GEA TDS Automation for Process Plants - Gea

GEA TDS Automation for Process Plants
engineering for a better world
GEA Process Engineering
GEA TDS ...
… is established internationally as a specialist for technically and
economically optimized process technology for the treatment of milk
products, food and juice. GEA TDS has the necessary know-how for
the design and manufacture of hygienic, aseptic and sterile plants
for the production of liquid and pasty products.
Our key products include a wide spectrum
of innovative solutions for process automation and services that range from the
provision of electronic process control up
to integrated, company-wide network
systems complete with the corresponding
management information systems.
For the MES level, we supply database-supported applications
for quality assurance, increasing productivity and verification
management.
Automation for Process Plants
Combined solutions at process and MES level
ERP-LEVEL
Track & Trace
Laboratory
Monitoring
MES-LEVEL
Data Acquisition
Recipe
Process Control
CONTROL-LEVEL
SQLServer
Global
Automation Brands
Process &
Instrumentation
PROCESS
GEA Process Engineering supplies automation solutions based on
superior industry expertise
Ever-increasing demands provide our
motivation. In a world which is in a state
of constant change, our mission as a
flexible solution developer with a global network of technology
and development centers is to provide perfect practice-oriented
solutions – whenever and wherever you need them.
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Engineering for Automation
Automation Engineering – for us this means hardware and software
concepts for process automation that are easily integrated in plants in
the dairy, food and fruit juice industries.
Our solutions are characterized by our
extensive know-how of the industry
sector and process engineering expertise,
which is reflected both in the targeted
selection of the hardware and the
functionality of the software solutions.
To implement our solutions, we use
field-tested modules and technologies
and follow international standards
(e.g. ISAS88, ISA-S95).
We use tested customizable software
modules which can be individually
combined to form an overall solution.
We make sure that our solutions can
be used on different platforms, which
offers the greatest possible independence
from suppliers.
Our services
■■ Consulting
–On-site assessment
–Design of control concepts
–Scheduling and resource planning
–Preparation of the functional specification (FDS)
■■ Hardware planning using a CAD system:
– Network overviews
– Cabinet layout plans and circuit diagrams
– Parts lists as well as cable and terminal plans
■■ Hardware commissioning with I/O check
■■ Software production
■■ Software commissioning with water and product run
■■ Production support and process optimization
■■ Factory acceptance tests
■■ Visualization solutions
Based on platforms from world market
leaders, our concepts are proven in
practice, yet individually designed,
scalable and future-proof.
With interfaces to ERP, laboratory,
warehouse and preventive maintenance,
the automation system forms the glue
that keeps everything together.
Scheduling
Electrical hardware planning
GEA engineering tools
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GEA engineering toolbox
Standardized object libraries
GEA engineering tools and standardized object libraries in connection with automation systems from market leaders
Plant concepts ...
... individually designed, scalable and future-proof. We use control systems
and system software from market leaders in the sector as a platform.
The core element of our automation
concept is a toolbox with standardized
software modules for specific technological
applications. These modules combine the
visualization level and the control level
into a customizable supervisory control
system. Process sequences are designed
by means of standard modules, such as
valves, motors, controllers and programs.
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The beneﬁts at a glance:
■ PLC programming is facilitated, as
essential functions are configured
via PC
■ The functions designed are easy to
comprehend, even for the technologist
■ Programmer independence
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Standardized and well-organized project structure
Shorter planning periods
Easy to expand
All settings and program parameters are held in an SQL
database, where they can be viewed and modified by
authorized users without the need of a programming unit
System-wide use of TAG numbers (according to PID) with
indication of the I/O address in the control system. Plain-text
display is also provided for alarm messages.
Simulation of the entire I/O system or individual components
for test purposes
Recording of operating cycles of the final control elements
and hours of motor operation
Recording and indication of all operator interventions
(Who? When? What?)
All parameter settings can be documented in Excel
Simulation for planning
and production
The standard GEA objects enable the
simulation of all signals. This allows
optimal testing of the process automation system prior to commissioning
and ensures that our team works with
a reliable, tested automation system
during this demanding phase of a project.
Simulation
Process visualization using tablet PCs
Language switching
Mobile operability for process plants
increases efficiency during the
commissioning phase and in the
everyday operation of the plant.
The process visualization and MES levels feature a language
switching function. This enables process operation in the
national language using country-specific character sets.
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OTAS® MES Solutions –
solutions at the Manufacturing
Execution System level
For the MES level (Manufacturing Execution Systems), we supply databasesupported applications for quality assurance, increasing productivity and
process verification. Our MES solutions, based on our extensive industry
know-how, provide the necessary transparency in the production process,
optimum use of resources and assurance of product quality. The software
modules can be individually combined to form a scalable overall solution.
As a simple solution for smaller plants
with basic requirements, the OTAS®
MES modules work on a Microsoft SQL
Express database which runs in the
background on a PC workstation. For
more complex plants, a separate database
server based on Microsoft SQL Server is
used. Communication with the control
level is effected via an OPC interface.
For the identification of e.g. fruit containers or manually added
ingredients we use mobile barcode scanners. Apart from the
identification function, the scanners display operator messages
that request operators to perform specific tasks.
Server cabinet
Product identification using mobile barcode scanners
ERP-LEVEL
Quality insurance
OEE-reporting
Traceability
Recipe
Reporting
Historian
PROCESS
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Master recipe
Production report
Scheduling list
OTAS® Recipe
… intelligent production control. OTAS® Recipe is a recipe system for the
convenient creation and management of recipes (product-specific target
data) designed especially for the food industry.
It enables technology-specific adjustment
of dosing quantities to raw material quality fluctuations (e.g. Brix value, % fat).
Features
Definition of dosing ingredients with material properties
■■ Definition of dosing points
■■ Definition of recipes on the basis of dosing ingredients
and process values
■■ Setting the dosing sequence
■■ Defining a basic quantity (partial batch)
■■ Working with different recipe types
■■ Manual definition of jobs or adaption from higher-level
systems such as OTAS® Connect
■■ Keeping a job list
■■ Automatic distribution of the job to partial batches
■■ Batch reports with target/actual value comparison
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Customization
■■ Connection of barcode scanners
■■ Connection of third-party systems
OTAS® Connect
… for integration with your ERP system. OTAS® Connect provides a
standardized interface to the software modules OTAS® Recipe and
OTAS® Track & Trace. Middleware enables data to be exchanged,
for instance to transfer production data to an ERP or inventory
management system or to receive work orders.
Features
■■ Bidirectional data exchange triggered
by events
■■ Customizable standard software
■■ Based on XML syntax
■■ Communication history stored in the
SQL server
ERP-System
Middleware
PLCs
SQL-Database
OTAS® Recipe
OTAS®
Connect
OTAS® Track & Trace
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OTAS® Monitoring
… for process optimization and verification. OTAS® Monitoring enables
you to record measured values and switching statuses simultaneously, thus
creating the necessary transparency for the optimization of production and
cleaning processes. The recorded history data can also be used to validate
individual batches or entire production volumes.
Features
■■ Batches can be selected by date/time
for graphical representation from an
archive overview
■■ To determine the exact values,
functions are provided such as:
– Zooming on the x-axis and the y-axis
– Shifting the time axis
– Actual value line
– Reference chart display
■■ Offline evaluation of measured data
using the Monitoring Viewer
– this data can be displayed on any
standard PC
Archive space limited only by the size of your hard disk
Online language switch-over
■■ Network-compatible
■■ Data can be exported to MS-Excel (CSV format)
■■ Can be integrated into automation systems that are already up
and running
■■ Import interface to the GEA engineering toolbox
■■ Can be linked to OTAS® Track & Trace for the immediate
display of transports
■■ Comments can be added
– Enumerations such as: step texts, cleaning objects,
batch numbers
– Drill-down function from enumerations
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Comment function in OTAS® Monitoring
Print layouts in OTAS® Monitoring
Monitoring
OTAS® Process Tracer
… for the recording and playing back of process information. Process
data is displayed in real time by the visualization system and archived
in a database at the same time. The OTAS® Process Tracer allows the
recorded historical data to be played back on the visualization system and
thus provides another view of the production process (only available for
Siemens WinCC).
Features
■ Timeline for selecting specific points
in time
■ Fast forward/reverse
WinCC Realtime
Visualisation
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Navigating in the WinCC application while the recording is
played back
Identification and preventing of operating errors
WinCC Historical
Visualisation
PLCs
• REC
SQLServer
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OTAS® Track & Trace
… traceability of your production for your safety. Legislation, retailers
and insurers place increasingly stringent demands on the traceability of
food products. OTAS® Track & Trace provides a high level of production
transparency by means of a graphical presentation of the whole
production process.
Process data is made available in a wellorganized manner via the integrated
Excel interface for further analysis. This
enables you to set up a high-performance
reporting system that is in fact independent
of any particular automation and system
supplier.
Features
■■ Online language switching
■■ Network compatibility
■■ Ease of operation for the user
■■ Transparency of production due to batch tracking
in the form of graphs and tables
■■ Customizable data fields for individual additional information
■■ Data can be exported in MS-Excel, CSV or HTML format
■■ Proven open data model
■■ Can be integrated into automation systems that
are already up and running
■■ Audit trail report
Customizable queries
■■ Can be configured by the user
■■ Event or time triggered
■■ Can be saved as XLS, CSV, TXT or printed out
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Track and Trace
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OEE report
Cleaning log
Utilization of CIP circuits
Reception log
OTAS® Report
… for your documentation. OTAS® Report enables you to document
production and cleaning processes. This is used for verification and
assessment of production efficiency. Reports contain key data relating to
raw material deliveries, quantities produced or cleaning processes (CIP).
Features
■■ Freely configurable reports
■■ Interactive table
– Autofilter & user filter
– Grouping
– Cascading
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Search functionality
Linking to OTAS® Monitoring and OTAS® Track & Trace
Results can be shown in GANTT charts
OTAS® Data Acquisition
… for the optimization of the efficiency of your plant. OTAS® Data
Acquisition is a powerful tool for analyzing production data and
consumption structures. It can be used for monitoring energy costs
and for source-related cost allocation. Configurable counter readings
are loaded from PLC control systems in accordance with requirements
and archived in a database.
In addition to time-controlled reading,
reading triggered by specific production
events is also possible. This allows you
to assign consumption data directly
to a product, a production batch or a
production shift.
The functionality is complemented by a
message log, which allows analyzing the
data in accordance with fault times and
fault frequency. The reports are output
to Excel tables. This facilitates individual
calculations and graphical evaluations.
Features
The configuration enables you to create counters
and events
– Management of any number of measuring
locations without software restrictions
– Management of different utilities such as power,
gas, water, etc.
–D
etermination of consumption and power output
data for counters that do not physically exist
(“virtual counters”)
–C
reation of a counter hierarchy by combining
individual counters into groups
– Triggered reading of counters
■■ The Report Configurator is integrated into MS
Excel as a separate menu item
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Boiler 1
actual deviation
Boiler 2
target deviation
Boiler 3
Comparison of steam boilers
Filling accuracies of a filler
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OTAS® Truck Management
… supports truck logistics and product tracking. OTAS® Truck Management
allows the registration of truck data in the raw material/product reception
and dispatch areas and the logistic organization of the trucks on the
factory premises, and thus forms an important element in the traceability
of deliveries.
Features
■■ Identification of trucks, either manually
or using chip-card readers, at various
stations on the factory premises
(e.g. CIP, gate keeper, milk reception)
■■ Chip cards or RFID can be used
■■ Barcode or manual registration of
deliveries
■■ Receipt slips can be printed for the
drivers
■■ Automatic or manual assignment of
unloading tracks depending on quality
■■ Front-end with tabular list of all
relevant information such as batch-ID,
vehicle identification, time stamp,
quantity, laboratory data, etc.
■■ Extensive search functions allow fast
and targeted access to the data
■■ Password and access management with
several hierarchy levels
■■ Online language switching (all languages
and characters are possible)
■■ Network compatibility
■■ Can be integrated into automation
systems that are already up and
running
Customization
Connection of chip-card readers
■■ Connection of printers
■■ Connection to laboratory systems
■■ Connection of third-party systems and PLCs
■■ Customer-specific functions can be added
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Online information about incoming tank trucks
OTAS® Laboratory
… efficient laboratory management for the food industry. OTAS® Laboratory
is particularly user-friendly and increases efficiency in the day-to-day
running of a laboratory.
It is ideally suitable for use in sectors
with a high variety of products and high
quantities of samples to be examined
in the laboratory, as is the case in the
food industry. Quality assurance in the
sense of ISO 9000–9004 is supported
by observing the required standards
where applicable. Another strong point
is the traceability of samples and a fast
overview of results.
Features
■■ Password and access management
with several hierarchy levels
■■ Online language switching
■■ Network compatibility
■■ Easy to operate in the laboratory
(special computer knowledge is not
required)
■■ Test plan oriented production of
samples
■■ Easy input of formulas in test plans
like in Excel
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Samples can be extended anywhere and anytime,
– e.g. by loading additional test plans, copying, deleting,
re-arranging analyses, subsequent input of formulas
Manual and automatic releasing of samples
Identification of samples using barcodes (barcode scanner)
Printing of sampling labels with barcode and plain text
Easy and flexible evaluation due to special evaluation module
incl. statistics, printout and export function to Excel
Can be integrated into automation systems that are already
up and running
Customization
■■ Connection of analysis equipment
■■ Connection to Truck Management
■■ Connection of third-party systems and PLCs
■■ Customer-specific functions can be added
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Dismantling in order to check seals
Registration of work performed on site
OTAS® Maintenance
… for preventive maintenance. In addition to recording run times, the
software is also used to count switching cycles. Limit values can be defined
for run times and switching cycles for preventive maintenance.
Energy Management ...
… for reliable data acquisition, prompt cost allocation and up-to-date
graphical presentation. Provides active and reliable support to comply with
DIN EN/ISO 50001 and DIN EN 16247-1. Quickly and easily via the web.
The energy portal provides an overview of consumption figures.
Monitoring and analysis
■■ Live charting using graphs and Gantt
bars (correlation between consumption
data and system states)
■■ Freely configurable, parameterizable
reports: Periodic comparisons, target/
actual comparisons, monitoring of the
success of process-related measures
■■ Clearly presented in a Sankey diagram
with actual values and periodic
comparison
■■ Evaluations available immediately after
data acquisition
■■ Reports are produced and transferred
automatically
■■ E-mail alarming in the event of limit
value violations, failure to receive
measured values, etc.
■■ Specific consumption figures
(according to articles, product groups,
periods)
Scalability and consumption types
Free grouping of components, plants, plant groups
(logical counters)
■■ Aggregation of data and cost allocation (virtual measuring
points for status determination)
■■ Acquisition of consumption data with free grouping according
to types, e.g. power, compressed air, refrigeration, heating
(gas, oil), water
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Saving potentials
Analysis is followed up by process-related measures or work
instructions to reduce consumption. Continuous acquisition and
evaluation allows monitoring of success, e.g.
■■ Cutting peak loads
■■ Minimizing downtimes
■■ Optimizing set-up times
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OTAS® Field Control –
solutions for locally operated
process units
OTAS® Field Control is a standardized automation solution for locally
operated process units. Its intuitive operation, using graphical interfaces,
allows for short commissioning times and rapid familiarization of your
operator staff.
OTAS® Field Control is based on Siemens
or Rockwell control systems and operator
terminals and generally includes the
necessary technology for remote support
via telephone network.
OTAS® Field Control is used e.g. for:
UHT systems, pasteurizers and thermizers,
mixers, deaeration units and CIP systems.
Design
■ PLC and color touch panel
■ Process flowchart visualization on the operator panel
■ Stainless steel cabinet
■ Profibus communication
■ Ethernet communication
(options: 12“, 15“, 19“ display)
■ Equipped for Teleservice
Performance data
■ Max. number of automation objects
(valves, motors, instruments): 300
■ Max. number of programs: 20
Presentation of process information
Program operation
PID controller
Fruit mixing plant
Program parameters and program steps
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We live our values.
Excellence • Passion • Integrity • Responsibility • GEA-versity
Kruppstraße 3, 48683 Ahaus, Germany
Phone +49 2561 8602-0
[email protected], www.gea.com
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Am Industriepark 2–10, 21514 Büchen, Germany
Phone +49 4155 49-0
06/14
Voss-Straße 11/13, 31157 Sarstedt, Germany
Phone +49 5066 990-0
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GEA TDS GmbH
444e
GEA Process Engineering
inform-werbeagentur.de
GEA Group is a global engineering company with multi-billion euro sales and operations in more than
50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and
process technology. GEA Group is listed in the STOXX® Europe 600 Index.

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