Introduction To Industry Scenarios
The core of food and beverage production is hygiene and sterility, CIP/SIP in place cleaning, 3A/EHEDG certification, high humidity and high temperature, foam/viscous media, frequent batch switching, food safety traceability, and 24-hour continuous production.
Typical measuring points:
Raw material processing: raw milk/juice/syrup storage tank level, blending tank level/pressure, ingredient tank weighing/level
Fermentation brewing: fermentation tank liquid level/pressure/temperature, saccharification tank liquid level, beer/wine fermentation pressure
Sterilization and homogenization: UHT sterilization machine pressure, homogenizer pressure, hot water/steam pipe network pressure
Filling and packaging: filling machine material cylinder pressure, buffer tank liquid level, conveying pipeline pressure
CIP cleaning: monitoring of liquid level in the cleaning solution storage tank, pressure in the cleaning circuit, and acid-base concentration
Public works: Purified water/ice water tank level, steam pressure, compressed air pressure
Adapt to Core Products
QDY30A food grade hygiene input type liquid level transmitter (316L stainless steel Ra≤0.8μm、 No dead corners, CIP/SIP tolerance, -20 ℃~125 ℃ IP68、 Anti foam)
QDY60 series special static pressure liquid level transmitter for viscous/foam media (flat film, anti adhesion, anti syrup/fruit syrup/yogurt viscous blockage, foam filtering algorithm)
QDW90A-3051 sanitary flange liquid level transmitter (3A certification, quick installation chuck, flat membrane anti scaling, fermentation tank/mixing tank specific)
QDKG food grade hygiene intelligent pressure switch/transmitter (0.075 grade, 316L, flat film, high temperature steam resistance, anti viscosity, sterilization/filling specific)
GLG sanitary grade anti-interference signal isolator/RS485 (2500V isolation, anti frequency converter/mixing motor interference, long-distance transmission in food workshop)
S803/SS803 Sanitary Digital Display Instrument (IP65, 316 shell, waterproof, on-site alarm, CIP area/filling line wall mounted)
Product Function
QDY30A/QDY60+QDW90A-3051 liquid level category (storage tank/fermentation tank/blending tank)
Liquid level of raw material storage tank (juice/syrup/raw milk): 316L sanitary level, no dead corner, anti foam, real-time monitoring of liquid level, linkage of feed/discharge pump, precise control of batching amount, ensuring batch consistency, preventing overflow/empty cans, and meeting food safety traceability.
Liquid level/interface of fermentation tank: quick loading chuck, easy disassembly and cleaning, 125 ℃ SIP resistant, monitoring liquid level of fermentation liquid and foam layer, controlling fermentation volume and ventilation, stabilizing fermentation environment, improving fermentation efficiency, and preventing foam overflow pollution.
CIP cleaning solution tank level: acid and alkali resistant, anti adhesion, monitoring the cleaning solution level, automatically proportioning acid and alkali concentrations, ensuring cleaning effectiveness, preventing cross contamination, and complying with GMP hygiene standards.
Ice water/purified water tank level: sanitary grade, long-term stable, real-time monitoring of water volume, ensuring stable cooling/production water supply, preventing water outages and shutdowns, and reducing energy consumption.
QDKG food grade pressure switch/transmitter (sterilization/filling/pipe network)
UHT sterilization machine pressure: resistant to high temperature steam, leveling film, anti vibration, precise control of sterilization pressure (150 ℃/0.4MPa), ensuring sterilization effect, eliminating microbial residues, extending product shelf life, and complying with food hygiene standards.
Filling machine material cylinder pressure: high precision, fast response, stable filling pressure, ensuring consistent capacity per bottle, reducing filling errors (± 0.5%), improving yield rate, and reducing material waste.
Fermentation tank pressure: Micro pressure type, sanitary grade, controlling the micro positive pressure inside the tank (50-200Pa) to prevent the invasion of miscellaneous bacteria, ensure pure fermentation, and enhance product flavor stability.
Steam/compressed air pipeline network pressure: temperature resistant, long-term stable pressure, monitoring pipeline network pressure, ensuring the stability of sterilization/heating/pneumatic valves, and preventing process control caused by insufficient pressure.
GLG sanitary grade isolator (strong interference/clean area)
Food workshop frequency converter/mixing motor interference: 2500V isolation, common mode rejection ≥ 60dB, cutting off ground loop, suppressing peak interference, DCS signal no drift/jump, no false interlocking, ensuring continuous production, data traceability Anhui Qidian Automation Technology Co., Ltd.
Long distance signal transmission in clean area: RS485+Modbus, signal attenuation free, packet loss rate<0.1%, real-time synchronization of central control and workshop data, meeting the traceability requirements of intelligent food manufacturing Anhui Qidian Automation Technology Co., Ltd.
S803/SS803 Sanitary Digital Display Instrument (Local/Clean Area)
CIP area/filling line on-site display: IP65 waterproof steam, 316 shell, high brightness LED, visual inspection reading, no entry into humid/high-temperature areas, safe and efficient, in compliance with clean area regulations.
Over limit alarm/interlock: relay output, linked sound and light alarm, emergency stop/valve closing, 1-second response, anti overflow/empty tank/overpressure accidents.
Data upload/accumulation: Modbus communication, connected to the food MES system, energy/material consumption statistics, fault tracing, meeting ISO22000 food safety system requirements.
Addressing Industry Issues
The hygiene requirements are strict, and ordinary instruments are prone to accumulate dirt and grime. Non sanitary instruments have blind spots, are difficult to clean, and breed bacteria, leading to product contamination, batch scrapping, and high food safety risks.
Foam/viscous medium (fruit juice/syrup/yogurt), inaccurate liquid level measurement
Ordinary liquid level meter is interfered by foam, stuck and blocked, data drift, large batching error, and poor batch consistency.
CIP/SIP high-temperature acid and alkali cleaning, instruments are prone to corrosion and damage
Ordinary instruments are not resistant to 125 ℃ steam/acid and alkali, and fail after 3-6 months, frequent replacement, affecting production, and high maintenance costs.
Unstable sterilization/filling pressure, multiple product quality defects
Large pressure fluctuations, incomplete sterilization, uneven filling volume, low yield rate, frequent customer complaints, short shelf life.
Strong electromagnetic interference, signal jumping and false alarm
Frequency converter/mixing motor interference, DCS false alarm and false shutdown, affecting production continuity and increasing manual intervention costs
Frequent batch switching, time-consuming cleaning/calibration
Ordinary instruments are complex to disassemble, slow to calibrate, long downtime for changing production lines, and low production efficiency.
Direct Customer Benefits
Quality and safety benefits (core)
Hygiene grade design: Microbial contamination risk reduced by 100%, batch scrap rate reduced by ≥ 95%, meeting 3A/EHEDG/GMP standards, and passing food safety audits.
Accurate control of liquid level/pressure: Batch consistency improved by ≥ 98%, filling error reduced by ≥ 90%, yield rate increased by 3% -5%, customer complaints reduced by ≥ 90%.
Reliable sterilization: The sterilization qualification rate is 100%, the product shelf life is extended by ≥ 30%, and the market competitiveness is improved.
Production efficiency and capacity benefits
Anti foam/anti blocking: the failure rate of liquid level measurement decreases by ≥ 90%, the unplanned downtime decreases by ≥ 95%, the annual effective production time increases by ≥ 12 days, and the production capacity increases by ≥ 3%.
Quick cleaning/production change: The quick installation design reduces disassembly time by ≥ 80%, shortens downtime of the production line by ≥ 50%, produces ≥ 50 batches per year, and increases revenue by ≥ 2 million yuan.
Automatic control: Reduce manual intervention by ≥ 70%, increase production efficiency by ≥ 40%.
Energy conservation, consumption reduction, and cost-benefit analysis (direct cost savings)
Accurate ingredients: Reduce material waste by ≥ 8%, save ≥ 8000 tons of raw materials annually for a beverage factory with an annual output of 100000 tons, and save ≥ 4 million yuan in costs.
Energy saving operation: Reduce steam/electricity consumption by 3% -5%, with an annual energy-saving/steam cost of ≥ 1.2 million yuan.
High reliability and long lifespan: The instrument has a lifespan of 2-3 years, with an annual maintenance cost reduction of ≥ 75% and a reduction in spare parts/labor expenses of ≥ 350000 yuan.
Compliance and Traceability Benefits
Accurate and traceable data: meets ISO22000/food traceability requirements, the data is authentic and cannot be tampered with, enhancing brand trust.
Clean and compliant: Verified by CIP/SIP, in compliance with national food safety production standards, avoiding production stoppage and rectification.
