Our client required us to add new lab tests to their system for collecting historical data at their high-production ethanol plant. They used Excel to track operational values and production test numbers which limited their accounting versions. We eliminated multiple spreadsheets to simplify their process. We implemented a single system that automatically imported lab data based on sample times. Operations staff entered “rounds” information easily. Accurate reports for additives and production use were generated. They could monitor fermentation progress more effectively with this change. We aimed to help them manage fermentation better and prevent issues. The competitive ethanol industry requires plants to maintain tight control over fermentation to reduce waste. Any method that helps a plant boost production holds value due to the low profit 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. Complex, real-time automation calculations use this data to provide accurate ethanol and additive reports, process monitoring, and change suggestions.
Technologies:
- We configure the tools to effortlessly search for and gather test reports on their own..
- The services keep an eye on the ethanol plant, look for additives and the conditions of the state, and check the accuracy of test results.
- Services track the process of grain transformation and assess the efficiency of mash production and operational time.
- Reporting systems keep a watchful eye on what is happening both at the site and in the lab to ensure everything runs smoothly.
- Operator graphics illustrate the process operation in each batch run. Operators can see at a glance when Ethanol is optimum. They can also observe the lab test values during every stage of the fermentation cycle. The system automatically assigns batch numbers whenever one batch empties and then fills. The system can set up to key off known events like an automated start of a yeast batch or timed events such as so many hours into the current batch.
Resolution:
Clients use visualization tools like ParcView and work task interfaces to track data. Clients can better monitor production by eliminating mistakes and setting privacy limits.
Reference: Ethanol Producers Magazine
