The subject of the invention relates to a production line, especially fully automatically controlled one, for producing fruit concentrates or juices, and to a method of controlling a fully automatically controlled production line for fruit concentrates or juices, whereby such a line comprises multiple interconnected devices performing consecutive phases of a technological process and functioning in such a manner that full automatization and controlling such a production line from one location is possible.

In fruit processing known and used production lines for producing concentrates comprise basic machinery such as those for unloading raw materials, for cleaning raw materials, presses, filters, clarification and storage tanks, conveyors typical for concentrate or juice production.

From the description of polish patent No P. 201486 there is a known device for processing juice comprising a tank connected by conduits and valves with feed pumps, with plate-type exchangers unit, with a coil and with plate-type filtering unit, whereby the coil and the exchangeable plate-type filtering unit are connected with each other by conduits and valves, whereas plate-type exchanger unit having advantageously five sections is connected with a cooling unit, and on the device's outlet there is also a mixing and dosing valve with a meter measuring temperature of an outgoing product.

From polish patent No P.202012 there is a known method and a device for juice filtration, especially for fruit juices, whereby the said device has an integrated juice chamber comprising two tanks for cloudy juice and one tank for cleared juice, whereby cloudy juice tanks have supply and mixing conduits 135° offset at the level of half way up of the integrated juice chamber height. Furthermore the cloudy juice tanks and the cleared juice tank in their upper part have a rinsing and spraying unit, and the bottom of each of the tanks is sloping towards one of a tank's axis, and furthermore the cloudy-juice tanks are interconnected in their upper and bottom parts by an arrangement of conduits and valves and by a feeding unit comprising a flow meter, a circulator pump controlled from a panel of a computer controlling unit, and a manifold supplying juice to the filtering membranes, whereas juice portion which is not cleared is redirected through conduits and through valves to a cloudy-juice tank, and the whole device is made of chrome-nickel steel.

The purpose of the invention was to create a production line which eliminates all the inconveniences present in known manufacturing lines of such type, as well as to create solutions allowing automatization and optimisation of production, reduction in maintenance and operating costs of machinery in such a line, energy usage reduction, and environmentally safe water and sewage management.

A production line for fruit concentrates or juices, especially fully automatically controlled one, according to the invention is characterised in that it consists of section I, section II, section III, section IV, section V, section VI, section VII, section VIII, section IX, section X, section XI, section XII, section XIII and these sections comprise an arrangement of machines performing particular technological operations which together constitute a process of producing fruit concentrate or juice as illustrated on the diagram, whereby section I of the line comprises machines designed for receiving and unloading truck or rail deliveries of raw materials including: a hydraulic tippler, optionally, a device for unloading freight delivered by waterways, a receiving storage tank, a shovel conveyor, a cross conveyor, a mobile conveyor, a reversible conveyor, silos, a slatted shutter slide, section II relates to hydrotransport of raw materials and comprises: a circulator pump, a drum filter, a screenings press, a buffer tank, an additional circulator water pump, section III comprises devices for removing debris from a raw material and for fractionation of a raw material including: a sorter, a destoner, a scraper conveyor, a vertical screw elevator, a bucket conveyor, a roller inspectionconveyor, an inspection modular belt conveyor, an intake hopper for transfers from trie inspection belt to a mill, a hammer mill, a knife mill, a crusher, in section IV, where process of depectinization takes place, there are following devices: a buffer tank, an enzyme dosing station, a motor pump, section V comprises a pulp heater and water treatment devices, section VI comprises devices for pressing and disposal processes, that is: a pulp tank, pumps for powering presses, a basket press IPS, a belt press, a water dosing unit, a horizontal screw conveyor placed under a press, an inclined screw conveyor, a sieve filter, a raw juice tank, in pasteurisationsection VII there are following devices: a pasteurisation section of a six-stage evaporation station, a tank for aromas, and a condensate tank, clarifying section VIII comprises a depectinization tank and a station for dosing clarifying agents, filtrating section IX comprises an ultrafiltration station and a tank for clarified juice, section X for concentrating juice comprises a six-stage evaporation station and a condensate tank, in juice standardization section XI an averaging tank with an upper agitator for storing products for shipment is located, section XII for storing products comprises a storage tank and a pump transporting juice from storage to tank vehicles, section XIII comprises washing station CIP, whereas in section XIV there are additional machines placed, such as: a tippler for pallet boxes, a receiving container, a hydro-pneumatic washer, whereby section XIV for additional machines for soft fruits is advantageously equipped with an unloading system for pallet boxes based on roller conveyors carrying pallet boxes to an automatic tippler equipped with a system for rinsing pallet boxes and for transporting unloaded boxes to their collection place, a master module for central control CK comprising subordinate sections A, B, C, D, E, F, G, H, I which manage listed above operational sections comprising production machinery together with a control signal circuit, as presented on the diagram. The equipment in sections I to XIV has been functionally and operationally unified and equipped with sensors, valve blocks with sensors, controlled valves, CCTV systems with cameras, detection systems, strain gauges, and connected together through an interface based on SIMATIC 7A system and on industrial visualization SCAD WinCC through distribution and control system SRS with Asi bus system wfthdistribution and control modulesA, B, C, D, E, F, G, H, I and then connected together into one control system witha central computer CK.

Each of the devices in sections I to XIV has a distribution and control system SRS connected by electrical and electronic installations for controlling and monitoring with the control and visualization system SCAD WinCCand connected with the distribution and control modules A, B, C, D, E, F, G, H, I.

The distribution and control modules A, B, C, D, E, F, G, H, I have the control system (SRS) which is connected by electrical and electronic installations for controlling and monitoring with the control and visualization system SCAD WinCC for monitoring and for diagnosing a particular device and which sends data to the central computer CK.

Some pieces of the production line equipment, such as: the receiving container and the buffer tank in sections I, II have been equipped with strain gauge measuring system which dispenses a certain quantity of a product distributed to the grinding section III.

Some pieces of the production line equipment, such as: the sorter, the destoner, the scraper conveyor, the vertical screw elevator, the bucket conveyor, the roller inspection conveyor, an inspection modular belt conveyor, the intake hopper for feeding materials from the inspection belt into a mill, the hammer mill, the knife mill, the crusher in section III have been equipped with an automated system for monitoring raw materials based on a multiple-axlespider-type industrial robot.

The circulator pumps in section II have built-in a tripled rum self-cleaning filter set and an automatic system for discarding solid fractions which separates impurities.

Some pieces of the production line equipment, such as: the hammer mill, the knife mill, the crusher In section III, have been equipped with a system for rotation detection and with magnetic sensors monitoring rotary movement and with strain gauge vibration meters.

The six-stage evaporation station w section VII is equipped with aninter-stage filtration system based on two automatically controlled plate filters where the process of soaking and sterilization of the filter plates takes place.

In the storage and the concentrate-averaging tanks in sections XI I XII a cooling system is combined with a ventilation system and with a system for measuring temperature of products stored in tanks. Each device in sections XI and XII has a built-in automatic system for triggering a washing process for a particular device in the production line which includes also preparation and delivery of washing agents controlled by the central computer through distribution and control module F.

A method for controlling a production, especially fully automatically controlled one, of fruit concentrates and juices according to the invention characterised by the fact that signals from equipment from sections I to XIV are transmitted by sensors to the controlling system SRS and by Asi bus system to modules A, B, C, D, E, F, G, H, 1, and next via the interface to the central computer CK which has a monitoring and registering program, and next the data is processed in the computer into a visualization and thus an assigned process is being monitored on an ongoing basis.

The central computer CK, advantageously, controls and monitors all the equipment in sections I to XIV and at the same time diagnoses them and records data.

The central computer CK controls ail processes in sections I to XIV and at the same time adjusts parameters and records.

The central computer CK performs management of supplementary components used in the process, controlling their concentration and dosage. The central computer CK enables Identification of each manufacturing batch located in the storage, including identification of a raw material used, production parameters and final parameters of a product.

The central computer CK sends reports to a plant technologist who supervises the manufacturing process.

The production line according to the invention enables to completely eliminate manual work and a high level of product uniformity is being achieved.

The line allows to eliminate all inconveniences and to introduce new solutions which enable production optimisation, reduction In maintenance and operating costs of machinery.Great emphasis has been put on energy usage and on water and sewage management, which reduces environmental footprint of this new technological line.

The object of the invention is shown on fig.1 which presents exemplary general layout of such an installation.

The example of implementation of the invention presents a production line and a method of controlling such a fully automatic production line for fruit concentrates and juices, where this line comprises: section I, section II, section III, section IV, section V, section VI, section VII, section VIII, section IX, section X, section XI, section XII, section XIII, section XIV and these sections comprise sets of equipment for performing particular technological operations which together constitute theprocess of producing fruit concentrate or juice, as presented on the diagram.

Furthermore the line comprises a master control section CK and subordinate sections A, B, C, D, E,F, G, H, I which manage the above mentioned operational sections comprising manufactory equipment together with a control-signal circuit,as presented on the diagram.

Section I comprises the equipment for receiving and unloading truck or train deliveries of the raw material, that is: a hydraulic tippler 1, optionally, a device for unloading cargo delivered through waterways 1a, a receiving storage tank 2, a shovel conveyor 3, a cross conveyor 4, a mobile conveyor 5, a reversible conveyor 6, silos 7, and a slatted shutter slide 8.

Section II for hydrotransport comprises a circulator water pump 9, a drum filter 10, a screenings press 10a, a buffer water tank 11, and an addrtionalcirculator water pump 12.

Section III comprises machinery for removing debris from raw materials and for fractionation of raw materials, that is: a sorter 13, a destoner 13a, a scraper conveyor 13b, a vertical screw elevator 14a, a bucket conveyor 14b, a roller inspection conveyor 15a, an inspection modular belt conveyor 15b, anintake hopper for feeding materials from inspection belt 15b into a mill, a hammer mill 17a, a knife mill 17b, and a crusher 17c.

In section IV process of depectinization takes place and there are following devices in this section: a buffer tank 18, an enzyme dosing station 19, and a motor pump 20.

Section V comprises a pulp heater 21 and water treatment devices.

Section VI comprises equipment for pressing and disposal processes, that is: a pulp tank 22, pumps for powering presses 23, a basket press IPS 24a, a belt press 24b, a water dosing unit 24c, a horizontal screw conveyor 24d placed underthe presses 24a or 24b, an inclined screw conveyor 24e, sieve filters 25, and a raw juice tank 26.

Section VII for pasteurisation comprises following equipment a pasteurisation section of a six-stage evaporation station 27, a tank for aromas 27a, and a condensate tank 27b.

Section VIII for clarifying comprises a depectinization tank and a station for dosing clarifying agents 29.

Section IX for filtration comprises an ultrafiltration station 30 and a tank for clarified juice 31.

Section X for concentrating juice comprises a concentrating station ofthe six- stage evaporation station 32 and a condensate tank 32a.

Section XI for juice standardization comprises an averaging tank 33 for storing produce for shipment with an upper agitator.

Section XII for storing products comprisesa storage tank 34 and a pump 35for transporting juice from storage facilities to tank vehicles.

Section XIII comprises a washing station CIP 36, whereas in section XIV there are additional machines placed, such as: a tippler for pallet boxes 37, a receiving container 38, and a hydro-pneumatic washer 39.

Section XIV for accepting soft fruits is equipped with an unloading system for pallet boxes based on roller conveyors carrying pallet boxes to an automatic tippler equipped with a system for rinsing pallet boxes and for transporting unloaded boxes to their collection place.

The production line eliminates all inconveniences and has such an equipment set which enables production optimisation, reduction in maintenance and operating costs of this equipmentGreat emphasis has been put on energy usage and water and sewage management which makes environmental footprint of this technological line smaller in comparison with other lines of such type.

The line is equipped with a system which self-optimises the technological process which in turn allows production output to be uniform and safe and where identification of each manufacturing batch in storage facilities is possible. The technological line is equipped with numerous devices connected together into one autonomous system which communicates with a user through a user-friendly and intuitive interface based on industrial system SCAD WinCC.

Individual devices are connected together into a uniform system for producing concentrates and juices. The entire system is composed of individual sections, in the first section, where the manufacturing process starts, operations related to receiving raw materials take place, that is there is a weighing system where inflows of raw materials and outflows of final product are being performed, and, thanks to the fact that this system is connected with the master system, data about the quantity of raw materials stored in silos is being automatically updated, and, at the same time, by monitoring current production capacity, the system calculates anticipated volume of purchases being planned. In exactly the same way the system updates the current stock of final products informing what quantity of raw materials can be purchased while taking into account current production volumes. The system allows also such information as estimated time of a truck unloading to be displayed.

After delivery trucks with raw materials have entered the facility, next they are directed to the unloading section, where unloading processes take place. By implementing a dry method of unloading, losses of raw materials, which occur in wet methods of unloading, whereby some amount of juice is being washed away by water, have been reduced.

The unloading system, supervised by personnel, is equipped with a system for blocking lorries doors, which enables fast and safe way of opening them and unloading the freight.

Next, raw materials are transported by the system of belt conveyors equipped with an appropriately designed system of cleaners which separate debris from raw materials.The system has an automatic system for transporting waste material to a press, from where they are being transferred to containers in form of solid waste.

The master system funnels raw materials using conveyances to appropriate silos. The process of filling silos is being monitored by CCTV systems and, based on that, the controlling system fills in and empties out silos in an appropriate order.

Furthermore, the transport system is equipped with an automatic system which funnels raw materials into appropriate containers in order to inspect their quality. These containers have a production batch number assigned during raw materials reception printed on them. The grinding section is equipped with an automatic system for inspecting quality of raw materials based on a multiple-axle spider-type industrial robot connected with the CCTV system which can identify raw materials that do not meet the criteria. A section for receiving soft fruits is equipped with an innovative system for unloading pallet boxes based on roller conveyors which transport pallet boxes to an automatic tippler equipped with pallet box rinsing system and for transporting unloaded boxes to the place of their collection.

Individual sections are controlled by the central system. The section for fruit pulp heating controlling and monitoring the technological process in accordance with a desired formula, controlled by the central system.Theautomatic section for pressing, the automatic section for pasteurisation, the flows of materials, the evaporating station, the raw juice tanks and all the sections which constitute the production line according to the invention are monitored and controlled from the central system.

The line has an equipment for depectinization and for monitoring a system for enzyme dosing, a station for clarifying, ultrafiltration, and sediment filtration, a station for evaporating and for condensing, concentrate receivers, an automatic storage which also keeps data on manufacturing batches, an automatic system for preparing the concentrate for sale, an automatic system for loading tanker vehicles including sterile loading, a multi-line CIP station, security systems, inspection of sewage wells and automatic shutters in primary ducts. The line has a master system for controlling, monitoring, diagnosing, reporting, preparing production formulas, generating reports and production settlements, showing production costs and quantities of materials needed for carrying out production.

The control of the line is carried based on control system SCAD WinCC which allows to integrate the whole production line into one system of control, inspection, diagnosing, reporting and archiving. The technological line is managed from one location, that is from the central control room. The controlling system automatically prepares the components of the production line and manages them.

A production line, especially fully automatic one, for producing fruit concentrates and juices composed of a set of devices which are grouped in sections and which constitute a production chain, comprising devices that are functionally and operationally unified and that are grouped in sections I to XIV, and whereby the said devices are equipped with sensors, valve blocks with sensors, controlled valves, CCTV systems, detection systems, strain gauges, and are connected together via an interface based on SIMATIC 7A system and on industrial visualization SCAD WinCC system through distribution and control system SRS with Asi bus into distribution and control module A.B.C.D.E.F.G.HJ, and next connected together into one control system with the central computer CK. .

Each one of the devices 1 to 36 in sections I to XIV is equipped with distribution and control system SRS connected by an electrical and electronic installations for controlling and monitoring the operations with the control system SCAD WinCC with visualization and connected with distribution and control modules A.B.C.D.E.F.G.H.I.

Distribution and control modules A, B, C, D, E, F, G, H, I are equipped with SRS control system which is connected by an electrical and electronic installation for controlling and monitoring the operations with the control system with visualization SCAD WinCC for supervising and diagnosing the equipment and which sends data to the central computer CK. Devices 2 and 11 in sections I and II are equipped with a strain gauge system for measuring required doses of a product to be passed on to fractionation line of section III. Devices 13 to 17c in section III are equipped with an automatic system for inspecting raw materials based on a multiple axle spider-type industrial robot.

Devices 9 and 12 in section II are equipped with a built-in tripleself-cleaning drum filter set and an automatic system for discarding solid fractions which separates impurities. Devices 17a, 17b, and 17c in section III are equipped with a system of rotation detection and with magnetic sensors monitoring rotary movement and with strain gauge vibration meters. Device 27 evaporating station in section VII is equipped with an inter-stage filtration system based on two automatically controlled plate filters where the process of soaking and sterilization of the filter plates takes place. In storage tanks 34 and in concentrate-averaging tanks 33 in sections XI and XII a cooling system is combined with a ventilation system and with a system for measuring temperature of products stored in the tanks. Each device in sections XI and XIV has a built-in automatic system which triggers washing process of the equipment and which includes also preparation and delivery of washing agents which is controlled by the central computer through distribution and control module F. Signals from the equipment in sections ! to XIV are transmitted through sensors to the control system (SRS) and by Asi bus system to distribution and control modules A, B ,C, D, E, F, G, H, I, and next, via the interface, to the central computer CK which has a monitoring and registering program, and, next, the data is processed in the computer into a visualization and thus an assigned process is being monitored on an ongoing basis.The central computer CK controls and monitors all the equipment in sections I to XIV and, at the same time, diagnoses them and records data. The central computer CK controls and monitors ail the processes in sections I to XIV and, at the same time, adjusts parameters and performs recording The central computer CK performs management of supplementary components used in the process, controlling their concentration and dosage.The central computer CK enables identification of each manufacturing batch located in the storage facilities, including identification of raw materials used, production parameters and final parameters of products.The centra! computer CK sends reports to a plant technologist who supervises the manufacturing process.

27b. Condensate tank