Understanding the Flow Simulator: The Juice Factory Dataset

Introduction

Mixer and Filler Process Overview

This document explains how syrup batching and bottling operations are represented in the historian. It provides context for each tag, the meaning of the data, how it behaves over time, and how the Mixer States can be interpreted to understand the process.

Process Summary

There are two primary departments represented in this data model: Mixing and Packaging.

Each department receives its own work orders.

Mixing work orders define the syrup batches to produce. Each order specifies the recipe and target volume. Mixers execute the batch, then transfer the finished syrup to a storage tank where it is held until needed. The syrup may later be used by Packaging or by other factory processes not covered in this document.

Packaging work orders define the products to bottle. The fillers consume the syrup concentrate from storage and blend it with water at the filler according to the recipe. Each filler runs its own work order independently, meaning different products can be bottled simultaneously on separate fillers.

Work orders, customer details, product descriptions, SKUs, and quantities are managed in the homegrown MES system, which is backed by a SQL database.

Syrup Preparation

Mixer tags and what they represent: Each mixer has a total capacity of 55 hectoliters(hl) per vessel. This capacity is relevant when evaluating fill duration, batch sizing, heating efficiency, transfer timing, and overall throughput.

Tag	Meaning	Data Pattern	Unit of Measure (UOM)	Interpretation
MX001.Product	Product/recipe assigned to batch	Constant during all non-idle states	Unitless (integer)	Defines batch identity; changes only when mixer returns to Idle
MX001.State	Operating phase of mixer	State transitions	Unitless (integer)	Indicates the step in the batch sequence
101-LT-001.PV	Mixer level	Continuous analog	Hectoliters (hl)	Ingredient fill, transfer, and residual tracking
101-TT-001.PV	Mixer temperature	Continuous analog	Degrees Celsius (°C)	Heating, soaking, mixing, and cooling behavior

Important behaviors:

A batch run is a multiday process
Product does not change during a batch; it changes only when the mixer returns to state 0 (Idle)
Level reveals when material is entering or leaving the vessel
Temperature reveals when heating and mixing phases are active
State defines which phase of the batch recipe is executing

Mixer State Definitions

State	Description	Observable Trend Behavior
0	Idle	Tank empty, heater on to maintain tank base temp
10	Prebatch Setup	Tank empty, heater on to maintain tank base temp
20	Ingredient Addition: Primary	Level rising rapidly; heater on and temperature climbing to production setpoint
21	Ingredient Addition: Secondary	Level rising steadily; temperature stabilizing after ramp
22	Ingredient Addition: Tertiary	Level rising slowly; temperature tightly controlled
23	Main Blend	Level steady; heater off and temperature falling; agitator running
24	Awaiting Transfer	Level steady; heater off temperature stabilized to room value; downstream tank may not be ready
25	Transfer to Storage	Level falling until near zero; temperature stable
30	Clean in place (CIP) / Sanitation	Heater off, temperature cycling based on cleaning process

Batch interpretation rules:

Batch begins when state enters 10 (Prebatch Setup)
Batch ends when state leaves 30 (CIP / Sanitation)
Product changes only after returning to 0

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Packaging

Filler tags and what they represent

Each filler has a maximum throughput capability of 950 bottles per minute. This value is useful when comparing actual runtime output against theoretical capacity, determining efficiency loss, and benchmarking performance across products and crews.

Tag	Meaning	Data Pattern	Unit of Measure	Interpretation
FL001.Product	Product running on filler	Constant during work order	Unitless	Links a filler run to upstream batch identity
FL001.State	Operating mode of filler	State transitions	Unitless (integer)	Determines whether filler is producing, configuring, waiting, faulted, or being cleaned
FL001.BottleCount	Good units produced	Increasing totalizer	bottles	Production output
FL001.BottleCount.Reject	Rejected units	Increasing totalizer	bottles	Quality losses
110-FQ-001.PV	Syrup flow	Increasing totalizer	Hectoliters (hl)	Syrup consumption
111-FQ-002.PV	Water flow	Increasing totalizer	Hectoliters (hl)	Dilution/water consumption
110-JQ-001.PV	Energy usage	Increasing totalizer	Kilowatt-hour (kWh)	Power consumption

Flow meter roles:

FQ-001 and FQ-003: syrup supply
FQ-002 and FQ-004: water supply
JQ-001 and JQ-003: energy

Filler State Definitions

State	Description
0	Idle: no production
10	Setup: changeover and configuration
20	Runtime: active bottle filling
21–29	Faults: equipment stopped due to failure condition
30	Clean in place (CIP): cleaning in place