automation used in dairy as well as food industry , use of PLC, SCADA, HMI etc.

1. AUTOMATION

2. INTRODUCTION
• Processes in small dairies were supervised and controlled by a few skilled people, who carried out most
operations manually and also cleaned the equipment by hand at the end of each run
• Cleaning-In-Place (CIP), introduced in the mid 1950s, is used at most of today’s dairies
• Machines are designed to be cleaned with detergent solutions, which are circulated through the
production lines according to a set cleaning program
• Extensive mechanization of dairy operations gradually became a reality, with the result that more and
more of the heavy manual labour was taken over by machines
• Every malfunction in the process, and every operator error, could have serious economic and qualitative
consequences
• Automation was the solution to handle these problems

3. WHAT IS AUTOMATION ???
• As the name suggest “Automation” means to perform automatic operations by means of
different kinds of machines
• Automation means that all actions needed to control a process with optimal efficiency
are handled by a control system on the basis of instructions that have been programmed
into it.
• It is used to reduce human interference and an efforts.

4. WHY DO WE NEED AUTOMATION ???
Demand is almost double than growth rate
Estimate: 180 MT by 2021-22 (National Dairy Plan, NDDB)
Labour cost is almost 50% of production cost
Increasing urbanization
To meet global trade standards

5. CONTROL LEVELS
Manual control
Unit control and supervision
Line control and supervision
Production management

6. MANUAL CONTROL
• All operations in the plant are carried out manually
Control module by push buttons, Pasteurizer plant lines

7. UNIT CONTROL AND SUPERVISION
• Each process unit is operated from its specific operator panel
• Each unit has standardize way to communicating with other unit and
supervisory system
• The complexity of the control systems is low, so the demands on the
local service organization are limited

8. LINE CONTROL AND SUPERVISION
• The operator supervises the plant or line from one or more
User Interfaces
• Coordination of routings and operation of units is done
from one or more plant PLCs

9. PRODUCTION MANAGEMENT
• The operator of the process supervises the execution of scheduled batches from one or more operator
stations
• One or more plant PLCs control the routings, and the plant server coordinates all activities in the plant

10. TOOLS OF AUTOMATION
Programmable Logic
Controller (PLC)
Supervisory Control
And Data Acquisition
(SCADA)
Human Machine
Interface (HMI) / Touch
Screen (TS)
Variable Frequency
Drive (VFD)
Enterprise Resource
Planning

11. WHAT IS PLC ???
• PLC – Programmable logic controller
• A Programmable Logic Controller, or PLC for short, is
simply a special computer device used for industrial
control systems.
• They are used in many industries such as oil refineries,
manufacturing lines, conveyor systems and so on.
• PLC implements logic control functions by means of a
program.

12. MAJOR COMPONENT OF PLC
PROCESSOR
POWER
SUPPLY
I M
N O
P D
U U
T L
E
O M
U O
T D
P U
U L
T E
PROGRAMMING
DEVICE
From
SENSORS
Push buttons,
contacts,
limit switches,
etc.
To
OUTPUT
Solenoids,
contactors,
alarms
etc.

13. OPERATION OF PLC …
• CHECK INPUT STATUS
First the PLC takes a look at each I/O to determine if it is
on or off.
• EXECUTE PROGRAM
Next the PLC executes the program
one instruction at a time.
• UPDATE OUTPUT STATUS
Finally the PLC updates the status of the outputs .It
updates the outputs based on which inputs were on during
the first step.

14. APPLICATION OF PLC…
• Manufacturing / Machining
• Food / Beverage
• Textile Industry
• Travel Industry
• Aerospace
• Printing Industry

15. ADVANTAGES
 Replacing Human Operators
• Dangerous Environments
• Beyond Human Capabilities
 Improves Productivity
Easily programmed and have an easily understood programming language.
 Improves Quality

16. DISADVANTAGES
 PLC Devices Are Proprietary
 Initial Costs Are High
 There's Too Much Work Required In Connecting Wires
 Unemployment Rate Increases

17. WHAT IS SCADA ???
• SCADA is “Supervisory Control and Data Acquisition” – real time industrial process control systems
used to centrally monitor and control remote or local industrial equipment such as motors, valves,
pumps, relays, etc
• A SCADA system gathers information (such as where a leak on a pipeline has occurred), transfers the
information back to a central site, then alerts the home station that a leak has occurred, carrying out
necessary analysis and control, such as determining if the leak is critical, and displaying the
information in a logical and organized fashion.

18. WHY SCADA ???
• Saves Time and Money
• Less traveling for workers (e.g. helicopter ride)
• Reduces man-power needs
• Increases production efficiency of a company
• Cost effective for power systems
• Saves energy
• Reliable
• Supervisory control over a particular system

22. HUMAN MACHINE INTERFACE
• A human machine interface (HMI) is an interface which permits
interaction between a human being and a machine.
• Human machine interfaces vary widely, from control panels for
nuclear power plants to the screen and input buttons on a cell
phone.
• Examples of input devices include keyboards, toggles, switches,
touch screens,

23. VARIABLE FREQUENCY DRIVE
• VFD or Variable Frequency Drives are used to run the
motors of single phase or three phase supply.
• VFD is used to accelerate and deaccelerate the speed
of motor with in a particular time.
• Drives commands: -
Start/Stop
Speed reference
Acceleration/ De-acceleration

24. ENTERPRISE RESOURCE PLANNING
• ERP- “A business management system that integrates all facets of the business, including
planning, manufacturing, sales, and marketing.”
• System, Application, Products in data processing environment

25. AUTOMATION IN DAIRY INDUSTRY

26. AUTOMATIC MILKING SYSTEM
• Automatic teat detection
• Automatic on/off milking
• In- line mastitis detection
• Real time Data collection