PROFIBUS automates the blending of fruit juice

Cargill is an international provider of food, agricultural and risk management products and services with activities in 67 countries with the head office located in Minneapolis, USA. Cargill Flavor Systems offers a range of food ingredients such as flavors, concentrates, blends and compounds. Fruit concentrates are produced in Amsterdam and flavors in Grasse (France) and Manchester. Fruits are pressed and concentrated already in the country of origin. After blending with flavors, stabilizers, sweeteners, vitamins etc. in the cargill plants in Amsterdam and Manchester, this base material is deliverd to the customers along with the formulation for further processing.

Solution: Tank farm automated with PROFIBUS
Regardless of whether an orange juice or apple juice carton is involved, the basis is always a concentrate offruit juices. Cargill Flavor Systems, one of the largest producers of fruit juice concentrate, uses Profibus for the process control of its new Intermediate Tank Farm in Amsterdam. Maintenance manager René Wichard of Cargill Flavor Systems is one of the main actors with regard to the recent automation project. René Wichard: “The process that is
involved is ‘blending’, that is, mixing different fruit juice concentrates according to customer demands. Customers from the beverage industry determine the specifications
for the concentrates that they want after which Cargill produces the required concentrates based on different fruit juice types but also colourings, flavourings and stabilisers.
The concentrates are supplied to Cargill in a frozen or highly cooled state. Next, they are pumped to the new Intermediate Tank Farm. This is the system where everything takes place: a complex of eight large stainless steel 30 cubic metre tanks. The orders are prepared in different batches. After release by the production laboratory, the batches are shipped to the customer in drums or by tanker.”

Benefits and conclusion
Replacing conventional 4-20 mA technology by PROFIBUS has proved to be very advantageous for the process optimization as well as for plant efficiency.
The important facts are:

  • Possibility of preprogramming the instruments
  • Saving many bundles of cables
  • Much more reliable results by weight determination through differental pressure measurement
  • Extensively reduced down-times through fast failure analysis using the diagnosis function of PA field devices
  • Ease of modification and expansion of the plant during a later stage.