MEMBERS:

ADANAQUE GUERRERO, DIANA GRACE - 201012428

KUMAGAI HUMAN, JAVIER KENTA - 201212301
DURAND YUCRA , SARA - 20
UNIVERSIDAD PERUANA DE CIENCIAS APLICADAS

INDUSTRIAL
TECHNOLOGY AND
AUTOMATIONS
RESEARCH PROJECT
Company: LAIVE

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EXECUTIVE SUMMARY
The objective we pose is provide valuable information on the
application of the core concepts of process technology and industrial
automation. The specific objective is centered on a real processand
the necessary control loops for the automation of that process.
Suggesting improvements in industrial automation is not only
relatively complex because of the number of solutions possible, but
also, and above all, because of the variety of applications. Ironically,
these in turn are responsible for the multitude of solutions available. If
the analysis of the basic needs is relatively standard, as they will
always involve connecting sensors, actuators, and field controllers
with each other, the options in architecture are numerous and can
impose the need for certain services. The required performances
expected fundamentally depend on the applications.
This paper traces the aplication and develop in an organization. The
principal stages of development are mentioned, from the initial
requirement specifications to the current state of standardization. The
diverse technical solutions are then analyzed and classified. In
particular, we study the general aspects, the medium access control
protocols, and application relationships.

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INDEX
EXECUTIVE SUMMARY.................................................................................... 1
1.

INTRODUCTION........................................................................................ 3

2.

GENERAL DESCRIPTION............................................................................4
MISSION...................................................................................................... 4
VISION......................................................................................................... 4
DISTRIBUTION PLANT.................................................................................. 4

3. DESCRIPTION OF THE PROCESS TO BE AUTOMATED................................6

I.

Pasteurization:...................................................................................... 7

4. ANALYSIS CONTROL OF LOOPS, MEASURES AND MANIPULATES

VARIABLES...................................................................................................... 8
5.

PROCESS AND INSTRUMENTS DIAGRAMAS (ISA S5.1)............................10

6. SELECTION OF AUTOMATIC CONTROL COMPONENTS (Sensors,

controllers, actuators).................................................................................. 12
7.

COST ANALYSIS...................................................................................... 14

8.

CONCLUSIONS AND RECOMMENDATIONS..............................................19

9.

SOURCES OF INFORMATION...................................................................19

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1. INTRODUCTION
Nowadays

because

of

the

technology

and

commercial

advancement, we confirm that we are facing a highly competitive

and

demanding

market, which

requires

varied

products

to

increasingly smaller cycles, that is why companies are looking up

to expand their market share by adopting various measures which
make

them

more

competitive.

These

organizations

have

discovered that industrial automation plays a key rolle in industrial

plants, so the implementation of automated systems contributes to
an increase in efficiency, effectiveness, quality and safety in
facilities in the whole organization.
The subject of Industrial Technology y Automation allows to
develop concrete improvement plants for the industrial sector,
applying

new

technologies,

especially

industrial

automated

systems that integrate and contribute to the competitiveness of

the whole organization.
For this reason, we will use these concepts to make a decision
regarding the analysis of a real process and the necessary control
loops for the automation of that process.
The company is Laive S.A., their commitment is to offer high
quality products at low prices. So, we're going to improve their
dairy processes to make the company more competitive.

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In the following paragraphs, we will present the progress of the

research project applying the basic concepts of the course in the
company and the context in which it is located.

2. GENERAL DESCRIPTION

Companys name: LAIVE S.A.

R.U.C.: 20100095450
Sector: Dairy processing.
Location: Av. Nicols de Pirola 601

Laive is an efficient and innovative dairy company, which offers

products

with

guaranteed

quality

and

recognized

brand

contributing a proper nutrition to their costumers.

This company is committed to be the best strategic agent to their
costumers

and

suppliers;

and

an

excellent

oportunity

of

profitability to the shareholders.

At the same time, Laive is committed to contribute to the growth
of their employees and the welfare of the community operating
with social responsibility.
Laive wants to be recognized as a leading food company in
innovation, technology with consumer-oriented products of assured
quality.

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MISSION
Be innovative, efficient and socially responsible company,
composed of committed people to produce and sell guaranteed
food through trusted brands contributing to healthy food for
costumers.

VISION
Be the leader in innovation of healthy dairy products.

BLOCK DIAGRAM

DOP

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DISTRIBUTION PLANT
The facilities of the yogurt processing plant are divided into five
zones,

separated

by

walls

with

spaces

that

allow

free

communication between areas:

Zone 1 which adjusts content of pretreated milk solids.
Zone 2: there occurs homogenization and pasteurization.
Zone 3 is the area of inoculum preparation, fermentation and
cooling.
Zone 4: in this area is carried out the addition of flavors, colors
and stabilizers.
Zone 5: where is packaged and cooled in yogurt in their
respective containers.

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3.DESCRIPTION OF THE PROCESS TO BE

AUTOMATED
YOGHURT MANUFACTURING FLOWCHART:

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Source: Personal compilation

Here we will have a general description of the process. Firstly, the
company verifies that the milk is clean, then strain the milk in a
sieve with care. Secondly, the company prepares the ingredients,
flavoring and coloring, soon starts the pasteurisation which mean
bringing the milk at high temperature and
temperature quickly.
during

fermentacin.

the lowering the

Next, we mantain a stable temperature

The

product

quality

depends

on,

fermentation time. Gel formation process takes place together with

viscosity changes. Later, homogenisation prevents the formation of
cream and improves flavor and consistency. It is done sharply to
prevent further acidification yogurt. Finally, we sweeteners,
stabilizers, and fruit juices are added, according to product and
close the airtight container to maintain the safety. It is important to
remember that conservation of the cold chain ensures healthy
quality after the products leaves the production site.

I.

Pasteurization:
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Pasteurization of the yoghurt base has two purposes: to reduce the

initial bacterial population to ensure a controlled fermentation after
inoculation of the starter cultures and to inactivate and denature
some enzymes such as lipases, whose actions affect the stability of
the base.
Pasteurization is performed in three stages: heating, holding and
cooling. In the case of yogurt, the treatment involves rapid heating - 9
s - to a temperature of 85 C sustained for a minute, followed by
cooling to 45 C which is the temperature of fermentation.
HTST pasteurization takes place in heat exchangers, plate or doubletube, which are configured to integrate the heat fluxes, using the heat
of the base leaving the support stage and to be cooled to preheat
incoming
exchanger.

base
Thus

it

is

possible to save energy

advantage about 90% of
the energy transferred
to the base.

IDEAL PASTEURIZATION CYCLE

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ACTUAL PASTEURIZATION CYCLE

4. ANALYSIS CONTROL OF LOOPS, MEASURES AND

MANIPULATES VARIABLES

a) There is one control loop (0303) on the given diagram that

consists on the valve (actuator) that is between the heat
exchanger and the deodorizer. This a cascade control because
we only have one manipulated variable (by the pump) and more
than one manipulates variables (base product flow and
temperature). Based in the base product temperature the flow
that will go to the deodorizer will be manipulated. This control
analyzes the quality (pH and concentration of lactic acid) of the
base product obtained by the pasteurization process of the heat
exchangers that will regulate the base product that will go
directly to the fermentation tanks or that will be send back as a
reflux to the deodorizer.

Measured Values: the process is controlled by following the pH

and the concentration of lactic acid

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Manipulated variables:
-

Base product flow

Fermentation tank level
Base product temperature

b) Another control loop is placed in the homogenization tank that

consists in another cascade control. Based in the flow of the
base product after pasteurization the temperature will be
regulated in the heat exchanger and will determine if there will
be a return to the pasteurization process. The controller will
determine if the base product temperature is between the
parameters needed to the homogenization. In case it doesnt
have the established temperature, the base product will be
send back to the heat exchangers.
Measured values: Base product temperature
Manipulated variables:
-

Base product flow in pasteurization

Pressure in homogenization tank (homogenizator)
Temperature in heat exchangers
Level in homogenization tank

C) Has been added a new control loop (0301) on the beginning,

regulating the feed of pretreated milk. It now has a weight meter
at the beginning that will weigh the milk entering to the system
and a pump that will send the milk though the pipes. The relay will
activate the pump depending of the signal send by the weigh
meter that will also activate the entering line valve.
-

Manipulated variable: weight of pretreated milk entering to the

line
D)

Flow of mixed milk, cream and sugar to the deodorizer

Like the last added control loop, has been added another

(0308) but to the cream feed of the system.

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- Manipulated variable: flow of cream entering to the system

E) Control loop 0301 A/B is a feed forward control that flow of mixed
milk, sugar and cream entering to the heat exchangers that will begin
the fermentation process. This is a feed forward control.

5. PROCESS AND INSTRUMENTS DIAGRAMAS (ISA

S5.1)

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6. SELECTION OF AUTOMATIC CONTROL

COMPONENTS (Sensors, controllers, actuators)
Among the many choices of precision measuring devices in the market,
we decided to propose a comprehensive action which consists in an
implementation for future automation. In the next lines, it shows the
principal elements that support our proposal:
I. Sensors:
Temperature Transmitter: A temperature transmitter is an electrical
instrument that interfaces a temperature
sensor

(e.g.

thermocouple,

RTD,

or

thermistor) to a measurement or control

device

(e.g.

PLC,

DCS,

PC,

loop

controller, data logger, display, recorder,

etc.). Typically, temperature transmitters
isolate,

amplify,

filter

noise,

linearize, and convert the input signal from the sensor then send
(transmit) a standardized output signal to the control device.
Pressure
Transmitter:
A pressure
sensor measures pressure,
typically of gases or liquids. Pressure
is an expression of the force required
to stop a fluid from expanding, and is
usually stated in terms of force per
unit area. A pressure sensor usually
acts as a transducer; it generates a
signal as a function of the pressure
imposed. For the purposes of this
article, such a signal is electrical.
II. Controllers:

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 Temperature controller: Temperature

Controllers Analog / Digital (PID), offer
a

quick

adjustment

and

provide

precise temperature management and

control

well

for

variety

of

applications to provide the best price,

design and easy operation. They will
be

the

ultimate

choice for your successful

control in any
Pressure

temperature application.
controller: Is a primary

element
to

connected to the pressure

be

through

controlled,

transforms

mechanical-pneumatic

tire

on a control
This signal is

signal.
amplified

and

pressure for a

driver

that

in

flow

produces

the

output signal.

III. Actuators:
Solenoid Valves: To open and close
the valves that allow the output to
the valve inputs.
Centrifugal
pump:

For

the

transportation of inputs

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7. COST ANALYSIS

TRIBLENDER
Machine Cost ($)
Maintenance Cost (c/3meses) ($)
Setup Fee (3 Technicians) ($)
Training Cost (2 operators - 2 Days)
($)
Hours Cost - Men (2 operators) ($)
Energy Cost ($)
Total Cost ($)

DESODORIZADOR
Machine Cost ($)
Maintenance Cost (c/3meses) ($)
Setup Fee (3 Technicians) ($)
Training Cost (2 operators - 2 Days)
($)
Hours Cost - Men (2 operators) ($)
Energy Cost ($)
Total Cost ($)

8500
80
220
70
0
7
8877

15000
100
330
70
0
9
15509

INTERCAMBIADOR DE CALOR
12000
Machine Cost ($)
90
Maintenance Cost (c/3meses) ($)
Setup Fee (3 Technicians) ($)
Training Cost (2 operators - 2 Days)
($)
Hours Cost - Men (2 operators) ($)
Energy Cost ($)
Total Cost ($)

450
0
0
3
12543

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BOMBA DOSIFICADORA
Machine Cost ($)

450
10

Maintenance Cost (c/3meses) ($)

Setup Fee (3 Technicians) ($)
Training Cost (2 operators - 2 Days)
($)
Hours Cost - Men (2 operators) ($)
Energy Cost ($)
Total Cost ($)

TANQUE DE FERMENTACION
Machine Cost ($)

1
0
0
2
463

4000
12

Maintenance Cost (c/3meses) ($)

Setup Fee (3 Technicians) ($)
Training Cost (2 operators - 2 Days)
($)
Hours Cost - Men (4 operators) ($)
Energy Cost ($)
Total Cost ($)

5
13
7
6
4043

PURCHASE OF EQUIPMENT AND MACHINES

To purchase the above machines, application must be made to list each
one so that the vendor give us the specifications of each team and the
terms of purchase. Then, we perform an analysis to gauge the feasibility
of implementing these machines, this will be done by IRR and NPV
analysis. For the above analysis, it was developed the company's
balance sheet. We must also coordinate with the supplier to reach an
agreement that specified and determined by what means and how it can
be delivered the product (machinery and equipment) and what is the
medium that suits us.
Below is the balance sheet of the company:
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Balance Sheet
Expressed in soles
Activo corriente
Caja Banco S/.
70,000.00
Clientes S/.
250,000.00
Mercadera S/.
500,000.00
Envases y embalajes S/.
200,000.00

T. Activo Corriente S/.

1020,000.0
0

Pasivo Corriente
Proveedores
Remuneraciones
Impuestos por pagar
T. Pasivo Corriente

Pasivo no corriente
Deuda largo plazo

Intereses y comisiones
Activo no corriente
Edificios e S/.
1
instalaciones 000,000.00
Vehculos S/.
1500,000.0
0
Herramientas y S/.
equipos 50,000.00
Terrenos
Mobiliario S/.
700,000.00

T. Activo no S/.
corriente 3250,000.0
0

T. Pasivo no corriente

Total Pasivo

Patrimonio
Capital

S/.
30,000.00
S/.
30,500.00
S/.
10,000.00
S/.
70,500.00

S/.
6
000,000.00
S/.
10,150.00
S/.
610,150.00

S/.
680,650.00

S/.
3580,350.0
0

Reservas
Resultados acumulados

T. Patrimonio

S/.
3580,350.0
0

Total Activo S/.

4270,000.
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00
Total
pasivo
patrimonio

y S/.
4270,000.
00

Below is an analysis of the costs that will be incurred for the purchase of
machinery and equipment important and necessary to be implemented
in the company.
SIGNIFICANT COSTS
Machine Cost ($)
Maintenance Cost (c/3meses) ($)
Setup Fee (3 Technicians) ($)
Training Cost (2 operators - 2 Days)
($)
Hours Cost - Men - Month (2
operators) ($)
Energy Cost - Month ($)
Total Cost ($)
CLCULO DEL TIR Y EL VAN
Aos
Inversin
Costo (S/.)
Produccin
semana

promedio

Ingresos

Hoy

0
-40983

27950
292
450
100
500
163
29455

4.1

200,000

200,000

210000

220500

231

800000

800000

840000

882000

963

la

Costos mensuales
Depreciacin

98,650

Margen Bruto

701350

Gastos Administrativos y Ventas 35200

108761.6
98650
103582.5 25
-8196.6
-8196.6
-8196.6
693153. 728220. 765041.
4
9
775
35200

114
06
-81
840
694

36960

Utilidades antes de Impuestos

666150

38808
407
726233.7 799
657953.4 691260.9 75
94

Impuesto a la Renta (30%)

199845

197386.0 207378.2 217870.1 239

2
7
33
88
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Utilidad Neta

460567. 483882. 508363. 559

38
63
643
506

466305

Depreciacin (+)
Flujo de caja

8196.6

8196.6

8196.6

819

468763. 492079. 516560. 568

98
23
243
106

466305

Tasa de descuento

0.1

Flujo de descuento
VAN

-40983
193839.053
468764.0 492079.3 516560.3 568
1938397.053 8
3
43
06
11%

TIR

0.1
0.1
0.1
0.1
426149.0 406677.0 388099.3 388
73
5
56
85

8. CONCLUSIONS AND RECOMMENDATIONS

The automation's proposal of the production process of the
company LAIVE, generates an investment of S/ 40,983, which is
accesible to the company.
The production size and profitability will sustain such investment
The possibility to automate the processes can eliminate the
employees's limitations in their operations, as well as the delays.
But, most important, reduces human error in the processes by
using standardized process that allows have disponibility and
diversity of production, and reach the costumer satisfaction.
The implementation save manpower and allows greater efficiency
and accuracy.

9. SOURCES OF INFORMATION
http://laiveesvida.com/
http://www.qo.fcen.uba.ar/Cursos/TecnoII/guia.pdf
http://www.sisman.utm.edu.ec/libros/FACULTAD%20DE%20CIENCIAS
%20MATEM%C3%81TICAS%20F%C3%8DSICAS%20Y%20QU
%C3%8DMICAS/INGENIER%C3%8DA
%20INDUSTRIAL/03/PROCESAMIENTO%20%20LATEOS/YOGURT.pdf
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 Slidess course.

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