CASE STUDY

ESE automates HTST and reduces risk for major producer of dairy proteins, nutritional products and powder blends

Location
Wisconsin

Challenge

An international manufacturer of dairy proteins, nutritional products and powder blends needed to update their HTST pasteurizer and the control systems associated with it. They produced an infant electrolyte drink which required a higher standard of quality control and a departure from the manual process was desired. Operators each had their own way of controlling the process and sanitation procedures. The customer also experienced foaming issues that negatively impacted the bottling process and resulted in short fills and variability. Additionally, there was a cross contamination risk to their product due to pressures dropping within their lines. .

Solution

ESE began by conducting a process engineering assessment. This found legacy hardware present and showed opportunities for automation and improved controls. ESE then upgraded the controls of the current HTST and CIP systems. New hold tube proximity switches were provided to confirm that the recipe had the right holding time via hold tube detection. An Ethernet switch was installed to bring other areas of the plant onto the production network. The existing VFD’s on DeviceNet were migrated to Ethernet. Additionally, HTST motors still using starters were integrated to implement VFD’s. FactoryTalk SE standalone HMI environment was provided which offered the customer the option to upgrade to FactoryTalk SE View Distributed HMI for future flexibility or expansion. Additionally, management now has the opportunity to archive process data.

Results

ESE successfully removed many of the manual aspects of the old system. The customer now has better control of their HTST and CIP systems which results in improved consistency, reduces the risk of cross-contamination and helps prevent product recalls. Within their new CIP system, they have better control flow of water and cleaning chemicals. Additionally, the automated reporting system results in better quality control and reporting.

eseincCase Study – ESE automates HTST and reduces risk for major producer of dairy proteins, nutritional products and powder blends