Sustainability initiatives and production loss reductions can be achieved by applying innovative in-line quality control points. Earlier this year, figures revealed that although more than 237,449 tonnes of milk were purchased in South Africa during February 2016, this number had shown a decline over the prior 12 months. Two months later, it was realised that milk would soon be added to the country’s list of costly staple foods, and Paul Makube, senior agricultural economist at FNB, stated: “Dairy farmers are facing production shortages and will likely run into supply issues in the coming months. Consequently, some dairy processors are already paying commercial farmers 60c more per litre on average for milk to ensure a consistent supply in winter. Poor pasture conditions due to the drought and the sharply higher grain prices have squeezed margins at farm level.”

Added to this woe is the rise of electricity costs, further affecting the bottom line of local dairy process plants.
Sustainability initiatives and production loss reductions can be achieved by applying innovative in-line quality control points. In addition, production time can be shortened, plant capacity increased and out off-specification batches reduced. Being the leader in process automation for the food and beverage industry, we understand the need for and importance of sophisticated instrumentation, and highly accurate, reliable hygienic measurements. Our instruments provide more information such as percentage milk fat, brix, viscosity, massflow and phase separation.

“For any business to run at an optimal level it needs to be able to accurately manage its products,” says Natlee Chetty, industry manager – food and beverage. “We offer best-in-class measurement technology so that process plants know exactly how much milk is received - be it in small tanks and vessels, silo tanks or plant mass balance.”

Level measurement in small tanks and vessels
The level in air eliminators, intermediate storage, balance and mixing tanks are reliably controlled with Endress+Hauser’s capacitive level probe, Liquicap M. Quick changes in temperature and pressure do not affect the accuracy. “The sensor is factory calibrated to your ordered probe lengths and thereby easy to install,” adds Chetty. With a response time of 0.3 seconds, it is the ideal solution for small balance tanks and in filling applications. “For reliable point level, our Liquipoint product is an ideal option,” she says.

Level measurement in silo tanks
Endress+Hauser’s Deltapilot has been perfectly adapted to harsh, fast changing process conditions. “This hydrostatic pressure sensor shows best performance with long-term stability and excellent accuracy even following CIP/SIP cycles,” explains Chetty. The hermetically sealed Contite measuring cell is condensate and climate proof. Remote electronics are available for extreme washdown or hard to reach areas. With a measuring range down to 25cm H2O, the Deltapilot is ideal for balance tank level measurement. Equipped with linearisation tables, it converts the process data to level or volume. “There are minimal temperature effects and fast recovery after CIP cleaning.”

Mass flow and density measurement with highest accuracy
Milk that has been received contains a significant amount of air that impacts all following processes. After elimination, the receiving temperature effects need to be considered. The Endress+Hauser Proline Promass Coriolis flowmeter directly measures the mass of the recovered milk, calculates the fat content and is temperature compensated. “Using this technology in the internal handover supplies a most accurate picture of the milk inventory,” continues Chetty.  “Volumeric measurement with our Promag H electromagnetic flowmeter is another option to achieve a temperature compensated volumetric flow balance.”

Endress+Hauser’s high accuracy instrumentation offers incalculable value within the critical milk standardisation and homogenisation process.

The company’s Proline Promass F is ideal for virtually all fluids and, in a dairy, measures several process parameters directly in the pipeline. “The fully drainable measuring tubes are stimulated with high frequency and therefore are immune to plant and system vibrations,” says Chetty. “The Promass F offers the highest accuracy and process available for flowmeters measuring the valuable fat content of your milk products.” This high performance instrument can be reliably used to control the standardisation processes in cream and whole milk.

Detecting and phase change between CIP and the product in the line
The Endress+Hauser Promag H sensor was especially designed following the requirements for hygienic applications in the dairy industry. It is thus ideal for batching, plant mass balance, receiving and feed lines of products or CIP flows. “Because it was designed for operation in dairies, it handles pulsating flow compensation and empty pipe detection. The integrated conductivity measurement allows for continuous monitoring of phase changes and product identification,” points out Chetty.

Increasing efficiency with faster response time
Endress+Hauser offers “Sensor on Tip” technology provides a seven times faster temperature response and ensures accurate information of exactly how safe a product is – all whilst saving on energy costs and increasing quality. The technology is found in the company’s following products:

Quicksens, the fastest sensor on the market (t90 of 1.5 seconds) for best performance in heat exchanging applications;

Strongsens, the most vibration resistant sensor that also helps improve long-term performance and reliability; and
Quickneck, the ideal temperature integration for critical control calibration.

“Our products meet the safety, reliability and uptime requirements of dairies, literally ensuring that there’ll be no tears shed over spilt milk,” concludes Chetty.