Our client wanted a system that would allow them to dynamically integrate their laboratory tests into the historical collection system so they could better track fermentation efficiencies. The objective was to better understand how to control fermentation and avoid operational errors.
OUR SOLUTION
We created a database system inside the Dataparc historical collection server that converts laboratory test data into the appropriate tag data after receiving it straight from the instruments. In turn, this data is utilized for dynamic, sophisticated automation computations that allow for detailed reporting on precise ethanol volumes and additives in almost real-time, as well as process monitoring and modification suggestions.
Technologies used by the system included:
- We install a service on the instrument(s) to monitor the presence of new test reports and scrape the test data.
- Services check for additives, state conditions, and confirm the accuracy of test results while keeping an eye on the ethanol plant’s operation.
- Services compute mash and uptime rates and keep an eye on grain processing.
- Reporting systems keep an eye on both lab tests and the site’s overall output.
- Operator graphics can show additional data, such as water treatment, additional tests for mash and salable products, tracking of tests during shipment, and even third-party tests verifying hygrometer and water values.
THE RESULTS
The clients have been able to track the data using visualization tools like ParcView and manage operational duties using standard interfaces. In order to concentrate on stricter production control, the clients have also been able to eliminate potential errors and establish threshold limits on data. The site now aims to run systems toward a golden batch, which can be identified through analysis and faster troubleshooting.