Integrated automation of a cheese production plant with a capacity of 600 tons of milk per day

Project Prerequisites:

Need in new modern comprehensive production control system during enterprise reconstruction.

Goal of the Project:

• Development, manufacture, supply, installation and commissioning of an automated process control system for the whole plant (the project was implemented jointly with LLC DALMIO)

• Maximum possible automation of production processes;

• Automatic preparation of production sites reports and analytical data.

Description of the Project:

The following areas were created and upgraded within the reconstruction:

1. Milk reception section;

2. Raw milk storage section;

3. Dissolution section;

4. Thermization section (UPO30000, UPO25000) with normalization of cream and product fat in the flow;

5. Cream storage and processing section (butter shop);

6. Thermized milk storage section;

7. Repasteurization section (UPO30000);

8. Cheese making section (cheese making vats);

9. Pre-pressing section for production of cheeses with dense structure;

10. Whey preprocessing section;

11. Raw whey storage section;

12. Whey pasteurization section (UPO30000, UPO25000);

13. Pasteurized/concentrated whey storage section;

14. Whey crystallization section;

15. CIP-washing section (4 CIP-stations, 12 circuits).

Each section is extremely highly automated; sections are controlled by setting the production program or switching routes.

A complex system of locks to protect against product loss and incorrect actions of the operator is implemented. The positions of valves on the line and on all crossing routes, mechanisms breakdowns are checked. Status of objects is checked (to avoid washing the tank with the product inside), the intervals of equipment washing mode using alkali and acid are checked, etc.

A complex system of production reports, statistics and analytics, product traceability was created. So, a report of consumed energy resources (electricity, steam, ice water, process water, compressed air, chemical solutions concentrates), manufactured products, technological operations can be created automatically for each section. It is possible to trace from the end product (cheese block) the entire production chain up to the numbers of milk tankers, from which the milk was taken for the production of a particular batch of product.

The system of input and control of laboratory values of the products at each technological stage was implemented.

The system of operational control of the enterprise work for quick analysis and identification of deviations in all production areas from the norm was implemented.

Results of the Project:

Implemented:

• A new modern high production line with completely updated technological equipment was commissioned;

• A conceptually new automated process control system was implemented;

• Collection of information about the state of control objects;

• Getting information on the current values of the parameters;

• Control and analysis of process parameters;

• System of identification and traceability of the end product;

• Processing of the received information and detection of deviations from the set mode;

• Control of emergency situations and ensuring, where appropriate, activation of automatic emergency shutdown algorithms;

• Local and remote control of process equipment;

• Getting information on the current state of technological objects by the operator (manager);

• Receiving and storing the information about the process parameters, the state of technological objects and their control signals in a database.