PRODUCTS

Blending

Digital In-Line Blending is a method of standardizing products or blending products together by introducing multiple streams of flow or components into a common pipe or small vessel.

Digital blending can be thought of as continuous standardization of product. Digital In-Line Blending is similar to batching in that ingredients and additives are metered together into a tank or pipe. However, it differs in that all the ingredients are metered simultaneously at accurately controlled rates using digital technology to assure that the product batch is within specification at all times. Digital In-Line Blending could refer to a continuous stream of small batches, those being whatever mixing residence time the process piping affords. One might say that a batch size, in Digital In-Line Blending, is determined only by the amount of mixing volume or residence time required prior to downstream operations or filling. Therefore, Digital In-Line Blending size may be as small as ounces in the head of a pump, or as large as gallons in a small batch tank or balance tank prior to downstream processing. There are a number of factors which dictate how small a batch can be. For example, if minimal agitation is required to standardize the product and if the product is not sensitive to In-Line mixing, then the product can be standardized or digitally blended together into a common piece of pipe or into the suction of a pump or through an In-Line static mixer. On the other hand, if the product requires additional mixing, such as emulsions, or requires some specific chemical reaction, then a vessel or tank will be required. It is possible that Digital In-Line Blending may use a small balance tank or vessel to achieve the proper agitation or mixing prior to further downstream processing.

The technique of continuous In-Line blending for product standardization is not a simple flow rate control scheme. It is a completely engineered, synchronized, accurate system. It utilizes a variety of meters specifically selected for each ingredient's unique physical characteristic. Typically a meter will generate a pulse for a specific unit volume. An example would be a component flowing at 50 gallons/min through a magnetic flow meter, which is equipped with a 2KHZ pulse output calibrated for 100 GPM full flow. This would be generating 1200 pulses per gallon. That is, we would be able to meter to better than 1000 parts of a gallon. By forcing the control system to maintain a plus or minus output accuracy of 1 pulse, this stream would be controlled to better than 1/1000 of a gallon.

Continuous digital blending technique does exactly that. It forces all the metered flows to respond to errors of plus or minus 1 pulse as metered. The overall system is synchronized by having a common demand for product total ratioed by each stream. This demand is then paced back by any stream which cannot keep up until the total product demand is low enough that the pacing stream can keep up. This means that the total product rate will never exceed the slowest ingredient's ability to deliver. The end result is that the total product, or blend, is optimized and balanced for ingredients and rate of production.

Digital In-Line Blending technique also provides for standardizing of product by component, in other words, accurate material balance.

Batching

JCS Controls' Batch Processing application software is compliant with the SP88 standard. Our approach is highly efficient and flexible because it is designed to not only meet the letter of the SP88 specification, but its true intent. The Control Recipe and execution is done in the PLC rather than in a PC, while Recipe Handling, the Master Recipe, Production Planning, and Batch Records are maintained in the Supervisory Computer.

This approach optimizes the system resources in several ways:

• the PLC becomes the real-time, industrial-strength workhorse it is designed to be
• the PC pulls only the necessary data from the PLC and converts it into usable information, then makes it available to other parts of the organization, on an as-needed basis
• network resources are optimized because the data remains where it is needed within the organization, and only that which needs to be shared is made available to other areas, freeing up network bandwidth as much
  as possible

JCS Controls offers:

• Total Integration capabilities: we supply Turnkey solutions because we understand the implications and importance of integrating the process design with the control system, plant equipment and utilities, and people
• Integration of Plant Floor Production systems with Business Systems through standard hardware, software, and networked operating environments
• Modular Systems: designed to be cost-effective, to expedite start-ups, and to facilitate maintenance, cleanability, as well as future enhancements, modifications, and process control flexibility
• Experience in process development and implementation specific to the Food, Beverage, and
  Pharmaceuticals industries
• In-Plant expertise: working effectively with Management, Operations, Engineering, and Maintenance

Process Control Systems

JCS has the ability to control your existing process. We will review your process and design a control system tailored to your needs. JCS has a online pinning chart function to allow the customer to make real time online changes to their sequenced process. All JCS control systems are supplied with documented electrical schematics, and operator manuals for ease of use and maintenance. We offer distributed control systems, allowing for ease of installation (Lower Cost) and a better fit for most applications.

Aseptic Process

Direct Steam Injection (Ultrasys^TM)

The JCS Controls, Inc. complete ULTRASYS^TM aseptic processor for low acid products assures product and process integrity. By coupling proven aseptic technology, and the best in aseptic equipment, with JCS Controls, Inc. process and control engineering expertise and know how, we are able to offer a system of superior performance at a most cost effective price.

The ULTRASYS^TM aseptic system, by JCS Controls, Inc., integrates the best available components to provide a complete system of the utmost efficiency. The key major components used are: a PHE preheater/cooler plate heat exchanger by APV, a Sanitary Hydrothermal steam injector manufactured to 3A standards, a JCS Controls Inc. custom designed flash cooler manufactured by JCS Controls, Inc., a proven best-of-the-line APV Gaulin aseptic homogenizer, G & H aseptic valves, G & H sanitary processing valves, Fristam proven pumps, and top-of-the-line utility valves by Baumann and Burkert. The ULTRASYS^TM can be coupled to a unique JCS Controls designed low acid sterile surge tank which is fabricated exclusively for JCS Controls, Inc. by DCI of Saint Cloud, Minnesota.

Our engineers have spent much time in research and development to configure the unique processing equipment arrangements and controls. Our customers are provided with a process which assures aseptic integrity, the best in product taste and flavor, and the most user friendly operator control strategy.

• Direct Steam Injection (Ultrasys^TM)
• Indirect Thermal Process
• Tubular
• Coil
• PHE
• FDA Filed Validated Systems
• CFR21 Part 13

CIP

JCS Controls designs, implements, and supports Clean-In-Place systems either as stand-alone systems or, preferably, with the control system integrated into the rest of the production process. This approach often reduces cost of equipment, maintenance, and controls. It also frequently improves plant productivity because cleaning time is reduced, thereby increasing the amount of time available for production.

JCS Controls' CIP System designs incorporate all aspects of the production process, from Raw Circuits and Receiving through to the Filler. In dairy operations, Trucks and Silos are also part of the CIP Process. CIP Control Systems implemented by JCS Controls are often integrated into a Plant-wide Control System strategy, as the CIP Controls can be implemented in the same PLC or Supervisory Computer as the Production Controls. This often further's a plant's progress toward plant-wide integration, as the CIP Controls become an integral component of the automated control system, which is frequently network-based, or can be upgraded to be supported in a networked configuration.

Because of JCS' understanding of the Process design and expertise within the Food, Beverage, and Pharmaceuticals Industries, we optimize plant resources and introduce more flexibility into the CIP system through technologically advanced Valve Cluster and Piping arrangements, as well as Flowverters.

JCS Controls' CIP Systems are typically controlled in a PLC, which gathers and reports data on a variety of status conditions, including Unit Status (by component) and Product Parameters (i.e., Product ID, percent fat, percent solids, etc.). A turnkey CIP System will usually be supplied on a skidded platform. JCS Controls designs, programs, tests, implements, and supports fully automated CIP systems, including all tankage and Controls, as well as training and documentation to ensure the cleaning process is successful even after the implementation is complete. The Control System incorporates Circuit Selection, CIP Status and Information Screens, Operator Interface (MMI) indicating selectable CIP Functions, and Alarms for Operator Action.

JCS Controls' CIP Offering Includes:

• Total Integration capabilities: we supply Turnkey solutions because we understand the implications and importance of integrating the CIP System design with the production process control system, plant equipment and utilities, and people
• Expertise in application implementation so the process is designed and implemented optimally to balance energy and material requirements, maximize life expectancy of the equipment and controls, and minimize cleaning costs (i.e. use of chemicals, time to clean, etc.)
• Modular Systems: designed to be cost-effective, to expedite start-ups, and to facilitate maintenance, cleanability, as well as future enhancements, modifications, and process control flexibility
• Experience in process development and implementation specific to the Food, Beverage, and
  Pharmaceuticals industries