Filling sensor reduces waste, allows faster changeovers

The Micro Motion 1500 transmitter from Emerson Process Management automates the filling and dosing process, reducing waste, improving product quality and allowing faster changeovers, the company claims.

The mass flow transmitter provides monitoring of ingredient temperature and density, providing immediate alarms for out-of-specification values, as well as records for later audits.

The transmitter offers precise control of the filling process using sensors and integrates into the machine control system to directly control pumps and valves, Emerson claimed.

"The integrated system simplifies the batch delivery control loop, eliminating the need for separate controllers, resulting in removal of communication time delays, and improved fill accuracy and response time,"​ Emerson stated.

The flowmeters provide direct mass measurement, accurate to better than 0.1 per cent, the company claims. The meters are used in control loops with the Micro Motion system.

The direct, predictive valve control from the transmitter uses measurements of each delivery to optimize the control accuracy for subsequent fills. It improves profitability by reducing product give-away.

The integration of the Micro Motion flowmeter into the valve control system also gives a faster response time by eliminating the normal pulse train linking the flowmeter to the controller.

Efficiency benefits arise from close integration of the Micro Motion Model 1500 within the filling machine, using a software protocol to speed up communications with the control panel software.

The operator has the ability to fill a wide range of container sizes, modify delivery quantities for each ingredient, and instantly select an alternative menu to create different product ranges on a single machine.

Productivity benefits arise from faster product changeover times on the delivery lines, using in-line clean-in-place (CIP) processes. This allows workers to clean the flowmeters on line, without having to dismantle the whole machine.

The "strip-down and clean" cycle previously required with mechanical flowmeter devices to eliminate cross contamination is eliminated. The same sensor, with no programme changes, can handle liquids or pastes and creams with varying viscosity, temperature, entrained air or suspended solids, while measuring mass flow directly.

The small size of the Micro Motion 1500 allows it to be installed in the machine control cabinet. The unit is designed for filling machines using short duration fill cycles, where all operator interface information is provided by the machine control panel, so it has no local display.

The transmitter comes with a built-in safety barrier. The transmitter can supply intrinsically safe power and wiring connections to the flow sensor, enabling safe operation in hazardous areas, and reducing the cost and complexity of filling machine cabling systems, Emerson stated.

The Micro Motion mass flow sensors enable the systems to work with a wide range of liquid feeds, in line sizes down to 0.1", providing performance independent of temperature, viscosity and product changes. The need for any further check-weighing is eliminated.

"This all adds up to increased efficiency and profitability,"​ Emerson stated.

The systems are available with European Hygienic Engineering and Design Group certification for use on sanitary and aseptic processes. The sensors are suitable for CIP and sanitise-in-place (SIP) processes.