Paramix CMX
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Contents
Innopro..............................................................................................................3
Example: "Innopro CMX xx" ..............................................................................3
The tasks of the Paramix include: .....................................................................3
Ratio control according to recipes stored in recipe memory..............................8
Pressure settings: .............................................................................................8
Vacuum pumps and sealing water supply.........................................................9
Primary syrup feed vessel 1703/ 03TP .............................................................9
Manual control valves of the Paramix .............................................................11
CIP sanitizing ..................................................................................................11
Starting up production .....................................................................................11
Start of production...........................................................................................11
Paramix electrical equipment ..........................................................................11
Numerical example for adding CO2 .................................................................12
CARBOBRIX...................................................................................................12
Principle of Brix measurement: .......................................................................12
Principle of CO2 concentration level measurement: ........................................12
Fault finding and rectification on the Paramix .................................................14
General: ..........................................................................................................14
The vacuum test: ............................................................................................14
Test to compare the syrup and beverage flowmeters: ....................................14
Test to compare the CO2 flowmeters..............................................................15
The visual and audible impression: .................................................................15
Carbonating area ............................................................................................15
The CO2 injector:.............................................................................................16
The right capacity setting: ...............................................................................16
The cooling system: ........................................................................................16
The parameters:..............................................................................................17
Foaming of the beverage when filling:.............................................................17
The Brix value varies:......................................................................................17
Error message Degasser not ready: ...............................................................18
Error message Mixing ratio too high/too low: ..................................................18
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Innopro
Example: "Innopro CMX xx"
The Paramix is a system that uses the batch blending method to produce
beverages. The CMX35, for example, is designed for an output of 35,000
liter/hour.
The tasks of the Paramix include:
1. Deaerating water
2. Mixing deaerated water with syrup
3. Carbonate and buffer inline ahead of the filler
Paramix 1 process flow
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The media are generally supplied through a distributor panel equipped with
valves 1401 – 1407/ 21VM - 27VM and diverter bends. The diverter bends have
been designed to eliminate connecting errors for production and CIP:
1 2
26VM 24VM 26VM 24VM 21VM
21VM
22VP
27VM 25VM 22VP 27VM
25VM
23VM
23VM 4011_975
4010_975
Diverter bend valves 1 Diverter bend valves 2
This bend (1) is used This bend (2) connects the
exclusively for cleaning the
syrup line from the syrup syrup line to the syrup tank
room and back. Cleaning of the Paramix system. It is
can be carried out required only for adding a
simultaneously with the component.
Paramix system or
separately.
Level switch LS1650/ 71LS and its
min/max contacts open or close valve
1301/ 21VP and thus the supply of
pretreated water in deaeration tank
1701/ 01TP. Here, the first stage of
the two-stage vacuum deaeration
system extracts 90% the oxygen from
the water and the second stage
extracts the remaining oxygen. The
deaerated water then contains a
maximum of 0.6 – 0.7 mg of O2 per
liter.
Vacuum pump 1101/ 11PX maintains
an approximately 90% vacuum in the
tank. The water is then sprayed
through spray tubes with small hole
into the bottom first deaeration stage of
this tank. This method increases
effective area of the water surface for
deaeration. While circulation pump Deaeration 1
1102/ 12PP repumps the water through
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the spray tubes into the second deaeration stage, CO2 is added (CO2 purging)
to decrease the partial pressure of the oxygen thereby improving the release
characteristics of the oxygen. The amount of CO2 added depends on the
temperature and is set by operating hand valve 1314/ 33VP.
In this second stage, the water is collected in a ring channel from where it is
drawn by mixing pump 1103/ 13PP. Because the circulation pump over delivers
the ring channel overflows and part of the water remains in circulation.
The mixing pump is a multi-stage pump. The first stage creates the vacuum (to
3-4 bars), the second stage adds syrup (5-6 bars in this case), and the third
and fourth steps are used for further mixing.
Syrup Outfeed
infeed
Drive block
Pressure buildup to 5-6 bars
Mixing syrup/water
From negative pressure to 3-4 bars Multi-stage mixing pump 1
The syrup is metered into the mixing pump by pump 1106/ 16PP from syrup
vessel 1703/ 03TP and metering valve 1513/ 34VC. When buffer tank 1702/
02TP is full, i.e. when in the meanwhile no product is to be mixed, valves 1302/
23VP and 1303/ 35VP close and the syrup and mixing pumps are stopped.
In order to decrease the negative
pressure from the deaeration tank, an
additional pump 1107/ (option) is
installed upstream to relieve the load
on the mixing pump only for higher
capacity systems (e.g. CMX 48)
Starvation sensors (LS1680/LS1681)
(72LE and 73LE) are integrated in
the pumps as run-dry safeties that
switch off the respective pumps in
time.
Dosing/mixing/cooling 1
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The mixed beverage can optionally be cooled before carbonating.
The required plate cooler can be connected after the mixing pump.
Air supply
Plate cooler 1
Carbonating 1
Venturi nozzle 1
Carbonating 2
This is then followed by inline carbonating 1802/ 21XI. CO2 is added in the pipe
by control valve 1522/ 37VC. (Some systems are equipped with only a manually
set CO2 flow control valve.)
When the beverage and CO2 system pressures are approximately equal, the
gas enters the beverage without foaming.
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Booster pump 1104/ 14PP is designed for 1/3 delivery in the buffer tank and 2/3
delivery back through bypass 1803/ 22FL. This effect improves inline
carbonating. The CO2 is completely dissolved when no more bubbles appear in
sight glass 1451/ 24SG.
This system is also capable of spray carbonation. This is achieved by opening
valve 1306/ 43VP to inject the product into the tank already pressurized with
CO2. Otherwise, this line is needed for CIP.
The Paramix output that should be based on
the filler output, is set at valve 1412/ 37VR.
The ideal setting is 5% more than the filler.
The tank is never emptied and because of the
relatively few number of stops, the Paramix
runs virtually continuously.
System output
setting 1
The CO2 is supplied through shutoff valve 1409/ 33VM and pressure reducer
1441/ 34PR equipped with pressure gauge PI 1605/ CP30 - 75PI. The pressure
reducer is set to 5.5 – 6 bars. This applies to the CO2 shroud above the product
in the buffer tank and to carbonating.
Dissolved CO2 and fluctuations in the fill level in the tank resulting from filler
stops, for example, could cause the pressure in the tank to exceed the
carbonating pressure. This excess and non-dissolved CO2 then escapes from
the tank back into the CO2 line and via carbonating back into the beverage.
No CO2 is lost. Valve 1414/ 32VS is only an overpressure safety valve.
The beverage is drawn out of the buffer tank by booster pump 1105/ 15PP and
is forced to the filler. This pump is required only for certain fillers, for CIP for
example. CO2 admission pressure is frequently sufficient.
For systems equipped with Carbobrix for measuring the CO2 and Brix levels,
pump 1107/ 17PP draws a sample out of the line leading to the filler and pumps
it back into the tank.
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Ratio control according to recipes stored in recipe memory
Syrup metering controller FFIC1510 / 74RC uses control valve
1513/ 34VC to regulate the syrup/product ratio (i.e. syrup/syrup
and water!). The product flow in FT1512/ 73FE is the reference
variable. The syrup flow is measured in FT1511/ 72FE. The
same reference variable is also transmitted to CO2 controller
FFIC1520/ 72RC with control valve 1522/ 37VC and CO2
flowmeter FT1521/ 71FE.
The controllers are SIPART control units or software controllers
in the PLC (S5-95U).
Product flow 1
Pressure settings:
The CO2 controller setting is in grams per liter (e.g. 8 g/l).
Pressure reducer 1441/ 34PR sets the fresh CO2 pressure at PI1605/ CP30 -
75PI to approx. 5.5 to 6 bars. A difference in pressure is set between this CO2
pressure and the beverage pressure indicated at PI1602/ CP40-75PI. The
beverage pressure is approx. 0.5 – 1 bar lower.
Set the difference in pressure to 0.5 – 1.0 bar at controller 1413/ 23VR.
Differential pressure setting
1
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Vacuum pumps and sealing water supply
The air pumped out of the deaeration tank is discharged to the atmosphere
through a sound absorber. Once a vacuum is created, only a small amount of
air is supplied according to the deaeration and the added CO2. Accordingly, only
a small amount of water is picked up that then flows back along the curvature of
the pipe.
The vacuum pump requires a supply of
sealing water. This water is practically
circulated. This is necessary in order to
equalize the pressure for the separator plate.
Cooler fresh water is added by fresh water
control valve 1551/ 31VS only if the
temperature at temperature controller TC1
550 is exceeded. As a result, warm water
must overflow.
The temperature of the water should not
exceed approx. 25°C since the boiling point
of water under a 90% vacuum is only approx.
35°C.
The water vapor would destroy the vacuum
thereby increasing the boiling point of the
water and recreating a vacuum. The boiling
point would drop again thus producing steam
and so forth.
This knocking could damage or even destroy
the pump.
This is why temperature control and regulation is so important.
Vacuum 1 setting
Primary syrup feed vessel 1703/ 03TP Syrup vessel 1
The vessel is under atmospheric pressure. The syrup should calm
under these conditions for exact metering.
Any gas bubbles will rise to the surface and dissipate. In some
systems (Gerolstein), a cushion of CO2 is placed over the syrup to
prevent contact with the air. In this case, the syrup vessel is
connected to a CO2 supply.
The fill level in the syrup vessel is controlled by level switch LS1670/ 71LS and
valve 1304/ 30VP.
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Manual control valves of the Paramix
The output of the Paramix is set manually using valve 1413/ 23VR.
The CO2 consumption is set at valve 1310/ 36VP. The CO2 mass flow rate is
measured in kg/h and indicated at FI1606/ 73F4.
The CO2 setting of systems not equipped with CO2 controllers is made at flow
control valve 1418/ CP30 - 37VC.
CIP sanitizing
The cleaning medium takes the same paths without a vacuum and without CO2
metering. Since the pumps are controlled by fill level sensors, the machine is
drained automatically.
Starting up production
Preparations as specified in the operating manual.
Start the deaerator and the step sequence will start. See Connecting Syrup
program. If necessary, purge any water through sight glass 1450/ 29SG and
valve 1408/ 32VM to the drain hole.
If CIP was previously run, the buffer tank must additionally be filled to maximum
with deaerated water in order to displace the air in the tank. Then drain the tank
(e.g. through the primary filler feed and filling valves, etc.). CO2 will be drawn in.
The sanitized CO2 lines will be blown dry with CO2.
Start the new product: All controllers will go into a transient state again (approx.
10 secs). The product runs into the tank and then stops.
The product in the tank will be discarded, i.e. it will be used to rinse the filling
valves including the piping. This also discards any residual water or residual
product.
Start of production
Press F9 for the booster pump to the filler (not always necessary since CO2
admission pressure is sometimes sufficient).
Paramix electrical equipment
PLC control (S5-95U is standard equipment), software controllers in S5-95U or
SIPART controller for both control circuits. Operating via Lauer PCS 95.
The principle of sensor CO2 flowmetering is heated to the reference
temperature and cooled by the flowing CO2. The energy required for heating is
the measure for cooling and thus also the measure for the flow.
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Numerical example for adding CO2
Cola: approx. 8 g 002/1 Mixer output: 48,000 l/h
8 g/I x 48000 I/h = 384 kg CO2/hour
1 kg 002 = 0.51 Nm3 >> 384 kg 002 = 195 Nm3/h CO2
CARBOBRIX
Online CO2 and Brix measurement. A pump pumps the samples taken in the
line leading to the filler back into the tank.
The Brix measurement is based on density measurement according to the tuning
fork principle where the medium dampens the oscillations. Laboratories
normally use the refraction of light method. If these values deviate, the
Carbobrix compensates accordingly.
The purpose of the Brix and CO2 measurement with Carbobrix is to monitor the
quality and not to intervene in the control. Alarms are issued when the
tolerances defined in the recipe are violated.
Principle of Brix measurement:
The measuring tube oscillates at a fixed frequency. The higher the density of
the product flowing through the measuring tube, the greater the damping.
Temperature measurement for correction.
Principle of CO2 concentration level measurement:
The sample is separated in the 'sampling space'. Pistons depressurize the
volume of sample thereby releasing the gas. The CO2 concentration level is
calculated based on the pressure and the temperature. This measurement is
updated every 30 seconds.
The CO2 value is included the Brix measurement as a compensation value.
Knurled switches for the product number for which the setpoints and deviations
are stored. The system uses this to generate the alarms.
Since laboratories frequently determine the Brix values by measuring the
refraction of light, deviations are possible. The values displayed can be
calibrated to the laboratory measurement.
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Overview of Paramix 1 pumps
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Fault finding and rectification on the Paramix
General:
• The Paramix is a complex machine in which complicated processes take
place due to different technological and physical parameters such as
vacuum, flow, pressure, temperature etc, which ultimately guarantee the
necessary beverage quality. Faultfinding is therefore difficult and requires a
certain amount of experience.
• The faults, problems and proposed solutions listed below are therefore not
complete but will make fault finding easier.
The vacuum test:
• A high vacuum is required for degassing the water. At the same time, the
temperature of the water is also crucial. Warm water degasses more easily.
The remaining oxygen is bonded by adding a small amount of CO2.
• Prepare the degassing tank manually or by initiating the program. Check the
vacuum. Now switch off all programs and wait for at least 15 minutes. Now
open the vacuum valve manually and read the vacuum once more. The
vacuum should not have dropped. If this is the case, try to find the leak.
Listen for air getting in at the tank and pipes, and re-seal the vacuum area.
Using a pocket torch, you can view the surface of the water in the two
stages and determine in which area the air is entering - first stage bottom,
second stage top.
• Bottom - Check the circulation pump shaft seal and the associated pipe
connections.
• Top - Open the butterfly valve in the water pump suction intake manually. If
bubbles escape in the top ring channel, check the water pump and/or mixing
pump shaft seals and the associated pipes. If air is entering in this area, the
dosing and carbonating function is faulty. Excess air collects in the buffer
tank and is drawn into the beverage during CO2 injection. The filling process
is irregular and tends to foaming.
• Check that the CO2 pressure is set to 3 bar and the carbon dioxide is open.
• Make sure that the hoses for the air supply and the carbon dioxide have not
been swapped over at the CO2 dosing valve.
Test to compare the syrup and beverage flowmeters:
• This test is required when a flowmeter has been replaced or the flows are
not correct.
• Supply the syrup primary feed tank continuously with water. The incoming
flow is best controlled by manual adjustment of the panel valves.
• Open all valves from the syrup tank to the buffer tank manually. Likewise
the buffer tank drain valve. You can adjust the water flow capacity using the
•
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syrup controller's manual function. Make sure that the capacity is not greater
than the measuring range of the syrup flowmeter. Compare the flow indicated
on the syrup and beverage flowmeters. After a short time, both flowmeters
should indicate the same value on the control panel.
Test to compare the CO2 flowmeters
• This test is required when a flowmeter has been replaced or the CO2 values
are not correct.
• The electronic flowmeter is only energized during production. In order to be
able to carry out this test, it is necessary to bypass the contactor.
• Caution: If you forget to remove the bypass, the flowmeter will be damaged
when cleaning is next carried out.
• Open all valves from the CO2 connector via the injector to the buffer tank.
Likewise the buffer tank drain valve. You can adjust the gas flow capacity
using the CO2 control valve's manual function. The electronic and
mechanical flowmeters have variations up to 20%. These variations are
normal, as they work using different measuring principles.
The visual and audible impression:
• If problems occur on the Paramix, the cause of the malfunction can often be
detected by external contamination and unnatural noises.
• Inspect the flange and screw connectors for leaks. There is no vacuum in
the machine when cleaning is being carried out. Caustic escapes from
leaking connections and is deposited as a white film. Retightening pipe
connectors and flanges is not always successful. Check the condition and
seating of the seals.
• Retightening a flange under vacuum is not usually successful. A
considerable amount of dirt is deposited at the point of the leak with the
sucked in air. The pipe must be disconnected and cleaned and then
carefully sealed.
• Look under the machine at regular intervals. Bolts can become loose and
fall out due to vibration.
• Check whether the machine vibrations and noises are normal.
Carbonating area
• The carbonating of the beverage is a physical process. Oxygen, pressure
variations, large temperature variations and crystalline elements in the water
have an adverse effect on the result.
• With stop-and-go operation, the buffer tank pressure is balanced by means
of a pressure-controlled overflow valve with downstream sound absorber.
When beverages with fruit fibers are produced or when caustic residues or
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crystalline elements are discharged via the sound absorber during CIP, the
sound absorber can become blocked. You may observe an above-average
increase in pressure in the buffer tank when the filler is not removing any
product. The pressure increase should be 0.2 to max. 0.5 bar. The CO2
overflow valve should switch at short intervals.
• Also check the setting of the drain valve in the overflow line. Adjust the
hand wheel so that the pressure in the buffer tank drops quickly at full
output.
The CO2 injector:
• Damage can occur in the case of high turbulence or vibration, e.g. the
injector cone can break off. If this occurs, the CO2 will not be adequately
distributed in the beverage and the gas will not be adequately bonded. You
will see vigorous bubbles of gas in the sight glass after the injector. Please
check the parts inside the injector and repair if necessary.
The right capacity setting:
• The output of the Paramix should be just slightly (ca. 1000 l/h) above the
real filling capacity of the filler (in l/h).
• If the output is too low, the buffer tank may become empty if the demand
from the filler is continuous. A vortex is formed due to the level in the buffer
tank being too low, and the beverage is mixed with CO2 in the pipe to the
filler. This beverage cannot be bottled. There is a problem in recognizing
this fault, as this only occurs in certain situations.
The cooling system:
• If the temperature of the beverage increases in an undefined manner and
the control valve for the coolant is fully open, the cooling medium supply is
usually insufficient, for example, because the dirt trap is blocked or the
refrigeration system is not providing the required output.
• Make sure that the coolant arrives at the required temperature and in the
required amount.
• Make sure that the plate cooler is not frozen up when coolant temperatures
are below 0 °C.
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The parameters:
• Check all appropriate parameters in the event of irregularities in the system
control and instrumentation functions. The values should correspond to the
settings made after commissioning.
Foaming of the beverage when filling:
• Check the finished beverage in the sight glass after the carbonating pump
(buffer tank infeed). If the beverage is milky or contains air bubbles, this is
a clear sign that there is air or oxygen enrichment in the system. It will be
necessary to prepare the buffer tank again, i.e. flood it with water, so that it
can be subsequently pressurized with pure CO2. After activating the
cleaning program, this software routine is automatically executed again
when production is started.
• Check the temperature of the beverage.
• Hold a pocket torch at an angle behind the sight glass after the carbonating
process. If the beverage is clear and appears to be without CO2 bubbles,
the problem is not normally to be found in the mixer.
• See also vacuum test.
The Brix value varies:
• When the machine is correctly set up and running continuously, the Brix
value only varies by approximately 0.02 to 0.03 °Bx. It is important to
analyze the Brix variation correctly.
• If the variations are slow and occur within 20 minutes, these usually stem
from the superimposed Brix control function. Switch this off and adjust the
setpoint for the syrup control manually.
• If the variations occur continuously, these frequently come from the water-
syrup ratio control function. Check the operation of the syrup control valve
and the positioner by switching the controller to MANUAL. Check that the
control valve is working correctly (position and movement of the valve rod
at 0%, 50% and 100%). Make sure that everything is in order mechanically,
all screws are tight and nothing is loose.
• If variations occur ca. 20 seconds (ca. 50 sec in the case of mixers with
cooling) after the Paramix has started, then the syrup valve delay time is
incorrectly set.
• Also check that the feed valve for the syrup tank is not too severely
throttled and that there are no air bubbles in the syrup.
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Error message Degasser not ready:
• The most frequent cause is a shortage of water in the upper stage of the
degasser. The cause is usually a defective shaft seal on the circulation
pump. No water escapes but air is sucked in. The air collects in the pump
housing and the output of the pump collapses.
Error message Mixing ratio too high/too low:
• Check the vacuum. If the vacuum is too low, the water pump is too strong
and the syrup pump does not have sufficient power to push the syrup into
the water pipe.
• Check for air entering the vacuum system (as described).
• Check the syrup feed and the operation of the control valve (as described).
• Check the flowmeters (as described).
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