A completely new, automated, and networked dairy plant.
It was undoubtedly the largest automation project we had ever implemented for a dairy. A complete production facility with cleaning stations, various tank storage areas, ultra-high-temperature (UHT) processing, and cream cheese production. The key requirement was to coordinate everything and integrate it into the plant within a short timeframe of less than a year—from the filling and butter-making machines to the fresh cheese cutter. And, of course, this had to be done using process control technology and control solutions that communicate with the rest of the plant.
It’s almost like AI. Thanks to the CIP system with its automated job list, downtime is significantly reduced.
All cleaning jobs are processed from a queue. The CIP system determines which items take priority on its own and, when the fully automatic mode is selected, requires no user intervention at all.
Connection to the new production facility
To connect the production hall to the existing plant, an extremely long pipeline was installed, in which a pig ensures the separation of product and water. Special detectors ensure that the pig can be operated blindly and in a controlled manner.
Automated acceptance
The right track, quantity verification, and inhibitor testing? Our automation system efficiently and seamlessly manages the dairy’s entire milk reception process. Route management is always integrated with materials management; everything is checked and controlled automatically.
Taking retrofitting to the next level. By migrating to modern SIEMENS-compatible XCPU controllers, the old S5 software can be replaced step by step and integrated with more up-to-date S7 systems.
Customized automation solutions for a comprehensive and efficient dairy production process.
UHT milk
Real-time transparency—
: Quality assurance for long-haul flights.
The biggest challenge here was the extreme distance between the tank and the existing facility. Using step chains, the cleaning status of the tanks along the entire supply line is clearly visible at all times. Thanks to the new visualizations of the tank farm, it can be operated intuitively and easily.
All processes at a glance: from ultra-high-temperature sterilization to real-time tank levels.
Cream
Process optimization in a highly sensitive field of application
Cream filling
The cream is transported via a long pig line from Production Line 1 in Hall 3. A pig prevents the cream from becoming diluted and the resulting product loss. The automation system enables the pig to be coupled and uncoupled, as well as the autonomous cleaning of the parking station.
Cream tank storage facility
An automated tank heating and cooling system ensures controlled cold-warm-cold cycles for cream maturation. Time and temperature are precisely and continuously monitored to ensure that the maturation process proceeds optimally.
Butter shop
Our automation system controls communication with the external butter machine. The visualization of the butter machine’s components is integrated into the overall visualization of the plant control system.
Buttermilk and sour whey
Focus on pressure and temperature monitoring
Cream cheese
Process automation for cream cheese – The supreme challenge
In cream cheese production, all system components must operate automatically and in sync to ensure consistent production without delays, product defects, or shortfalls. From the automatic swapping of the holding tanks to the precise coordination of the finishing process. Everything here works in tandem—individually programmed and, of course, fully automated.
Bringing opposites together
The particular challenge in automating cream cheese production lies in synchronizing batch and continuous processes—in a way that prevents any downtime.
automation excellence
Maximum control. Our automation solutions support teams and processes. The rest is a breeze for your operators.
System startup
An automated checklist with clear recommendations for action to ensure maximum production readiness and maintain an overview of production operations.
reliable temperature control
Optimal control when monitoring valves and timings during sterilization and fermentation, with defined procedures in the event of a malfunction.
automated level control
Ensures a consistent production flow and maximum efficiency during plant operation by minimizing downtime.
Synergies
Project acceleration through exceptional process expertise and joint process optimization with the plant manufacturer during the project planning phase.
