ABB automation increases capacity 10x for Tate & Lyle food additive plant

When Tate & Lyle acquired Biovelop, a Swedish manufacturer of oat based food ingredients in 2013, the factory in Kimstad, Sweden was modernized and expanded by installing automation systems, variable speed drives, motors, motor control cabinets  and valve positioners from ABB Automation. In 2016 the remodeled plant celebrated the first anniversary of operations with the new systems and significantly increased production capacity.

The global market for specialty food ingredients, including health and wellness products, is growing, with annual sales of $51 billion and annual growth rate of 4-5%. Oat ingredients have been actively involved with this trend as they offer some key nutritional and functional benefits. In particular, oat contains beta glucan, a soluble fiber that has been shown to lower cholesterol and reduce post prandial glycaemic response – claims that have been approved by the European Food Safety Authority (EFSA). In fact, it was these properties of the grain that made the sector an attractive one to Tate & Lyle, and triggered the decision to diversify its portfolio into this sector.

“We have seen a more than tenfold increase in capacity with the same number of shift operators compared to four years ago,” said Annika Werneman, Tate & Lyle plant manager. “It’s a huge change in such a short time, and it means that we’ve gone from a low-level facility to one that can deliver high quality product to our customers globally.”

Advanced automation technologies in the plant run critical food processing equipment -including pumps and decanters: material handling machinery is also used to transport the dry food products. ABB delivered automation equipment that included 85 variable speed drives (VSDs), with power ratings ranging from 0.37 kW to 55 kW, as well as ABB MNS 3.0 motor control cabinets and low voltage motors. ABB also delivered 44 Digital Electro pneumatic positioners (TZID-C) , which use the Hart protocol to communicate with the control valves.

“We needed a process that was highly automated and could run 24 hours, seven days a week, all year long,” Werneman continued. This meant building a system that enabled Tate & Lyle engineers to digitally interact with the system, commission (start) devices, and diagnose performance deviations or failures from anywhere in the world. This not only helps ensure operational consistency, but also reduce the total cost of ownership by enabling staff to manage the processes without being physically present at each site.

Such interactivity was enabled by the ABB fieldbus automation for the drive controls, providing flexibility as well as remote monitoring of the plant performance. “I like that ABB designed the system so that the fieldbus responsible for device control is split from the fieldbus used for asset management,” explained Leo Dijkstra, power & controls team leader Europe at Tate & Lyle. “This ensures that I can make any changes to the configuration of the devices without the risk of the whole network going down.”

At Tate & Lyle, they place great importance not just on what they do, but how they do it. “We are working continuously wherever we can to reduce the environmental footprint of our operations,” said Dijkstra. ABB was well placed to help as it has developed a portfolio of products and solutions that improve industrial energy efficiency.

“In our pump applications alone, we are using up to 50 percent less energy thanks to the variable speed drives, and these have been running non-stop for the last two years without a single failure,” Dijkstra continued. “What’s more, ABB was so quick to deliver products that we even had the first VSD delivered in just a few days.”

Although the nearest ABB support is only a ten-minute drive away from the Kimstad factory, the fieldbus flexibilities in the drives enable Tate & Lyle to rely on its own staff to handle the ABB equipment remotely. “Our work with Tate & Lyle illustrates the benefits of digitization, which can yield immense productivity and output gains from existing facilities,” said Petter Hollertz, area sales manager at ABB. “The improvements at this plant also show what great teamwork between the equipment supplier and the user can accomplish, as we worked together as true partners on this project.”

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Diabetes plant for Novo Nordisk chooses Emerson

Another Novo Nordisk greenfield pharmaceutical project has chosen Emerson Automation Solutions to achieve a fast project start-up: this Emerson release gives the following information.

Emerson advises: “Global healthcare company Novo Nordisk has awarded Emerson a $40 million automation systems and services contract for a new US-based drug manufacturing facility to help battle the global diabetes epidemic. The largest project in its history, Novo Nordisk’s new $2 billion plant in Clayton, North Carolina, will leverage Emerson Project Certainty methodologies and automation technologies to help ensure the plant achieves a tight project construction schedule to meet a construction target of 2020.

The new 825,000-square-foot production facility will help the Danish drug company increase manufacturing capacity and meet its goal of doubling production of diabetes drugs over the next decade. According to the Centres for Disease Control and Prevention, more than 29 million Americans are living with diabetes, with another 86 million living with prediabetes.

“Our extensive experience in the life sciences industry and integrated offering for capital projects and automation perfectly positions us to help Novo Nordisk deliver its largest project in history,” said Mike Train, executive president, Emerson Automation Solutions. “Together we can design and deliver this world-class manufacturing facility to be ready on time, and to quickly deliver these important diabetes medicines.”

Novo Nordisk will implement elements of the Emerson Project Certainty approach to help reduce project complexity and achieve the tight project schedule. This transformational approach leverages automation technology, which serves as a central nervous system in a plant, and new methodologies, to reduce costs and complexity and accommodate late-stage project changes.

Novo Nordisk selected Emerson’s integrated portfolio of automation technologies and services, including its DeltaV distributed control system (DCS) and Syncade manufacturing execution system (MES). Emerson will also provide smart automation technologies including valves and measurement instrumentation.”

E+H acquires Blue Ocean Nova

A new Endress+Hauser press release says the company is further expanding its portfolio of products, solutions and services in the field of process analytical measurement, by  acquiring Blue Ocean Nova AG, a manufacturer of innovative inline spectrometers for monitoring quality-relevant process parameters. 

Blue Ocean Nova will operate under the umbrella of the Endress+Hauser centre of competence for liquid analysis headquartered in Gerlingen, Germany: the 15 employees currently located in Aalen, Germany will be retained. “The intelligent process sensors developed by Blue Ocean Nova will enhance our offering in the field of process analytical measurement, adding a strategic building block,” said Dr Manfred Jagiella, Managing Director of Endress+Hauser Conducta GmbH+Co. KG. As a member of the Group’s Executive Board he is also responsible for the analytics business. 

Innovative concept

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The process sensors developed by Blue Ocean Nova cover the relevant optical spectroscopy regions of UV-VIS, NIR and MIR to analyze liquids, gases and solids inline. The innovative technology allows the spectrometer to be directly integrated into the measurement probe, even in explosion-hazardous areas. The sensors can furthermore be automatically cleaned and easily integrated into process control systems.

The systems from Blue Ocean Nova are utilized in the food & beverage, oil & gas, chemicals and life sciences industries for applications such as concentration and moisture measurements and for measuring relevant quality parameters. The technology enhances the Group’s portfolio, which already encompasses Raman spectroscopy, tunable diode laser absorption spectroscopy (TDLAS) and process photometers.

Extensive experience

Blue Ocean Nova was founded by Joachim Mannhardt and Stefan Beck in 2015, bringing extensive product development experience in the field of industrial spectroscopy and process analytical measurements to the company. “Endress+Hauser opens the door to international markets and customers for us,” explains Stefan Beck. Joachim Mannhardt adds: “We’re convinced that our technology will be an ideal enhancement to Endress+Hauser’s optical portfolio.”

Endress+Hauser acquired Blue Ocean Nova effective 31 October 2017. Both parties agreed not to disclose the details of the transaction. Joachim Mannhardt and Stefan Beck will remain on the management team of the innovative company. “With this acquisition, we are continuing to pursue our strategy of strengthening the process analytical measurement portfolio and in the future supporting our customers from the lab to process,” says Manfred Jagiella.