Transcript Presentation - University of Auckland

Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Can Process Analytical Technology Lead
to Real-time Quality Management
for Dairy Food Products?
Brent Young*, Nick Depree, Taj Munir
and David Wilson
*[email protected]
Innovation to Transform the Dairy Value Chain
Processing & Supply
Chain
Farming
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
The Nature of Dairy/Food Materials
•
•
•
•
Biological sources of variation
Highly perishable
Properties are time dependent
Properties are often not well characterised
Presents considerable challenges
– to process design, control and optimisation systems
– to sustainably produce safe, consistent and
economically viable products
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Traditional Real-time
Process Control Solutions
State of the art:
Stainless steel & PLCs
– Temperature,
pressure and flow
instrumentation
– Uni-variate
monitoring
– Manual control
common
– Minimal optimisation
Challenge: We have real-time process control for some variables.
But what about real-time quality (RTQ) control!?
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
What is RTQ? Is it PAT?
PAT Definition:
Process Analytical Technology* involves the
systems approach in the planning, design, control
and optimization of processing plants.
This is a model based framework that
encompasses new enabling technologies for most
areas of the processing industry.
Challenge: Is PAT simply an evolution of what we have done all along?
* US Department of Health and Human Services, Process Analytical Technology, FDA, 2004
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
What is RTQ? Is it PAT?
1. Process analysers
– Fusion of models and latest sensors for better
monitoring
2. Design, data acquisition and analysis tools
– Multivariate models for deeper process analysis
3. Process control tools
– Targeted models for optimisation
– Mini models for exception detection
4. Continuous improvement and knowledge
management tools
– Holistic approach that integrates methodologies
– Driven by the customer & regulatory authorities
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
What is RTQ? Is it PSE?
Process Systems Engineering (PSE) and Product Expertise
Identify
Needs
Model
Development
Model
Validation
Experimental data from
laboratory/pilot plant
TA Instruments ARG2 Rheometer
University Dairy Viscosity Testing Rig
Model
Calibration
Model
Deployment
Process and Product data
Fonterra Te Rapa Process Plant
Innovation to Transform the Dairy Value Chain
Processing & Supply
Chain
Farming
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
What is RTQ? Is it PSE?
Equipment
Integration
1950s-70s
1980s-90s
Tools: Simulators
Optimisation
1990s2000s
Traceability
2010s
Pinch Tech
Steam
Soft Sensing
MPC*
SCM**
Smart Sensors
Multivariate
PAT Tools
Objects
Large Scale
Codes
Data Driven
Exception Based
dM
 w f  wl  wv
dt
d  xmi M 
 z mi w f  xmi wl  ymi wv
dt
dM g
dt
 wvi  wv
Model DAEs
Types:
* Model Predictive Control
** Supply Chain Management
Innovation to Transform the Dairy Value Chain
Processing & Supply
Chain
Farming
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
RTQ: A refocus for our aims
Equipment
Integration
Optimisation
Traceability
1950s-70s
1980s-90s
1990s-2000s
2010s
dM
 w f  wl  wv
dt
d  xmi M 
 z mi w f  xmi wl  ymi wv
dt
dM g
dt
 wvi  wv
Primarily interested in
equipment design &
operation
What are my mass &
energy balances?
I’m happy with my
equipment,
but how do I save energy &
operating costs?
Final QA found something
amiss
What happened, where &
how much product is
affected?
Challenge: Capturing a customer-centric view in a traditional engineering environment
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Two Views
Customers
ERP
Enterprise
Historian
RTO
Plant
Optimal control
Equipment
Advanced control
Process
Regulatory control
Plant
Challenge: Do we have two masters?
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
What are we doing?
• Multivariate Exception Based Modelling
–
–
–
Data Mining and Rectification
Sensitivity and Factor Analysis (e.g. MPCA)
Fault Detection and Diagnosis
• Models for control (e.g. MPC)
–
–
What are appropriate models?
What level of fidelity?
• Always maintain a Customer/Client focus
Challenge: Building something useful without full-scale dynamic modelling
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
How are we doing it?
Platform
Technologies
Rapid Prototyping
Building mini-models
R/MATLAB/Python
(Tools within) Pavilion
Steady State & Dynamic
Modelling
VMGSim
MATLAB
Graphical User/Operator Interface Pavilion
Challenge: Building a flexible proto-typing environment,
not getting bogged down producing commercial software.
Challenge: Reflective Visualisation – getting timely
information to make informed decisions now & tomorrow.
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Visualisation
Operator Displays
Is this the best we can do?
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Basic Ideas
• Not a standard operator’s display
– We already have those
• Data is graphical
– Dense, big screens
– A3 paper
• Focus on the future
– What might happen & when
– Future gets uncertain
• Consistent Colour design
– Low impact
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Careful design of charts – resolution, colour, aspect ratio:
Typical graphics layouts
Ref: Tufte’s The Visual Display of Quantitative Information
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Advanced Visualisation
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Sparklines
– small, intense, word sized graphics. Placed
inline with text, show flow and change of data
Fonterra Baseline Capability:
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Colour Maps & HMI Design
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Chart improvement
– Clarity, Resolution, Data Density
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Focus on the future
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Design, Data Acquisition & Analysis Tools
• Data driven techniques
–
–
Data Mining & Rectification
Sensitivity & Factor
Analysis
–
–
Fault Detection & Diagnosis
–
–
PCA
PCA & Discriminant Analysis
Traceability
–
Bayesian Belief Networks,
Transfer Entropy
• Model based techniques
– Process Simulation
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Next steps…
• Focus on the future: Does it work?
– Mini tools to tell you what will happen
– Countdown
• Two screens: two types of information
– Dashboards: (useful or naff?)
– Super big screens, or multiple screens?
– Always visible? Build your own?
• Getting away from trends & PFDs:
– Moving “blobs”
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
This mini tool warns against blockage of
the SFB – increasing DT between 2 probes
indicates poor flow or sticky powder
This right hand plot shows a zoom into
small detailed region using the mini-tool
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
A mini tool looking at stability of feed solids to drier
Example stable for most of cypher but sudden change at end
Real version is interactive version
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Vitamin D Dosing Mini Tool
With over dosing (right)
Without (below)
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Coffee Sediments SQC
Coffee sediments scores plot (right)
N.B. colours are start/middle/end of run
How to display in real time for operators?
-> ‘Snakes on a Plane’ planned! (e.g. below)
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Acknowledgments
I2C2
•Drs Irina Boiarkine & Ville Rimpilainen (UOA)
•Arrian Prince-Pike (AUT)
Fonterra
•Advanced Process Control Group,
Drs Tristan Hunter & Nigel Russell (Fonterra)
Primary Growth Partnership Program (PGP)
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
Can Process Analytical Technology Lead
to Real-time Quality Management
for Dairy Food Products?
Brent Young*, Nick Depree, Taj Munir
and David Wilson
*[email protected]
Innovation to Transform the Dairy Value Chain
Farming
Processing & Supply
Chain
Ingredients & Dairy
Solutions
Consumer Products
Dairy Primary Growth Partnership Programme
We never said we were statisticians.