Dairy production

1. Motion business Using variable speed drives, motors, softstarters and mechanical power transmission 2019 3AXD50000477814 A Dairy production Boosting productivity, reliability and energy efficiency

2. Dairy production Content of this presentation • Challenges facing dairy production personnel • Dairy production stages benefitting from motors and drives • Unlocking the potential in motor-driven applications • Dairy-specific features and functions of ABB products • From factory floor to cloud • Keeping production running • With you, wherever you are in the world

3. Challenges facing dairy production personnel

4. Challenges and solutions for dairy production personnel Increasing profitability without compromising quality Challenges for food and personnel safety Solutions for food and personnel safety Challenges for energy efficiency Employees must not be exposed to hazards from heat exchangers to risks associated with hot liquids, process steam and contaminated products Equipment must meet strict hygiene standards to avoid contamination and avoid dairy product recalls Solutions for energy efficiency Energy bill and carbon footprint must be reduced Focus on heavy consumers such as pasteurization, spray drying, homogenizer, heating/ boiling Remote monitoring keeps personnel away from danger Safe torque off ensures machinery comes to a safe stop Dust ignition-proof motors and drive packages comply with hazardous area legislation Stainless steel IEC Food Safe motors help to keep hygiene areas sanitized ABB Ability™ Smart Sensors help spot energy saving opportunities among low power applications ABB Ability™ Operations Data Management Zenon helps detect ways to optimize energy and resource consumption.

5. Challenges and solutions for dairy production personnel Increasing profitability without compromising quality Challenges for productivity improvement Solutions for productivity improvement Challenges for operation and maintenance Demand is for batches of different quantities and variants with quicker delivery Manually extracting data is time-consuming Need access to correct data to turn into usable information Solutions for operation and maintenance Operational costs must be controlled without compromising safety of plant, personnel or end-product Avoid plant shutdowns which are costly, spoil goods and incur reputation damage Safely interlink processes from production to logistics and warehousing through fieldbus and built-in sensors Open fieldbus systems allow easy drive integration to any PLC or similar control system - gives greater insight and production control Soft starting avoids sudden shock loading, leading to less mechanical wear and tear Stainless steel motors last five times longer than standard in washdown ABB AbilityTM Condition Monitoring offers early failure warning

6. Dairy production stages benefitting from motors and drives

7. Dairy processes benefitting from motors and drives Controlling the details boosts productivity 5 1 1 7 2 8 6 3 4 5 2 3 7 6 4 8

8. Unlocking the potential in motor-driven applications

9. Unlocking the potential in motor-driven applications Energy saving, improved productivity and greater safety Pumps Compressors One of the biggest single energy consumers SynRM IE4 motor-drive provides energy savings of between 20 to 60 percent across speed range Avoid wear and tear to mechanical parts, and ensure uptime Drives extend compressor speed range, while softstarters are suitable for motors running at full speed Ultra-low harmonic drives reduce harmoniccontent by up to 97 percent compared to aconventional drive Motor and drive packages to vary wateror glycol flow rates Avoids traditional throttling valves,achieving the right compressor speedto circulate the right amount of coolingmedia Dedicated software measures motor torque and speed to avoid cavitation that could damage milk-fat globules Clean-In-Place (CIP) with easy-to-use pump control software gives correct pressure and flow rate to pipe clean and fill functions Shorter cleaning time with less water and cleaning materials used High energy user Up to 60 percent energy savings comparedto throttled control system Often located in hygienic areas Stainless steel IP69 motors and paint-freemotors remove the need for shroudedpump motors and offer 360 degree accessfor cleaning and sanitation

10. Unlocking the potential in motor-driven applications Energy saving, improved productivity and greater safety Conveyors Centrifugal separators Control centrifuge speed without generating vibrations Drive automatically changes to maximum torque above 46 Hz, achieving speed control without over-dimensioning Flying start drive function saves time and reduces equipment wear Regenerative braking feeds braking energy back into the mains, lowering energy consumption Direct torque control enables accurate controlover entire speed range Requirement for precise, smooth and consistent control and synchronization of conveyor speeds Drive’s built-in brake chopper provides precise control of conveyor deceleration rate(s), without external hardware Safe torque off (SIL3) prevents unexpected movement of conveyor Eliminate costly downtime which can lead to spoilage and waste Best-in-class sealing system means less maintenanceand increased process uptime Motor-drive package delivers lowermaintenance costs by reducingmechanical stress of gears andbelts

11. Unlocking the potential in motor-driven applications Energy saving, improved productivity and greater safety Mixers Cooling towers Belt driven cooling towers are costly to maintain due to mechanical parts wear Unique cooling tower package from ABB eliminates start-up current peaks, with fewer parts, low noise level and increased safety Lower total cost of ownership High starting torque, wide mixing speed range and precise control are required to ensure best quality end products Direct torque control optimises production speed and process up-time by providing accurate speed control and adapting to the mixing load Safe torque off improves operational safety

12. Dairy-specific features and functions of ABB products

13. Dairy-specific features and functions of ABB products Variable speed drives Fieldbus compatible • Use information such as milk flow rates and separator centrifuge speeds to get the VSD to adjust motor speed and torque • Get detailed insight into productivity performance and quality control through fieldbus comms connecting VSD with plant monitoring systems Anti-cavitation software • Extend pump lifetime and secure the process by detecting cavitation and ensuring optimal process or liquid flow Energy efficiency • Control operating costs by seeing energy costs in local currency, kWh and CO2 emissions Functional safety • Safely stop applications like mixers and separators using in-built safe torque off (safety level SIL3) Flying start • Reduce wear and save time by starting a motor while the load if still spinning Slide 13 June 18, 2019

14. Dairy-specific features and functions of ABB products Variable speed drives Repeatability • Accurately adjust conveyor speed to suit filling rates of products with varying viscosities, such as milk, yoghurt and cream Low harmonics • Eliminate supply disturbances that could trip production with built-in active supply unit and integrated low harmonic line filter Soft pipe filling • Increase lifetime of piping and pump system by avoiding pressure peaks Reduced noise • Protect staff health and safety with lower motor noise through adaptive switching frequency control Ingress protection • IP55 for washdown zones Slide 14 June 18, 2019

15. Dairy-specific features and functions of ABB products Softstarters Built-in bypass Reduce system complexity and size, saving time and money during installation Reduce heat generation from internal losses by activating bypass at full speed Flexible communication Operate in local and remote mode by accessing all major communication protocols and built-in Modbus-RTU Harsh environment use Ensure uninterrupted production in dusty or wet environments with IP66 keypad and coated electronics

16. Dairy-specific features and functions of ABB products Motors Food Zone 1 IP69 for water rating ensures suitability for aggressive, clean in place washdown procedures Uses H1 grease to lower risk of food contamination Splash Zone 2 Eliminate risk of paint chips entering food chain with paint-free motor Uses H1 grease to lower risk of food contamination Surface is easy to clean Dry Zone 3 Prevent dust explosions with certified dust ignition proof motors ABB AbilityTM Smart Sensor ready Widest product offering https://www.youtube.com/watch?v=Nl4mQ2R0bH4

17. Dairy-specific features and functions of ABB products Mounted bearings Splash Zone 2 Stainless steel or corrosion resistance bearings in stainless or polymer housing Extend bearing life in harsh washdown conditions using factory-filled food grade grease Food Zone 1 Smooth stainless-steel housing without a grease fitting to minimize harboring points IP69 for water rating for aggressive, clean-in-place washdown procedures Sealed and lubed-for-life bearings to minimize maintenance costs Dry Zone 3 Multiple housing styles, bore sizes and locking mechanisms Variety of sealing options to protect the bearing from contamination Roller bearings have patented easy-on, easy-off adapter mounting and removal system ABB AbilityTM Smart Sensor ready https://www.youtube.com/embed/7KTC50Lv-lo?controls=0&rel=0

18. Dairy-specific features and functions of ABB products Gearing Food Zone 1 Two-piece harsh duty seal Factory-filled USDA/FDA compliant using H1 food grade synthetic oil Totally enclosed, no paths for contamination Some models available in quill style or 3-piece coupled NEMA Splash Zone 2 13 step coating system Provides 3x the corrosion resistance of epoxy paint Factory-filled USDA/FDA compliant using H1 food grade synthetic oil Dry Zone 3 Premium sealing systems used to keep contaminants out and lubrication in Accessories available for protection and safety in high humidity, excessive dusty and dirty, or even extremely dry environments

19. Dairy-specific features and functions of ABB products Drives and motors packages Globally certified motors and drives packages Tested and certified motors and drives for potentially explosive atmospheres • Guarantee people and plant safety according to global regulations Synchronous reluctance motor (SynRM) and drive High efficiency IE4+ motor and drive packages saves energy across all dairy applications Suitable for retrofits, motor same size as IE2 induction motor of same power Upgrading to highest efficiency level is easy without mechanical mods Motor runs very quietly compared to induction motor No rotor currents means losses totally eliminated, leading to improved efficiency, longer bearing lifetime and less dissipated heat losses + Cooling tower packages Reduce energy, vibration, noise and maintenance costs using a package that removes the gearbox from cooling towers Special low-speed permanent-magnet motor

20. From factory floor to cloud

21. ABB Ability™ digital services ABB AbilityTM digital advantage ABB Ability™ Life Cycle Assessment ABB Ability™ Energy Optimization ABB Ability™ ConditionMonitoring for powertrains Analyze energy savings potential across a plant using ABB drives and motors. ABB Ability™ Life Cycle Assessment service gives a comprehensive picture of your drives and motors technical infrastructure. The most critical assets and clear priorities for maintenancecanbe set. ABB Ability™ Condition Monitoring for powertrains enables full transparency on all parameters for drives, motors, mounted bearings and pumps.

22. From factory floor to cloud ABB AbilityTM Condition Monitoring for powertrains 1 2 3 4 Intelligent powertrain Turning data into info Accessing data Digital advantage Comprises transformer, drive, motor, bearing and application (e.g. pump) - equipped with sensors and cloud connectivity. Data collected from drive’s inbuilt sensors, loggers and smart sensors. Condition monitoring gives detailed information on temperature, vibration and stress levels. Dashboards offer transparency of data. The right person is exposed to the right information at the right time.

23. Configuring powertrains Customizing the digital service plan 6 1 2 3 4 5 Enjoy the customized service Start monitoring Activate access to the Condition Monitoring basic feature Choose one or more assets you want to protect Install connectivity devices Pick optional features and customize Remote assistance Backup Management Smart sensor Alarm Management Offline Data Collection NETA-21 Asset Health Condition-based Maintenance

24. Dairy-specific features and functions of ABB products Integrating sensor and drive data with cloud-based analytics ABB Ability™ Digital Powertrain includes all components such as drives, motors, bearings and applications like pumps • a digital solution that integrates sensor and drive data with cloud-based analytics along entire chain from drives and motors, to pumps and bearings. • features its own monitoring services that sends measurement data to cloud, which is visible to operator on simple dashboard.  • assets that functioning correctly are shown as green; amber indicates a warning condition and that something needs to be checked, while red indicates that something is either in, or heading towards, a fault condition. 

25. Dairy-specific features and functions of ABB products ABB AbilityTM Smart Sensor for motors, pumps and mounted bearings Improved safety Enables easy access to motors, pumps and mounted bearings in locations that are difficult or dangerous to access Minimized unplanned downtime Failures can be detected well before equipment needs to be shut down, avoiding unplanned downtime Reduced maintenance costs By changing from scheduled to condition-based maintenance, service costs can be considerably reduced Try & Buy Try & Buy program for motors enables testing of Smart Sensor technology without risk

26. Keeping production running

27. Keeping production running From spare parts to cloud-based remote monitoring Global ABB service units, complemented by ABB authorized value providers, cover your installation throughout its lifecycle. Maximize performance, uptime and efficiency throughout the life cycle of your assets. From spare parts and technical support to cloud-based remote monitoring solutions, ABB offers the most extensive service offering to fit your needs.

28. Keeping production running From spare parts to cloud-based remote monitoring Global service network 24/7 Comprehensive bundling of relevant services into one contract to suit your needs. Agreements Training Comprehensive and professional training either at ABB premises or your own. “I need operational excellence, rapid response, improved performance and life cycle management.”

29. Keeping production running From spare parts to cloud-based remote monitoring Installation and commissioning Technical support and repairs Spares and consumables Highly-trained and reliable installation & commissioning experts at your service. Quick and accurate response during emergencies and efficient support during planned production breaks. Authentic, high-quality ABB spares and consumables with quick delivery.

30. Keeping production running From spare parts to cloud-based remote monitoring Engineering and consulting Ways to identify and improve the reliability, usability, maintainability and safety of your production processes. Extensions, upgrades and retrofits Advanced services Gain the unique ABB Ability™ digital advantage through data collection and analytics with advanced services. Up-to-date systems and devices with the best possible performance level.

31. Keeping production running From spare parts to cloud-based remote monitoring Replacements Fast and efficient replacement services to minimize production downtime. End-of-life services Maintenance Systematic and organized maintenance and support over the life cycle of your assets. Responsible dismantling, recycling and reusing of products, according to local laws and industrial standards.

32. With you, wherever you are in the world

33. With you, wherever you are in the world Global network ABB operates in over 100 countries with its own manufacturing, logistics and sales operations Wide network of local authorized value providers that can quickly respond to your needs Stock availability features short delivery times for many products backed by 24- hour spare parts delivery ABB collaborates with baked goods producers to develop custom products, services and solutions ABB has seven global R&D centers with more than 8,000 technologists and invests $1.5 billion annually on innovation