Our high-production ethanol plant client asked us to add new lab tests to their historical data collection system. Before our system, the client tracked operation values and production test numbers in Excel. These restrictions limited which “version” of Excel could be used to make accounting numbers. Our company eliminated multiple spreadsheets and switched to a single system that imported lab data automatically based on sample times, let operations staff enter “rounds” information, and made accurate additive and production use reports. They could better monitor fermentation progress. The change was made to learn how to control fermentation and avoid problems. Due to high competition in the ethanol industry, fermentation must be tightly controlled to reduce waste. Any way a plant can increase production by adding products is acceptable due to low margins.
Quality Control Solution
The Dataparc historical collection server has a database system that takes data from instruments and turns it into the right tag data. It works like this. This data is then used for complex, real-time automation calculations that provide accurate ethanol and additive reports, process monitoring, and change suggestions.
Technologies:
- We set up the instrument(s) to automatically find and scrape test reports.
- The services monitor the ethanol plant, search for additives and state conditions, and verify test results.
- Services Monitor grain processing and determine mash and uptime rates.
- Reporting systems closely monitor the activities at the site and in the lab.
- Operator graphics can show how water is cleaned, extra tests for mash and products that can be sold, tracking of tests while they are shipped, and third-party tests that confirm the hygrometer and water values.
Resolution:
Visualization tools like ParcView and work task interfaces help clients track data. By eliminating mistakes and setting privacy limits, clients can better monitor production. The site is analyzing and testing faster to find a “golden batch”.
Reference: Ethanol Producers Magazine
