2017-00

TECHNOLOGY AND INDUSTRIAL AUTOMATION

Fruit Juice
Production
Automated

MEMBERS:

 KATHERINE HUAYTA
 YAZMIN PAREDES
 ESTUARDO CASTAÑEDA
 RENATO CUBA
 CARLOS BARRENA

SECCIÓN: IN196

[1] 2017-00
CONTENT
ABSTRACT:..........................................................................................................................................5
CHAPTER 1:........................................................................................................................................6
INTRODUCTION..................................................................................................................................6
THEORETICAL FRAMEWORK...............................................................................................................8
OBJECTIVES OF THE AUTOMATIC SYSTEM.......................................................................................20
CHAPTER 2.......................................................................................................................................23
DETAILED DESCRIPTION OF THE SYSTEM OPERATION:....................................................................23
CHAPTER 3.......................................................................................................................................26
ANALYSIS OF THE CONTROL LOOPS, VARIABLE MEASURES AND MANIPULATED............................26
CHAPTER 4. DIAGRAMS (ELECTRICAL, PNEUMATIC AND INSTRUMENTATION)...............................34
CHAPTER 5.......................................................................................................................................35
ELECTION OF SENSORS, CONDITIONERS, CONTROLLERS, POWER CONTROLS AND ACTUATORS
REQUIRED TO AUTOMATE THE PROCESS.........................................................................................35
1. SENSORS:..............................................................................................................................35
2. CONDITIONERS.....................................................................................................................38
3. DRIVERS:...............................................................................................................................39
4. POWER CONTROLS:..............................................................................................................40
5. ACTUATORS..........................................................................................................................41
CHAPTER 6.......................................................................................................................................42
CONCLUSIONS:...............................................................................................................................42
RECOMMENDATIONS:...................................................................................................................43

[2]
 LIST OF FIGURES

Figure 1. Fruit Juice – Orange and Tangerine.....................................................................................8

Figure 2. Louis Pasteur the scientist who discovered pasteurization...............................................10
Figure 3. Orange...............................................................................................................................10
Figure 4. Tangerine...........................................................................................................................11
Figure 5. Water................................................................................................................................13
Figure 6. Automated Process of Fruit Juice......................................................................................21
Figure 7. Operation of the Extractor................................................................................................21
Figure 8. Pasteurizer.........................................................................................................................22
Figure 9. Industrial Orange Juice Operations Diagram.....................................................................25
Figure 10. FRUIT TANK.....................................................................................................................26
Figure 11. Washed...........................................................................................................................27
Figure 12. Conveyor belt..................................................................................................................27
Figure 13. Selection Fruit..................................................................................................................28
Figure 14. Juice Extractors................................................................................................................28
Figure 15. Filtering...........................................................................................................................29
Figure 16. Deaeration.......................................................................................................................30
Figure 17. Pump...............................................................................................................................30
Figure 18. Pasteurizer.......................................................................................................................31
Figure 19. Heat exchanger...............................................................................................................31
Figure 20. Mixing Tank.....................................................................................................................32
Figure 21. Packing............................................................................................................................32
Figure 22. Cooling.............................................................................................................................33
Figure 23. DIAGRAM.........................................................................................................................34
Figure 24 PLC....................................................................................................................................40

[3]
 LIST OF TABLES

Table 1. Orange Nutritional Information..........................................................................................11

Table 2. Tangerine Nutritional Information......................................................................................12
Table 3. Main Areas of Orange Production in Peru according to the ministry of Agriculture...........13
Table 4. Main Areas of Orange Production in Peru according to the ministry of Agriculture...........14
Table 5. Fruit Consumption by Geographic Area according to INEI..................................................14
Table 6. Fruit Consumption Kg/Persona...........................................................................................15
Table 7. GDP annual historical and projected agriculture of Peru....................................................17
Table 8. GDP Annual Agriculture Projected History of Peru.............................................................17
Table 9 Artisanal production of Peru (thousands of liters)...............................................................18
Table 10 : GDP Manufacturing and Artisanal Production of Peru....................................................19
Table 11. Sensors present in the automatic natural juice system....................................................37
Table 12. Baking system actuators...................................................................................................41

[4]
ABSTRACT:

The present project describes the operation of an automatic system for the production of
fruit juices, where an analysis of the process and the control loops necessary for the
automation of the same was carried out. In addition, this real process allowed to apply
and identify various concepts of process technology and industrial automation, thus
selecting the elements necessary for optimal operation: measured and manipulated
variables, controllers, actuators, sensors, power controllers, among others. In this way, a
feasible control route was developed for the production of natural juices, and the cost
analysis of its implementation.
Keywords: Automatic system for juice production, automation, control loops, process
variables

[5]
CHAPTER 1:

INTRODUCTION

The automatic control of processes is one of the many disciplines whose development has
taken place at an unbridled speed. The intensive use of the techniques of this control has
as its origin the evolution and technification of the measurement and control technologies
applied to the industrial environment.

Its study, analysis and application has made possible the universal recognition of its
various benefits and advantages related to the industrial field, where one can appreciate
one of its greater applications due to the need to control a large number of variables, in
addition to the increasing complexity of the systems. Automatic process control serves
mainly as a cost reduction issue associated with the generation of goods and services. In
addition, it increases the quality and production volumes of an industrial plant, eliminates
errors and increases the safety of the processes.

Before the mass application of control techniques, man was the one who put into practice
his computational capacities and even his physical force to achieve the execution of the
control of a process or machine related to the production. At the present time, on the
contrary, various tasks and calculations associated to the manipulation of the variables
have been delegated to computers, controllers and specialized drives for the achievement
of the system requirements.

The present project includes a detailed analysis of the equipment that is part of the
process of production of industrial juices, which briefly explains the operation of the
system and the process through which our main input is fruit. Analyzing its different
stages such as fruit reception, washing, fruit selection, juice extraction, juice filtration,
juice deaeration, juice pasteurization, concentration of the juice and finally, the packaging.
This analysis will identify the existing and necessary control loops for the automation of

[6]
this process, variables that are measured and manipulated, as well as strategies. In
addition, it will be possible to observe the diagram that represents this system to give us
an idea of how this control system works, the same one that has brought multiple benefits
to the companies that already adopted this automated procedure.

Later, they present some concepts to considering:

Automatic: Science that tries to replace in a process the human operator, by mechanical,
electrical or electronic devices.

Automation: Automatic application to industrial processes.

System: A set of elements that relate to each other in an orderly way, contribute to
achieve a goal.

Automatic control system: A set of physical components connected or related to each

other, so that they regulate or direct their action by themselves, that is to say, without
intervention of external agents, correcting also the possible errors that appear in its
operation.

System Variables: These are the quantities that are subject to control and that define
their behavior (speed, temperature, position, etc.)

Input: Excitation that is applied to a control system from an external power source, in
order to trigger a response.

Output: Response provided by the control system. Disturbance: Unwanted signals that
adversely affect the operation of the system.

[7]
THEORETICAL FRAMEWORK

As we know, at present, a large number of Peruvians consume fruit in different ways. For
example: Fresh fruit, Juices, in foods, etc. However, in this project we will focus on the
consumption of fruit juice like orange and mandarin. The benefits of fruit juices are: They
contain no fat and provide simple sugars by delivering healthy energy. They are rich in
minerals such as calcium, iron and phosphorus. In addition, they contain vitamins A and C,
our body assimilates 85% of its nutrients, so it is ideal to consume a glass of fruit juice a
day, among others.

According to Law D.S.No. 007-98-SA - Sanitary Surveillance of Food and Beverages for
Human Consumption, any company that produces food or beverages must perform a good
sanitary control and control in production.

Figure 1. Fruit Juice – Orange

and Tangerine

[8]
 1. History of fruit juice:

The first need of this industry arose in the military, especially when they traveled across
the sea. Scurvy, a disease very common at that time, is caused by the lack of vitamin C,
which was suffered by seamen (and pirates) until in the eighteenth century began to give
portions of lemon juice to avoid it.
The industrial revolution, between the second half of the eighteenth century and the
beginning of the nineteenth, propitiated the movement of the population towards the
cities and the distance of ways of life more linked to the field and to the work of the earth.
A large mass of people had no direct access to food as they had until recently.
This led to the need to bring plant and animal products in another way, with the obligation
that many of them were treated so that they were kept in good condition for longer to
reach the cities.
That conservation treatment is grateful to Louis Pasteur, the scientist who discovered
pasteurization, a process by which food can be stored, stored and distributed over great
distances without fear of losing their good condition.
Through pasteurization, microorganisms that can alter the state of food are eliminated
without affecting nutritional properties. This advance was key for the juice packaging
industry to make a qualitative leap.
It is also necessary to wait until the industrial revolution to be able to point the emergence
of the more massive consumption because to produce, to pack and to transport the juice
a very specific technology is necessary.
It was in the United States that the way to produce juices arose as we know it now, when
in 1869 the company "Welch", located in New Jersey, began to bottle fruit juice. In Florida,
one of the places where more oranges are produced, industry came into force in the
1920s.

[9]
 Figure 2. Louis Pasteur the scientist who discovered pasteurization

2. Main Inputs:

Fresh Fruit:
Oranges: Oranges are a citrus fruit in the Rutacea family and originated in Southeast Asia.
There are many varieties of oranges; Valencia, Persian, Naval, Jaffa and the Blood.
Oranges are classified into two categories, bitter and sweet, being sweet the most popular
consumption.

Figure 3. Orange

[10]
In this process will be used the orange Valencia that has as properties:

  37.00 -
 Energetic
51.00
Value:
(Kcal.)
  8.25 -
  Carbohydrates:
10.20 (g)
  0.90 -
  Protein:
1.10 (g)
  0.10 -
  Fat:
0.40 (g)
  1.60 -
  Fibers:
1.70 (g)
Table 1. Orange Nutritional Information

It should be noted, in addition that the Oranges stimulate the nervous system, are
therefore effective against nervous convulsions, migraines, cramps and insomnia. Its
richness in vitamins and trace elements make it the best ally against stress and
depression.

Tangerine: The Tangerine is a fruit that has become the new star product of Peruvian
exports and with enormous prospects of development, as the main consumer markets
such as the European Union, the United States, have barely received limited volumes since
the Peru, plus Russia, which is the world's leading consumer.

Figure 4. Tangerine

[11]
In this process will be used the common mandarin that has as properties:

Calories 44,70 kcal.

Fat 0,20 g.

Cholesterol 0 mg.

Sodium 1,10 mg.

Carbohydrates 9,20 g.
Fiber 1,80 g.
Sugar 9,20 g.
Proteins 0,63 g.
64,99
Vitamin A Vitamin C 32,02 mg.
ug.
Vitamin B12 0 ug. Calcium 34,53 mg.
Hierro 0,30 mg. Vitamin B3 0,41 mg.
Table 2. Tangerine Nutritional Information

In addition, it should be noted that the carotenoids present in mandarins due to high
vitamin A have been shown to reduce the risk of liver cancer. Therefore, Tangerine orange
juice received by patients with hepatitis C reduced the risk of developing liver cancer due
to its high content of cryptoxanthin beta. Finally, tangerine have a high level of limonene
that has anti-cancer effects and also helps prevent breast cancer.

WATER:
As we know, water is a substance that can be found in three states: Liquid, Gaseous, Solid.
In this project, we will use water for the washing of fruits and in some more processes that
will be specified later. Most fruits are increasingly considered as foods of a healthy diet.
However, their widespread use can and does in fact lead to a significant number of
processes of infectious origin. Therefore, proper washing and good hygienic measures
make it possible to obtain a product in perfect safety conditions.

[12]
 Figure 5. Water

3. Statistics on Fruits and Natural Juices:

Peru is one of the countries that harvests for more months a year. The sale of citrus goes
increasing year by year by approximately 40%. Next, we will show the main areas of
orange and Tangerine production in Peru.
Main Areas of Orange Production in Peru

Main Areas of Orange Production in Peru (2007)

Region Has TM Performance (TM/has) % Part. T
National 26,358 379,969 14.42 100%
Ica 879 25,503 29.03 7%
Lima 1,960.0 50,839 25.94 13%
Junín 11,302.00 177,489 15.7 47%
Cuzco 1,933 25,737 13.31 7%
Huánuco 865 11,213 12.96 3%
San Martín 1942.0 24,377 12.55 6.00%
Ucayali 624 7,637 12.24 2.00%
La Libertad 243 2,797 11.53 1%
Tumbes 17 351 21.17 0%
Others 6,595 54,025 8.19 14%

Table 3. Main Areas of Orange Production in Peru according to the ministry of Agriculture

[13]
 Main Areas of Tangerine Production in Peru (2007)

Region Has TM Performance (TM/has) % Part. T

National 9,899 187,165 18.91 100%
Lima 3,689.0 112,565 30.51 60.10%
Junín 3,561.00 39,700 11.15 21.20%
Ica 678.2 18,360 27.07 9.80%
Puno 547.0 4,903 8.96 2.60%
Ucayali 479.8 4,405 9.18 2.40%
Others 943.9 7,233 4%

Table 4. Main Areas of Orange Production in Peru according to the ministry of Agriculture

Fruits are one of the most important foods in our country. Therefore, the following table
will be shown that will show the average fruit consumption in the Country.
Average consumption per person Annual fruit according to geographical area

Average Consumption Per Person Annual Fruit According to Geograplical Area

Rest of Area Natural Region

Main types of
Lima the
Fruits
Total Metropolitana1 Country Urban Rural Costa Sierra Selva
Peach(kg) 1.1 1.6 0.8 1.3 0.5 1.4 0.9 0.1
Strawberry(kg) 0.7 1.4 0.3 0.8 0.0 1.1 0.1 0.0
Lemon(kg) 3.4 4.8 2.8 3.9 1.6 4.8 1.7 2
Tangerine(kg) 4.8 7.4 3.7 5.6 2.3 6.5 3.7 0.6
Mango(kg) 1.6 2.1 1.4 1.8 0.9 1.9 1.4 0.6
Apple(kg) 6.1 6.5 5.9 6.6 4.5 6.4 7.2 1.8
Orange(kg) 6.4 6.7 6.2 6.9 4.5 6.8 7.1 2.7
Papaya(kg) 3.2 5.3 2.3 4.0 0.5 4.3 2.2 1.4
Banana(kg) 26.4 14.7 31.6 23.8 34.9 16.5 12.1 104.3
Watermelon(kg) 1.4 1.8 1.2 1.7 0.5 2.1 0.6 0.7
Grapes(kg) 2 2.7 1.7 2.4 0.8 2.5 1.7 0.8

Table 5. Fruit Consumption by Geographic Area according to INEI

[14]
 Table 6. Fruit Consumption Kg/Persona

In this graph it can be observed that banana is the most consumed fruit in Peru with a
26.4 kg / person annually. Second, you will find the orange with a 6.4 kg / person. Third,
you will find the apple with a 6.1 kg / person. Finally, it is in the fourth place the mandarin
with a 4.8 kg / person.

Production and consumption of fruit juices in Peru

In Peru, the production of juices, nectars and various soft drinks comes in growth. This is
generated mainly by domestic demand and the worldwide tendency to choose products
made with natural ingredients that care and improve the health of people. In addition, an
aggressive promotional campaign, focusing on young people as a target audience, as they
do not have enough time to make their own juices.
Exports and imports of fruit juices add up to US $ 55 million in 2014, an average increase
of 12% per year compared to 2013, proving the national tendency to choose natural fruit
juices.

[15]
This growth can also be verified according to indicators of the agricultural sector that has
been growing since 2011 has grown by an average of 1.4% and currently accounts for
approximately 6% of the total Gross Domestic Product (GDP), compared to 1.6% in the
Year 2014, according to information from the Ministry of Agriculture and Risk. This growth
is due to the investments that are giving to the agricultural sector, mainly in the renewal
of programs in the jungle center.

The growth of the agricultural sector in Peru according to statistical data from the Central
Reserve Bank of Peru was calculated a constant growth of the agricultural sector.
In addition, with respect to agricultural production, the constant growth continues to
2019 as shown in the following graphs.
In Peru, the production of juices, nectars and various soft drinks comes in growth. This is
generated mainly by domestic demand and the worldwide tendency to choose products
made with natural ingredients that care and improve the health of people. In addition, an
aggressive promotional campaign, focusing on young people as a target audience, as they
do not have enough time to make their own juices.
Exports and imports of fruit juices add up to US $ 55 million in 2014, an average increase
of 12% per year compared to 2013, proving the national tendency to choose natural fruit
juices.

This growth can also be verified according to indicators of the agricultural sector that has
been growing since 2011 has grown by an average of 1.4% and currently accounts for
approximately 6% of the total Gross Domestic Product (GDP), compared to 1.6% in the
Year 2014, according to information from the Ministry of Agriculture and Risk. This growth
is due to the investments that are giving to the agricultural sector, mainly in the renewal
of programs in the jungle center.
The growth of the agricultural sector in Peru according to statistical data from the Central
Reserve Bank of Peru was calculated a constant growth of the agricultural sector.

[16]
In addition, with respect to agricultural production, the constant growth continues to
2019 as shown in the following graphs.

Annual historical and projected agriculture of Peru

Table 7. GDP annual historical and projected agriculture of Peru

Source: BCRP, Millions of new soles

GDP Agropecuario (millions of

Porcenjate of
Year Production (million soles) soles)
GDP

2009 20,873.00 22,180.00 6.29%

2010 21,766.00 22,940.00 6%
2011 22,658.00 24,060.00 5.91%
2012 23,991.00 26,570.00 6.16%
2013 24,366.80 26,220.00 5.75%
2014 24,698.01 26,690.00 5.72%
2015 25,463.01 27,614.15 5.65%
2016 26,228.01 28,839.61 5.62%
2017 26,993.02 29,935.00 5.57%
2018 27,758.02 31,252.68 5.55%
2019 28,523.02 32,627.80 5.53%
2020 29,288.02 34,063.44 5.51%

[17]
 Table 8. GDP Annual Agriculture Projected History of Peru
The Current Craft Market

According to statistics from the BCRP of production in 2014, the production of nectars and
soft drinks made by SMEs and MYPES has been increasing since 2011 constantly until
today. This is due to the increase of investments in these sectors and the tendency to
consume natural or semi-industrialized products that cause enough people to change
their preferences for this type of products.

Table 9 shows the growth of artisanal production from 2011 to 2015 with constant growth
already mentioned.

Artisanal Production of Peru

Table 9 Artisanal production of Peru (thousands of liters)

source: BCRP 2016

Table 10 shows a comparison of the production of nectars and how its production volume
has varied according to the value of manufacturing GDP from 2011 to 2015, generating
GDP expectations for the following years is in Average 4%.

[18]
 Manufacturing and Artisanal Production of Peru

GDP Manufacturing National artisanal

(million soles) production (liters)

164,168.00 1,158,560.70
196,049.00 1,449,350.80
200,339.00 1,808,305.84
200,874.00 1,818,294.19
212,927.00 2,064,562.78

Table 10 : GDP Manufacturing and Artisanal Production of Peru

Source: Statistical table BCRP 2016

[19]
OBJECTIVES OF THE AUTOMATIC SYSTEM.

The manufacture of natural fruit juices within the industry is characterized by being an
automated system, with greater control and standardized processes to be more
productive in manufacturing. In addition, the automated online fruit juice production
shown in Figure 6 aims to:

1. Improve productivity, reducing the costs of producing fruit juices and improving
fruit quality.

2. To improve the working conditions of the personnel, eliminating the painful works
and increasing the security.

3. Perform operations impossible to control intellectually or manually, such as

extracting juice from the fruit in large volume and manufacture in large quantity
juices in the shortest expected time.

4. Improve the availability of juices, being able to provide the necessary quantities at
the right time.

5. Simplify the maintenance so that the operator does not require great knowledge
for the manipulation of the productive process.

6. Integrate the management and production of fruit juices

[20]
 Figure 6. Automated Process of Fruit Juice

Figure 7 shows the operation of the juice extract in-line, in which we can observe that the
fruit is placed, then the cutter is lowered and the juice comes out. One of the main
processes in the production of fruit juices is the pasteurization, since it allows to take the
juice to 80 ° -90 ° C during 20 or 30 seconds, soon to cool it abruptly. The machine can be
seen in figure 8.

Figure 7. Operation
of the Extractor

[21]
Figure 8. Pasteurizer

[22]
CHAPTER 2.

DETAILED DESCRIPTION OF THE SYSTEM OPERATION:

The operation of the Production System for concentrated and frozen orange juice begins
with the entry of the fruit that will be transported to the plant in trucks, its function is to
leave the fruit in the Fruit Storage Tank (F110) containing water for Minimize the damage
of the discharge of the product, this is controlled with a level sensor and a pneumatic
valve. In this part of the storage silos process, moisture and temperature must be
controlled to maintain the fruit in optimum conditions.
After the raw material is in a fruit tank, it is transferred to the Fruit Wash Tank (F-111),
which is supplied by a water storage tank (F-113) mixed with sodium hypochlorite to
remove the impurities in The surface of the fruit, the water storage tank will be made of a
plastic material, since hypochlorite must be diluted to reduce its corrosive effect, being
controlled with a level sensor and a concentration analysis of chlorinated water. The fruit
is discharged on a conveyor belt (J-112) where there will be a selection of manual fruit. In
addition, an inspection will be carried out with different control instruments that will
select the raw material by its color, texture, flavor, Aroma and general physiological state.
At the end of the band, carry the fruit and enter the Fruit Selector (H-120) by size that is
responsible for selecting the fruit according to its size. First, the larger fruits, then the
medium fruits and finally the smaller fruit.
After the fruit picker passes to the juice extractors (H-121) separating the husk, bagasse,
seeds, juice, pulp and part of the oils, the oil will be transported to the liquid separator
(D-123) Which will be responsible for recovering the essence of fruit and oils from the
previous juice extraction process, to finish its process in the cooling tank (D.124). Then
the product is transported to the Filtration process (H-122) which will allow us to remove
the membranes and skins of the fruit that fell into the juice, this classification can be done
by meshes that will filter the solid waste set.
At the end of this separation process the juice is transported to a de-aeration tank (D-130)
which has a vacuum pump (L-131) to discard the set, the thickness of the tank must be

[23]
considered to guarantee the safety of the tank. process. Following the process, the juice
leaves the deaeration tank to be transported to the Plate Pasteurizer (E-140) which will
carry the juice rapidly at 80-90 ° C in the period of 20 to 30 seconds, then cool it down
sharply and maintain the quality of the juice. The already pasteurized juice can follow two
paths. The first one is carried to the descending film evaporator (E-150) which will be
responsible for achieving a higher concentration, by evaporation of water, the second is
transported directly to the heat exchanger (E-151) that will reduce the Temperature so
that it can be mixed with the fresh product which was not concentrated without suffering
any deterioration. They will then be mixed in the Mixing and Homogenization Tank (M-
152) where it will be possible to recover the components of the aroma of the game that
were evaporated in the concentration process.
Finally, the juice is transported from the mixing tank to metal drums with a double inner
polyethylene bag which will prevent its contact with the metal part of the drum Packing
unit (P-160), having the finished product is carried to The refrigeration unit (P-170) that
allows to keep stored the already packed concentrate at a temperature of 23ºC.

[24]
 DIAGRAM OF PROCESS OPERATIONS

Activity Quantity
Operation 8
Inspection 0
Combined 1

Figure 9. Industrial Orange Juice Operations Diagram

[25]
CHAPTER 3.

ANALYSIS OF THE CONTROL LOOPS, VARIABLE MEASURES

AND MANIPULATED

1. Fruit tank (F-110): in this part the type of controls is performed, one level and the
other flow. The first control of the level of the water is basically so that it does not
surpass the tank, of such way when putting the fruits all this in order. This control
when it is at the proper level closes the valve and stops the water. The other
control is the flow, this is basically filled with the tank, so that it has a speed so it
does not take too long. This control complemented with the control of the level is
not of the fruit washing section at the entrance. The control loop is closed, the
measured variable is the water level and the flow, and the manipulated variable is
the water that is introduced into the machine.

Figure 10. FRUIT TANK

2. Chlorinated water storage tank (F-113): here we have a control of the level of
chlorinated water, in addition to a flow control. The control of the chlorinated water level
takes care of the check when the level is too low to be refilled, all this is with an alarm that
controls the correct level of the tank. On the other hand, we have the control of the flow,
this is responsible for cleaning the fruits by a shower, the flow must be optimal for
cleaning is correct. The control loop is closed, the measured variable is the chlorinated

[26]
water level and the chlorinated water flow, the manipulated variable is the chlorinated
water used to clean the fruits.

Figure 11. Washed

2. Conveyor belt (J-112): in this part a speed control is performed, so that the fruits
that were washed in a correct way were not damaged when being transported so
they cannot go neither very fast nor Very slow because it can be damaged. This
control verifies that the speed is adequate, in case of exceeding the alarm and the
rule, the same if the belt is going very slow. The control loop is closed, the
measured variable is the speed of the belt, and the variable manipulated is the
power of the machine.

Figure 12. Conveyor belt

[27]
 3. Selection of fruits by sizes (H-120): here the fruit picker has a weight controller,
this identifies the different types of fruit and their weight in such a way that it
separates by each type. The control loop is closed, the measured variable is the
weight of the fruit, and the variable manipulated is the power of the machine.

Figure 13. Selection Fruit

5. Juice Extractors (H-121): In this part, the quantity controller, which covers the tooth of
how many fruits per hour. If it does not comply, the operator has been alerted to check
the problem. A closed control loop is used, a measured variable number of fruits, and the
manipulated variable is the power of the machine.

Figure 14. Juice Extractors

[28]
6. Filtering (H-122): In the filtrate we will put a level controller, with which we can identify
the level they want to fill in the tank, once filled the juice will go to the next process. The
controller is basically to identify and prevent the juice from coming out of the container. A
closed loop will be used, the measured variable is the level of the juice, and the
manipulated variable is the juice.

Figure 15. Filtering

7. Deaeration tank (D-130): here we will have a level controller also which will see the
appropriate stop for the tank. This tank works with a pump to exhale the air to the juice,
the controller will notify us when it reaches the correct point and then it will go to the
next process of the juice. The control loop will be closed, the measured variable is the
level of juice, and the manipulated variable is the juice.

[29]
 Figure 16. Deaeration

8. Vacuum pump (L-131): this pump is responsible for removing the air from the previous
process, for which we have an air pressure control loop, this control of the load made sure
that the process is performed The correct way The control loop is closed, the measured
variable will be pressure, and the variable manipulated is the power of the machine.

Figure 17. Pump

9. Plate Pasteurizer (E-140): In this machine we will have a temperature controller, this
controller is in charge of maintaining the temperature of the juice between 80ºC and
[30]
90ºC. The juice must be kept at this temperature so that the juice has a good quality at the
end, if it is not between those intervals to raise an alarm for an operator to adjust the
temperature. The control loop is closed, the measured variable is the temperature, and
the manipulated variable is the power of the machine.

Figure 18. Pasteurizer

10. Heat exchanger (E-151): The heat exchanger has a temperature controller in which we
will lower the temperature to a certain suitable level. The controller is not indicated if the
level is correct, if it is smaller or bigger the operator realizes and can correct it. It has a
closed control loop, the measured variable is the temperature, and the manipulated
variable is the power of the machine.

Figure 19. Heat exchanger

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11. Mix tank (M-152): In the mixing tank there will be a level controller which will verify
that it is suitable. Simply here we will try to homogenize the whole product so that it
leaves the best possible quality. The control loop is closed, the measured variable is the
level of the juice, and the manipulated variable is the power of the machine.

Figure 20. Mixing Tank

12. Packing unit (P-160): In the packaging unit a time controller will be placed, in which
the optimum time must be measured to avoid losses, if the time is greater than indicated,
it will have to be regulated. The control loop is closed, the measured variable is the
estimated time, and the manipulated variable is the power of the machine.

Figure 21. Packing

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13. Cooling unit (P-170): The cooling unit will have a temperature controller which should
be adequate to store the products in a correct way. The control loop will be closed, the
measured variable is the temperature, and the manipulated variable is the power of the
machine.

Figure 22. Cooling

Measured variables:

 Water level
 Water flow
 Chlorinated water level
 Strap speed
 Number of fruits
 Processing time
 Juice temperature
Manipulated variables:

 Power from machines.

 Steam inlet flow passing through the valve.

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CHAPTER 4. DIAGRAMS (ELECTRICAL, PNEUMATIC AND INSTRUMENTATION)

Figure 23. DIAGRAM

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CHAPTER 5.

ELECTION OF SENSORS, CONDITIONERS, CONTROLLERS,

POWER CONTROLS AND ACTUATORS REQUIRED TO
AUTOMATE THE PROCESS
1. SENSORS:
The sensors used in the automatic natural play process are explained below.
1. Level Sensor (F-110)
Sensor to detect the level of water in tank F110
2. Level Sensor (F-111)
Sensor responsible for positioning in the conveyor belt that is sent from
tank F110
3. Level Sensor (F-113)
Sensor identifies level of chlorinated water for the washing of the fruit in
the transit of the conveyor belt
4. Weight Sensor (H-120)
Sensor identifies in 3 weights
5. Temperature Sensor (H-121)
Positioning sensor so you can follow the process of squeezing
6. Temperature Sensor - 80 - 90 ° C (E-140)
Sensor detects that temperature is maintained in the proper range,
otherwise sends signal to regulate it
7. Presure Sensor (E-140)
Sensor detects that the presure is maintained in the proper range
8. Temperature Sensor (E-150)
Sensor detects that temperature is maintained in the proper range,
otherwise sends signal to regulate it
9. Caudal Sensor (P-170)

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 Sensor detects that the caudal is maintained in the proper range, otherwise
it sends signal to regulate it
10. Level Sensor (M-152)
Sensor detects the level of juice in the macro tanks so that they do not
overflow, once reached its maximum level, it is directed the pipes to the
next macro tank
11. Position Sensor (P-160)
Sensor detects the bottle to be able to direct it to the filling of juice of juice
12. Level Sensor (P-160)
Sensor measures the level of juice filling in the bottles so that it does not
overflow
13. Position Sensor (P-160)
Position sensor for sealing with an aluminum cap
14. Position Sensor (P-160)
Position sensor to place label on the bottle
15. Temperature Sensor (P-160)
Temperature sensor for the label and can be stuck in the container
16. Caudal Sensor (L-131)
The flow sensor will serve to know the amount of juice extracted that circulates
through the pipes
17. Level Sensor (D-130)
Level of chlorinated water for the washing of the fruit in the transit of the
conveyor belt
18. Level Sensor (D-130)
Sensor identifies level of chlorinated water for the washing of the fruit in
the transit of the conveyor belt
19. Level Sensor (H-122)
Sensor measures the level of juice filling in the bottles so that it does not
overflow
20. Caudal Sensor (L-131)
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 The flow sensor will serve to know the amount of juice extracted that circulates
through the pipes
21. Presure Sensor (E-151)
Sensor detects that the presure is maintained in the proper range
MACHINE SENSOR APLICATION
F-110 LEVEL Sensor to detect the level of water in tank F110
F-111 LEVEL Sensor to detect the level of water in tank F111
Sensor identifies level of chlorinated water for the washing of the
F-113 LEVEL
fruit in the transit of the conveyor belt
H-120 WEIGHT Sensor measures the weight of the fruit and then classifies i
Sensor detects that the temperature is maintained in the proper
H-121 TEMPERATURE
range
Sensor detects that the temperature is maintained in the proper
TEMPERATURE
range, otherwise it sends signal to regulate it 80-90 º C
E-140
PRESURE Sensor detects that the presure is maintained in the proper range
Sensor detects that the temperature is maintained in the proper
E-150 TEMPERATURE
range, otherwise it sends signal to regulate it
Sensor detects that the caudal is maintained in the proper range,
P-170 CAUDAL
otherwise it sends signal to regulate it
Sensor detects the level of juice in the macro tanks so that they
E-152 LEVEL do not overflow, once reached its maximum level, it is directed
the pipes to the next macro tank
POSITION Sensor detects the bottle to be able to go to juice filling
Sensor measures the level of juice filling in the bottles so that it
LEVEL
does not overflow
P-160 POSITION Position sensor for sealing with an aluminum cap
POSITION Position sensor to place label on the bottle
Temperature sensor for the label and can be stuck on the
TEMPERATURE
packaging
The flow sensor will serve to know the amount of juice extracted
L-131 CAUDAL
that circulates through the pipes
Sensor identifies level of chlorinated water for the washing of the
D-130 LEVEL
fruit in the transit of the conveyor belt
Sensor measures the level of juice filling in the bottles so that it
H-122 LEVEL
does not overflow
The flow sensor will serve to know the amount of juice extracted
CAUDAL
E-151 that circulates through the pipes
PRESURE Sensor detects that the presure is maintained in the proper range

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 Table 11. Sensors present in the automatic natural juice system

2. CONDITIONERS

The signal conditioners have been used in the automated natural juices system described.
These are devices that convert one type of electronic input signal into another type of
signal.

• Amplification:
When a signal is amplified, the magnitude of the signal increases. The conversion of a 0-10
mV signal to a 0-10 V signal is a clear example of amplification.
• Linearization:
Convert a non-linear input signal to a linear output signal. This is common for
thermocouple signals.
• Cold junction compensation:
Used for thermocouples. The signal from this is adjusted to compensate for fluctuations at
room temperature.
• Excitation:
Many sensors require a form of excitation to function. Voltage calibrators and
temperature resistive detectors (RTD) are two common examples.

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3. DRIVERS:

 In the automatic natural juice system, the Programmable Logic Controller (PLC) will
be used.
 To this PLC come all the variables to be controlled according to different processes
in which you can measure the temperature, weight, level of filling, among others.
 The PLCs operate sequentially and cyclically, ie once the program is finished, starts
again.

The elements contained in a PLC are:

 Central processing unit:
 This is responsible for the decisions to be taken related to the control of the
machine or process. During its operation, the CPU receives inputs from different
devices, executes logical decisions and controls the outputs according to the
established program.

Input and output modules:

 They are the section of the PLC where sensors and actuators are connected and
through which the PLC monitors and controls the process.
 Power supply
 Converts high line current voltages to low voltages required by the CPU

Some controls observed in the process of automatic natural juice are:

 Speed Controller of the conveyor belt, controls an established speed
 Water pressure controller in the wash
 Pressure controller in the process of squeezing

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 Figure 24 PLC.

4. POWER CONTROLS:

In the automatic natural juice system, the Inverter inverter will be used to control the
speed of the process motors.

A frequency inverter is a device or system for speed control for AC induction motors,
which is fed at a constant voltage and frequency, and gives the motor a variable voltage
and frequency.

Its operation is based on that it is fed to the equipment with an alternating current (AC)
voltage, the equipment first converts the AC to direct current (DC), through a bridge
rectifier (diodes or SCR's), this voltage is Filtered by an internal capacitor bank, in order to
smooth the rectified voltage and reduce the emission of variations in the signal; Later in
the inversion stage, which is composed of transistors (IGBT), which turn on and off in a
certain sequence (sending pulses) to generate a square wave of CD voltage at a constant
frequency, and its average value has the Frequency sine waveform applied to the motor

The most commonly used inverters use PWM (Pulse Width Modulation) modulation and
use rectifier diode bridge rectifier stage.

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5. ACTUATORS
MACHINE ACTUATOR APLICATION
F-110 PIPE ON/OFF ALLOW WATER IN THE TANK UNTIL THE SENSOR INDICATES IT
F-111 FRUIT POSITIONER ON/OFF DELIVER FRUIT TO WHITE WHEN NEEDED (J-112)
F-113 PIPE ON/OFF ALLOWS HYPOCHLORITE INCOME IN CHLORINATED WATER TANK
H-120 SELECTOR ON/OFF SELECT THE FRUIT BY SIZE INDICATED BY THE SENSOR
H-121 EXTRACTOR ON/OFF PRESSURES IN THE FRUIT TO EXTRACT JUICE, SHELL AND PULP
H-122 FILTER ON/OFF SEPARATE THE PULP OF THE JUICE TO HAVE TWO NEW COMPONENTS
D-130 DESAIRADOR ON/OFF REMOVE JUICE JUICE AIR MOLECULES
L-131 PUMP ON/OFF EJECT PRESSURE SO THAT THE JUICE CAN BE TRANSPORTED BY PIPES
E-140 OVEN ON/OFF INCREASE TEMPERATURE AT 80-90 ° C AND DECREASES TO 0-4 ° C
E-150 EVAPORATOR ON/OFF EVAPORATE JUICE AND ALLOW HIGHER CONCENTRATION
E-151 OVEN ON/OFF HEAT EXCHANGER THAT DECREASES TEMPERATURE
M-152 MIXER ON/OFF THE COMPONENTS ARE MIXED BY HELICES TO RECOVER AROMA
OVEN ON/OFF HOT LABEL FOR IT TO BE FOUND IN THE PACK
P-160
ARM ON/OFF CARRY THE CONTAINER AND SEALED TO THE REFRIGERATION UNIT
P-170 ARM ON/OFF POSSES THE CONTAINER IN THE STORAGE CONTAINING A TEMPERATURE OF 23 ºC

Table 12. Baking system actuators

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CHAPTER 6.

CONCLUSIONS:

1. In conclusion, according to the INEI, it can be observed that the growth of the
agricultural sector has been keeping constant with an increase of approximately
1.5% per annum since 2011, which has not been used to the maximum for fruit
juice consumption. Farmers have the need to export their products and not
generate added value to their raw material.
2. Also, it can be concluded that the natural fruit juices sector in Peru is growing
steadily from 2011 to the present, due to the growth of small and medium-sized
companies producing natural juices.
3. In conclusion, through the work it was possible to show the technical viability of
the implementation of an automated plant for the production of fruit juice, based
on the use of the instruments of control and management of the different
processes for the production.
4. The position sensors chosen for the transmissions are inductive and non-
capacitive, because if any foreign object falls into the belt by mistake it could be
detected by the capacitive sensor and affect the control of the leaks.
5. The use of sensors in each process of the automatic natural juice system is
indispensable, since in this way the variables in question can be measured (speed
of the belt, temperature in the ovens and motors, humidity in the pre-baking
oven).
6. It is necessary to use a conditioner for machines of the automatic baking system,
because it is necessary to convert the signal of direct current to voltage signal so
that it can be read correctly by the PLC
7. To control the speed of the conveyor belts we use a speed variator (inverter) that
works by transforming the frequency in percentages that we established to

[42]
 regulate the effort that the motor makes and in this way to manage the speed of
the strips.

RECOMMENDATIONS:
1. Maintenance of machines, sensors, actuators, etc. must be taken into account.
Used in this process to avoid economic losses from production.
2. It should be taken into account that in the future companies that produce natural
juices can evaluate new areas or processes that can be automated, since this
allows you to reduce times, improve the efficiency of your processes (decrease
errors) and increase your productivity.
3. It is recommended to use two energy boards so that energy consumption is not
concentrated in one, as this could generate short circuits that would affect the
production.
4. It is recommended to search the instruments at the lowest possible price, but to
meet the necessary quality standards with the help of control instruments.
5. Proper maintenance of both the controllers and the motors of the machines is
recommended. Also, periodic checks should be performed on the installed sensors
and actuators to verify that they are working correctly.
6. It is recommended to reprocess the losses that come out of the fruit extraction
process to have a more efficient process and to generate greater utility. In
addition, you can take advantage of all the fruit to give rise to other byproducts
that allow to make the process more efficient and economically profitable.
7. It is recommended to carry out a supplier search that complies with all the
requirements established in the area of product design. In addition, advance
negotiations of the region's crop campaign, serving as an incentive for farmers and
securing the matter Premium in season of scarce.
8. Proper maintenance of both the controllers and the motors of the machines is
recommended. Also, periodic checks should be performed on the installed sensors
and actuators to verify that they are working correctly.

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9. The position sensors of the strips must be on the opposite side to the position
sensors which indicate the arrival of the bread in the oven.

REFERENCE SOURCES

 National Institute of Statistics (2014) Social and environmental

statistics(http://www.ine.gov.ve/documentos/Boletines_Electronicos/
Estadisticas_Sociales_y_Ambientales/
Encuesta_Nacional_de_Consumo_de_Alimentos/pdf/Boletines/201402.pdf ) (Date
of consultation: February 5, 2017)

 Central Reserve Bank of Peru (2014) Statistical data, agricultural sector

(http://www.bcrp.gob.pe/estadisticas.html) (Date of consultation: February 6,
2017)

 GROOVER, Mikell P. (2007) Fundamentals of Modern Manufacturing: Materials,

Processes and systems. Mexico, D.F : Prentice-Hall Hispanoamericana. (Date of
consultation: February 10, 2017)

 BEORKREM, Christopher (2013) Material strategies in digital fabrication. New

York :Routledge. (Date of consultation: February 11, 2017)

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