CONTROL OBJECTIVES

There are 7 control objectives which include:

1) Ensure safety
2) Maintain product quality
3) Smooth plant operation and production rate
4) Equipment protection
5) Environmental protection
6) Profit optimization
7) Monitoring and diagnosis

For this project, we have chosen three control objectives for the pasteurization of yogurt manufacturing.

 Ensure safety
The hazard analysis and critical control points system is a logical scientific process control system for
eliminating hazards at critical areas in the food production chain. The application of HACCP is based on
technical and scientific principles that assure food safety. To increase yogurt safety for consumer, destroying
disease causing microorganisms (pathogens), that may be present while the pasteurization is one of the
solutions. Pasteurization is primarily used to make products safe to eat or drink, increase shelf life and to reduce
spoilage. However, it can also be used to alter the properties of the end product. For example, pasteurization of
yoghurt milk denatures the proteins, enabling the yoghurt culture to grow and making the product both more
viscous and more stable. The use of pasteurization to kill pathogenic bacteria has helped reduce the transmission
of diseases, such as typhoid fever, tuberculosis, scarlet fever, polio, and dysentery. It is important to note that
foods can become contaminated even after they have been pasteurized. For example, all pasteurized foods must
be refrigerated. If the pasteurized food is temperature-abused (e.g., if yoghurt are not kept refrigerated), it could
become contaminated. Therefore, it is important to always handle food properly by handling it with clean hands,
preventing it from becoming contaminated, and keeping it at a safe temperature.

 Maintain product quality

Process control can reduce variability in the end product, which ensures a consistently high-quality product.
In pasteurization process of yogurt, the process needs to be maintained at a specific point to maximize its
quality. Excessive presence of bacteria in product can make it spoil faster. The main purpose of pasteurization
is to be able to lower the presence of microbial organisms in food. This would require a heat source that uses
high temperature levels that could neutralize heat-sensitive bacteria. Pasteurizing food helps it last longer while
still locking in the nutrients that are inherently found in food. Although sterilization may kill more bacteria in
food, it can adversely affect the taste and quality of the product, which is why many food manufacturers prefer
pasteurization more. To further help slow down the growth of bacteria, food is refrigerated to keep
microorganisms at a manageable level. Therefore, it is very important to control pasteurization of yogurt
processing. Otherwise, the yogurt quality cannot be maintained and will drop easily.
  Equipment protection
In a typical setting, milk is pumped from a feed tank to a shell and-tube or regenarator, where it reaches the
required temperature. Steam or hot oil is used as heating medium. The hot milk enters an insulated holding
tube, where it is kept for a certain time. The product is then cooled, prior to storage and packaging. During
pasteurization, heat-exchanger fouling occurs. Fouling lowers the efficiency of heat transfer, causes an increase
of pressure drop, limits the operational time of the plant and endangers process hygiene. Therefore, cleaning is
required on a daily basis. Because a significant fraction of time is spent on cleaning, optimal operation of the
pasteurization equipment is of considerable importance to the milk industry.

PROCESS VARIABLES

1) Manipulated variable:
Flow rate of pasteurized yogurt in the regenerator

The milk is pumped into the regenerators, fluid flow rates used to satisfy the temperature combination
of the yogurt pasteurization proposed in this process. The flow rate is regulated by a metering or timing pump.
In the regenerator section, the product is pre-warmed by hot product flowing through regenerator plates.
Magnetic flow meters (shown on the right) can be used to measure the flow rate, since the magnetic flow meter
continuously senses flow rate, it will signal the electronic controller if the actual flow exceeds the set flow rate
for any reason. If the flow rate is exceeded for any reason, the flow diversion device is put into diverted flow.
As the heating process starts, the flow rate of yogurt in the regenerator must be manipulated to ensure the output
temperature of yogurt that pass in the tank meet the desired temperature of yogurt. Other than that, if the flow rate
of yogurt solution exceed the required value, it might cause the problems in composition of yogurt, therefore the
production is not efficient and reduction in profit.

2) Controlled variable:
Temperature output of the yogurt solution

In order to get the desired output temperature, we need to manipulate the temperature of yogurt in the
regenerator. The reason to achieve the desired temperature of yogurt solution is to prevent the yogurt from
overheating, thus causing the process to be inefficient. In addition, with the help of sensor which is thermostat,
it will regulates the temperature and helps control the temperature in the pasteurized regenerator by making
small adjustments to heat or cool down the process. Hence, the temperature of yogurt in the regenerator will be
proportional to the output temperature of the yogurt products.

3) Disturbance variable:
The inlet temperature of yogurt into pasteurization regenerator

The main idea of pasteurization is to make sure the process of heating yoghurt below the boiling point
to destroy microorganisms and the product follows the desired temperature. However, during the process, there
will be disturbances in the milk feed temperature. The balance, or constant level tank sometimes cannot provides
a constant supply of milk or the overflow level are not control to below the level of lowest milk passage in
regenerator. Therefore, it cannot helps to maintain a higher pressure on the pasteurized side of the heat
exchange.
MATHEMATICAL AND DYNAMIC MODEL

1) Dynamic modelling of a continuous blending system of Yoghurt

a) Overall mass balance

The percentage needed for the culture is 4% in order to have a perfect pasteurization of yoghurt.

𝑉𝑝
d = w1 +𝑤2−𝑤out
𝑑𝑡

Assumptions :

1.Liquid density, ρ and volume V are constant.

2.Flow rates 𝑤2 and 𝑤 are constant.

b) Component Mass Balance

𝑥1=0.04, 𝑥 2=0

𝑑(𝑉𝑝𝑥)
= 𝑤1𝑥1+ 𝑤2𝑥2−𝑤𝑥 (Unsteady State) - (1)
𝑑𝑡
0= 𝑤1𝑥1+ 𝑤2𝑥2−𝑤𝑥 (Steady State) - (2)
Subtracting (2) from (1)
dx
ρ𝑉 = 𝑤1𝑥’1- 𝑤𝑥’
𝑑𝑡

the two deviation variables are defined as

𝑥’1≅𝑥1− ẋ1
𝑥’′≅ 𝑥 −ẋ

ẋ is constant it follows that

dx d(x −ẋ) dx′

= = - (3)
𝑑𝑡 𝑑𝑡 𝑑𝑡

Substitute (3) into (2)

dx′
ρ𝑉 = 𝑤1𝑥’1- 𝑤𝑥’
𝑑𝑡

dx′
Since 𝑥 1=0.04 ,2=0 ρ𝑉 = 𝑤1(0.04) − 𝑤𝑥
𝑑𝑡
 c) Laplace
The pasteurization system is initially assumed at the nominal steady state. Thus, (0)= ẋ and 𝑥′(0)=0

𝜌𝑉[𝑋′(𝑠)−𝑥′(0)]= 𝑤1(0.04)(𝑠)−𝑤𝑋′(𝑠)
𝑋(𝑠)[𝜌𝑉𝑠+𝑤]=𝑤1(0.04)(𝑠)

d) Transfer Function
Rearranging gives the transfer function

w1(0.04)(s)
𝑋(𝑠)=
ρVs+w

X′(s) w1
=
0.04(s) ρVs+w

Divide the numerator and denominator by 𝑤

X′(s) K1
= 𝐺(𝑠)
0.04(s) τs+1

Where constants K1 and τ are defined as

w1 ρV
𝐾1= , 𝜏=
w w

X′(s) w1 K1
= =
0.04(s) ρVs+w τs+1

Assume 1 = 200kg , ρ = 1000kg/m3, V=0.8m/s

200
G(S)=
800s+1