Optimization

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Presentation to

CoFE 2016 September 14, 2016

Introductions Pablo Coronel, PhD Director, Food Processing Chemical Engineer (EPN, Ecuador, 1995) PhD Food Science (NC State University, 2005)

Awards 2002 IFTSA Product Development Competition 2009 Industrial Achievement Award 2015 Industrial Achievement Award 2015 Industrial Scientist Award 2015 IFT – EXPO Innovation Award 2015 Edison Award 2016 Edison Award 2010 USDA-ARS Technology Transfer 2015 NC State FBNS Outstanding Alumnus 2015 NC State CALS Outstanding Alumnus

CRB Overview

CRB Overview Full-Service Provider

900 staff

Engineering Architecture Construction Consulting Commissioning

nationwide

$100MM Prof Services

18% LEED accredited 2015 Plant of the Year

$350MM

Mars Chocolate North America Greenfield Confectionery Facility

Design / Build Annual Revenue

Awards 14 offices

2007 2009 2010 2011 2013

Office Locations

Boston Philadelphia

Kalamazoo

Rockville San Jose

Boulder

Kansas City

St. Louis

Los Angeles

Raleigh

San Diego Atlanta Dallas

San Juan

Industry Commitment

Discipline Breakdown ARCHITECTURE

CONSTRUCTION

90 210

PROCESS & PACKAGING

220 185

MEP

Industry Awards & Recognition #2 and #13

American Concrete Institute

________________________________

Honorable Mention

Sustainability

________________________________

_____________________________

Bulk Biologics Facility Shire HGT, Lexington, MA

Project BioCork Centocor Biologics, Ltd, Cork, Ireland

2009

2010

2011

2011-2012

Equipment Innovation & Process Innovation

Company of the Year Award

________________________________

________________________________

Inhalable Insulin Facility MannKind Corporation, Newbury, CT

The first ever Design & Construction company to receive this award twice

Engineering NewsRecord ranked CRB #2 in Pharmaceuticals and #13 in Industrial Process

2012

MidWest Lab Renovation, Under $10MM ________________________________

R&D Lab Renovation CEVA Biomune Lenexa, KS

2013

________________________________

Low Rise Buildings Mars Chocolate North America Topeka, KS

2014

2015 Plant of the Year Confectionery Manufacturing Facility Mars Chocolate North America Topeka, KS

2015

CA Top Projects Award of Merit, Interior/ Tenant Improvement High Honors & Technology Award _______________________________

Laboratory of the Year Award, R&D Magazine

________________________________

Engineering News-Record Laboratory Tenant Improvement Project Celgene Corporation San Diego Facility Integration ________________________________

KC ASHRAE Technology Award Kansas Bioscience Authority Incubator Lab Project Olathe, KS

Flexible Volume Manufacturing Project Biogen Idec RTP, NC

Southeast Award of Merit, Manufacturing ________________________________

Engineering News-Record Beta Facility Herbalife Winston-Salem, North Carolina

Specialty Areas of Service

Food Process Expertise PROFITABILITY QUALITY Innovation:

Design: • • •

•

Unit operations Thermal process Equipment selection and sizing Hygienic Design and review

• • • • •

Scale-up Modeling New technologies Non-thermal Start-up

FOOD SAFETY: Compliance with applicable regulations cGMP - HARPC - FDA – USDA-FSIS Third Party qualifications: BRC – SQF-GFSI Thermal Process Authority (FDA – LACF)

Optimization: • • • •

Run-Time Operational parameters CIP optimization Utilities

Packaging Expertise

Sample Packaging Projects/Services:

Capacity

Quality

• New and duplicate mold sets/dies • New vendor qualification • New manufacturing location • New line at existing manufacturing location

• In specification but not performing on the packaging line or in transportation and warehousing • Supplier Audit

Productivity / Savings • Light weighting • Down sizing • Material optimization • Vendor production site change • Efficiency Studies

Innovation • • • •

New technology New materials New line equipment Process Assessment or Revision

Operations Improvement Methodology

Data driven decision making Systematic approach to identify and quantify improvements Tracking of metrics that meet project goals Scoping of improvements to provide a clear path for implementation

Thermal Process Design and Optimization Engineering Approach

Thermal Process Design

Define Problem Think about it Model it

Pilot

Solved!

IT IS NEVER EASY!!

Thermal Process Design

GOAL is well defined: • • • • •

Preserve food product for long(er) shelf life Preservation by thermal treatment Product must be Safe (microbiological) Obtain products of high Quality (mmmm?) Balance of Quality and Safety is the PROBLEM?

Thermal Process Design Thermal Process must balance Quality and Safety? • Traditionally these have been the two main factors • Designers are now pushed to find designs which have flexibility, longer run times, cleanability, efficiency, carbon foot print and low cost of production

Flexibility presents many challenges • • • •

Shorter runs of more specialized products Process must be able to adapt to many final products Cleaning time must be short Change-over must be very quick

Thermal Process Design Scale up from lab scale or kitchen scale to production Muppets’ Swedish Chef practicing process design for food products

• Based on experience and Best Proven Practices • Require many iterations or experiments - time • There is no systematic exploration or design of innovative processes

Process Systems Engineering for Thermal Processing

Process Systems Engineering Process Systems Engineering is a branch in Chemical Engineering that allows the systematic exploration and improved decision taking for the design, construction, operation, and control of conversion processes Scale up and experimentation are shortened with support of mathematical modeling Unit Operations are chosen based on the transformations needed to achieve a product, and these may include one or more transformations Methods and techniques for this decision taking are integral part of PSE. Modeling, Simulation and Optimization are the most advanced tools

Process Systems Engineering Reactive Distillation (Siirola – Eastman Chemical)

Traditional

After P.S.

Process Systems Engineering Conceptual Process Synthesis Analysis

Systematic generation of processes • Transformations required for the process are combined generating many alternatives • Properties of the materials and products are both the input and the objective

Heuristics are used to determine whether the routes are possible • Operations can be combined or extraforces used to increase transport rates

simulations performance process and product quality

flowsheet equipment operating data

Process

Product physical and functional properties

molecular structure morphology

Synthesis optimization

Superstructure optimization

Objective

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Process Systems Engineering Process Systems Engineering principles from the chemical industry should apply in the food industryC.. Raw Materials

Processing

Basic Chemicals

Processing

Industrial Products fibers, films, specialty chemicals

Processing

Consumer Products drug delivery patches post-it cosmetics

C or maybe we need to think it a bit more

Food Process Systems Engineering Food Products are different???? • Products are based on Consumer needs/wants – not on purity • Have many components; and may have several phases • Phases may not be in equilibrium • Raw materials have “natural variation”

• Rheology is complex • Functionality is important • Structure determines the performance of the product

Engineering for Structure Hair Conditioner

Low shear

Bread

High Shear Proper kneading

Fertilizer

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Low kneading

Engineering for Structure

Flour Water Oil/Fat Emulsifier Thickeners Salt Sugar Flavors

Engineering for Structure Nano-scale ( 103 m)

Supply Chain Engineering

Unit Operation Products Control

Factory

Modeling to understand effect of meso-processing in the microstructure

Supply chain

Product Driven Process Design Process Synthesis

Product Driven Process Design

Product is specified but process is not

Neither product nor process is specified

Focus on models of manufacturing process

Focus on models of product properties

Search technique to select among process alternatives

Search technique to select among product alternatives

Goal is lowest cost manufacturing process

Goal is added value through enhanced product properties

Product Driven Process Design • Process Design for Food Products needs to be a systematic process • Properties of the input materials and final products can be estimated within a range • Basic transformations can be listed and explored theoretically – Structuring depends on processing – Constraints determine the possible transformation networks and this include legal/regulation, microbial, flavor, etc.

Ingredients

?

Product

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Product Driven Process Design goal

Selection of: unit operations interconnections, dimensioning and cost estimation

develop an cost efficient and flexible process for the conversion of available raw materials into a target product

scope Constraints Safety – Microbiology Legal - Regulatory Cost Availability

Ingredients Thermodynamic state of ingredients Model of properties

Ingredients

? Selection of process units Interconnections Equipment sizing Operating conditions Basic cost estimate/model

Product

(Range of) products with specifications and for each product the production rate

Product Driven Process Design Ingredients

?

A Change of phase

Product

A1

B1

C1

B Separation/merging C Reaction

A2

B2

C2

D Change of spatial distribution A3

B3

Process Design • Determine the conversions needed to obtain the product • Create a network of conversions

C3

Product Driven Process Design

Ingredients

?

Product

Process Design • Properties need to be analyzed and modeled to provide best possible processing choices

• Conversion network is converted into Unit Operations by adding constraints • Unit Operations need to match conversions

• Cost is a major factor • Flexibility needed in plant to prepare for possible new products

Product Driven Process Design Modeling and Simulation Processing must be simulated to help with decision taking and speed up innovation

Properties of ingredients, and final products are used in modeling the effect of Processing in the Structure

Operations are also simulated and drive cost savings

Ingredients

?

Product

Product Driven Process Design Start Framing Level

Framing Level

Consumer Wants

Consumer Wants

GO

Product

Product

Input/Output

Input/Output

Task Network

Task Network

Mechanisms-Operating window

Mechanisms-Operating window

Multi Product integration

Multi Product integration

Equipment selection

Equipment selection

Multi Product-equipment integration

Multi Product-equipment integration

GO

Level of detail / refinement

Approval Marketing Supply Chain

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Level

Activity of the level

0

Framing level.

Define product within project and business context.

1

Consumer wants: Determine product attributes using qualitative/quantitative descriptions. Translation of qualitative to quantitative functions.

2

Product function: Define product properties Convert quantifiable attributes into a set of product properties

3

Input-output level. Specify streams input/output. Choose inputs (ingredients) and the descriptors of the output (microstructure, flavour profile and microbiological status). Determine performance parameters such as economic potential, hygienic considerations, flexibility, pumpability, availability.

4

Task network. Define the fundamental tasks needed to go from input to output, taken from a cluster of tasks. Tasks that require a certain sequence or that belong together without any doubt are grouped, to reduce the number of sequencing possibilities. Then, a network is made from the selected tasks and clusters.

5

Mechanism and operational window. Select mechanism and principles that can be used to perform a task. Includes driving forces and kinetics. Operational window of the problem (time, P, pH, shear, T, etc.) is defined.

6

Multi product integration. Look for overlaps and possibilites of combined production. Outcomes of steps 0 – 3 for the different products are compared. Scale-effects are taken into account.

7

8

Scope & knowledge

Generate Alternatives

Analyze performance of alternatives

N Evaluate Select

Equipment selection and design. Select unit operations. Integration possibilities should be considered (e.g. by combining tasks with the same driving force that are close together in task network). The operational window from step 3 is compared to the operating boundaries of the unit. Then, the final design of the units and final flowchart are made. Multi Product-equipment integration: Optimize flow sheet. Multi-stage scheduling based on strategy on level 0

Development program

Feasible? Y

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Report

Product Driven Process Design Modeling results are meticulously obtained, numerically sound, and visually represented

Challenges Transformation of consumer attributes to measurable properties. EG. Spreadability to viscosity • Modeling of structured products attributes

Effects of microstructure on the performance of products • Modeling of microstructure effects

Effects of processing into microstructure Decision making for task networks • Control objectives • Heuristics 35

Conclusion Product Driven Process Design provides a systematic approach at generating innovative and cost efficient processes Must include consumer – product – process - supply chain considerations

Models of properties, products and processes are needed

Constraints determine the possible processes

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