SOLIDFLOW METER — AN ALTERNATIVE TO THE WEIGHT MEASURING METHOD IN FOOD INDUSTRY

Modern technological production processes in the food industry include the technological operation of accurate batching of various bulk materials, being a part of the food product. The component composition of the product essentially defines both its consumer properties, and the expenses for its production, which requires the most careful attention to organization of batching process. The proper selection and accurate batching of the components to be mixed allow to produce more different product trade marks based on the same basic components.
Use of conventional methods of weight batching is associated with the need to use complex and expensive electromechanical devices and significant costs of their maintenance, and special upgrade of the production pipe lines.
The task of flow measurement and proportional batching of bulk components in the pipelines is solved more efficiently, using the latest microwave flow meters for bulk materials manufactured by SWR Engineering (Germany). The principle of operation of such instruments is based on interaction of high-frequency electromagnetic field with the particles of bulk material. The probe signal is reflected from the flying particles, is received by sensor and measured by frequency and amplitude. The instrument operates in the particle counter mode. Due to the selective receiving by the frequency, only the signals from the moving particles are processed, i.e. with the Doppler shift, and the signals from the stationary buildups, deposits, sediments, etc. are suppressed.

New microwave flow meters allow not only to simplify many processes, but also radically to change the idea of the bulk material flow measurement method.
The peculiarity of such flow meters is that they can be mounted directly into the pipeline without disrupting its integrity and with the minimal requirements to curvature of the pipeline sections, at the same time there is no need in additional material flow conditioners and there are no obstructions for the material flow.
For the cases of flow of the low-density bulk material, flowing with the relatively high speed, the today's industry started using SolidFlow flow meters developed specially for the flow measurement of bulk materials transported through the metal pipelines, which were positively appraised by the specialists. SolidFlow meters are the flush type instrument set in the metal pipelines to measure the flow of the dust, powders, granulates with the fraction of 1 nm...1 cm. The instrument consists of sensor set in the channel and processing unit (transmitter) set at the distance to 1000 m from the mounting place. For the pipes up to 200 mm, one sensor shall be set, for the pipes over 200 mm — two or three sensors connected to the same transmitter. Maximal diameter of the channel for setting SolidFlow instrument is 600 mm.

The flow meter is fixed with the sleeve welded to the outer pipeline wall, through which 20 mm hole is drilled in the pipeline. Inside the hole (channel) the sensor (returned echo sensor) is mounted so that its receiving surface does not extend beyond the inner wall of the pipeline.
SolidFlow flow meter measures the flow of bulk materials at the material flow rate 20 t/h and can work both in the pneumatic transport, and at the areas of free fall — at the discharge of the screw feeders (batchers), silos, etc.

The flow meter is fixed with the sleeve welded to the outer pipeline wall, through which 20 mm hole is drilled in the pipeline. Inside the hole (channel) the sensor (returned echo sensor) is mounted so that its receiving surface does not extend beyond the inner wall of the pipeline.

SolidFlow meter measures the flow of bulk materials at the material flow rate 20 t/h and can work both in the pneumatic transport, and in the areas of free fall — at the discharge of the screw feeders (batchers), silos, etc.
SolidFlow microwave flow meter is also used for the need of particularly accurate batching of small amount of ingredients.
SolidFlow meters are widely used at the enterprises of the leading manufacturers — Estrella, Kraft Doods, Nestle, Procter & Gamble and others.

In the baking industry, the proportions of the ingredients determine the structure and quality of the bakery products. If the ingredient proportion is wrong, the product quality can be worse. In production of bakery products, it is necessary to exactly follow the recipe, in order to ensure high quality. Application of SWR Engineering equipment for batching of ingredients allows to produce a high quality product and to reduce process waste.
The instrument was set in vertical section of the pneumatic pipeline, feeding wheat flour from silos to the production tanks successively with the triple beam balances, batching 60 kg of flour for the process chain.

As for the triple beam balances, a number of complaints was received from the workers of the plant, because they are often out of order, require regular maintenance, repair and calibration, and in some technological regimes, their performance hardly suits the pneumatic transport.
The test results showed high efficiency and perspective of microwave flow meters, the metrological characteristics identified during testing complied with the technical documentation requirements, and with more precise calibration, the measurement error did not exceed 0.5 rel. %. The flow meter was used at the production capacities of the flow up to 5 t/h.
SolidFlow flow meter is recommended to be used in the food industry for the organization of technological accounting of bulk products and the establishment of proportional batching systems.
The bulk products (flour) accounting system consists of a sensor (1), installed in the pneumatic pipeline, transducer (2), controller (3) and regulators (4). Thus, the material flow rate can be adjusted, and the flow of material can be cut off, in case of emergencies. SolidFlow meter allows to measure required amount of bulk material and to supply to the process chain. The system allows to control the process also manually (the operator), and to record and document an array of the quantitative indicator data of the process in graphic or tabular form, which is the basis for the introduction of automated document flow at the enterprise.

Flour process accounting chart

SolidFlow meters are successfully used for the solution of the problem typical for many processes associated with batching of strictly defined amounts of ingredients to get the final product, in proportional batching and mixing systems, e.g. various kinds of flour.
The system consists of two sensors (1), installed in the pipeline prior to mixing, transducer (2), controller (3) and regulator (4). Different types of flour are mixed in the same pneumatic pipeline to obtain a homogeneous mass.
Application of such system of proportional batching allows to shift the mixing process into continuous mode and guarantees precise batches distribution through the pipelines. The information supplied to the APM allows the operator to control the process, but with the significant reduction of the human factor impact, which is essential for safe and optimal control. Such technical process results in high quality end product.
The innovative high technologies and the experience obtained by the specialists of our company in implementation of the proposed products at the enterprises, allow us proudly proclaim that the products of SWR Engineering comply with the highest world standards. The instruments are accurate enough to be used in process accounting and flow process control. Practical experience obtained by the specialists of our company in implementation of the proposed products at different enterprises, showed that the economic effect of implementation of SolidFlow flow meters can comprise to 5-10% of total production expenses, and the payback period can range from 6 to 12 months.