1 MUST HAVE SHOULD HAVE COULD HAVE

2 Module # C Functions that need to be considered for Batch Material Transfer Controls presented by : Rodger Jeffery company: Mettler Toledo duration: 30 mins

3  BY FEEDING THE EXACT AMOUNT OF MATERIAL  IN THE SHORTEST POSSIBLE TIME  EVERY TIME  IN ALMOST ANY MARKET  IN MOST APPLICATIONS  WITH VIRTUALLY ANY MATERIAL How does it improve manufacturing efficiency ?

4 Manufacturing Areas Batch Blend Formulate Dose Fill Raw Materials Granules Powders Liquids Slurries Primary Markets Food & Beverage Chemical Specialty Chemical Pharmaceuticals Other Measurement Tools Scale Platform Load Cell systems Flow Meters Where would it be applicable ?

5 Start Feed Stop Feed Weight Time Target Weight Starting Weight Fast Feed Cut Off Feed Cut Off Historical Preact AND Jog Mode T1T1 USE KNOWLEDGE OF PREVIOUS ERRORS DEPLOY “BRUTE FORCE” ENGINEERING TRY TO “THROTTLE” PROCESS VIARIABILITY SLOW DOWN THE PROCESS USE KNOWLEDGE OF PREVIOUS ERRORS DEPLOY “BRUTE FORCE” ENGINEERING TRY TO “THROTTLE” PROCESS VIARIABILITY SLOW DOWN THE PROCESS T0T0 T2T2 T3T3 Jog Historical Control of the Material Feed (Transfer) Phase

6 MUST HAVE SHOULD HAVE 1. Managing the Material Transfer Phase

7 must-have function must-have functions BASIC should-have function should-have functions BEST PRACTICES Managing the Material Transfer Phase

8 # Scale Devices # Flow Meter Devices Max # Devices Max # Materials Q.i LITE Q.i DEMONSTRATION 2. “ SHOULD HAVE FUNCTIONS“ - for BEST PRACTICE nHistorical Adaptive Pre-Act nReasonableness checking nSlow Step Timer nCommand states (status, error handling) nMaterial feed states (status, error handling, overflow) nWeigh/flow digital filtering nDiagnostics nControl Modes - Manual/Automatic control nReset Capability nEstimated time to complete nFlow alarm management 1. “ MUST HAVE FUNCTIONS” - for MINIMUM OPERATION Material type (GIW, LIW) Control target management (fixed bias) Setpoint type (absolute, additive) Tolerance check Dump to empty (cut-off approach & setpoint) Pre-feed condition checks (stable scale, vessel overflow) Post-feed check and report (for accurate & reliable data) Drain time management Instrument zero shift management Interface driver for data between instrument and controller Abnormal situation management

9 MUST HAVE SHOULD HAVE COULD HAVE 2. Optimizing the Material Transfer Phase - PAC

10 Start Feed Stop Feed Weight Time Target Weight Starting Weight Dynamic Spill Scale Reading Actual Weight Fed Historical Preact ACCEPT NATURAL PROCESS VARIABILITY LEARN FROM THE PROCESS ADAPT TO THE NATURAL PROCESS VARIABILITY USE MODEL BASED - PREDICTIVE ADAPTIVE CONTROL ACCEPT NATURAL PROCESS VARIABILITY LEARN FROM THE PROCESS ADAPT TO THE NATURAL PROCESS VARIABILITY USE MODEL BASED - PREDICTIVE ADAPTIVE CONTROL Feed Cut Off T0T0 Optimizing the Material Transfer Phase - PAC

11 must-have function must-have functions BASIC should-have function should-have functions BEST PRACTICES could-have function could-have functions OPTIMIZER Optimizing the Material Transfer Phase

12 2. “ SHOULD HAVE FUNCTIONS“ - for BEST PRACTICE nHistorical Adaptive Pre-Act nReasonableness checking nSlow Step Timer nCommand states (status, error handling) nMaterial feed states (status, error handling, overflow) nWeigh/flow digital filtering nDiagnostics nControl Modes - Manual/Automatic control nReset Capability nEstimated time to complete nFlow alarm management 1. “ MUST HAVE FUNCTIONS” - for MINIMUM OPERATION Material type (GIW, LIW) Control target management (fixed bias) Setpoint type (absolute, additive) Tolerance check Dump to empty (cut-off approach & setpoint) Pre-feed condition checks (stable scale, vessel overflow) Post-feed check and report (for accurate & reliable data) Drain time management Instrument zero shift management Interface driver for data between instrument and controller Abnormal situation management 3. “BENEFICIAL FUNCTIONS”- for BEST PERFORMANCE nAdaptive Predictive Feed Control (PAC) nOverlapping feed management nInstrument cross check maintenance nGroup Feeds nAdaptive 2 Speed Feed nData Management Material Feed Records Error Logging Material Path SPC Reports Configuration Logging Optimizing the Material Transfer Phase …measure, manage, control, reporting DEMONSTRATION

13 Material In Suspension D V 0 V 1 Material in suspension varies dependent on initial velocity (V 0 ), flow rate and distance Dependent on the material transmission characteristics of the valve TECHNOLOGY BREAKTHROUGH THE 4 COMPONENTS OF DYNAMIC SPILL

14 SPILL Flow Q MAX W LAG = Q MAX F W SUSP = Q MAX g W VLT = Q MAX K V Total SPILL: Total SPILL (TS) = K 1 Q MAX + K 2 Q MAX 2 NOTE:Total SPILL can be negative SUSPMAXDEC(1) WgQF -=·-= )ADñ(52.2 /QF V 3 MAXDEC(2) ··-= )Añ(62.2 /QTQFFF V 2 MAX DEC(2)DEC(1)DEC ··-·-=+= 3. TECHNOLOGY BREAKTHROUGH THE 4 COMPONENTS OF DYNAMIC SPILL Simpler Engineering + Consistent Production = Efficient Manufacturing

15 PAC algorithms for almost any feed characteristic AcceptableProblematic Targe t 1 Speed Feed - K1 or K2 (in-feed model based predictive adaptive control algorithm) 2 Speed Feed- K1 or K2 (in-feed model based predictive adaptive control algorithm) 1 Speed Feed - Spill Only (pre-feed preact control algorithm) 2 Speed Feed - Spill Only (pre-feed preact control algorithm)

16 UNIONCARBIDE - UCAR

17 Recipe - 4 ingredients Ingredient 2Feeder 1MP1206 kg Ingredient 5Feeder 5MP5155 kg Ingredient 6Feeder 6MP6284 kg Ingredient 9Feeder 8MP8180 kg Batch Cycle time improvements PRE Q.i 320 seconds POST Q.i 170 seconds Feed Control improvements PRE Q.i < 0.9 kg at 3 sigma POST Q.i < 0.25 kg at 3 sigma Capital Savings Engineering Effort 30% less Overall Cost20% less UNIONCARBIDE - UCAR

18 Level 4: MEDIUM to LARGE – Advanced to Complex Automatic (Q.i) This Metamucil plant applied the Qi technology early With the previous system operations had to adjust 25 batches a week due to deviations in material additions. The control system was reengineered using Honeywell’s PlantScape controller and 8 Qi matrollers. Material Feed deviations were reduced to the point that only 1 batch a week requires adjustment. This is a 25 to 1 improvement that has had a very positive impact on operations. This Metamucil plant applied the Qi technology early With the previous system operations had to adjust 25 batches a week due to deviations in material additions. The control system was reengineered using Honeywell’s PlantScape controller and 8 Qi matrollers. Material Feed deviations were reduced to the point that only 1 batch a week requires adjustment. This is a 25 to 1 improvement that has had a very positive impact on operations.

19 An example of the improvements brought by the Qi can be found in the 2004 re- control of the Augusta ABC. The Augusta ABC was using the advanced predictive material deliver techniques in the form of an older Honeywell TDC3000 control application and doing quite well with control (Lbs. deviation from target as a % of full scale with over 500 samples used to derive one standard deviation) ranging from 0.05% to 1.11%. In May of 2004 the TDC3000 was replaced by a Rockwell application using the Qi. As can be seen in the table “Augusta ABC June Deviations from Target” the Qi offers significant improvement for many of the materials over the traditional methods with a range of 0.04% to 0.30%. It also shows that the previous TDC3000 system was doing very well on several materials without significant changes from the Qi. The values in italics and blue indicate at least a 0.05% change, note all were positive improvements. The black values show relatively little change, all 0.03% or less with any negative changes 0.01% or less which would indicate minor process variations.