Production Planning, Modeling and Control of Food Industry Processes (Advances in Industrial Control)

"This book provides a new approach to the control of food transformation processes, emphasizing the advantage of considering the system as a multivariable one, and taking a holistic approach to the decision-making process in the plant, considering not only the technical but also the economic implications of these decisions. In addition, it presents a hierarchical structure for the global control of the plant, and includes appropriate techniques for each of the control layers. The book addresses the challenges of modeling food transformation processes, using both traditional system-identification techniques and, where these prove impractical, models based on expert knowledge and using fuzzy systems. The construction of optimal controllers for each of these types of models is also discussed, as a means to close a feedback loop on the higher-level outputs of the process. Finally, the problem of production planning is covered from two standpoints: the traditional batch-sizing problem, and the planning of production throughout the season. Systematic season-wide production planning is built upon the models constructed for the control of the plant, and incorporates market- and business-specific information. Examples based on the processing of various foodstuffs help to illustrate the text throughout, while the book's closing chapter presents a case study on advances in the processing of olive oil. Given its scope, the book will primarily be of interest to two groups of readers: food engineering practitioners and students, who are familiar with the characteristics of food processes but have little or no background in control engineering; and control engineering researchers, students and practitioners, whose situation is just the opposite, and who wish to learn more about food engineering and its specific challenges for control. Advances in Industrial Control reports and encourages the transfer of technology in control engineering. The rapid development of control technology has an impact on all areas of the control discipline. The series offers an opportunity for researchers to present an extended exposition of new work in all aspects of industrial control." -- Springer Series Editors’ Foreword 7 Acknowledgements 9 Contents 10 1 Introduction 13 1.1 Characteristics of Food Processing Industry 13 1.1.1 Variability of Raw Inputs in Food Industry 17 1.1.2 Difficulty of Online Measurement of Food Properties 18 1.1.3 Complex Nature of Food Processes 20 1.2 Characteristics of the Automatic Control of Food Processing Industry 21 1.2.1 Types of Variables and Process Dynamic Layers 21 1.2.2 Convenience of Hierarchical Control 23 1.2.3 Characteristics of Each Controller Layer 24 1.3 Food Processing Examples 28 1.3.1 Virgin Olive Oil Production Process 28 References 32 2 Modeling and System Identification 34 2.1 Crisp Modeling 35 2.1.1 First Principles Modeling 37 2.1.2 Black-Box Versus Gray-Box Versus White-Box Modeling 40 2.1.3 Prediction Error Methods 42 2.1.4 Subspace Identification 45 2.1.5 Design of Experiments 49 2.2 Fuzzy Modeling 51 2.2.1 Introduction to Fuzzy Logic 52 2.2.2 Types of Fuzzy Logic Systems: Mamdani Versus Takagi–Sugeno–Kang 54 2.2.3 Fuzzy Cognitive Maps 57 2.2.4 Neuro-Fuzzy Modeling 62 2.2.5 Identification of Fuzzy Models Parameters 63 References 67 3 Control of Lower-Level Dynamic Layers 68 3.1 Control of Continuous Processes 69 3.1.1 Basic PID Control 69 3.1.2 Two-Degree-of-Freedom Control 88 3.1.3 Feedforward Control 93 3.2 Control of Batch Processes 94 3.2.1 Iterative Learning Control 95 3.2.2 Run-to-Run Control 100 References 102 4 Control of Higher-Level Dynamic Layers 103 4.1 Feedforward of Input Characteristics 105 4.1.1 Production Objective Selection Based on Input Properties 105 4.1.2 Set-Point Selection of Intermediate Process Variables 112 4.2 Feedback of Final Product Properties 117 4.2.1 Model Predictive Control 117 4.2.2 Run-to-Run Control 122 References 126 5 Production Planning for Food Transformation Processes 127 5.1 Batch Production Planning 127 5.1.1 mrp Model 128 5.1.2 Other Optimization Problems 135 5.1.3 Solution to the Optimization Problems 137 5.2 Production Planning for Varying Input Products 140 5.2.1 Optimization Problem Definition 141 5.2.2 Models of the Evolution of the Raw Product and the Process 145 5.2.3 Types of Optimization Problems and Solutions 147 References 148 6 Case Study: Virgin Olive Oil Production Process 150 6.1 Traditional System Identification: Thermomixer Heat Transfer 150 6.1.1 Physical Modeling of the Heat Transfer 151 6.1.2 System Identification Approach 153 6.2 Continuous Process Control: Thermomixer Temperature 155 6.3 Batch Process Control: Batch Thermomixer 157 6.4 Fuzzy Low-Level Modeling: Crusher 161 6.5 Fuzzy High-Level Modeling: Paste Preparation 164 6.5.1 Definition of Nodes 166 6.5.2 Definition of Relations 167 6.5.3 Fuzzy Cognitive Map Model of the Paste Preparation 168 6.6 High-Level Control: Paste Preparation Set-Point Determination 172 6.6.1 Achievable Production Objectives 176 6.6.2 Selection of the Optimal Production Objective 182 6.6.3 Inclusion of Feedback: Run-to-Run Control 186 6.7 Production Planning: Selection of Harvesting Dates 194 6.7.1 Model of the Evolution of the Olive Properties 195 6.7.2 Process Models 195 6.7.3 Optimization Problem Definition 197 References 201 7 Conclusions and Future Directions 203 7.1 Conclusions 203 7.2 Future Directions 205 Index 208 Front Matter ....Pages i-xiii Introduction (Pablo Cano Marchal, Juan Gómez Ortega, Javier Gámez García)....Pages 1-21 Modeling and System Identification (Pablo Cano Marchal, Juan Gómez Ortega, Javier Gámez García)....Pages 23-56 Control of Lower-Level Dynamic Layers (Pablo Cano Marchal, Juan Gómez Ortega, Javier Gámez García)....Pages 57-91 Control of Higher-Level Dynamic Layers (Pablo Cano Marchal, Juan Gómez Ortega, Javier Gámez García)....Pages 93-116 Production Planning for Food Transformation Processes (Pablo Cano Marchal, Juan Gómez Ortega, Javier Gámez García)....Pages 117-139 Case Study: Virgin Olive Oil Production Process (Pablo Cano Marchal, Juan Gómez Ortega, Javier Gámez García)....Pages 141-193 Conclusions and Future Directions (Pablo Cano Marchal, Juan Gómez Ortega, Javier Gámez García)....Pages 195-199 Back Matter ....Pages 201-202