2 - 7 Mixing - DesignGuide

Tetra Pak Processing System
Plant Solutions
Handled by Owner Approved by Date Version Page
Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 1 (16)
Design Guide
Process Cell
Mixing
Copyright © 2008 Tetra Pak Processing Systems, Lund Tetra Pak Internal
Plant Solutions
Design guide – Reception
Content
1 Welcome to the design guide – Mixing 3

2 Mechanical design demands 4
2.1 General 4
2.2 Interfaces 4
2.2.1 Interface to Powder handling systems 4
2.2.2 Interface to Automatic Liquid handling systems 4
2.3 Material demands 5
2.4 Dimensioning/Engineering/Choice of components 5
3 Design elements and detailed functionality, Mixing station 6
3.1 Transportations 6
3.1.1 CIP phase 7
3.1.2 Production Phase 8
3.2 Storage, buffer tanks 8
3.2.1 CIP phase 9
3.3 Tetra Almix 9
3.3.1 Set Up phase 9
3.3.2 Emptying phase 9
3.3.3 ManAdd phase 10
3.3.4 Design element, G21 10
4 Design elements and detailed functionality, Blending & Dosing 11
4.1 Blending 11
4.1.1 Production Phase 12
4.1.2 Design element, blending 15
4.2 Dosing 16
4.2.1 Design element, dosing 16
Plant Solutions
1 Welcome to the design guide – Mixing

The main purpose of this document is to supply guide-lines and rules to engineer a Mixing
station or a blending/dosing functionality in a Plant. The guide-line is written in the form of a
reference document, i.e. for every issue you find tangible information guiding you to a good
solution for the given requirements.
The main users of the document will be the pre-project engineer to do pricing and quotations
as well as the implementation organization to do the detailed engineering on order received.
The document includes all important issues like interfaces, design elements, etc.
NOTE! This document is made for YOU, NOT TO BE GIVEN TO THE CUSTOMER!
Plant Solutions
2 Mechanical design demands

2.1 General
It is very important to create a good working area for the operators working in the mixing
station area, especially in how equipment is placed and how transports are planned
because many interactions are manual and repeated many times.
2.2 Interfaces
For other general interfaces see Process Path Design guide.
2.2.1 Interface to Powder handling systems

The powder handling systems are not described in this document, only the connections to
the systems. The interface for transport of powder to the Tetra Almix must be solved
regarding
• accuracy of dosing for automatic systems (load cells and flexible connections)
• risk of stoppage in the transport due to vault building in silos (vibrators, hammers
etc)
• no flow due to compressed product in pipe for automatic systems (intermediate
hopper close to Tetra Almix, simple stop valve instead of rotary valve on powder
silos)
• no flow due to compressed product in pipe for manual systems (extra compressed
air connection on powder pipe to increase transport capability)
• how the cleaning should be performed, the powder connection must be
completely dry before powder transport starts (disconnection of hose to Tetra
Almix during CIP, permanent solution with block and bleed)
• how and where connection to Tetra Almix is done (always below liquid surface
when having vacuum in vessel)
2.2.2 Interface to Automatic Liquid handling systems

The liquid handling systems are not described in this document, only the connections to
the systems. The interface for transport of liquids to the Tetra Almix must be solved
regarding
• accuracy of dosing especially when having vacuum in the vessel (flow meters,
load cells and flexible connections)
• how the cleaning should be performed (disconnection of hose to Tetra Almix
during CIP, permanent solution with block and bleed)
• how and where connection to Tetra Almix is done (liquid connection could be
above liquid surface even when having vacuum in vessel)
Plant Solutions
2.3 Material demands

General material demands are stated in the Process Path Design guide.
Vilka krav ställer produkten (lye & acid?) på den rostfria utrustningen (GEP) Sedan kanske
hela sektionen åker in i ett eget dokument.
General Gjsdfjd
2.4 Dimensioning/Engineering/Choice of components

General mechanical demands are stated in the Process Path Design guide. Below is only
highlighted the specific demands for a reception.
Plant Solutions
3 Design elements and detailed functionality, Mixing station

To fulfill the previously chosen functionality in the mixing area, the transportations (i.e.
incoming and outgoing lines to and from buffer tanks and Tetra Almix) and the buffer
tanks, design elements and phases are chosen from chapter below.
Phase adjustments for the mixing area are also described in this chapter.
3.1 Transportations
To choose the functionality of the transportations in the mixing area, see process path
transportation.
There are some functions shown in the table below that are important and common for
all the transportations and configurations in the mixing area (i.e. incoming and outgoing
line to buffer tanks and line to Tetra Almix). Each function has a relation to a phase
which belongs to a unit (i.e. production line). The function is put into practise by a
design element, if applicable
Function Phase Design Config

element 1 -4
Transportation Production G01,G10- X
G12
Cleaning CIP VG11- X
VG55
Emergency Production N/A X
emptying
Flush 2 Production VG11- X
VG55
Maintenance Maintenance N/A X
Drain Production VG11- X
VG55
Note: X means that the function is applicable in the configuration
Plant Solutions
The functions that differs between the transportations are shown in the table below
Transport: Incoming line to buffer tank

Function Phase Design Config Config Config Config
Element 1 2 3 4
Heating Production E30-E33 X X X X
Cooling Production E20-E22 X
Queuing of Production N/A X X X X
productions
Connection to XferOut Q10-Q54 X X X X
buffer tank
Transport: Line to Tetra Almix
Element 1 2 3 4
Heating Production E30-E33 X X X
Cooling Production E20-E22 X
Connection to Xfer N/A X X X X
Tetra Almix
Connection XferIn N/A X
from Tetra
Almix
Transport: Outgoing line from buffer tank
Element 1 2 3 4
Heating Production E30-E33 X X
Cooling (bypass Production E20-E22 X X X
Tetra Almix)
Queuing of Production N/A X X X X
productions
Connection to XferOut Q10-Q54 X X X X
line from tank
outlet
3.1.1 CIP phase

Production lines:
The cleaning is initiated from the main control room.
Plant Solutions
3.1.2 Production Phase

Main step sequence can be found in PFS_Mixing.
Product change
If product A is pushed by product B (see Mixing Sales Guide, Material Separation). The
mix product that is left in the circulation line will be mixed with the new product.
Queuing
If queuing source and destination tanks no filling and emptying should be taken place at
the same time.
Cooling & Heating
Parameters and additional steps are added to the production phase.
3.2 Storage, buffer tanks

To choose the functionality of the buffer tank, see process path storage.
Below table shows the functionality described in PFS_Mixing (PPR process path
storage) and applicable in the mixing area. Each function is connected to a phase which
belongs to a unit (i.e. buffer tank). The function is put into practice by a design element.
element 1 2 3 4
Common Filling & V11 - V32 X X X
inlet/outlet Emptying
Separate Filling & V11 - V32 X X X
inlet/outlet Emptying
Cleaning CIP V11- V32 X X X X
Agitation Agit G01-G03 X X X X
Heating Heating E10-E22 X X
Cooling Cooling E10-E22 X
Sampling QA B10-B40 X X X X
Cleaning CIP X41-X43 X X X X
devices
Maintenance Maintenance N/A X X X X
Waiting Wait N/A X X X X
Manual ManAdd N/A X X X
addition
Automatic AutoAdd X
addition
Plant Solutions
3.2.1 CIP phase

Buffer tanks:
The cleaning is initiated from the main control room.
3.3 Tetra Almix

To choose the functionality of Tetra Almix, see mixing guidelines on Business Unit
Dairy Beverage & Prepared Food homepage at Orbis.
Below table shows the functionality described in PFS_Mixing (PPR process path
storage) and applicable in the mixing area as well as functionality local in the Tetra
Almix unit. Each function is connected to a phase which belongs to a unit (i.e. Tetra
Almix). The function is put into practice by a design element
Function Phase Internal Design Config Config Config Config
Tetra element 1 2 3 4
Almix
phase
Emptying Emptying G21 X
Manual ManAdd G21 X X X X
addition
Automatic AutoAdd G21 X X X X
addition
Circulation Internal G21 X
circulation
Vacuum Set Up Vacuum G21 X X X X
Agitation Set Up Agitation G21 X X X X
Cooling Cooling G21 X
Heating Heating G21 X
Sampling QA G21 X
Waiting Wait G21 X
3.3.1 Set Up phase

The Set Up phase is a configuration phase where the operator via e.g. a recipe configure
if agitation or/and vacuum should be enabled.
3.3.2 Emptying phase

This phase is only used to empty the content when running Tetra Almix as a batch mixer.
Plant Solutions
3.3.3 ManAdd phase

This phase is to be used when adding ingredients manual. In Tetra Almix several of
manual addition functions exist. E.g. ManAdd_1, ManAdd_2, Lance
3.3.4 Design element, G21
The interface from the liquid line into the mixing unit is a normal Xfer. The interfaces
from the mixing unit to the buffer tanks are normal Xferin’s (see configurations).
The level in the mixing unit must be controlled by the incoming flow (other alternatives
exist).
Process connections
The Almix unit connections are described by Business Unit Dairy Beverage & Prepared
Food.
Plant Solutions
4 Design elements and detailed functionality, Blending & Dosing

To fulfill the previously chosen functionality for blending and dosing, design elements
and phases are chosen from chapter below.
Phase adjustments for the blending and dosing functionality are also described in this
chapter.
4.1 Blending
To choose the functionality of the transportations constituting the blending functionality,
see process path transportation.
Transport: Line 1 (Master)

Function Phase Design
element
Transportation Production G01,G10-G12
Cleaning CIP VG11-VG55
Emergency Production N/A
emptying
Flush 2 Production VG11- VG55
Maintenance Maintenance N/A
Drain Production VG11-VG55
Transport: Line 2 (Slave)
Function Phase Design
element
Cleaning CIP VG11-VG55
Emergency Production N/A
emptying
Flush 2 Production VG11- VG55
Maintenance Maintenance N/A
Drain Production VG11-VG55
Plant Solutions
4.1.1 Production Phase

The production phase Master (Line 1) and Slave (Line 2) must have some
interconnection signals between each others step sequences to synchronize the
production flow.
The Production “Master” has to divide the production line into two parts. The first part is
called Fill/FlushToMixPoint and the second Fill/FlushToDest.
Fill/FlushToDest
Fill/FlushToMixPoint
Line 1
Line 2
4.1.1.1 Production sequence

The sequences below visualize the need of new signals and steps. The new steps are shown
as green boxes.
New parameters:
Parameter name Description Unit

ProductAvailable Product available at MixPoint Boolean
ProductRequest Product request Boolean
FillToMixPoint Fill volume to mix point kg / litre
FlushToMixPoint Flush volume to mix point (enabled by flush 2 command) kg / litre
Following are to be considered:

o Total volume are displayed and calculated by Production “Master”
o Flush 2 is selected from Production “Master” faceplate concerning both production
lines
o The various production modes are to be disabled
o No batch change on the fly
Plant Solutions
Production Production
”Slave” ”Master”
Idle Idle
Wait for source Wait for source
FillToDest FillToMixPoint
Product available
Wait for product
Wait for product request
available
Product request
Production FillToDest
Production
Flush initiated by volume calculation and flush 2 is

selected
FlushToDest FlushToMixPoint
Draining FlushToDest
Completed Draining
Completed
Main step sequence can be found in PFS_Mixing (PPR Process Path

Transportation).
Plant Solutions
4.1.1.2 Flush volume calculation

The flush from Master and Slave has to be synchronized. Meaning, when flush 2 from line
2 has finalized the flush 2 “part FlushToMixPoint” from line 1 has to be finalized. To
synchronize the finalizing of the flushes, the start for each flush has to consider the
individual flow rates and the line volumes. Picture and calculation below visualize an
example.
FlushToDest = 200 l
FlushToMixPoint = 100 l
M
Line 1
FlushToDest = 20 l
Line 2
Flow speed is set to 50% of the speed from the

master production line (Line 1)
Total volume = 10 000 l
Start flush Line 1:

Flush of line 1 will add an extra 50 % from line 2 since this line is running 50% of line 1
 100+50 = 150 litre in point M.
 To flush the whole line 1, 200 litre is add to the 150 litre = 350 litre
Flush line 1 will start 10 000 litre – 350 litre. When total volume has a value of 9650 litre
flush will be initiated.
Start flush Line 2:

Flush of line 2 will add an extra 200 % from line 1 since this line is running twice the
speed of line 2
 20 + 40 = 60 litre in point M.
 To flush the whole line 2, 200 litre is add to the 60 litre = 260 litre
Flush line 2 will start 10 000 litre – 260 litre. When total volume has a value of 9740 litre
flush will be initiated.
Plant Solutions
4.1.2 Design element, blending
The Blending connection consists of two parts, one distribution Qxx which belongs to the
“Master”, Line 1 and one CIPR and drain connection belonging to the “Slave”, Line 2.
The Qxx and Vxx design element could be chosen dependent on product and flexibility
need. All these design elements are described in Process Path Transportation.
The interface from the line 2 into the master line 1 is a normal Xferout.
Plant Solutions
4.2 Dosing
To choose the functionality of the dosing, please, contact Business Unit Dairy Beverage
& Prepared Food. Also information regarding internal functions, process connections and
implementation are available here.
4.2.1 Design element, dosing

Design elements for dosing are shown below:

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Tetra Pak Processing System

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 1 (16)

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 2 (16)

Design guide – Reception

1 Welcome to the design guide – Mixing 3

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 3 (16)

1 Welcome to the design guide – Mixing

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 4 (16)

2 Mechanical design demands

2.2.1 Interface to Powder handling systems

2.2.2 Interface to Automatic Liquid handling systems

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 5 (16)

2.3 Material demands

2.4 Dimensioning/Engineering/Choice of components

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 6 (16)

3 Design elements and detailed functionality, Mixing station

Function Phase Design Config

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 7 (16)

Transport: Incoming line to buffer tank

3.1.1 CIP phase

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 8 (16)

3.1.2 Production Phase

3.2 Storage, buffer tanks

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 9 (16)

3.2.1 CIP phase

3.3 Tetra Almix

3.3.1 Set Up phase

3.3.2 Emptying phase

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 10 (16)

3.3.3 ManAdd phase

3.3.4 Design element, G21

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 11 (16)

4 Design elements and detailed functionality, Blending & Dosing

Transport: Line 1 (Master)

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 12 (16)

4.1.1 Production Phase

4.1.1.1 Production sequence

Parameter name Description Unit

Following are to be considered:

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 13 (16)

Wait for source Wait for source

Flush initiated by volume calculation and flush 2 is

Main step sequence can be found in PFS_Mixing (PPR Process Path

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 14 (16)

4.1.1.2 Flush volume calculation

Flow speed is set to 50% of the speed from the

Total volume = 10 000 l

Start flush Line 1:

Start flush Line 2:

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 15 (16)

4.1.2 Design element, blending

Markus Andersson Ferdinand Franz Mikael Odelius 2009-11 1.0 16 (16)

4.2.1 Design element, dosing

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