The Challenges and the Solutions

1. Project execution

Once the CENTUM VP operator selects the correct SOP, detailed SOP settings are automatically performed. Even inexperienced operators can easily recognize and confirm the recipe and the SOP on the display terminal before production starts. As a result, the plant is able to consistently maintain high quality and operate the plant safely, without errors.

In the food industry, clean-in-place (CIP) is a very important method for eliminating contamination. CENTUM VP system enabled the plant to reduce CIP time by 50% and drastically reduced steam consumption while maintaining high plant availability. 

CENTUM VP features a standard long-term trend function that can store a year's worth of data on more than 200 tags that are sampled at 2-minute intervals. This function ensures complete traceability in batch processes. 

Plant engineers and Yokogawa Engineering working on the project team were able to transfer all the complex plant procedures to CENTUM VP within 2 weeks and visualize all procedures during the engineering stage, allowing for short turn around with minimum production loss.

About CIP’s Positive Results

CIP is used in many kinds of operations to maintain sanitary conditions. In acid/base concentration measurement, concentrations and methods for cleaning piping and tanks are all different.

To maintain efficiency, reduce energy consumption, and achieve high productivity, it is important to smoothly manage a complex sequence of functions involving the execution of CIP between batch processes.

About the CENTUM VP Batch Management Package

The CENTUM VP Batch Management Package is compatible with the ISA-88 (IEC 61512) batch control standard and 21 CFR Part 11 regulations. Web-based trend, report, and analysis functions support the analysis of batch process productivity, equipment, and recipes.

System Details

CENTUM VP, CENTUM VP Batch 3000 (Batch Management Package)