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JBS Immersion Tank

Optimizing Immersion Tank Temperature Control

JBS turned to Altus technology to enhance the temperature control system of the immersion tank used in the preparation of pork carcasses. This system plays a key role in the slaughter process at the JBS Ana Reck facility.

Optimizing Immersion Tank Temperature Control

The immersion system, which prepares pork carcasses for cleaning by submerging them in heated water, previously used a continuous steam injection to maintain the temperature. However, with its simple ON/OFF setup, the system would occasionally cause the water to overheat, affecting the quality of the submerged meat.

Another challenge in this process was with the pig transport belt, which would sometimes fail without triggering an alert, bringing the process to a halt. As a result, carcasses remained submerged for longer than necessary while operators worked to troubleshoot the issue. These failures at this critical stage of the process led to a monthly loss of around 450 pigs.

Data Collection

Real-time monitoring of operational variables through smart sensors, providing up-to-the-minute data

Diagnostics

An advanced alert and diagnostic system offering full oversight of every stage of the process

Cost Efficiency

A highly sophisticated control system designed to reduce product waste during this phase of the operation

Flexible Development

Nexto System technology enables the development of customized programs for special use cases

Solução de alta eficiência para controle de temperatura

A High-efficiency Solution for Temperature Control

Para reduzir o desperdício de produto nesta etapa do processo, a equipe de manutenção da JBS desenvolveu um sistema com válvula proporcional e controle PID utilizando a CPU NX3005 em conjunto com módulos de entradas e saídas da Série NX, o que permitiu manter a temperatura da água dentro dos níveis tidos como aceitáveis.

The system also includes a 10” P2 HMI and sensors positioned at critical points throughout the process, which continuously monitor and alert operators to any temperature fluctuations in the tank. Additionally, in the event of a transport belt failure, the system pinpoints the exact location of the issue.

This solution has virtually eliminated product losses during this part of the process, both by stabilizing the water temperature and ensuring smooth operation of the transport belt. It has also improved the efficiency of the steam boiler that heats the water, resulting in lower energy consumption and reduced water use.

Independência e segurança com a tecnologia Altus

Independence and security with Altus technology

To ensure the team could fully leverage the capabilities of the Altus PLCs and other equipment used in the modernization, we provided tailored technical training to the maintenance staff at the client's headquarters.

Carlos Henrique Azambuja, JBS automation technician and developer of the process logic, emphasized the readiness of the Altus technical team in assisting with adjustments and noted how the training programs were pivotal to the project’s success. "A lot of what I know today came from Altus' online certification training," he says.

Jairo de Quadros, the unit’s maintenance and project coordinator, highlights that the independence offered by Altus’ technology platform is one of its key advantages. "The autonomy I get from using Altus PLCs is incredibly reassuring. It gives me confidence in our daily operations. I truly believe in and trust your (Altus) products," Jairo stated.

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Company

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JBS Immersion Tank

Optimizing Immersion Tank Temperature Control

Data Collection

Diagnostics

Cost Efficiency

Flexible Development

A High-efficiency Solution for Temperature Control

Independence and security with Altus technology

Headquarters

São Paulo Branch