Method for beverage blending and proportioning

The present invention relates to a method and apparatus for improving quality and increasing syrup yield within a beverage proportioning system. The method and apparatus of the present invention is contemplated to be adaptable to existing proportioning and blending systems to provide a highly accurate control of the proportional blending. This control is a function of the mass flow of the components input to the proportioner. From this mass flow determination and adjusted volumetric flow value for each component is determined. The ratio of the calculated volumetric flow of the water to the syrup is used to determine a signal to control the proportional blending. Adjustment of the blend ratio is made by comparing the calculated ratio to the set beverage values. The invention also determines the accuracy of the adjustment and the efficiency of the overall blending and proportioning system.

FIELD OF THE INVENTION 
The present invention relates to a method and apparatus for improving 
quality and increasing syrup yields within a beverage blending system. In 
particular, the present invention relates to a method and apparatus for 
controlling the proportional blending of two or more components of a 
carbonated beverage by means of the mass flow of the components. 
BACKGROUND OF THE INVENTION 
The preparation of beverages, particularly carbonated beverages, includes 
the mixture or blending in exact proportion of a flavor syrup with water. 
The proportion standards for a particular beverage are typically set by 
the owner of the syrup recipe and the associated trademarks of the 
beverage. These proportion standards are a fixed operational requirement 
for the bottler who is a licensee of the recipe owner. 
Typically, the conformity of the blended beverage to the proportion 
standards is determined after the beverage has been prepared. This 
determination is made by a downstream analyzer system or by lab analysis. 
If it is found that the already blended beverage does not fall within the 
required standards, the batch is disposed of at substantial cost to the 
bottler. 
There are a number of blending and proportioning systems found in the prior 
art. However, these prior art devices do not adjust the proportioning 
process to account for changing conditions as contemplated by present 
invention. 
Pahl, et al. U.S. Pat. No. 2,724,581 shows a blending and proportioning 
system for carbonated beverages including separate storage tanks for the 
syrup and water components. Each tank includes a level sensing float that 
controls a valve in the input line to the tank. The level sensors produce 
control signals in accordance with the level of the fluid retained within 
the tank. Blending is controlled by pumps driven by a single electric 
motor having a variable speed transmission. The ratio of pump speed 
determines the capacity of water and syrup supplied to the blender. 
Witt et al. U.S. Pat. No. 3,237,808 and Mojonnier U.S. Pat. Nos. 4,732,582 
and 4,801,471 show beverage proportioning and blending systems including 
separate component tanks each having level sensor-type valve control 
mechanisms therein. The blending is performed by orifice assemblies which 
operate in conjunction with the fluid level within the associated tank to 
define the relative flow rate into a blending chamber. 
Johnson, et al. U.S. Pat. No. 4,397,189 also shows a flow rate measurement 
system including level sensors for determining flow rate through control 
values. 
Smith U.S. Pat. No. 3,583,415 shows a beverage proportioning and blending 
system in which the concentrated syrup is raised in temperature in a heat 
exchanger. The heated syrup is supplied at a constant pressure head so as 
to attempt to maintain an accurate volumetric flow. 
Rudick U.S. Pat. No. 4,753,370 shows a beverage mixing system in which the 
amount of unsweetened flavor concentrate input into the mixing nozzle is 
controlled by a peristaltic pump. 
Peckjian U.S. Pat. No. 4,795,061 shows a beverage blending and 
proportioning pump which is controlled by the maintenance of the water 
source at a constant pressure and flow rate. 
Skoli, et. al. U.S. Pat. No. 4,350,503 shows a blending and proportioning 
system in which the level of the water supplied to a de-aerator chamber, 
upstream from the blending chamber, is constantly controlled based upon 
the downstream need for the water component by the system. 
Shannon, et al. U.S. Pat. Nos. 3,991,911 and 4,252,253 show computer 
control systems for dispensing a plurality of mixed drinks to desired 
specifications while maintaining inventory and sales data. 
SUMMARY OF THE INVENTION 
The present invention is a method and apparatus for controlling the 
proportional blending of beverage components as a function of the mass 
flow of the components. The present invention preferably includes Coriolis 
mass flow meters within both the syrup input line and the water input line 
of a proportioner within a blending system. The proportion of the water 
and syrup within the blend is calculated as function of the mass flow 
signal from the Coriolis meters. This calculated proportion value is 
compared to the fixed standard for the particular beverage or from an 
actual density determination of the fluids. Adjustment of the proportional 
blending is automatically made as function of these calculated and fixed 
values and related comparisons. Furthermore, an overall efficiency of the 
blending and proportioning system may be determined.

DETAILED DESCRIPTION OF THE DRAWINGS 
In the figures where like numerals indicate like elements, there is shown 
in FIG. 1 a typical blending and proportioning system including a 
proportion analyzer at the discharge end. For purposes of the present 
invention this typical blending system need not be described in complete 
detail. Reference is hereby made to U.S. Pat. No. 4,801,471 to Mojonnier 
which describes a blending and proportioning system similar to those 
typically found in existing bottling plants. This Mojonnier patent is 
herein incorporated by reference. 
The blending and portioning system of FIG. 1 includes a water input 10 
which feeds a cooler 12. The cooler 12 feeds one portion of a proportioner 
14. A syrup supply 16 feeds a separate portion of the proportioner 14. 
Filtered water from inlet 10 or syrup from supply 16 may pass through 
scrubbing units (not shown) or other apparatus as desired prior to input 
into proportioner 14. The input flow into the proportioner 14 from both 
the water line 18 and syrup line 20 is controlled by means of valves 22 
and 24, respectively. Valves 22, 24 receive control signals from floating 
control members (not shown) within the storage tanks 26 and 28 of the 
proportioner 14. These float valves may be similar to those shown and 
described in U.S. Pat. No. 3,272,020 to Witt et al. and U.S. Pat. No. 
4,737,037 to Mojonnier. These patents are also herein incorporated by 
reference. 
Storage tanks 26 and 28 feed lines 32, 34, respectively, which exhaust into 
blending tank 30. Water line 32 into tank 30 includes a micrometer or 
similar type control valve 36. Valve 36 is used to make minute adjustments 
in the relative proportion of the water flowing into blending tank 30. 
Existing proportioner systems may typically include a valve similar to 
that shown in U.S. Pat. No. 3,237,808 to Witt et al. This Witt patent is 
herein incorporated by reference. Syrup line 34 may also include a control 
valve (not shown). However, due to the large proportion of water in a 
typical beverage, as compared to the syrup, minute control of the relative 
proportion of the components is more easily accomplished by adjustment at 
the water input. A total flow control valve 38 is also provided at the 
inlet to blending tank 30. 
Blending tank 30 includes a float member 40 similar to that used along with 
valves 22 and 24. The signals from the float member 40 is used to control 
the downstream pumping of the blended beverage. The blended beverage from 
blending tank 30 is input into a carbonator 42. After carbonation, the 
beverage flow is directed towards a bottling apparatus (not shown). 
The actual proportion of syrup and water within the blended beverage is 
determined by a downstream beverage analyzer 44. The analyzer 44 takes 
samples from the flow into the bottling apparatus. The samples are used to 
determine the accuracy of the blend as performed by the proportioner 14 
and compare it to the fixed standards. If an on-line analyzer 44 is not 
provided, periodically samples are manually withdrawn from the flow and 
lab analysis is conducted to determine the proportion result. 
Typically, sugar based beverages are analyzed by making a brix 
determination of the sugar within the overall blend. In the case of diet 
soda, the analyzer typically uses a titrated acidity determination. 
Methods of analyzing the beverage include internal reflection spectroscopy 
and infrared absorbtion. 
Upon a finding that the blended beverage is outside of the standards set by 
the recipe owner, adjustment of the proportioning is made at valve 36 or 
at some other position within the system. Analyzer 44 may also serve to 
control the blend. Such an analyzer/controller is manufactured by the 
DuPont Corporation and is sold under the designation "DuPont Colormeter". 
This DuPont system includes an external water valve which inputs 
additional water into the flow at the position of the analyzer. The system 
compensates for errors of the proportional blending by operating the 
proportioner on the "high" or rich end of the blending standards. The 
addition of water downstream of the proportioner adjusts the proportion of 
the blend. However, if the analyzer fails to adjust the beverage into the 
proper proportion, the product will be outside of the fixed standards. 
This may occur, if the beverage blend moves into the "low" range. In this 
situation manual micrometer control must be made to realign the proportion 
into the desired range. The portion of the batch prepared outside of the 
fixed standards must then be disposed of prior to continuation of the 
blending and bottling process. 
In FIG. 2 there is shown a beverage blending and proportioning apparatus in 
accordance with the present invention. This apparatus generally includes a 
proportioner 50 similar to proportioner 14 shown in FIG. 1. At the water 
inlet 52 to proportioner 50 is positioned a flow meter 54 to determine the 
mass flow rate of the water input into the water storage tank 56. 
Similarly, at the syrup inlet 58, there is a second mass flow meter 60 
which determines the mass flow rate of the syrup input into the syrup 
storage tank 62 of the proportioner 50. Flow meters 54 and 60 are 
preferably of the type known as a Coriolis mass flow meter. Coriolis-type 
mass flow meters are preferred because of their high accuracy in 
determining the mass flow rate and total mass flow without reference to 
the temperature or viscosity of the fluid. The size and operational 
capabilities of meters 54, 60 will depend upon the flow rates into the 
proportioner 50 and the number of storage tanks therein. The flow meters 
as generally preferred for use with the present invention are those 
manufactured by the K-Flow Corporation of Millville, N.J. 
At the inlet side of water storage tank 56 is a flow control valve 64. The 
inlet to syrup tank 62 includes a similar valve 66. These valves 64, 66 
are controlled by a float sensors (not shown) within tanks 56 and 62, 
respectively. A fixed orifice valve 76 is positioned at the outlet 78 of 
the syrup tank 62. A micrometer control valve 72 is located at the outlet 
74 of water storage tank 56. Outlets 74 and 78 feed blending tank 80. The 
outlet 82 of blending tank 80 feeds carbonator 84. The carbonator 84 feeds 
pump 86 which directs the flow into a bottling or container filling 
apparatus (not shown). A float control (not shown) within the blending 
tank 80 outputs a signal which may be utilized downstream of the 
proportioner 50 by pump 86 to control the overall flow rate or speed of 
the system. 
The signals from the flow meters 54, 60 are fed to a controller 68. Signals 
from the carbonator 84 are also fed into controller 68. Controller 68 in 
turn sends a signal to an electronic actuator 70. Actuator 70 is used to 
adjust micrometer control valve 72 at the outlet 74 of water storage tank 
56. The actuator 70 controls the throttling or shut off of the valve 72 by 
a rotary motion based upon a remote control signal from controller 68. 
Actuator 70 as contemplated by the present invention may take any form as 
desired, such as geared electronic actuator A300 manufactured by the Flow 
Control Division of Milton Roy Industries. Adaptation of the actuator 70 
to operate valve 72 may require a yoke bracket (not shown) or the like to 
be fit between the torque output of the actuator and the rotational knob 
of the micrometer. Such adaptation is contemplated to be within the skill 
of the art. 
Controller 68 may also be used to adjust the blending performed by variable 
speed pumps at the outlet of the proportioner storage tanks. Such a system 
is shown in Pahl, et al., U.S. Pat. No. 2,728,581. This Pahl, et al., 
patent is herein incorporated by reference. The adaptation of the present 
invention to operate along with this Pahl type system is contemplated to 
be within the skill of the art. 
Controller 68 operates under the following preferred method for adjusting 
the proportional blending of a beverage. FIGS. 3, 3A, 3B, 4 and 5 show 
flow charts for this preferred method. 
As particularly shown in FIG. 3, at start-up, the controller 68 reviews 
certain controls within the system. First, the controller 68 determines 
whether or not the mix or lift pumps (not shown) within the system are 
operating. If the pumps are not operating, the control program will not 
continue. If the pumps are operating, the controller 68 proceeds to the 
next step. There is a initial period at start-up where the signals from 
the flow meters 56, 60 and from other elements in the system may be 
unstable. A time delay is input into the system to permit stability to be 
achieved prior to making the initial flow meter readings. Upon exceeding 
the delay time, controller 68 moves to the next step. The final 
preliminary step taken is to determine whether or not the end run remote 
switch (not shown) has been actuated. This end run switch will prevent 
further operation of the control program at any time during the blending 
operation. Upon completing the start-up procedure, the signals output from 
the flow meters 54, 60 are zeroed to indicate the start of a new batch. 
Also, the memory of the previous batch calculations is cleared. 
A proportioning and blending system is required at different times to 
produce many different types of beverages under different blending 
recipes. The appropriate fixed data related to a particular beverage to be 
blended must be identified to properly instruct the controller 68 during 
further operation. The particular beverage to be run through the system 
will be selected at start-up. This selection actuates the retrieval of 
data from stored memory for the particular beverage. Thereafter, the syrup 
and water flow meter signals are read and the batch is initiated. 
As particularly shown in FIG. 4, the first determination made by the 
controller 68 during a batch run is whether or not the drink is a sugared 
drink or whether or not such is a diet or other non-sugar sweetened drink. 
This determination particularly relates to the density of the syrup. 
The first calculation for a sugar-free syrup by the controller uses the 
mass flow signal from flow meter 60 to determine the volumetric flow rate 
of the syrup. The volumetric flow of the sugar-free syrup can be 
determined from the following equation: 
EQU GPMS.sub.sf =M.sub.s /(8.333.multidot..sub.Dsf) (1) 
(GPMS.sub.sf =gallons per minute of the sugar-free syrup; M.sub.s =the mass 
flow rate of the syrup; and D.sub.sf =the density of the sugar-free 
syrup.) Typically, the density of the sugar-free syrup can be estimated to 
be one, i.e. substantially the same as water at 20.degree. C. However, 
controller 68 may be set to read a different density value for the 
sugarfree syrup (D.sub.sf) as determined by the bottler or as set by the 
drink recipe owner. 
The determination of the volumetric flow rate of a sugared syrup as a 
function of the mass flow is also a function of its density. This density 
value for a sugared syrup may be calculated as a function of published 
brix values. Curves providing this information are published by the 
National Bureau of Standards at Table No. 113. The brix value for a 
particular beverage syrup changes during the blending operation. 
Therefore, the density for each particular drink must be calculated. This 
density value is calculated by the resultant equation of a least squares 
regression on the published curves. This equation is as follows: 
EQU D.sub.su =D.sub.su +K.sub.(x+1) .multidot.(DN.sub.std 
.multidot.R.sub.i).sup.x (2) 
(D.sub.su =density of the sugared syrup; K=a constant corresponding to the 
least squares calculation; x=the coefficient value within the calculation; 
DN.sub.std =the standard drink number for the particular beverage being 
prepared; and R.sub.i =the ideal ratio for mixing the particular syrup 
with water.) The calculation using this equation includes the following 
constant (K) values: 
K(.sub.1)=0.9987881 
K(.sub.2)=0.003715599 
K(.sub.3)=0.00002321195 
K(.sub.4)=-0.0000002270948 
K(.sub.5)=0.000000003156378 
K(.sub.6)=-0.00000000001398131 
The series of calculations start at x=5 and D.sub.su =K(.sub.1) with each 
subsequent calculation being made for x-1. 
From this density calculation (D.sub.su), the flow rate of the sugared 
syrup can be determined as a function of the mass flow signal from flow 
meter 60 by the following equation: 
EQU GPMS.sub.su =M.sub.s /(8.333.multidot.D.sub.su) (3) 
In the same manner the output of water flow meter 54 is used to calculate 
the volumetric flow rate of the water as a function of its mass flow. This 
volumetric flow rate is determined from the following equation: 
EQU GPMW=M.sub.w /(8.333.multidot.0.998234) (4) 
In this equation, a fixed value for the density of the water at 20.degree. 
C. is used. 
The advantage of using Coriolis type mass flow meters as part of the 
present invention is due to the accuracy of the mass flow determination 
made therefrom. This mass flow determination is made without reference to 
the viscosity or temperature of the fluid. Thus, the volumetric 
determinations made by equations (1), (3) and (4) are essentially free of 
fluid temperature and viscosity considerations. Ultimately the accuracy of 
the blending control by the present invention is checked against 
laboratory analysis by the bottler. Further, calculations made by the 
controller 68 require lab analysis input, such as the standard drink 
number (DN.sub.std) This data and the density values used to calculate the 
volumetric flow for the water and the syrup (sugar and sugar free) and 
other calculations within the system are made on the assumption that the 
fluid is at 20.degree. C. Since the signal from the mass flow meter is not 
temperature dependent, this assumption provides accurate results. 
The density value for a sugared syrup, as well as the sugar-free syrup and 
the mixing water, may also be determined by utilizing the mass flow meters 
54 and 60. Typically, Coriolis type flow meters are capable of determining 
the density of a fluid as well as its mass flow rate. Thus, the actual 
brix value of the syrup may be used to determine the volumetric flow rate 
into proportioner 50. 
As particularly shown in FIG. 5, the calculation of the volumetric flow of 
the sugar-free syrup uses the mass flow signal from flow meter 60 as well 
as the density signal therefrom. Thus, the density of the sugarfree syrup 
(D.sub.sf) in equation (1), above, is an actual value rather than an 
assigned value. 
The determination of the volumetric flow rate of a sugared syrup as a 
function of the mass flow and density flow readings is somewhat more 
complicated than for the sugar free syrup calculation. This calculation 
generally involves substituting an actual drink number for the syrup 
(DN.sub.syr) within equation (2). The temperature of the squared syrup 
becomes a significant factor in determining of the drink number value. The 
variation in temperature in the sugar-free syrup is not considered 
significant for purposes of determining a volumetric flow. Thus, the 
measured density readings from the densitometer portion of the Coriolis 
meter requires correction to 20.degree. C. 
The temperature correction factor is calculated by the resulting equation 
of a least squares regression duplicating the curves at National Bureau of 
Standards Table No. 120. The resultant equation based upon this regression 
is as follows: 
EQU T.sub.cor =T.sub.cor +KT.sub.(xt+1) .multidot.D.sub.mea.sup.xt (2a) 
(T.sub.cor =temperature correction variable factor; KT=a constant 
corresponding to the least squares regression; xt=the coefficient value 
within the regression; and D.sub.mea =the measured density value from the 
flow meter 60.) The regression for this equation includes the following 
constant (KT) values: 
KT(.sub.1)=-0.004109494 
KT(.sub.2)=0.007006943 
KT(.sub.3)=-0.00194279 
KT(.sub.4)=-0.001908077 
KT(.sub.5)=0.001467323 
KT(.sub.6)=-0.0002886857 
The calculation starts at xt=5 and T.sub.cor =KT(.sub.1) with each 
subsequent calculation being made for xt-1. 
The measured density is corrected to 20.degree. C. by the following 
equation: 
EQU D.sub.cor =((T.sub.syr -20).multidot.T.sub.cor)+D.sub.mea (2b) 
(D.sub.cor =the corrected value of the measured density and T.sub.syr =the 
actual temperature of the syrup.) 
From this corrected density value (D.sub.cor), the weight percent sugar or 
brix of the sugared syrup can be determined by a least fit squares 
regression of National Bureau of Standards Table No. 113. This regression 
equation is as follows: 
EQU DN.sub.act =DN.sub.act +KD.sub.(xd+1) .multidot.D.sub.cor.sup.xd (2c) 
(DN.sub.act =the actual syrup brix for the specific syrup; KD=a constant 
corresponding to the least squares regression; and xd =the coefficient 
value within the regression). The regression for this equation includes 
the following constant (KD) values for the density to bricks conversion: 
KD(.sub.1)=-241.5639 
KD(.sub.2)=183.5383 
KD(.sub.3)=-16.72519 
KD(.sub.4)=289.5726 
KD(.sub.5)=-293.833 
KD(.sub.6)=79.9125 
The calculation starts with DN.sub.act =KD(.sub.1) and xd=5 with each 
subsequent calculation being made for xd-1. 
Typically, a correction factor is used by bottlers for the individual syrup 
formulas to correct the true brix value after the solution is diluted to 
the ideal ratio. This correction factor can be included into the actual 
calculations as follows: 
EQU DN.sub.std =DN.sub.act /SYP (2d) 
(SYP=the syrup correction factor variable.) From this point the standard 
drink number (DN.sub.std) can be input into the original equation (2) so 
as to continuously calculate the density of the syrup and the 
corresponding volumetric flow rate of the syrup via equation (3). 
In the same manner, the output of water flow meter 54 can be used to 
calculate the volumetric flow rate as a function of its mass flow and its 
density flow rate. This volumetric flow rate is determined from the 
following equation: 
EQU GPMW=M.sub.w /(8.33.multidot.D.sub.w) (4a) 
(D.sub.w =the density of the water from the meter 54.) 
The result of each of these equations is to provide a volumetric flow rate 
which is fixed at a 20.degree. C. temperature factor. As particularly 
shown in FIG. 3A and 3B, from the volumetric flow rate values a calculated 
ratio for the beverage being blended within blending tank 80 may be 
determined as well as other aspects of the blending process. 
The ratio of the blend is determined by the following equation: 
EQU RATIO=GPMW/GPMS (5) 
(GPMS=either the calculated volumetric flow of the sugarfree (GPMS.sub.sf) 
or the sugared (GPMS.sub.su) syrup.) 
The blending of a particular beverage is typically determined as a function 
of its target drink number. This target drink number is the proper brix 
value for the sugar in the blended beverage as set by the beverage recipe 
owner. The bottler must conform to this fixed value in preparing the 
beverage. However, in preparing each batch of syrup (prior to blending), 
the "standard" drink number (DN.sub.std) for the syrup batch may not 
conform to the target value. A standard drink number for the batch is 
determined by the bottler through lab analysis by mixing the syrup with 
water in the exact proportion desired by the beverage owner at a 
controlled 20.degree. C. The standard and target drink numbers are 
typically part of the data read by the controller 68 from stored memory at 
the start of the batch. The difference between the target drink number and 
the standard drink number for the batch of syrup provides the bottler with 
an indication of the original setting of the micrometer in order to 
produce a beverage in conformance with the target value. 
Adjustments to the blend during operation of the proportioner require a 
determination of the drink number for the beverage at the time of the 
adjustment. This actual drink number can be calculated as a function of 
the standard drink number for the syrup batch and the ideal blend ratio 
for the particular beverage: 
EQU DN.sub.cal =((R.sub.i /RATIO).multidot.DN.sub.std)+B.sub.off (6) 
(DN.sub.cal =calculated drink number and B.sub.off =adjustment value.) The 
offset adjustment value may be set by a bottler or by the beverage recipe 
owner in order to adjust the equation in view of past calculations to 
arrive at the target. This value may typically be equal to zero (0). 
For sugared drinks the calculation of the drink number can be altered 
linearize the new standard drink number calculation. This variation is 
calculated by the following equation: 
EQU DN.sub.cal =((Log(R.sub.i)/Log(RATIO)).multidot.DN.sub.std)+B.sub.off (6a) 
The same equation can be used to calculate the drink number for the 
sugar-free drink. However, the standard control drink number (DN.sub.std) 
input by the operator is used rather than the calculated standard drink of 
equation (2d). 
The bottler is typically permitted by a beverage recipe owner to produce 
the beverage within a certain percentage range of the target, such as 
between 100% and 102% of the target drink number. Due to the accuracy of 
the present invention in determining the actual drink number and 
controlling the blend, a bottler may identify a set point within this 
target range. This set point will likely be the lowest possible 
consistently obtainable value in the target range. The calculated drink 
number (DN.sub.cal) may be compared to the target and set points by the 
following equations: 
EQU TGT.sub.%=(DN.sub.cal /TGT).multidot.100 (7) 
EQU SET.sub.% =(DN.sub.cal /SET).multidot.100 (8) 
(TGT.sub.% =percentage of the calculated drink number to the targeted drink 
number; TGT=the target drink number; SET.sub.% =percentage of the 
calculated drink number to the set point value; and SET=the set point for 
a particular bottler.) From these percentage values a determination can be 
made as to whether of or not an adjustment of the blend is required. 
Adjustment will be discussed in further detail below. 
The volumetric flow rate determinations of equations (1), (3) and (4) may 
be used to calculate the total flow rate out of the proportioner 50 by the 
following equation: 
EQU GPM.sub.tot =GPMS+GPMW (9) 
Further, the total flow for the particular batch at any particular time can 
be determined from the total mass flow signal received from the flow 
meters 54, 60: 
EQU FLOW.sub.tot =MS.sub.tot /(8.333 .multidot.D.sub.syr)+MW.sub.tot 
/(8.333.multidot.0.998) (9a) 
(MS.sub.tot =the total mass of the syrup; MW.sub.tot =the total mass of the 
water; and D.sub.syr =the density of the syrup-D.sub.sf for sugar-free 
syrup or D.sub.su for sugared syrup.) 
One variation in the blending of a beverage is the solubility of the 
CO.sub.2 input into the beverage by the carbonator 84. This variable is 
determined as a function of the temperature and pressure within the 
carbonator 84. Published curves for these determinations in graph format 
are produced by the American Bottling Association. This variable is 
typically reported in volumes of CO.sub.2. 
A least squares method may again be utilized to calculate the temperature 
factor of the carbonation as a function of the changing conditions in 
carbonator 84. The least squares regression for this temperature component 
is as follows: 
EQU T.sub.CO2 =T.sub.CO2 +KC.sub.(xc+1) .multidot.T.sub.carb xc (10) 
(T.sub.CO2 the temperature coefficient for carbonator; KC=the coefficient 
value within the calculation; xc=the position within the regression; and 
T.sub.carb =the temperature in .degree. F. in the carbonator.) The 
constants within this regression are as follows: 
KC(.sub.1)=0.3529254 
KC(.sub.2)=0.008671118 
KC(.sub.3)=-0.000007131652 
KC(.sub.4)=0.000002720279 
KC(.sub.5)=-0.00000003849611 
KC(.sub.6)=0.000000000177644 
The calculation starts at xc=5 and T.sub.CO2 =KC(.sub.1) with each 
subsequent calculation being made for xc-1. 
An additional factor must be determined prior to calculating the volumes of 
CO.sub.2 added to the beverage. This factor is a result of the pressure in 
the carbonator 84 and can be determined by the following equation: 
EQU P.sub.fac =(P.sub.CO2 13.7)+0.075 (11) 
(P.sub.CO2 =the pressure within the carbonator system.) The constant values 
within this equation 11 have been determined from the same published 
sources of the American Bottling Association as for equation (10). 
From the determination of the temperature coefficient and the pressure 
factor in the carbonator 84, the volumes percent of carbonation can be 
determined as follows: 
EQU VOL.sub.CO2 =(P.sub.fac /T.sub.CO2)+C.sub.off (12) 
(C.sub.off =offset adjustment value.) Typically, the volumes of CO.sub.2 is 
determined by a shake test outside of the carbonator. The present 
calculations are being performed in line. Therefore, the readings made by 
in line sensors may not provide an accurate value. This determination may 
be adjusted (C.sub.off) to provide a value that is within the desired 
specifications of the bottler. The offset value is provided so as to 
account for the standard variations in the calculation from the normal 
mode of testing. 
The total volumetric flow determination (FLOW.sub.Tot) can be used to 
predict the number of cases which should be produced by a particular run. 
EQU CASE.sub.proj =(FLOW.sub.tot .multidot.128)/CONT.sub.vol /CASE.sub.size ( 
13) 
(CONT.sub.vol =the volume in each particular container and CASE.sub.size 
=the number of containers to be input into a case.) 
The controller 68 may be set to receive a pulse signal for each bottle or 
container passing through the bottling apparatus. From this pulse count, 
the actual total number of cases produced is determined by the following 
equation: 
EQU CASE.sub.Tot =P/ CASE.sub.size (14) 
(P=the number of pulses received from the bottler.) 
An efficiency estimate may be made by using the volumetric calculations for 
the projected case total and comparing this value to the actual number of 
cases which have been produced: 
EQU CASE.sub.lost =CASE.sub.Proj -CASE.sub.Tot (15) 
Also, an efficiency determination for the entire system can be made by 
evaluating the run time and the maximum obtainable cases per minute. This 
efficiency calculation is as follows: 
EQU EFF=((P/T.sub.run)/CPM).multidot.100 (16) 
(T.sub.run =the time of the batch run and CPM=the determined maximum cases 
per minute value seen during the particular batch run.) The maximum cases 
per minute during the run and the comparison to the overall output of the 
run are values which are usually desired by the bottler. 
All values calculated can be displayed on a screen for observation during 
the run. These calculated values can be averaged over a number of cycles 
by the controller 68 and may also be displayed as a function of the 
average over a specific period of time such as 1 minute. The time averages 
can also be charted on a graph and displayed accordingly. 
The controller 68 may be used to evaluate various other operating functions 
of the system. By connecting the sensors within the system to the 
controller 68, certain alarm signals may be defined to determine whether a 
critical error exists in the system. With a critical alarm, an acknowledge 
signal may be required in order to continue the operation or calculations 
of the system. 
From the calculated values, a determination can be made of the adjustment 
required by the valve 72 in order for the proportioner 50 to blend the 
beverage in line with the set point of the bottler. The first 
determination is the variation of the calculated drink number from the set 
point: 
EQU ERROR=DN.sub.cal -SET (17) 
If there is an variation between these two values, an adjustment is 
required. From the error value a control signal may be directed to 
actuator 70 for appropriate adjustment of the micrometer valve 72 to bring 
the blended beverage into line with the set point and, thus, the recipe 
owner's target. This adjustment may be determined by the following 
equation: 
EQU M.sub.adj =((ERROR.multidot.GAIN)+(ERROR.multidot.T.sub.E /T.sub.K))/100 
(18) 
(GAIN=a multiplication factor for the ERROR signal; T.sub.K =an integral 
time constant in repeats per minute; and T.sub.E =the elapsed time from 
the last adjustment.) The value for the integral time constant is 
discretionary and is contemplated to be set as part of the programing of 
controller 68, rather than being set by the bottler. Therefore, this value 
would not be changed after installation. 
As can be seen from the equations, a calculated drink number (DN.sub.cal) 
which is greater than the set point (SET) will result in a positive error 
(ERROR) signal. This positive error will be converted into a positive 
value for the adjustment (M.sub.adj) of valve 72. This positive value will 
increase the amount of water within the blend and decrease the resulting 
drink number (e.g., for a sugared beverage, reduces the brix value for the 
sugar in the blended beverage). Thus, the next calculation made for the 
error (ERROR) signal will be decreased. If this newly calculated drink 
number is not equal to the set point and, thus, the error signal is not 
equal to zero, the micrometer will be adjusted again. A calculated drink 
number that is less than the set point will approach a zero error value in 
the same manner, but from the opposite direction. 
The micrometer adjustment calculation of equation (18) would produce a 
change in the setting of the valve 72. The setting value for a 
micrometer-type valve is typically expressed in mils over the total length 
of the valve movement. A calibration factor may be required to direct the 
actuator 70 to adjust the micrometer within the proper proportions. 
Further, a different calibration may be required to provide a readout of 
the mil position of the micrometer in the bottler's normal units. 
Upon initial start-up of the system, the bottler would manually or through 
the controller 68 open the valve 72 to a recommended value for the drink 
specification. Thereafter, it is also possible to manually adjust this 
valve for any additional changes other than those made by the actuator 70 
in response to the control signals from controller 68. The most common 
error (ERROR) will be the result of the start-up position of the valve 72. 
The setting of this valve 72 at start-up is typically an estimate. Once 
the blended beverage has been adjusted to the target range, the only 
changes that would be required to maintain the blend within that range and 
at the set point would be initiated by the actuator 70 via the 
calculations and control signals of controller 68. 
The adjustment of the valve 72 by controller 68 preferably includes a range 
limit. This range would prevent the controller from adjusting the valve 72 
at too great a variation without further authorization from the bottler. 
It is contemplated that a plus or minus 2% variation in the micrometer 
setting would be a sufficient limit for this purpose. If a greater value 
were calculated by the controller 68, such may be the result of an unusual 
error within the system. An audible alarm would then initiate a warning to 
the bottler that a significant change has occurred within the system. The 
bottler will be required to cancel the calculated result or approve the 
change and initiate a new 2% control limit. This scheme ensures a quality 
control with limitations. This will confirm that the variations are a 
normal fluctuation within the system rather than a miscalculation or 
unusual error. If the user does not agree with the value change, the 
product will not deviate off specification without further proof that such 
is required. 
The system in accordance with the present invention has been found to be 
highly accurate in controlling the operation of the proportioner and for 
maintaining the blend within the standard set by the beverage owner. It is 
contemplated that the present invention can be adapted to existing 
bottling systems throughout bottlers within the United States. The present 
invention will incorporate into the existing bottling system a highly 
accurate means for automatically controlling the proportional blending of 
the beverage. The ultimate accuracy of the control initiated by the 
present invention may continue to be determined as a function of an 
analyzer which is either downstream in the system or which is performed in 
the lab. However, by the application of the present invention into the 
existing bottling plant, it is contemplated that the need for disposal of 
already blended beverage which is not made in accordance with the 
requirements of the recipe owner will be eliminated after achieving a 
consistent setting for the control valve in the proportioner. 
The present invention may be embodied in other specific forms without 
departing from the spirit or essential attributes thereof and, 
accordingly, reference should be made to the appended claims, rather than 
to the foregoing specification, as indicating the scope of the invention.