SIT 2015 Sugarscope PDF

Dynamic Imaging Applications
in Sugar Production
Alan O’Donoghue, JM Canty International Ltd.
S.I.T Annual Technical Conference

Mitsui Sugar Co. Ltd, Osaka, Japan
17-20 May 2015
JM Canty, Inc. · Buffalo, New York · Phone: (716) 625-4227 | JM Canty, Ltd. · Dublin, Ireland · Phone: +353 (1) 882-9621
Dynamic Imaging - Introduction
Dynamic Imaging operates on the basic principle of capturing a real time view of a
process, to either support an operator in making process related decisions, or to feed
image analysis software which performs specific process measurements
A typical Dynamic Imaging consists of 3 common hardware components;

Viewing Medium Imaging Sensor Process Lighting
Canty’s unique glass / metal Canty’s systems use Gigabit Canty’s background is in
fusion technology forms a 1 Ethernet technology, vessel / process lighting, with
piece construction incorporating high colour over 40 years of experience
component, capable of sensitivity, and are designed in the field. Each light system
withstanding high process specifically for process vision uses either halogen or LED
pressures & temperatures applications, and can be technology, and is specifically
utilised with a variety of designed to suit the imaging
lenses (micro, macro, sensor type it is combined
standard) depending on the with
specific application
Dynamic Imaging Sugar Industry Applications
Production Applications
Turbidity Analyser
Fuseview Sight Glass
SugarScope™ Crystal Growth Analyser
Centrifuge Camera Control
Quality Control Applications

Sugar Crystal Size Analysis
Sugar Crystal Colour Analysis
Clarifier Output - Turbidity Analyser
Mounts fully inline to give real time indication of colour / turbidity on clarifier outlet
Cantyvision Client software measures the amount of light entering the camera CCD chip from the
light source through the liquid stream, which is related to the turbidity of the fluid
System has the capability to discount bubbles from the calculation, meaning that it is only the
colour / turbidity of the fluid which is measured
Crystallisation Monitoring - Manual Viewing
Unique Manufacturing Process
Our unique glass recipe (BoroPlus™) is heated to it’s
molten point and poured into the centre of a metallic ring
The BoroPlus™ glass fuses / bonds to the metal and is

slowly cooled
The metal compresses on the glass due to it’s higher

coefficient of expansion, putting it under radial
compression
By fusing glass to metal, a high pressure, high safety,

hermetic seal is formed, resulting in a one piece
construction Fuseview™ sight glass
Tempered sight glasses, cannot be fully

tightened in place for fear of cracking the
window and ruining the batch.
Therefore, there is not a full vacuum seal which

causes leaks, and means more energy is
required to boil the liquid.
By using a Fuseview™ the user is tightening

on metal so cannot over torque and damage
the window. A full seal is maintained, and so a
full vacuum is achieved, meaning huge energy
savings
The energy required to heat a volume of liquid from one temperature to another can be
calculated using the formula Q=mCp(T2-T1)
Q = energy required T1 = starting temperature
m = mass T2 = finishing temperature
Cp = specific heat
To heat 1 litre of water from 20°C to a boiling point of 100°C (ambient; 14.7 psi)
Q=1(4.186)(100-20) = 334.88kJ / 0.093kWh per litre
To heat 1 litre of water from 20°C to a boiling point of 80°C (vacuum; 6.9 psi)
Q=mCp(T2-T1)
Q=1(4.186)(80-20) = 251.16kJ / 0.070kWh per litre
To heat 1 litre of water from 20°C to a boiling point of 60°C (vacuum; 2.9 psi)
Q=mCp(T2-T1)
Q=1(4.186)(60-20) = 167.44kJ / 0.047kWh per litre
Pressure vs Energy to Boil 1 Litre of Water
0,1
0,08
Energy (kWh)
0,06
0,04
0,02
0
0 2 4 6 8 10 12 14 16
Pressure (PSI)
Boiling Temp. 25,000 Litre Pan 60,000 Litre Pan 95,000 Litre Pan
100°C (14.7 PSI) $232.50 $558 $883.50
80°C (6.9 PSI) $175 $420 $665
60°C (2.7 PSI) $117.50 $282 $446.50

Based on starting temperature of 20°C
Based on average USA 2014 energy price of $0.10 per kWh
Crystallisation Monitoring – Crystal Size (Sugarscope™)
System features unique fused glass

technology and fibre optic lighting
Side mounts onto the crystalliser vessel to

provide live images of the sugar crystals
as they grow
Provides early detection of seeding

problems, allowing for recycling of the
batch if necessary without wasting energy
continuing with the process
Cantyvision Client software allows for

crystal size / shape analysis
Seeding Seeding + 30 Minutes Seeding + 60 Minutes
Seeding + 90 Minutes Seeding + 120 Minutes Seeding + 150 Minutes
Return on Investment:
With the annual increase in the production of large grain sugars, it is critical that we optimize our Pan Yields,
Crystallization Times and Utilities in producing these products. By having operator’s continuously view /
measure the crystallisation process, it is felt that the below can be achieved;
• Reduce boiling times by 33% thus increasing number of batches

• Overall increase yield by 10% (250,000 lbs/day)
• Reduction in annual water / steam usage by 33% (3,200 gals to 2,110gals per strike, 545,000
gals/4,523,500 lbs. of steam per year)
Increasing by 250,000lbs/day, would save ½ a shift of processing labour per week, which is 9 less melt days
required per year. This gives a saving on staff payments of ~$22k per year.
Reducing water / steam usage by 4,523,500 lbs would give a saving of ~$30k based on current energy costs.
Total savings for 1 year: ~$52k

Estimated total procurement / installation cost: ~$25k per unit (x2)
Payback duration: <12 months
Centrifuge Monitoring - Batch
Ethernet camera & light
combination unit provides remote
view into the centrifuge for
continual process monitoring
Cantyvision Client software can be

used to provide real time
continuous measurement of
product thickness on the wall of
the centrifuge
The intensity of light reflection

from the surface of the product
can be used as an indication of
surface fluid / filter process
performance
Centrifuge Monitoring - Batch
Centrifuge Monitoring - Continuous
Ethernet camera & light combination unit
provides remote view into the centrifuge for
continual process monitoring
Cantyvision Client software can be used to

provide real time continuous measurement
of colour line position
• Allows the operator to adjust the feed
conditions to maintain a constant colour line
position
• Avoid washing above the colour line
(inefficient due to spacing on screen and
subsequent liquid carry over)
Final Product QC – Particle Colour / Size
Both particle analysis and colour analysis

can be performed by the one system
Product fed in front of first camera for

colour speck (front lighting)
Product fed in front of second camera for

particle size (back lighting)
Images retrieved and sent to Cantyvision

PC
Final Product QC – Particle Colour
Vision based colour analysis works by passing the sugar crystals in front of a camera an light
source (front lighting) to capture images of the particles
These images are analysed in real time by Cantyvision Client to provide information on the
colour of the particles on a number of different colour scales (YUV, RGB, CIELab)
Various colour zones can programmed to only monitor particles of a particular colour
ie. whiteness of sugar / black speck detection
Final Product QC – Particle Colour
Final Product QC – Particle Size
Vision based particle analysis works by passing

the sugar crystals between a camera an light
source (back lighting) to capture images of the
particles
These images are binarised by the Cantyvision

software
These images are analysed in real time by

Cantyvision Client to provide information on a
number of different parameters (major axis, minor
axis, perimeter, aspect ratio etc.)
Final Product QC – Particle Size
OUTPUT OPTIONS
OPC - Open Connectivity for Process Control
Canty provides both an OPC client and server to connect
Cantyvision software to our customers’ digital control systems.
This comes standard with Cantyvision
4-20mA Output - Ethernet Output Module

Canty also offers an Ethernet 4-20mA current loop
Cantyvision across a network, and convert it to a 4-20mA
current loop signal. This is a separate DIN rail mounted
module that can be purchased as an accessory.
MS Excel Output
PPM, PPB, major diameter, minor diameter,
area and perimeter are measured and logged
into an Excel spreadsheet for each particle
detected.
Thank You!
For Further Information on this

product please visit
www.jmcanty.com.

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Dynamic Imaging Applications

Alan O’Donoghue, JM Canty International Ltd.

S.I.T Annual Technical Conference

A typical Dynamic Imaging consists of 3 common hardware components;

Quality Control Applications

The BoroPlus™ glass fuses / bonds to the metal and is

The metal compresses on the glass due to it’s higher

By fusing glass to metal, a high pressure, high safety,

Tempered sight glasses, cannot be fully

Therefore, there is not a full vacuum seal which

By using a Fuseview™ the user is tightening

100°C (14.7 PSI) $232.50 $558 $883.50

80°C (6.9 PSI) $175 $420 $665

60°C (2.7 PSI) $117.50 $282 $446.50

System features unique fused glass

Side mounts onto the crystalliser vessel to

Provides early detection of seeding

Cantyvision Client software allows for

Seeding Seeding + 30 Minutes Seeding + 60 Minutes

Seeding + 90 Minutes Seeding + 120 Minutes Seeding + 150 Minutes

• Reduce boiling times by 33% thus increasing number of batches

Total savings for 1 year: ~$52k

Cantyvision Client software can be

The intensity of light reflection

Cantyvision Client software can be used to

Both particle analysis and colour analysis

Product fed in front of first camera for

Product fed in front of second camera for

Images retrieved and sent to Cantyvision

Vision based particle analysis works by passing

These images are binarised by the Cantyvision

These images are analysed in real time by

4-20mA Output - Ethernet Output Module

For Further Information on this

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