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HOSOKAWA ALPINE

Aktiengesellschaft & Co. OHG

ALPINE PROCESS AUTOMATION


FOR THE FIELD OF PROCESS ENGINEERING

P.O. Box 10 11 51
D 86001 Augsburg, Germany
Delivery address:
Peter-Drfler-Strae 13 25
D 86199 Augsburg, Germany
Phone.: +49 (0) 821 / 59 06-0
Fax:

+49 (0) 821 / 57 35 78

E-mail: mail@alpine.hosokawa.com
www.alpinehosokawa.com

Subject to change without notice.


All information in this brochure is purely
informative and non-binding. Our quotations are
authoritative with regard to orders.

Hosokawa Alpine is a member of the Hosokawa Micron Group, responding to


global needs through emphasis on materials science and engineering. The
Group is an international provider of equipment and technology for powder
and particle processing, plastics processing and confectionery products. The
Group maintains facilities for research, engineering, manufacturing and
service in each of the world's major industrial markets.

Hosokawa Alpine 2004. Printed in Germany.

PROCESS TECHNOLOGIES FOR TOMORROW SM

ALPINE
ALPINE PROCESS AUTOMATION
PROCESS
AUTOMATION
Hosokawa Alpine offers optimal
process solutions.
Process technology and automation engineering
are tailored to the requirements
and come from one single source.

PROCESS AUTOMATION

CONTROL TECHNOLOGIES FOR TOMORROW

PROCESS TECHNOLOGY
KNOW-HOW

QUALIFICATIONS

ASSEMBLY

DOCUMENTATION

The assembly teams comprise electrical

Automation technology from Hosokawa

Together as a team, process engineers and

Alpine is nothing more than process tech-

electrical engineers develop the optimum

The operating manuals for our automation

engineers and erection engineers who work

Training has always played an extremely

nology know-how translated into software

solution for each customer. Dependent on

systems are written and compiled by process

jointly on completion of the systems. Our

important role at Hosokawa Alpine, not

and hardware. A team of experienced

the process and degree of required auto-

engineers for process engineers. This saves

electrical engineers are always present

only on the mechanical sector, but also on

electrical engineers develops the basic

mation, modular automation components

your operating personnel time and increa-

during test runs and acceptance tests to

the electrical sector. Our new generation of

principles for our automation technology

are individually combined. The customers

ses the operational reliability.

check that all customised requirements

mechatronics engineers and electronics

and makes sure that the module interfaces

profit from our process technology

have been met and function perfectly.

engineers for systems engineering is trained

mesh optimally and that all modules are

expertise.

ARCHIVING

in our own workshops in a practice- and


customer-oriented manner, thus ensuring a

seamlessly documented.

constant high standard of quality.

Every delivered process solution is archived


by us on our premises. This gives our customers the assurance of being able to refer to
the original program at any time.

SPECIAL SOLUTIONS
Frequent examples of customised process
solutions

are

medium-voltage

control

panels for customers of our Minerals &


Metals Division, and software packages
plus documentation as per 21CFR Part 11

AUTOMATION MODULES

for customers from the pharmaceutical

Our PlexControl process automation system comprises 4 modules,

can be combined with the PlexView and PlexConnect modules

industry.

each of which is described in detail on the following pages. The

dependent on the required level of automation.

minimum equipment of a system is PlexWire and PlexLogic, which

USER-FRIENDLY AND
RELIABLE IN OPERATION
VARIANTS

always
Building on this system, we are able to react
quickly and professionally to customer
requirements and wishes, for example, we:
- program the visualisation unit to the

- include new developments and


technologies
- effect the connection to upstream or
downstream production stages.

required language
- set up a password or recipe management

PLEXCONTROL

The solutions from Hosokawa Alpine are


user-oriented

and

proven

in

practical operation, a result of the many


systems we have running under productionscale conditions in our application testing

PlexWire

PlexLogic

PlexView

PlexConnect

centre in Augsburg.
The practical experience thus gathered has

On request, we integrate an automatic on-

led to constant optimisation of the mecha-

MODULE

MODULE

MODULE

MODULE

line particle size analysis with setpoint/

nical process technology and the measuring

CONTROL CABINETS

CONTROL PROGRAM

PROCESS VISUALISATION

TELESERVICE

- integrate new components

actual comparison - e.g. from Malvern Ltd. -

and automation technology of our systems,

CONTROL PANELS

(PAGE 5)

(PAGE 6)

(PAGE 7)

- carry out risk analyses

not only mechanically but also from an

meaning we are able to offer our customers

(PAGE 4)

- take new standards and directives into

automation technology viewpoint into the

a high degree of user-friendliness, zero-

process to increase the efficiency of the pro-

defects manufacturing and reliability in

duction system.

operation.

feature

account

PROCESS TECHNOLOGIES FOR TOMORROWSM

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ALPINE
MODULE
PROCESS
AUTOMATION PlexWire

MODULE
PlexLogic

The control
program module

The control cabinet


and control
panel module

The SimaticS7 automation system is

Together with the documentation of the

engineers. It is thus possible to concentrate

employed for the process control. The pro-

program, for which the Step7 options are

fully on process optimisation during the

grams are generated in Step7's own pro-

made use of, a software program is created

commissioning phase, without having to

The control cabinets are built based on these

gramming languages AWL and preferably

that matches your process exactly but is

worry about whether the unit functions or

in ensuring an efficient and reliable produc-

We use the object-oriented CAE systems


Eltime and Koramis for preparation of

circuit diagrams. To guarantee a high stan-

KOP or FUP. They are universally structured

nevertheless flexible enough to allow quick

not.

tion sequence. All the safety, switching and

the circuit diagrams. Because of the modular

dard of control cabinet quality, Alpine in-

and documented.

and easy process changes or upgrades.

operating elements must be coordinated to

structure of our circuit diagrams, we are able

house directives for control cabinets are

suit the production process and the environ-

to design your control cabinet to reliably

systematically applied.

Tested program modules are used for the

The software for the process control

prises the program listing, the hardware

mental conditions at the site of production.

meet the individual requirements. This also

structuring, thus avoiding programming

includes the sequences for automatic,

configuration of the PLC as well as various

Our control cabinets make full allowance for

means that besides the prevailing IEC and EN

Before a control cabinet leaves our premises,

errors. The program modules can be retrie-

maintenance, and cleaning modes as well

reference documents. The entire documen-

these requirements.

standards, we can factor your own in-house

it is inspected and tested under acceptance

ved from libraries and permit an efficient

as the necessary start-up and shut-down

tation package is delivered on CD-ROM.

standards into the equation.

conditions by the responsible electrical or

program generation for your process

sequences. Over and above this, the

All the control programs, their documenta-

automation engineers to make sure that it

control.

required control algorithms and fault

tion and date of issue are archived on our

handling routines are pre-installed.

premises in accordance with ISO 9001 and

The control cabinet plays an important role

Prior to the planning stage, we investigate

The control program documentation com-

the special demands of your production

The circuit diagrams include the wiring dia-

fully meets all your requirements in terms of

sequence as well as the restrictions created

grams, terminal designations, cable lists,

function and quality as well as those laid

by the supply network, the environmental

installation plans, configuration plans for

down in the IEC and EN standards.

conditions (e.g. system or control cabinet in a

PLCs, general drawings and parts lists for the

function of the software is carefully tested

potentially explosive atmosphere, i.e. gas

control cabinets.

by the responsible process and automation

can be retrieved at any time.


Before the process control is delivered, the

and/or dust), and then systematically convert


this knowledge into a viable concept.

PROCESS TECHNOLOGIES FOR TOMORROWSM

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ALPINE
MODULE
PROCESS
AUTOMATION PlexView

MODULE
PlexConnect

The teleservice
module

The process
visualisation module

The process sequence and the process

These visualisation systems also include

The PlexConnect module makes it possible

changes to both the process control and

prepare the service assignment or main-

parameters are represented graphically on

archives for process data and trend curves,

to set up a connection between Hosokawa

the visualisation system without any of our

tenance measures in a targeted manner.

screen. The system flowchart forms the basis

and offer the possibility of creating a recipe

Alpine's premises and your production

engineers needing to be on site. It is also

The availability and efficiency of your system

for representation of the process, and is for-

management feature and of integrating

system in the form of a point-to-point

possible to plan system maintenance and

are thus kept at a very high level.

matted, animated and supplied with the

report generators.

connection via the telephone network (ana-

in the event of a total breakdown, we can

logue or ISDN). This method ensures that

diagnose the fault over the telephone and

required process parameters. An important


criterion hereby is that the flowchart is easy

In the case of all systems that must fulfil the

the data security and access security of your

to read and the process sequence easy to

requirements stipulated in 21CFR Part 11,

system remains intact; by simply pulling the

follow. Colour-coding is used to highlight

the mechanisms necessary for ER (Electronic

telephone connector out of its socket, you

Recording) and ES (Electronic Signature) are

can effectively interrupt any external link to

pre-installed.

your system.

system also includes:

Besides the program listing, the documen-

The beauty of the teleservice module is that

The process is also operated by means of

- a fault indication system,

tation for the PlexView module also

you can optimise your system and make

the visualisation unit. The user interface is

- a fault indication memory,

includes a user manual for the visualisation

simple in design and the user is guided

- a password management feature,

system. The documentation package is

intuitively through the various menus. The

- and a simple on-line trend indication.

delivered on CD-ROM.

text is in the native language of the user.

If required, a simple recipe management

Menus that are reserved exclusively for

feature can be created.

important information for the user, whereas


less important information is kept in the

Besides the functions necessary for opera-

background.

tion and monitoring, every visualisation

maintenance personnel, for example, can


be protected by means of suitable access

In the case of more

rivileges. This eliminates the possibility of

elaborate

operating errors and the necessity of addi-

where, for example,

tional training measures.

the requirements laid

CUSTOMER'S PRODUCTION SYSTEMS


ATP SYSTEM

ASP SYSTEM

TTC SYSTEM

COATING

processes,

TS Adapter

down in 21CFR Part 11


must be fulfilled, PCDependent on the requirements, there are

based

a number of different visualisation systems

systems are used.

available. For simple processes, Windows-

The software packages


WinCC (Siemens) and

CE-based operating and monitoring systems


are used. The software elements used are
Protool (Siemens) or Zenon (Copadata).

visualisation
Modem

Zenon(Copadata) are

Analogue phone network

used in these instances.


Modem

SERVICE STATION AT HOSOKAWA ALPINE

PROCESS TECHNOLOGIES FOR TOMORROWSM

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ALPINE
INTEGRATED
PROCESS
ON-LINE
AUTOMATION PARTICLE
SIZE ANALYSIS

ELECTRIC EXPLOSION SAFETY


AS PER 94/9/EC

As a measure of optimising
the process control, our systems can be
equipped with a real-time
on-line particle size analysis system.

To order, all of our systems can also be equipped with an on-line


particle size analysis system. The analysis system is then either

EX I-CABLES

installed direct in the fines ducting or in a bypass ducting, whereby the fines are supplied via a sampling station.

INHERENT
SAFETY
CERTIFICATE

The software to evaluate the particle size distribution forms


part and parcel of the visualisation software, and records and

It is very often the case in the chemical,

evaluates the measured values. This also means that the user has

pharmaceutical and foodstuffs industries

a standard and universal operating structure available and that

that potentially explosive products are

special training for the on-line particle size analysis is superfluous.

processed. Our systems offer a high level of


safety when processing such products and

In view of the fact that the measured values can be allocated to

have proved themselves time and again

The advantage of such a system becomes apparent during process

individual batches, the data can also be used within the scope of

over the years.

management. With the on-line particle size analysis system, the

a quality control system, and suitably edited and output by a

production system is always kept at an optimum operating point,

report generator.

GAS-EX
Zone 0
Control panel
Drive technology
Actuators (valves)
Sensors
Measuring technology

Many applications call for frequent system

DUST-EX
Zone 20

Zone 1

Zone 2

Zone 21 Zone 22
n

= available

e.g. independent of quality fluctuations in the feed product. As a

cleaning, whereby the vapours of the

result, end product that deviates from the desired specifications,

solvents and cleaning agents used are

The process components delivered by

i.e. oversize or undersize product, is kept to an absolute minimum.

often explosive. Particular care is therefore

Hosokawa Alpine and the associated

And this in turn saves costs when processing high-grade,

essential when selecting and laying out the

control panels and cabinets all fully meet

As a result of the long years of experience

expensive products and also during the running-in phase, when

electrical equipment of a system installed in

the requirements laid down in the pre-

in laying out and planning systems in

process experience is lacking.

a gas Ex zone and thus in potential danger

vailing

potentially explosive atmospheres, we are

of a gas explosion.

directives, especially 94/9/EC (ATEX).

national

and

international

in a position to design such systems


efficiently and reliably. The solutions that
result are tailored exactly to the requirements of our customers and guarantee not
only optimum explosion safety but also a
high degree of economic efficiency.

PROCESS TECHNOLOGIES FOR TOMORROWSM

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ALPINE
QUALIFICATION
PROCESS
AUTOMATION
Grinding systems for pharmaceutical
active substances must be qualified, and
by applying our sequence routines, this is
always guaranteed.

QUALIFICATION

OQ PROTOCOL
FROM THE

Essential tasks during the manufacture of

compare the URS with the achieved produc-

which is generated in the Software Specifica-

HARDWARE SPECIFICATION (HWS)

pharmaceutical products are to record and

tion result in the Performance Qualification

tion (SwS). During preparation of the soft-

TO THE INSTALLATION QUALIFICATION

archive the process and system data so

(PQ). If the grinding process constitutes only

ware, we make exclusive use of development

(IQ)

that they can be duplicated at any time, to

one of several production stages within an

environments (Step7, Zenon, WinCC) and

protect the data against unauthorised

entire manufacturing process, the PQ of the

operating systems (Windows 2000, Windows

In the form of data sheets, the Hardware

access and to document compliance with

complete process is provided by the system

CE) which are already accepted and wide-

Specification (HwS) stipulates the com-

these requirements.

user.

spread in industry. The program sequence

ponents (PC, SPS, field units) that are

plan is further detailed in the module speci-

necessary to fulfil the FS and the SwS. We

During the qualification process, we orient

FROM THE FUNCTIONAL

fication, which forms part of the Software

make exclusive use of equipment and units

ourselves to the GAMP (Good Automated

SPECIFICATION (FS) AND THE

Specification. This makes it possible to redu-

which are generally considered to be

Manufacturing Practice) and FDA (Food and

SOFTWARE SPECIFICATION (SWS)

ce the specification documentation to the

industrial standards, which are accepted

Drug Administration) directives, in which

TO THE OPERATION QUALIFICATION

by the pharmaceutical industry and for

special automation technology require-

(OQ)

which all the documents and certificates


necessary for the qualification, such as

ments are stipulated.


The Functional Specification (FS) is determi-

equipment data, equipment descriptions,

The IQ protocol documents that the equip-

All the sequences necessary to qualify a

FROM THE USER REQUIREMENT

ned together with the customer and inclu-

manufacturer's declarations or Ex certifica-

ment has been correctly installed, includes

system are defined by us in in-house stan-

SPECIFICATION (URS) TO THE

des details of the grinding principle and all

tes, are already on hand.

cross-references from the equipment data

dards, the protocols and documents are

PERFORMANCE QUALIFICATION (PQ)

major peripheral conditions such as site of

to data sheets, and records the results in

standardised and have proved themselves in

installation, Ex-zone categorisation, safety

line tests, with which the function of the

practical operation.

The User Requirement Specification (URS)

requirements, etc. The FS is documented in

individual units as well as the complete

Once the system is qualified, we can react

contains the main product specification and

the form of a P+I (piping and instrumenta-

signal flow can be controlled.

quickly and professionally to customer

thus the requirements with respect to the

tion) diagram and a description of the grin-

requirements, integrate new components,

grinding system. Using this as a basis, we

ding system.

perform risk analyses, take new clauses in

then define the characteristic parameters

The P+I diagram shows the process-technolo-

standards and directives into account or

of the grinding process, the product fine-

gical sequence within the system and forms

integrate newly developed technologies.

ness, the throughput per hour and finally

the basis of the program sequence plan,


minimum. To permit testing the faultless

URS

PQ

function of all the sequences defined in these documents, we prepare the Operation

PQ-Protokolle

FS

OQ
SwS

Qualification (OQ) protocols, which are


simultaneously used to prove the correct
function of the grinding system. The advantage of the modular structure of our specifi-

OQ-Protokolle

HwS

h
IQ

IQ-Protokolle

Installation
Softwareerstellung

cation is that double and multiple tests of


one and the same function are avoided
during the OQ tests. This saves time and furthermore keeps the test records within
acceptable limits.

THE V-SHAPED MODEL SHOWS THE


FUNDAMENTAL SEQUENCE OF A
SYSTEM QUALIFICATION AT HOSOKAWA ALPINE

PROCESS TECHNOLOGIES FOR TOMORROWSM

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