Process optimization while cutting down on costs: End-to-end sensor solutions in food and beverage technology

Baumer: The production of mayonnaise and salad dressings confronts metrology with some really demanding challenges. Frequently changing recipes, many ingredients of different textures and specific filling levels bring conventional instruments to their limits. The Baumer sensor solutions with CleverLevel, CombiPress and CombiLyz optimize the production processes at Homann’s to ensure the high quality of their gourmet products.

Since 1978, the Homann location in the German city of Bottrop has been producing premium convenience food. Gourmet salads of the Homann and Nadler brand are popular and well-known far beyond the region.

Both traditional brands belong to the Theo Müller Group. Two years ago, in close collaboration with Baumer they elaborated on new concepts for process optimization in the manufacture of mayonnaise, salad creams and dressings.

Limit level detection in storage, mixing and buffer tanks

Precise and reproducible switching operations are a must, even in apparently simple tasks of limit level detection. In storage tanks, the conventional capacitive level switches, commonly known as „micro wave switches“ provide only limitedly reliable performance. They require medium-specific configuration. Outside the thresholds, the low dielectric constant of some media like edible oil (DK ?r <10) may cause measuring errors if a film of lye has remained on the sensing tip after cleaning. To Homann, this was one criterion to decide for CleverLevel, the configurable universal level controller. Operating on frequency sweep technology, it will reliably detect the filling level of any media (fig.1) as one-sensor solution for both oil and water.

Depending on recipes and dielectric properties of ingredients in mixing tanks, Homan used to deploy product combinations of capacitive limit switches and vibrating forks. According to the media, response times ranged from very slow to highly sensitive which resulted in impaired process efficiency. Homann replaced their conventional solution with CleverLevel which has an extremely fast response time. Baumer helped to find out the optimum configuration which is conveniently changed and visualized via FDT/DTM-based FlexProgram software.

Once the mayonnaise, salad cream or dressing is fully emulsified and dispersed, it is pumped into buffer tanks until being added to the salad in a later production step. Here, medium-specific viscosity and adhesion play an important role (fig.3). Conventional solutions using vibrating forks and capacitive limit switches were prone to measuring errors caused by adhering media. CleverLevel is maintenance-free and not affected by media adhesion. Unpredicted downtime for system ventilation and pump revision now belong to the past.

Frank Piatkowski, responsible application and process engineer at Homann’s: „CleverLevel is the one-sensor solution for different media and applications. Since deploying CleverLevel, we have been experiencing a significant reduction in technical malfunctions“.

Measuring hydrostatic pressure in tanks of vinegar, edible oil and glucose Homann’s Bottrop location has a large outdoor vinegar tank. For consistent level monitoring they were looking for a precise and reliable but yet easy, convenient and outdoor-capable solution. Homann decided for pressure transmitter CombiPress. Thanks to 0.1% (MEW) accuracy and active temperature compensation, it solidly performs in providing unambiguous measured results, independent of media and ambient temperature. Easy configuration via the large touchscreen eliminates the need for an additional operating unit. The robust housing with high IP67 rating reliably endures harsh outdoor conditions and wet areas.

Capable of detecting medium-specific density and filling levels, Homann has CombiPress also installed in glucose containers and horizontal tanks of edible oil. Especially here, CombiPress excels with its integrated linearization function. Baumer also offers the matching adaptors for optimum process connection.

Frank Piatkowski is content: „Whether indoor or outdoor“, he says, „the Baumer sensors contribute towards hassle-free automation and once installed, they are neither “susceptible nor perceptible“.

Conductivity measurement in CIP processes

Every cycle in dressing or mayonnaise production entails CIP cleaning (Cleaning in Place). The reproducible process precisely defines detergent dosing under consideration of pressure and temperature. At the Homann CIP installations in Bottrop, dosing needed to be improved - and new conductivity sensor CombiLyz came into play. Thanks to fast response time it ensures precise measured results at a maximum deviation of < 1%. The measuring connection of the inductive sensing element provides a 6.6 mm wide channel which even will tolerate fabric or solid-containing media. Homann successfully optimized detergent dosing and cut down on raw material costs.

„The innovative Baumer products will again be part of our considerations when investing into new and state-of-the-art CIP installations”, explains Frank Piatkowski. „Baumer tackles our requirements in terms of optimization or specialized products as incentives for new developments and ensures expert implementation.“

At Baumer, hygienic designs and stringent mandatory product certifications are a matter of course. All Baumer process sensors deployed at Homann’s comply with the high EHEDG standards and are certified by the European Hygienic Equipment Design Group. Furthermore, compliance to EN 1935/2004 and EN 10/2011 for food-safe products will reduce the total Hazard Analysis and Critical Control Points (HACCP).

Baumer Group

The Baumer Group is an international leading manufacturer and developer of sensors, encoders, measuring instruments and components for automated image-processing. Baumer combines innovative technology and customer-oriented service into intelligent solutions for factory and process automation and offers a uniquely wide range of related products and technologies. With around 2,300 employees and 37 subsidiaries and in 19 countries, the family-owned company is always close to the customer. Industrial clients in many sectors gain vital advantages and measurable added value from the worldwide consistency of Baumer’s high quality standards and its considerable innovative potential. For further information, visit www.baumer.com on the internet.