FOOD INDUSTRY
Industry focus
Optimised process engineering
INNOVATIVE
State-of-the-art technology to maximise You need fresh ideas to be successful in the food industry. An innovative approach is required not only to meet regulations on hygiene, safety and traceability, but also to face the demands for increasing automation and reducing costs. The solution lies in the fast, smooth introduction of new technologies and the uninterrupted operation of your systems. You can meet the criteria to ensure your company is successful through effective, target-oriented engineering to produce a consistent process chain and
Picture: Ampack Ammann GmbH & Co. KG
seamless documentation for the entire system.
profits in the food and beverage industry New requirements for foods and beverages The demand for processed foods is constantly rising and consumers are showing increased interest in health-conscious food and first-class, fresh processing of ingredients. The legislator has tightened regulations on hygiene, labelling, waste disposal and emissions to prevent production being detrimental to either health or the environment. The strong competition and the power of distribution add up to produce enormous pressure on costs and a need to increase productivity.
Shoulder to shoulder: producer and supplier The manufacturing and production processes in the food and beverage industry are varied and complex. Every plant consists of a range of systems and components which need to work smoothly together to provide problem-free production. Food producers and suppliers of, for example, process engineering, conveying and packaging machinery solutions, are faced with the joint challenge of countering the demands of the market with new solutions: High-performance, automated plants and the use of robots reduce production and personnel costs and increase production speeds, while the modernisation and upgrading of existing plants increase system efficiency and flexibility Use of more effective sterilisation and cleaning equipment and clean room solutions to prevent food contamination Improved quality thanks to the increased use of sensors to control the product mixture and monitor production Improved quality control thanks to new methods of foreign-body detection, e.g. microwave thermography, ultrasound and core resonance spectroscopy Introduction of new technologies to aid traceability (RFID, barcodes, intelligent labels) Optimisation of all systems and components to ensure consistent workflow During the planning and operation of a new or improved plant, you – as the manufacturer or supplier – are faced with the challenge of cutting your costs and reducing your time to market. The answer lies in consistent plant planning, high levels of standardisation in engineering and complete, stringent documentation of the entire plant.
The right partner: EPLAN Software & Service Based on the motto of 'efficient engineering', EPLAN Software & Service offers you innovative, practical solutions for the food and beverage industry. The EPLAN system provides a consistent basis for all information and allows effective, cross-disciplinary, parallel work. Standardisation guidelines lead to smooth interaction between all machines and systems and minimise coordination time and costs. Interfaces connect engineering to product data management (PDM) and commercial systems and ensure data consistency throughout the company. The integration of all those involved ensures process consistency across the entire value creation chain.
There is a name for engineering expertise in the food and beverage industry: EPLAN Software & Service
WIDE RANGE OF FUNCTIONS
A wide range of process stages in food The production of food and beverages consists of a range of individual processing stages. Process engineering describes how raw materials are processed into finished products. The necessary production and packaging lines are developed on this basis. EPLAN solutions provide tailored support in this area: You can benefit from a consistent workflow – from production of the flowchart through implementation planning to complete, intelligent documentation for plant servicing.
Cooling
Washing
Baking
and beverage production
Portioning
Sorting
Packing
Individual process stages Mixing Crushing Separating Heating Cooling Drying Filling
Portioning Filling Packing and many more
Optimise your value chain, benefit from consistent engineering and maximise your company profits. Keep your focus on process engineering and opt for a strict solution with clear time and cost benefits. Utilise the
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For your benefit We at EPLAN Software & Service can support you along the way to the consistent development of your food or beverage plant with our innovative, practical solutions and expert consultancy services.
FLEXIBLE
Consistent, standardised plant planning The effective, legally-compliant manufacture of food demands highperformance systems. This requires optimum interaction between all the disciplines involved in the engineering of the whole plant. The EPLAN Platform therefore provides consistent core data and perfect links between the individual expert systems involved in the process engineering, fluid and electronic configuration and measurement and control engineering. Consistent data, standardisation guidelines and complete documentation across the entire life-cycle ensure a consistent process chain within your PLM strategy – which saves time and costs. Mechatronic components
Fluid engineering
3D construction
Sorting of goods (sorting good/bad items)
Sheet metal construction
Handling of goods (vacuum)
Welded components
Packing of goods
Conveyor belt/roller variant construction
Transport of packaging
Housing
Mechanical
– from the flowchart to the final documentation
Electrical engineering
Control cabinet construction
Performance drives
Control engineering
Electrical controller
3D assembly construction
Safety engineering
Control panel layout in 3D
Machine monitoring
Control cabinet cooling, air-conditioning
Machine cabling
Virtual control cabinet and control panel wiring
PLC control (digital/analogue)
NC production integration
Picture: MIWE Michael Wenz GmbH
Measurement and control engineering Measurement systems and sensors for monitoring process parameters
PROCESS-RELATED
High-performance systems need cons P&ID describe processes
Workflow describe
Fluid construct pneumatics
PLT structure
Specification
Electro-technology wire signals
Process technology
Engineering
The profitability of a food plant is largely dependent on the technical and economic design. This means that careful planning of the process engineering is of major importance to the economic viability of the plant and therefore the company as a whole. Use a tried and tested, practical solution in process technology to optimise your workflow – from the flowchart through implementation planning to documentation.
istent process engineering The right way to start – a plant overview Process engineering describes how raw materials are processed into finished products. This involves using a range of key documents: Pipework and instrument flow diagram (P&ID) Lists of measurement points Nominal widths of pipes Measurement, control and monitoring equipment Only once the P&ID diagram has been approved can implementation planning begin. Use the EPLAN Platform to create a consistent basis for your process engineering. Use the entire performance spectrum of the modules and expert systems to plan and implement your plant successfully.
Consistent solution for process engineering The add-on P&ID module allows you to produce accurate plant diagrams as a first step and then accomplish your basic engineering as part of the process engineering. The Operational Sequence Module allows you to display path-time diagrams which serve as the basis for control engineering and design. EPLAN PPE is the perfect solution for subsequent device design, detail engineering, validation and documentation in process engineering. Thanks to the consistent core data for the EPLAN Platform and the standardised approach, you can save valuable time and real money in process engineering.
Seamless integration into implementation planning You can boost productivity further by means of seamless integration of fluid, electronic and control engineering. EPLAN Electric P8 and EPLAN Fluid also access the higher level EPLAN Platform device database. If the plant overview is added to, the changes are automatically available across all disciplines. If a new fluid engineering drive for a process valve is added to the R & I, the fluid engineer, for example, is automatically offered an additional valve to fit and the control engineers can use a navigator to connect the additional control units to the subsequent signals required using drag and drop.
An overview of the benefits Increased productivity in process engineering by means of comprehensive integration into the EPLAN Platform Time saving and minimisation of errors in implementation planning thanks to the central database and automatic reporting of changes in the process technology Transparent, complete and consistent engineering documents accelerate commissioning and maintenance of the system Standard-compliant documentation: colour-coding of process media and consistent display of symbols in accordance with DIN EN ISO 10628, code letters per EN 61346, measurement points DIN 19227-1, EN 62424, etc.
FUNCTIONAL
Recipe for success: simple configuration No two food and beverage plants are the same. Different functions and processes – such as weighing, measuring, sorting, sifting, shaping and rolling – are carried out in different orders for different end products. This individualisation, combined with the demand for standardised, lowmaintenance and, above all, energy-efficient plants represents a real challenge for plant constructors. Opt for functional engineering and make the most of reduced time to market, increasing quality and falling costs.
Project
Standardisation
P&ID
Mixing Dosage ...
Mixing 1 Mixing 2 Dosage
Mechanics 3D models
CAx fluid/circuit diagrams control cabinet construction
Programming HW code PLC code
of individual plants Definition of wide range of functions Functional, module based engineering is the key to a new, effective approach. Even with such a wide range of different plants, large numbers of modules and components can be reused. This is based on consistent standardisation of the individual plant functions, including milling, crushing and pelleting. Trained EPLAN consultants work with you to highlight the different processes and describe every aspect of a different function, e.g. dosage, both from the point of view of energy efficiency and in terms of the different disciplines, such as mechanics, fluid engineering, electrical engineering and PLC.
Automated integration of process engineering into detail engineering The P&ID is used to describe the processes within a plant. This information is automatically applied to the detail engineering. This provides the starting point for functional engineering. Standardised modules are put together to form a complete system configuration. The control system makes sure that only tested system components can be defined. The next step is the automatic generation of the engineering documents. Equipment list/ERP Mechanical production and order parts lists Mechanical construction drawings Hydraulic and pneumatic plans Circuit diagrams PLC programs
Benefits that pay off Securing company know-how by recording all components of a food and beverage plant Improving quality by using tried and tested error-free components Minimising throughput times by means of parallel processes and automated documentation Simple maintenance and servicing throughout the entire life-cycle thanks to consistent error-free documentation Streamlining effect thanks to reuse of defined components
ORGANISED
Product data management (PDM) ensures life-cycle Statutory regulations and increasingly complex food processing methods mean using more and more new technologies. Therefore, the trend is moving more towards specialisation in plant engineering, leading to an increasing number of suppliers. Consistent, seamless documentation is a must to ensure smooth cooperation among all the companies involved. Use a high-performance PDM solution to reflect the complex interaction between all the organisations, people and disciplines involved. You can benefit from a differentiated approval process which ensures the as-built status of every customer project and allows you to trace this precisely at any time.
Convincing benefits Efficient product generation process and complete documentation of the as-built status by means of supplier integration Save time and money thanks to permanent access to complete, up-to-date data across the company and all departments High level of transparency of plant documentation based on defined approval and amendment workflows Improved quality thanks to seamless documentation and standardised processes Minimised coordination and improved cooperation among different disciplines and all companies involved
transparent plant documentation throughout the entire EMSR technology
Mechanical construction
Purchasing/ distribution Fluid technology
Electrical engineering Customers
Service Suppliers
Partners
Top quality thanks to complete data transparency A PDM-based workflow is perfect for fast, simple generation of as-built documentation as it allows, for example, projects to be checked in and out and approval and amendment processes to be defined. This allows optimum embedding, control and administration of documentation from different suppliers. An open EPLAN Platform allows seamless integration into the PDM workflow. All documentation for expert systems, such as EPLAN Electric P8, EPLAN Fluid and EPLAN PPE, can be administered centrally within the PDM system. All items saved can be displayed centrally and complete factory-independent parts lists can be drawn up.
Simple implementation Expert EPLAN consultants analyse all people, data, software, organisational structures and workflows involved in the engineering process. The second stage is to work together to produce a strategy for introducing product data management and the related processes. The focus is on integrating the PDM solution into the existing IT structure of your company, linking to the EPLAN Platform and optimum integration of all companies involved.
The rapid introduction of new technologies and the uninterrupted operation of plants in the food sector require effective engineering and integrated documentation. Give yourself a competitive edge with more efficient process engineering, functional engineering and effective product data management.
Professional partner The requirements in the food and beverage industry are varied and demand fresh ideas and solutions to be successful in the marketplace. We at EPLAN Software & Service can provide comprehensive know-how and support you on the road to success. Extensive industry experience makes us the ideal contact for any questions relating to engineering in the food sector. We will work together with you to find the right strategy for your company.
Security for the future Sustained success means future-proof solutions and partners. For more than 25 years, we have been monitoring developments and trends in the engineering sector. All our efforts are focused on achieving long-term added value for our customers. As a part of the Friedhelm Loh Group, we can benefit from the strength and the size of the famous group. Around the world, we offer you the necessary stability and security for your investments – now and in the future.
EPLAN – some impressive facts Founded in 1984 Part of the Friedhelm Loh Group 50 distribution and service centres around the world 550 EPLAN employees and 200 employees with partners Over 80,000 users
TRUSTWORTHY
EPLAN – Your partner in the food industry
IMPRESSIVE
You can trust us too Leading names from across the food industry speak for themselves Air Liquide Espana . Alois Dallmayr Kaffee GmbH & Co. KG . Alpenland Maschinenbau GmbH . Ampack Ammann GmbH & Co. KG . Berglandmilch reg.Gen.m.b.H. . Bosch Packaging Technology . Brauerei Diebels GmbH & Co. KG . Coca-Cola HBC Austria GmbH . Conditorei Coppenrath & Wiese GmbH & Co. KG . DIOSNA Dierks & Söhne GmbH . Dr. Oetker Nahrungsmittel KG . Elopak Corprate Offices . FERRERO OHG mbH . FrieslandCampina Germany GmbH . GENERAL ELECTRICA ONUBENSE, S.A. . Griesson - de Beukelaer GmbH & Co. KG . Henkell & Co. Sektkellerei KG . HiPP Produktion Gmunden GmbH & CoKG . Johnson & Johnson . KHS Asbofill GmbH . KHS Corpoplast GmbH . KHS Kisters Maschinenbau GmbH . KHS Maschinen-und Anlagenbau GmbH . Kraft Foods Deutschland Produktion GmbH . Kraft Foods Österreich GmbH . Krombacher Brauerei . Lindt & Sprüngli (Austria) GmbH . MEYPACK Verpackungssystemtechnik GmbH . Milchwerke Berchtesgadener Land Ciemgau eG . Miwe Michael Wenz GmbH . Multivac Marking & Inspection GmbH & Co. KG . Multivac SeppHaggenmüller KG . Nestlé Deutschland AG . Neuselters Mineralquelle . pester pac automation . PHILIP MORRIS . Privatbrauerei Gaffel Becker & Co. . Privatbrauerei Moritz Fiege . Procter & Gamble GmbH . Radeberger Gruppe AG . Robert Bosch GmbH . Römerwall Naturbrunnen und Getränke GmbH & Co. KG . Sachsenmilch Leppersdorf GmbH . somic Verpackungsmaschinen GmbH & Co. KG . Tetra Pak GmbH & Co.KG . Unilever Deutschland Produktions GmbH & Co. OHG
FOOD INDUSTRY
International
efficient engineering
Our customers work around the world – and so do we EPLAN has seven branches in Germany and representatives in over 50 countries around the world, so is always around wherever you need advice. Over 25,000 customers have trusted us with more than 80,000 installations. Rely on a partner with consistent focus on practicality, extensive experience, individual service and an international presence. EPLAN Software & Service, part of the Friedhelm Loh Group, represents continuity and security of investment.
EPLAN Software & Service GmbH & Co. KG An der alten Ziegelei 2 40789 Monheim am Rhein . Germany Phone:+49 2173 3964-0 Fax: +49 2173 3964-25 info@eplan.de . www.eplan.de Design/Layout::www.team-mt.de::04/2012