1. 10/07/2009 Matthias Schuetzeberg Slide 1 Calibration Management In Food & Beverage

2. 10/07/2009 Calibration Management Calibration Service Utilities and Calibration Management Matthias Schuetzeberg Slide 2 Calibration definitions Calibration refers to the process of verification that an instrument is within its designated accuracy.verificationaccuracy This is usually accomplished by formal comparison with a standard which is traceable to national standards and certified reference materials standard certified reference materials upper + lower tolerance Calibration Management

3. 10/07/2009 Calibration Management Calibration Service Utilities and Calibration Management Matthias Schuetzeberg Slide 3 Should you adjust after calibration? Instruments are calibrated to ensure accuracy After adjustment is not automatically a part of the procedure, but a conformity statement always is required Adjusting a defective instrument is a mistake Calibration after adjustment is a must to confirm Standard (Traceable to the national standard) Measuring Instrument e.g. pressure, flow, temperature Output value Determine relationshi p Input value Information about value Indicate deviation Calibration Management

4. 10/07/2009 Calibration Management Calibration Service Utilities and Calibration Management Matthias Schuetzeberg Slide 4 Why and when do you calibrate? For a new instrument To ensure compliancy At a specific frequency when a specified usage (operating hours) has passed when an instrument has had a shock or vibration which potentially may have put it out of calibrationshockvibration whenever observations appear questionable Calibration Management

5. 10/07/2009 Calibration Management Calibration Service Utilities and Calibration Management Matthias Schuetzeberg Slide 5 Reasons for Calibration What can be a reason for calibration? - Lining is deformed - pollution/scaling on the lining - Electronics defect - Coil current is changed - Combination of factors - Legislation demands - … What could be the consequences when there is a deviation discovered? - Production loss  cost loss? - Environmental impact? - Personal impact? - Lost of enegy - money lost... Calibration Management

6. 10/07/2009 Calibration Management Calibration Service Utilities and Calibration Management Matthias Schuetzeberg Slide 6 Compliance and Traceability Product Batches Process Instruments are measured by Reference Standards are calibrated against are traceable to are traceable to are traceable to calibrated instruments are traceable to production batches Calibration Management Software provides traceability from product batches to process instruments through to reference standards in both directions This facilitates deviation handling and compliance Calibration Management

7. 10/07/2009 Calibration Management Calibration Service Utilities and Calibration Management Matthias Schuetzeberg Slide 7 What do you do when…? …there is deviation found? Adjusting the K-factor? Replace instrument? …. - How do you record this? - Who manages this? - When is this done? - Which departments are involved? - What is the history of the instrument? - …? Calibration Management

8. 10/07/2009 Calibration Management Calibration Service Utilities and Calibration Management Matthias Schuetzeberg Slide 8 Tell me, how do I find the calibration certificates when the auditor wants to see them? I need information about your results … Tell me which assets where reported with a deviation last year and how this is solved...... I need help, please tell me how to reduce costs on maintenance and calibration over the life cycle. Calibration Management

9. 10/07/2009 Calibration Management Calibration Service Utilities and Calibration Management Matthias Schuetzeberg Slide 9 Hyperlink Integration W@M Life Cycle Management “I need more information!” PC= Product Center SC= Service & Sales Center CER “We know more!”  Serial# Work order / Calibration information Endress+Hauser Product center Serial number Order code Manuals Certificates Purchase info Events: Production info Calibration info Repair info FlowPressureLevelTemperatureAnalysis Endress+Hauser Sales center Maintenance reports Calibration reports Service reports Repair reports Inspection reports within maintenance or calibration contracts Dynamic hyperlink / Web Services Calibration Management System Your application Our information Calibration Management

10. 10/07/2009 Calibration Management Calibration Service Utilities and Calibration Management Matthias Schuetzeberg Slide 10 Accredited and traceable calibration Diameter 1 mm up to 2000mm Total Accuracy 0f 0.05% Economical for single devices Requirements Delivery to the factory Flowmeter must be cleaned Recalibration in the factory Calibration Management

11. 10/07/2009 Calibration Management Calibration Service Utilities and Calibration Management Matthias Schuetzeberg Slide 11 Short shut down time only during the calibration No mounting or demounting of the sensor Recalibration on traceable international standards Advantage for a recalibration in field Calibration Management

12. 10/07/2009 Calibration Management Calibration Service Utilities and Calibration Management Matthias Schuetzeberg Slide 12 Inline calibration in field SCS-calibration in Reinach / Cernay Calibration rig accredited according to ISO/IEC17025 Mobile calibration rig By the customer Traceable recalibration Calibration Management

13. 10/07/2009 Calibration Management Calibration Service Utilities and Calibration Management Matthias Schuetzeberg Slide 13 Calibration in field Movable calibration riggs Temperature Pressure pH Instruments Calibration Management

14. 10/07/2009 Calibration Management Calibration Service Utilities and Calibration Management Matthias Schuetzeberg Slide 14 100 % 50 % 0 % 25 % 75 % Total Operation Costs Project Costs Time Percent total cost Start up Source: Automation Research Corporation …. Most operating costs relate to equipment maintenance Where to save the most money or time ? Total Cost of Operation is much larger than initial project cost! Calibration Management

15. 10/07/2009 Calibration Management Calibration Service Utilities and Calibration Management Matthias Schuetzeberg Slide 15 40% 20% 0 Source: ARC Process improvements Unplanned Breakdowns Inventory Costs Downtime Defects Equipment Life Workforce Efficiency Equipment Productivity 40% 20% Cost Reductions 60% What are the areas in terms of cost savings … Calibration Management

16. 10/07/2009 Matthias Schützeberg Slide 16 Calibration Service in the Food Industry

17. 10/07/2009 Calibration Management Calibration Service Calibration in Food Industry Matthias Schützeberg Slide 17 What is Calibration? Calibration = quality assurance (‘value added service’) Comparison of the Unit Under Test against a traceable reference standard. Adjustment = error correction (‘established service’) Reduction of deviation to the smallest possible value UUT Measuring Instrument Standard Determine relationship Indicate deviation

18. 10/07/2009 Calibration Management Calibration Service Calibration in Food Industry Matthias Schützeberg Slide 18 Calibration of instruments TPPC/MEG, No. 18 But there is still more to safe your money

19. 10/07/2009 Calibration Management Calibration Service Calibration in Food Industry Matthias Schützeberg Slide 19 Lines Modules >10,000 modules Components 4,000 separators 4,000 homogenisers 20,000 heat exchangers 5,000 freezers Automation Scope of agreement

20. 10/07/2009 Calibration Management Calibration Service Calibration in Food Industry Matthias Schützeberg Slide 20 Consider the total cost Direct cost Indirect cost

21. 10/07/2009 Calibration Management Calibration Service Calibration in Food Industry Matthias Schützeberg Slide 21 Example: 2 temperature transmitters not calibrated Alrox Lacta deaeration module Differential temperature transmitters indicates ΔT 4°C 1. Reality: 2°C Not sufficient deaeration. Effects the product quality 2. Reality: 6°C Overtreatment. Increased energy consumption and product losses. 40.000 € per year Very few € 100 kg/h × 5000h x 0.08 €/kg = 0,08 € = steam and cooling water cost/kg

22. 10/07/2009 Calibration Management Calibration Service Calibration in Food Industry Matthias Schützeberg Slide 22 Calibration Aseptic VTIS UHT-treatment module Temperature transmitter indicates 140 °C Reality: 142 °C 5000 hours production per year 2 °C temperature difference = 30 kg steam per hour 30 kg × 5000 h × 0.04 €/kg = 6000 € per year Very few €

23. 10/07/2009 Calibration Management Calibration Service Calibration in Food Industry Matthias Schützeberg Slide 23 Just some Questions - general Did you ever ask yourself… …how can I ensure the quality of my product? …how can I fulfill my calibration and maintenance obligations of my critical instruments? …are my calibration cycles set correctly? …are there more efficient calibration procedures than my current ones? …how can I optimize my maintenance cost. …is it possible to work with one supplier for all my calibration needs?

24. 10/07/2009 Matthias Schützeberg Slide 24 Thank you very much for your attention!