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Sugar Starch & Yeast
Perspectives in Liquid Process Analytics
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News INGOLD Leading Process Analytics
Automated pH Measurement System Lowers Maintenance and Increases Accuracy The batch manufacturing of industrial and food grade starches can be a chemically aggressive and difficult environment for measuring pH. A METTLER TOLEDO solution lead to significantly lower maintenance costs with an ROI of less than 90 days.
World-leading manufacturer Our customer is one of the world’s leading manufacturers of agriculturally derived products; including HFCS, ethanol, and industrial and food grade starches. Starches, such as corn starch, can be modified into a variety of useful materials ranging from starches for food ingredients and animal nutrition, to bio-based plastics and biofuels. Traditional technology Batch chemical modification of starches occurs through the adjustment of pH using strong acids and bases, as well as the addition of powerful oxidizers such as ethylene and propylene oxide. Maintaining the correct pH is critical to the yield of the reaction and for ensuring the functional characteristics of the final product.
For pH measurement our customer had been using a stationary electrode screwed into a port in the side of the process vessel, which would remain in place throughout the cycle. At the end of the batch an operator would have to pull the electrode, wash it and leave it stored wet until the next batch. When the next batch was ready the operator would re-calibrate the electrode and re-insert it into the process. This traditional technology worked well as long as the electrode was maintained between batches. Without maintenance, however, the electrode would usually not respond properly during the cycle. In the food grade process a hygienic housing was a requirement, and the use of
glass electrodes was an obvious concern; however our customer had tried non-glass ISFET technology from a number of different manufacturers and was unable to get consistent results.
METTLER TOLEDO’s solution After carefully examining the process, we recommended the following system which would meet all our customer’s requirements:
Customer’s expectations Our customer was looking for a pH system with the ability to monitor glass impedance and to alert the operator in the event of a problem. Further, they required an electrode that, if cared for properly, would eliminate any in-process drift and provide accurate reliable results.
■ InPro 3250 SG pH electrode: Offers
Another major requirement was for reduced maintenance. The customer estimated that pulling the electrode, cleaning it and then re-calibrating it prior to batch startup was taking approximately 40 minutes per batch, and three to four batches were being run each day across six vessels.
pH electrode InPro 3250 SG
exceptionally high performance and accuracy. Extremely resistant to harsh chemical environments ■ InTrac 798 e retractable housing: Can extract, water flush and lay up wet. Very safe operation due to absence of external moving parts. EHEDG compliant ■ EasyClean 150 automated rinsing unit: Provides completely automatic electrode rinsing ■ Transmitter M400: Designed for continuous, accurate, reliable measurement of demanding process applications. Systems were installed into each of the six vessels.
Automatic cleaning system EasyClean 150
Publisher / Production Mettler-Toledo AG Process Analytics Im Hackacker 15 CH-8902 Urdorf Switzerland Illustrations Mettler-Toledo AG
Subject to technical changes. © Mettler-Toledo AG 12/08 Printed in Switzerland.
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Transmitter M400
Improved yield and quick payback The improved accuracy and resilience of the METTLER TOLEDO system has allowed our customer to increase the yield from the batch process. Further, the automated system eliminates the need to manually handle electrodes. The time saved on maintenance is on the order of 40 minutes 3 3 batches / day (minimum) 3 6 vessels, totaling a labor saving of 12 hours / day. The entire installation, integration and equipment purchase had a payback of less than 90 days based on maintenance savings alone, with improved product quality being an additional bonus. To discover the right solution for you, go to: www.mt.com/PRO-pH
Retractable housing InTrac 798 e
M400 Transmitter Series – for Digital or Analog Sensors
Switching to Digital Technology Made Easy With M400 Transmitters METTLER TOLEDO has introduced digital sensors with Intelligent Sensor Management (ISM) functionality for the measurement of pH, redox potential and dissolved oxygen. The new M400 transmitter series offers the ideal solution for analog and digital sensors.
Maximum flexibility The new M400 series of multi-parameter transmitters were designed with ISM in mind. The series supports full ISM functionality, including advanced diagnostics and our “Plug and Measure” feature. All M400 transmitters provide “mixed mode” connections for measurement of both conventional analog and modern digital sensors. This means that users who have already integrated digital measurement technology into their processes also have the opportunity to connect an analog sensor to an M400 transmitter, if required. Digital sensors are recognized by the transmitter, and the “Plug and Measure” functionality enables immediate system readiness. The M400 series feature an integrated universal power supply that can be operated with voltages of 100 to 240 V AC at 50 or 60 Hz, and 20 to 30 V DC, so complexity is minimized for warehousing and logistics. The M400 series covers all relevant measurement values such as pH, redox, conductivity, and amperometric and optical dissolved oxygen. In addition, it also offers an auxiliary temperature value from pH electrodes and DO sensors. Unique diagnostics One of our customers’ frequently asked questions in regard to pH measurement is, “What is the life span of an electrode?” Our standard answer has been, “It depends
on electrode type, process conditions and maintenance regime.” The M400 series together with the ISM sensors provide a different answer. Intelligent sensor diagnostics measure the current process conditions (parameters such as pH, temperature, glass and reference electrode impedance) and calculates, together with statistical data (calibration history, zero point, slope, response time, CIP / SIP / autoclave counter) the remaining life span of the electrode. The diagnosed results are displayed via the following features: ■ DLI – Dynamic Lifetime Indicator: Constant, dynamic prognosis of the sensor life span based on the current process conditions ■ TTM – Time to Maintenance indicator: Constant, dynamic calculation of the maintenance intervals based on the DLI information ■ ACT – Adaptive Calibration Timer: Constant, dynamic calculation of the calibration intervals based on the DLI information Output adaptability Processing of the measurement signals can be done over four analog 0 / 4 ... 20 mA connections. The information from the DLI, TTM and ACT can be used to set relay contacts which indicate when a sensor should be exchanged, maintained or calibrated.
A complete system M400 measurement systems are complemented by the iSense Asset Suite for maintenance management and calibration of ISM sensors. For further details, go to: www.mt.com/M400
Transmitter M400, compatible with analog and digital sensors
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ISM and iSense – a Unique Concept
Intelligent Sensor Management Intelligence Starts in the Head You want to optimize your processes, reduce maintenance and suffer less downtimes. METTLER TOLEDO’s Intelligent Sensor Management (ISM) for pH and DO can do it all – and more!
Why do I need ISM? Intelligent Sensor Management reduces the installation, maintenance, and calibration effort for METTLER TOLEDO’s new digital sensors to a minimum. This considerably improves your process reliability, productivity and system availability. ISM for advanced process analytics A sensor with ISM technology is equipped with an integrated chip in the sensor head that stores all relevant parameters, and algorithms that provide enhanced sensor diagnostics. Now you know more than precise process measurements; you also know when a sensor needs calibrated, cleaned or replaced. So now you can conduct maintenance only when it is required!
Quick sensor replacement with “Plug and Measure” Calibration values and calibration history are stored in the microprocessor in the sensor head. This allows sensors to be pre-calibrated in the controlled environment of a maintenance shop or laboratory, then stored ready for use. Replacing a failing sensor with a pre-calibrated one is quick and simple. Complete sensor asset management Using a standard PC and METTLER TOLEDO’s proprietary iSense software, true asset management is at hand. With iSense you can store the complete sensor calibration history in a database. Thanks to iSense, the fast and easy exhange of pre-calibrated sensors saves you time and improves process control.
When is a sensor about to fail? As well as recording the process measurement precisely, the ISM sensor continually monitors itself, therefore it can estimate its own lifetime! The Dynamic Lifetime Indicator makes sensor maintenance more efficient and more dependable. Process reliability is greatly improved as process downtime and loss of product quality due to sensor failure are minimized. Further features ■ All transmitters from METTLER TOLEDO can be used with ISM sensors. ■ Connection of ISM sensors requires only two cables instead of up to eight with analog sensors ■ Digital signal transmission is extremely stable, even under very harsh conditions. METTLER TOLEDO – intelligent solutions Our wide product range covers all high demanding applications in the Food industry. Discover more at: www.mt.com/ISM
iSense Asset Suite
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Latest Developments in Analytical Sensors
Chemical Sensors Forum 2008 Where Science and Industry Meet In September, around 50 experts from 6 countries met in Zurich, Switzerland to exchange ideas and opinions on analytical sensors in different application segments. METTLER TOLEDO contributed with a presentation on latest trends in more user-friendly in-line measurement systems.
Great location Zurich is always worth a visit! The attendees of the Chemical Sensors Forum held their congress on Zurich’s famous mountain – the Üetliberg. Perfect meeting conditions provided the framework for fruitful presentations and valuable exchange of know-how.
METTLER TOLEDO anticipates trends In 14 presentations, experts from the Pharmaceutical and Food & Beverage industries, as well as industrial and academic researchers, presented their latest instrument designs and measurement results.
Forum topics The two-day forum was organized by the Zurich University of Applied Sciences as an interdisciplinary event for experts on chemical sensors from academia and industry. The sessions and panel discussions addressed the following topics: ■ Trends in industrial sensor research & development ■ Visions and trends in academic sensor research ■ User’s needs: Does research in industry and universities fulfill user requirements?
A common trend throughout all application segments was clearly identified: the latest developments in the field of sensor technology lead to a more frequent use of sensors in all segments – in process analytics as well as in clinical and research laboratories. Another overall trend also became apparent: users of analytical equipment would prefer measurement systems with better usability and a lower maintenance requirement. METTLER TOLEDO’s solutions are already meeting the above stipulations.
METTLER TOLEDO’s contribution METTLER TOLEDO gave two examples of how to accomplish greater userfriendlness for in-line analytical equipment. Firstly, a significant development in the measurement principle, e.g. from amperometric to optical dissolved oxygen, can lead to improved reliability and easier sensor handling. Secondly, a powerful tool for optimizing maintenance intervals and avoiding unscheduled process downtime is METTLER TOLEDO’s Intelligent Sensor Management (ISM) concept. This technology is available for process pH, conductivity and dissolved oxygen measurement systems. The ISM offering is completed by the iSense software package for maintenance and pre-calibration of field sensors in a safe and clean environment, e.g. a laboratory or workshop. Acknowledgement We would like to thank the Zurich University of Applied Sciences for the invitation to this congress and look forward to the next Chemical Sensors Forum. For more information on addressing these challenges, go to: www.mt.com/ISM www.mt.com/PRO-pH
pH electrode InPro 3250 i
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Transmitter M420
Process Analytics Product Catalog New Edition 08 / 09 Available Get an overview of the latest INGOLD and THORNTON products available for your process application with the new product catalog 08 / 09.
The catalog offers comprehensive overviews on product features and specifications, benefits and recommended application areas, order details and much more for process analytics measurement solutions. The product catalog covers complete measuring solutions for these parameters: ■ pH ■ Dissolved oxygen and O2 in gases ■ Ozone ■ Dissolved CO2 ■ Conductivity ■ Turbidity ■ TOC ■ Flow The featured product range includes: ■ Electrodes / sensors ■ Housings ■ Process connections ■ Transmitters / analyzers ■ Cleaning and Calibration systems ■ Cables ■ Accessories Order your copy of this useful desk tool today! Mettler-Toledo Ltd 64 Boston Road Beaumont Leys Leicester LE4 1AW Tel: (0)116 235 7070 Fax: (0)116 236 5500 Email:
[email protected] Mettler-Toledo AG Process Analytics Im Hackacker 15 CH-8902 Urdorf Switzerland
www.mt.com/pro Visit for more information
