Cross-functional process technology

Standardised process modules are bringing significant technical and economic benefits in areas - such as filtration, heating and cleaning - that span a range of industries and applications.

The automobile industry is showing how to master the twin challenges of keeping investment and operating costs as low as possible while meeting requirements for quality, performance, safety and documentation. They are building a wide range of models and brands on one standardised vehicle platform. The manufacturers are deliberately moving away from individual production to a module-based system.

Big advantages in production and qualification

In the production of equipment and manufacturing systems for the beverage and food industry, standardisation extends to the areas of quotation processing, engineering, construction, assembly and automation, as well as purchasing and supplies of components. Savings of around 15% can be achieved along the whole value-added chain through in-company repetition and scale economies. According to GMP (good manufacturing practice), the parameters relevant to process and production technology not only have to be achieved, they also have to be certified and documented. In this task, too, standardisation is a great benefit: The necessary documents can then be generated quickly and with minimum efforts in a predefined procedure. Experience has shown that without a modular system, often 10 to 20% of the investment costs go on GMP qualification alone.

Skid modules enable individual adaptation

The basis for any standardised process component is a frame-mounted module, or skid. On this stainless steel frame the system components are pre-mounted mechanically and electrically, and already function-tested before delivery. In parallel with this the system manufacturer carries out the qualification required by GMP, including documentation. Skid design lends itself, of course, well to individual adaptation. This includes, for example, built-in measurement technology or the valves or pumps used.

The finished module has standard transport dimensions and is therefore suitable for delivering on a truck or in a container. Because of this extensive preparatory work at the manufacturer’s plant, the system can very quickly be commissioned at the place of application, in line with GMP requirements. Essentially, only the input and output flows have to be set up and operating resources such as power and water connected up. In later operation all the components are easy to access, which simplifies all processes from visual monitoring to replacing even the tiniest components such as seals. Maintenance procedures are also correspondingly facilitated.

Large systems also benefit

Standardised process components therefore reduce costs and effort, both for the operator and for the systems manufacturer. This win-win effect makes this ‘platform strategy’ so interesting for many process components in the brewing, beverages, dairy and food industries. These include CIP/SIP systems as well as water-processing systems, flash pasteurisers and even entire membrane beer filtrations for breweries with an annual production of up to 1.5 million hectolitres.

Larger producers also benefit from the skid idea, despite the construction limitation, because the standardised modules can be combined with each other and used either as single functional units or as a full system. The systems are then fitted together from several skid units at the point of application. Today it is possible to create entire brewhouse lines or kieselgur filter cellars with considerable outputs.

What else is also possible in the field of process technology worldwide using modular solutions will be on show at drinktec in Munich, from 16 to 20 September 2013.