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Process Analytical SolutionsOptimizing Sugar Industry Processes

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INGOLDLeading Process Analytics

THORNTONLeading Pure Water Analytics

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Representative (main o�ce) Market organization (main o�ce)Representative (branch o�ce) Market organization (branch o�ce)Manufacturing

MET

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METTLER TOLEDO Group

Our company specializes in providing precision instrument equipment and related services to industrial customers. In 2010, METTLER TOLEDO generated revenues of US$ 2 billion. The company’s stock has been publicly traded on the New York Stock Exchange since 1997.

Worldwide presenceWe have a worldwide distributor network and a workforce of more than 11,000 employees. We sup-port our customers in industry by providing comprehensive solutions for each step of their manufacturing processes – from receipt of materi-als throughout all manufacturing stages through to final packaging control, logistics and shipping.

METTLER TOLEDO instruments are used in research and development, manufacturing process control and

for quality control. The pharmaceu-tical, biotech, chemical, food and beverage, and cosmetic industries are among the principal users.

Innovation and qualityOur company enjoys an excellent reputation as an innovator demon-strated by R&D expenditures above the average for the industry. We make every effort to achieve the highest level of quality, by applying Total Quality Management at both product and process level, particu-larly as part of the support we

provide to our customers to help them comply with international guidelines.

Process Analytics DivisionWithin the METTLER TOLEDO Group, the Process Analytics Divi-sion concentrates on in-line analyt-ical system solutions in industrial manufacturing processes. The Divi-sion consists of two business units, Ingold and Thornton, both in-ternationally recognized leaders in their respective markets and technologies.

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Ingold and Thornton – Leading Process and Pure Water Analytics

Both Ingold and Thornton have long track records in providing innovative, high-quality solutions for process measurement.

Solutions for the Sugar industry

Ingold was founded in 1948 by Dr. Werner Ingold. Today, Ingold provides the broadest available range of in-line analytical measure-ment solutions for industrial pro-cesses in the biotechnology, phar-maceutical, chemical and beverage industries. One of the latest devel-opments involves Intelligent Sensor

Management (ISM) solutions for easy handling and reliable perfor-mance in demanding applications such as sugar refineries.

Thornton Inc, founded in 1963 by Dr. Richard Thornton, an MIT Professor, has been part of the Process Analytics Division since

2001. Thornton’s leading market position is demonstrated by its innovative analytical instruments and sensors for the parameters re-sistivity, conductivity, Total Organic Carbon (TOC), pH, dissolved oxygen (DO) and ozone.

Ingold and Thornton solutions con-tribute to the optimization of pro-duction processes, with innovative measurement technology that offers:

• accuracy and reliability• reproducibility• traceability• user-friendliness• robustness

An experienced team of application specialists and service technicians are ready to help you improve your processes and attain:• sustained high product quality• optimized yield• lower maintenance costs• increased process control• reduced downtime

InPro® 3250 i InPro® 8400 4000TOC

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Greater Process Safetyand Reduced Maintenance

ISM transmitter M400

• Mixed mode input

• Multi-parameter

• Full Intelligent Sensor Management capabilities

Intelligent Sensor Management (ISM®) is an innovative new concept for process analytical measurement solutions. With ISM sensors, mainte-nance becomes predictable, failure in the process is avoided, and trace-ability is simple.

Built-in intelligenceISM sensors feature an on-board microprocessor. This brings a num-ber of benefits that non-ISM sen-sors cannot match; including, stored calibration data and predic-tive diagnostics.

Pre-calibration in the labWith ISM, buffer solutions do not have to be taken to the measuring point for sensor calibration. In-stead, using iSense Asset Suite software, sensors can be calibrated

conveniently in a lab then stored until they are required. ISM’s Plug and Measure feature means mea-surement point start up with pre-calibrated sensors is fast and reliable.

High traceabilityiSense Asset Suite software records the history of all ISM sensor activi-ties such as calibration and main-tenance. Complete documentation of ISM sensor assets is available at the touch of a button.

Process safetyBeing able to predict when a sen-sor is going to fail and therefore prevent its use in the next batch would be extremely useful. This is precisely the function of ISM’s Dynamic Lifetime Indicator (DLI). By constantly monitoring process conditions and sensor “health”, the DLI provides a clear indication of a sensor’s remaining lifetime.

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ISM sensors

• Digital sensor-transmitter communication ensures

signal transmission stability

• Measurement electronics in the sensor results in

higher accuracy

iSense Asset Suite

• Verification and calibration of ISM sensors in a

convenient location

• Documentation of sensor calibration and maintenance

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Sugar, Bioethanol and CogenerationIncreased Process Safety and Efficiency

In order to optimize yield, production processes in the Sugar industry must be monitored through various analytical parameters. METTLER TOLEDO’s in-line analytical measurement systems evaluate process con-ditions accurately and reliably at every critical step and assist in achiev-ing high quality final products.

Optimized yieldProcess reliability throughout sugar, bioethanol and energy co-generation production needs to be high and consistent. In-line mea-surement and control of pH, con-ductivity, turbidity and TOC enables yield and efficiency optimization.

High qualityEnsuring purity of sugar products is only achievable through tight pro-cess control. METTLER TOLEDO’s range of sensors and transmitters provide real-time, continuous, accurate data on processes to allow for immediate corrective actions.

Easy implementationFrom the very start of production to the very end, METTLER TOLEDO provides measurement solutions that will make the processes more efficient and more cost-effective. METTLER TOLEDO’s innovative measurement systems offer simple, user friendly installation and operation.

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Sugar Industry Processes

Beet Sugar

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Cane Sugar Bioethanol Cogeneration

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Highly resistant pH electrodeInPro 4800i

• Resistant to strong oxidizing media and solvents

• Sensor diagnostics provide continuous monitoring of

sensor “health”

Beet Sugar ProductionGreater Yield and Process Efficiency

Extreme conditions of temperature and pH and the harsh chemical envi-ronment in the beet sugar production process demand a great deal from measurement systems. METTLER TOLEDO’s wide range of devices for pH, turbidity and conductivity with breakthrough Intelligent Sensor Manage-ment (ISM) technology enable better reliability, increased process safety and greater efficiency.

Avoiding yield losses thanks to reliable pH measurementYield losses due to, for example, acid or alkaline degradation of sac-charose or color formation due to bacterial infection can be avoided by continuous monitoring and con-trol of pH with METTLER TOLEDO’s pH sensors InPro 3250i and InPro 4800i are designed to withstand various process environments such as the presence of oxidizing media, solvents, high temperatures and abrasive sugar crystals. Decades of experience in designing analytical sensors means METTLER TOLEDO pH electrodes produce precise mea-surements at varying levels of pH and have a long service life.

Turbidity measurement for higher productivityThe control of sugar filtrate’s turbid-ity levels is simple with METTLER TOLEDO’s turbidity solutions. Early detection of filter breakthrough

eliminates time consuming re-filtra-tion, allows for high juice quality throughout the entire campaign and also eliminates the damage or performance losses of downstream plant components caused by un-wanted particles.

Pure and white sugar by monitor-ing conductivityConductivity measurements pro-vide a check on the purity of the

mixed feed syrup in crystallization chambers. METTLER TOLEDO’s so-lutions measure conductivity quickly and accurately, thereby enabling rapid response to pro-cess changes. The four-electrode sensor InPro 7108 can withstand rigorous cleaning procedures and provide the highest safety in harsh chemical process environments.

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Robust turbidity sensorInPro 8400

• Designed for high measuring and

cleaning temperatures

• Flexible installation options:

bypass or main pipe

Compact conductivity sensor InPro 7108

• Hastelloy option for aggressive

cleaning solutions

• Compact design

Multi-parameter transmitter M400

• Full ISM functionality

• Accepts both analog and digital

ISM sensors

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Two-electrode conductivity sensorInPro 7000

• Highly accurate in low conductivity range

• Highly accurate cell constant (± 1%) for best

measurement results

• Robust VarioPin connector for safe signal

transmission

Cane Sugar ProductionHigh Product Quality

Accurate measurement of analytical parameters leads to high yield and product quality in sugar production from cane. METTLER TOLEDO’s range of analytical instruments with in-built Intelligent Sensor Management technology, enable better process safety, reduced downtime, low main-tenance and reliable results.

pH sensors for surviving the toughest process conditionsHigh sugar concentration in the juice and the addition of chemical products in the liming and sulfita-tion steps necessitates that pH measurement devices withstand rough process conditions. In order to maximize production uptime, METTLER TOLEDO’s in-built Intelli-gent Sensor Management (ISM) family of pH sensors have been de-signed to function in extreme envi-ronments where fast, accurate pH measurement is required.

Identification of ion breakthrough with conductivity measurementQuick and precise measurement of conductivity helps to hasten the re-sponse to changing process condi-tions. This along with pH monitor-ing helps in early identification of ion breakthrough and hence main-tains ion exchangers at peak per-formance level.

METTLER TOLEDO’s conductivity sensor InPro 7000 along with the multi-parameter M400 transmitter withstand aggressive solutions and are suitable for processes with fre-quent CIP cycles. They are easy to install with a wide measuring range. In-built ISM features enable reduced sensor configuration and maintenance while increasing pro-cess uptime and safety.

Monitoring turbidity levels to detect filter breakthroughMETTLER TOLEDO’s in-line turbidity measurement systems: In Pro 8400 sensor and Trb 8300 transmitter have been designed to monitor low levels of turbidity to immediately warn of filter breakthrough. The sen-sor is resistant to any unwanted coatings and hence maintains peak accuracy and process safety.

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Turbidity transmitterTrb 8300 F/S

• Intuitive menu operation

• Detects trace turbidity levels

Robust turbidity sensorInPro 8400

• Designed for high measuring and

cleaning temperatures

• Flexible installation options: bypass or

main pipe

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pH electrode InPro 2000i

• Flowing liquid electrolyte ensures fast response and

accurate measurement

• ISM Plug and Measure feature for fast start up

Bioethanol ProductionBetter Control and Higher Yield

Yeasts supporting fermentation require tightly controlled pH conditions for maximum conversion of the natural sugar into alcohol. With METTLER TOLEDO’s pH measurement solutions with Intelligent Sen-sor Management, production of bioethanol from cane in higher yield has become significantly easier.

Monitor pH, improve productivityTight control of pH results in higher yields in yeast fermentation pro-cesses where sugar is converted to alcohol. In the yeast recovery pro-cess, pH is maintained at a low level to keep the recovered yeast in a healthy condition.

With in-built Intelligent Sensor Man-agement (ISM) technology, METTLER TOLEDO’s pH measure-ment solutions provide accurate, reliable results. Robust, longlife electrodes tolerate repeated clean-ing cycles. ISM features ensure sensor installation is fast and error-

free, and that maintenance is low and downtimes reduced. Retract-able sensor housings provide greater automation flexibility and process safety.

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Multi-parameter transmitter M400

• Accepts analog or digital ISM sensors

• Full Intelligent Sensor Management capabilities

Retractable housing InTrac 776e

• TriLock safety feature prevents escape of measuring

medium

• Sensor maintenance without process interruption

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Total Organic Carbon analyzer 4000TOC

• Reliable on-line TOC validation

• Uses proven ultraviolet oxidation with differential con-

ductivity to effectively determine TOC concentrations

Optimized Energy CogenerationBattling Corrosion

Continuous monitoring of analytical parameters in the boiler house indi-cates when a corrective action is needed either in the water treatment system itself or in the steam/condensate cycle. Analytical devices from METTLER TOLEDO featuring Intelligent Sensor Management (ISM) tech-nology increase the safety of production processes and reduce mainte-nance costs.

Scaling and corrosion prevention through pH monitoringPrevention of incrustation and cor-rosion of pipes and boiler necessi-tates maintaining the pH of boiler feed water within a specific range. METTLER TOLEDO’s low mainte-nance InPro 3250i pH sensor with InFit 761 housing is designed to meet the demanding process con-ditions and is highly robust and reliable.

TOC monitoring for inhibiting oxidationContinuous Total Organic Carbon monitoring helps to protect turbines from corrosion caused by organic acids. A system comprising the

4000TOC analyzer and M300 transmitter offer a cost-effective so-lution for fast and reliable TOC monitoring.

Conductivity measurement for avoiding ion contamination Conductivity is measured in puri-fied water to identify contamination by ions, and also to control the

cleaning and regenerating steps of the ion exchanger resins used in the water treatment system. METTLER TOLEDO’s 2-electrode sensor InPro 7000 with the M400 transmitter measures very low lev-els of conductivity in the cogenera-tion process, for instant warning of exchanger breakthrough.

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Multi-parameter transmitter M300

• One or two field-configurable channels for a wide

range of parameters

• Plug and Measure simplicity with ISM

Two-electrode conductivity sensor InPro 7000

• Designed for high accuracy in very low to medium

conductivity water

• Available in a wide selection of process connections

Visit us online to discover how METTLER TOLEDO products and solutions can improve processes at your facility. • product information• white papers• application notes• on-demand webinars• videos

4www.mt.com/pro-sugar

Sugar Competence Center The Latest News on Applications and Products

For more informationwww.mt.com

Mettler-Toledo AGProcess Analytics Im Hackacker 15CH-8902 UrdorfPhone +41 44 729 62 11

Subject to technical changes©12 / 2011 Mettler-Toledo AGPrinted in Switzerland