Dare We Discuss Dairy Webinar Slides

| Food and Beverage | Dare We Discuss Dairy? |
© Yokogawa Electric Corporation
Dare We Discuss Dairy?
Food and Beverage Webinar
Dairy Challenges and Solutions

1
Presenters
Host
Guy Nuechterlein
Process Control &
Instrumentation Consultant
gnuechterlein@duncanco.com
Gerald Hardesty
Food and Beverage Product
Marketing Manager
gerald.hardesty@yokogawa.com
Presenter
Jason Pittman
Field Application Sales
Specialist – Instrumentation
Jason.pittman@yokogawa.com
Presenter
Glenn Bisceglia
Field Application Sales
Specialist – Network Solutions
Glenn.Bisceglia@yokogawa.com
Presenter

Agenda
2
1. Dairy market overview, industry trends,
challenges, and opportunities
2. Applications and solutions through the
dairy production process
3. Summary | Q&A

 Chemical
 Oil and Gas
 Power
 Pulp and Paper
 Water and waste water
 Food and Beverage
 Pharmaceutical
Yokogawa – A leader across industries

4
Dairy market overview, industry
trends, challenges, and
opportunities

 Growing competition from dairy alternatives
 Plant-based products: oat, almond, soy,
coconut, etc.
 Nut and plant milk grew 9% in 2018
 Consumers drink 37.0% less cow’s milk
today than in 1970s with butter and frozen
products remaining nearly flat
(1)
 Animal welfare and emissions
5
 Yogurt and cheese present one of the larger
opportunities, as there are fewer competitive
alternatives
 Yogurt + Cheese demand has more than
doubled, but still only makes up only 13% of the
total dairy market
(2)
 America produces 30% of the world’s cheese.
 Focus on the key nutrients dairy offers
consumers to differentiate from alternatives
and ensure they remain competitive in an
evolving market.
 Transparency with consumers with regard to
production processes and corporate values
will gain more attention from health-conscious
consumers
Dairy Industry: Challenges and Opportunities
(1) https://www.ers.usda.gov/amber-waves/2014/june/trends-in-us-per-capita-consumption-of-dairy-products-1970-2012/
(2) https://www.ibisworld.com/industry-insider/analyst-insights/opportunities-and-challenges-dairy-industry
Challenges Opportunities

Regulatory Compliance
Cleanliness: 3-A
Data Integrity: FDA 21 CFR Part
11
Performance
Right capability for the
application
Reliability
Reduce unplanned
downtime
Consistent product
Interoperability
Integrate instrumentation
via EtherNet/IP
Cost Efficiency
Reduce waste
Increase profitability
Requirements that drive success

Applications and solutions
through the dairy production
process
7

Dairy Processing Plant Overview
8

9
Dairy Processing Plant – Delivery, Deaeration, and Storage

| Flow GVP_Food & Beverage_Milk_IG_P2020063001| June 30, 2020 |
10
Milk unloading station
 Aeration
 Milk contains 6% air by volume on average
 But incoming milk can contain 10% air by
volume, or even more.
 Too high air content can cause problems
 Inaccuracy in volumetric measurements
 Incrustation of heating surfaces in pasteurizers
(fouling)
 Loss of efficiency, precision, and stability in
processing
 The milk should first pass an air eliminator,
then be measured and pumped to reception
tanks.
But which flow meter technology
performs best under aeration?

11
Milk unloading station – Yokogawa flow solution
Solution
Benefits
Situation
Traditional unloading stations use a
magnetic flowmeter
Coriolis mass flowmeters are now
preferred  Aeration and higher
accuracy requirements
ADMAG AXG TI ROTAMASS TI
• Dual frequency excitation gives stable
measurement even under aeration
• Advanced flow noise diagnostic can
monitor the level of air flowing through
the pipe
• Unique design (box-in-box), not affected
by pipe vibrations
• Optimize excitation frequency (150 Hz
nominal) doesn’t affect the milk structure
(no product separation)
• High driving power allow to work with
high aeration without signal loss

12
Liquid raw material unloading
• Alcohol products
• Aromatic Chemicals
• Beverage bases
• Citrus Products
• Cocoa (chocolate liquor)
• Coloring and flavors
• Dairy products
• Egg and egg products
• Essential Oils
• Fruit Juices
• Mineral oil
• Nut products
• Pharmaceuticals
• Soy based products
• Sugar alcohols
• Syrups & Sweeteners
• Vegetable oils
• Vinegar
• Whey
• Yeast
Raw material delivery measurement
Make sure you get what you paid for!
ROTAMASS TI
Not just milk…

13
Milk Receiving Storage – Yokogawa Pressure Solution
Courtesy of Paul Mueller Website
EJA565E Hygienic and
Sanitary Pressure Transmitter
• Milk is received and stored in tall, vertical silo tanks.
• Hydrostatic pressure measurements are the most
commonly used to track inventory levels.
Situation
• Great variance in silo tank height
• Difficult to standardize on a single transmitter range
• Changing environmental conditions impact measurement
accuracy
Challenge
• High performance pressure transmitter with great
turndown
• Allows simplification of equipment purchasing and
inventory by reducing the number of unique models that
are necessary.
• Highly actuate and stable inventory measurements
even during temperature swings.
• Fit almost any tank from any manufacturer
Solution
EJA565E

14
Dairy Processing Plant – Milk Processing

15
Milk Balance Tanks – Yokogawa Pressure Solution
• Milk processing begins with the balance tank, which
receives raw milk from bulk storage and milk that was
recycled from the pasteurizer because it did not meet the
minimum temperature limit.
Situation
• Balance tanks are relatively small  very precise level
control is needed to prevent overfill.
• Unexpected recycle stream could provide an upset.
• Balance tanks provide the initial head pressure for the
Pasteurization systems  an upset in the level can cause
further process control upsets.
Challenge
• Active temperature compensation helps maintain highly
accurate and stable tank measurements even when
mixing the primary raw milk and recycle streams.
• Fast response times allow for quicker adjustments to
improve the level control and avoid overspill.
Solution
EJA565E

16
Dairy Processing Plant - Pasteurization

17
General milk pasteurization
 What is Pasteurization?
 Process of heat treatment of a product to reduce enzymatic activity and kill pathogenic bacteria
 The main purpose of pasteurization in dairy plants is to make the product safe for use and to extend product shelf life
 Involves heating every particle of milk to a specific temperature for a specified period of time and cooling it again without
allowing recontamination.
 Pasteurization is an important pre-treatment stage in a chain of dairy processes such as, cheese making
and cultured milk production
https://microbenotes.com/milk-pasteurization-methods-steps-significance/

18
Pasteurization - HTST
High Temperature Short Time (HTST) Pasteurization
 Most common pasteurization method in US
Process Components
 Multipart heat exchanger
 Calibrated holding tube
Procedure
 Product is forced between metal plates or pipes heated externally by hot water
 Product is heated to 161°F (72°C) for 15 seconds.
 Product is cooled mainly by regenerative heat exchange
 Chilling the milk to 39°F (4°C) for storage requires a cooling medium
 Ice water, brine, or alcohol solutions

19
Pasteurization – Yokogawa flow solution
 ADMAG TI for:
 Milk (AXG[][][]-H)
 Hot and cold water : AXG[][][]-H or, if sanitary
fittings are not required, AXW (PTFE)
 Condensate
 Digital Yewflo for:
 Saturated steam
 Mass flow measurement with /MV option
 Hot water or saturated steam can be used as the heating medium in pasteurizers
 Most commonly used heating medium is hot water

20
Pasteurization Heat Exchanger Control – Yokogawa Pressure Solution
• Minimum pressure differential between the raw inlet and
heated outlet must be maintained
• Reversing this or leakage could contaminate product
Challenge
• Active temperature compensation helps maintain highly
stable pressure measurements even when comparing
small differential values
• Fast response times allow for quicker adjustments to
ensure minimum differential is maintained and untreated
milk does not contaminate pasteurized product
Solution
EJA565E

21
Recorders in Food and Beverage

22
Large Milk Producer Example
 Side by side comparison of facilities current paper
chart with SMARTDAC+ paperless recorder
 Standalone unit – main or back-up/integrated (optional)
 Free-hand messages on screen
 Barcode scanning w/ message insert
 Advanced Security option (FDA 21 CFR Part 11)
 Door lock for physical security
 Results
The case for paperless recorders

23
Pasteurization Heat Exchanger Control – Yokogawa NetSOL Solution
• All Pasteurization process conditions including product
temperature (hot and cold), pressures, and divert valve
position must be recorded, stored, and readily available
for audit and traceability requirements.
Challenge
• The SMARTDAC+ Paperless Recorder can monitor and
control all parameters of the pasteurization process,
including controlling the diverter valve and alarming of
temperature and pressure conditions.
• Secure electronic records and signatures meet FDA 21
CFR Part 11, PMO and HTST compliance
requirements.
Solution
SMARTDAC+

Batch Recording and Audit Trail
 Challenges
 Huge batches (i.e. 50,000+ pounds)
 Constant monitoring and recording of process conditions required
 Back up data from many PLCs to a single recording device?
 Loss, damage, or tampering of records could result in being forced to
scrap a batch worth $100,000 or more!
 Solution Benefits
 Integrate and back up multiple PLCs to protect data against cyber
attack or PLC failure
 Audit trail function logs any operation and setting changes, the reason
for the change, and who made the change for greater process
transparency and tracking during audits
 Secure electronic records stored as 3 identical files in 3 separate
locations (SD card, internal memory, and FTP server)
 Validation protocol document and on-site service are available to
help customers prove FDA 21CFR Part 11 compliance
 Door lock to prevent physical tampering
 Multiple user access levels to provide proper privileges for each user
as defined by the Admin
24
SMARTDAC+ Paperless Recorders
• Advanced Security (/AS) option adds FDA 21 CFR Part 11
Compliance
• Secure electronic records – 3 copies / locations of the same file
• Monitor and/or control from a single device
• Proprietary operating system protects against cyber attack

25
Dairy Processing Plant Overview

26
Centrifugal separator
 Separators ensure excellent product quality and high performance
in milk skimming, by preventing intake of destructive air.
Cream
Skim milk
Whole milk
Solids
 Separator: system to
separate fat from milk
 Separator is based on
centrifugal force
 Fat globules
aggregated and floated
to the surface where
they formed a layer of
cream on top of the
milk

27
Milk standardization
 Standardization is a blending
process
 Involves adjustment of the fat content
of milk, or a milk product, by addition of
cream or skim milk to obtain a given fat
content
 Efficient fat control system needs
accurate and repeatable flow and
density measurement
 For cheese making, precise density
measurement of the cream additive
and whey cream is needed

Milk and Fat Content Measurement
 Challenges:
 Magnetic flowmeters only read volume and do not account for
fluctuations in milk consistency or fat content
 Inner part of a magnetic flowmeter tube gets covered by a non-
conductive layer of fat  signal loss
 Solution benefits:
 Coriolis measurement technology enables users to
measure mass flow, density (fat content) and temperature
simultaneously, using only a single measurement device
 Continuously recording the fat content of the milk allows
producers to monitor milk quality from different suppliers to
avoid overpayments
 Consistency in raw materials is essential to achieving
consistency in the taste and quality of the final product.
 Coriolis meters experience no issues with non-conductive
fluids or coating of components.
• Accurate mass and density flow measurement,
even under high vibration
• Tube health check
• Self-draining and hygienic design
• Concentration and calculation tools
• In-line CIP/SIP
• Sanitary clamp or thread process connection

29
Clean-in-place (CIP)

30
CIP: Clean-In-Place
 Clean the installation (inside pipes, machines,
etc.) without removing anything
 CIP objectives are
 Physical cleanliness – visible debris
 Chemical cleanliness – microscopic residues that
affect taste or smell
 Bacteriological cleanliness – attained by disinfection
 Sterile cleanliness – destruction of all microorganisms
 The cleaning cycle in a dairy comprises the following
stages:
 Recovery of product residues by scraping, drainage and
expulsion with water or compressed air
 Pre-rinsing with water to remove loose debris
 Cleaning with detergent (alkaline and acid)
 Rinsing with clean water
 (Optional) Disinfection by heating or with chemical agents
and final rinse
Centralized Decentralized

31
CIP: Clean In Place – Yokogawa Pressure Solution
 Challenge
 A pressure pump must be controlled to provide a specific
turbulent flow velocity in order to remove contaminants and
rinse away any chemicals used in the cleaning process.
 A loss in pressure could indicate a failure, leak or wear that
would require downtime to repair or replace the pump.
 Solution
 Standardize purchasing and spare part inventory by reducing
the number of unique products required
 High performance and excellent turndown
 Active temperature compensation helps maintain highly stable
pressure measurements to better control the CIP process and
help detect pump issues to avoid unplanned downtime
INLET
OUTLET

CIP: Clean In Place – Yokogawa flow solution
 Magnetic flowmeters are best for the aggressive but conductive fluids in CIP
 ADMAG TI works perfectly even with pulsating flow
 Preventing measurement drift over time is critical to ensure effective CIP
 ADMAG TI built in verification enables users to verify device without removing it from installation
ADMAG AXG TI

33
CIP: Clean In Place – Yokogawa Conductivity solution
 Challenge: Conductivity measurements
are critical for clean-in-place (CIP) and
water-for-injection (WFI)
 Inaccurate conductivity readings could cause
runtime losses and increase costs in material
and energy usage
 Solution
 Distinguish the liquid that is flowing through the
process pipes, enabling users to optimize their
cleaning and sterilizing process.
Reduces operating costs
Improves precision in boundary surface
measurement
Chemical Solution (High
concentration) Conductivity
Sensor
Fresh water (Distilled water)
Contacting Conductivity Sensor
 Wide measurement range: Single sensor
measures from 1 μS/cm – 2000 mS/cm
 Early detection of sensor failure and decline
 Steam sterilization possible: temperatures of
-10 to 130 °C) and pressures no greater
than 2 MPa {20 kgf/cm2
 Real-time diagnostics and sensor
wellness
 Early sensor polarization
detection
 Flashing display for visual error
notification

CIP: Clean In Place – Yokogawa NetSOL solution
 Challenges
The clean-in-place (CIP) process is mandated by
regulatory agencies to ensure food safety.
Entire system must be controlled and monitored to
provide a specific turbulent flow velocity in order to:
 remove contaminants
 and rinse away any chemicals used in the cleaning
process
CIP records must be kept, just like production records
 Benefits
Record and monitor the temperatures of the cleaning
agents from a single device
1.0
SP-P-20200908-01
Solution:
SMARTDAC+ Paperless Recorders
• Advanced Security (/AS) option adds FDA 21 CFR
Part 11 Compliance
• Secure electronic records – 3 copies / locations of
the same file
• Monitor and/or control from a single device
• Proprietary operating system protects against
cyber attack

Summary | Q&A
35

 Dairy industry has it’s
challenges, but
opportunities for
optimization and efficiency
abound
 Yokogawa products and
solutions can help
overcome challenges
throughout the process
Summary
36

37
Summary – Applications using Yokogawa Products today
• Membranes
• Silo unload/load
• Heat treat
• HTST
Pasteurization
• Evaporator
• Fresh Cheese
• Water and lactic
acid deliveries
• Ricotta cheese
• Water and Lactic
acid deliveries
• Spray Dryer slurry
feed line flow rates
• Measuring
numbers of
deliveries and
gallons of liquid for
these processes
• Deproteinized whey evaporation process
• Milk flow to cheese vats
• Calcium precipitate process
• Ricotta liquid whey concentrate delivery
• Whey Reconstitution slurry delivery
• Air Scrubber discharge waste water
• Measuring numbers solids/whole pounds for liquids in
a batch system
• Membrane
equipment
• Ultra-filtration
• Nano-Filtration
• Micro-Filtration
• Reverse-
osmosis
• Whey
• Reconstitution
• Silos - Milk,
whey, water
• Water
Treatment
tanks/lines
• Cheese cooking
process lines
and tanks.
• Measuring
levels and line
pressures
• Water Treatment
• HTST
• HTST-pasteurization (milk, cream, whey, permeate)
• Electronic records:
• tank temperatures used for batching
• silo storage temperatures
• tank and line pressures
• CIP system records temp, flow, pressure, conductivity,
and time
• CIP systems
• Water Treatment
• Chemical dosing
• CIP/COP tanks to measure chemical additions
ADMAG TI ROTAMASS
SMARTDAC+
EJA565E
EJA564E
pH Conductivity

38
Food and Beverage Offering
https://web-
material3.yokogawa.com/2/301
03/files/BU-P-20200904-
01_Food_and_Beverage_Indus
try.pdf
https://www.yokogawa.com
/us/industries/food-
beverage/

© Yokogawa Electric CorporationCopyright © Yokogawa Corporation of America
39
Fully Stocked | Fully Staffed | Fully Safe
Yokogawa factories and warehouses are ready to ship!
Need it now?
Call us at (800) 888-6400
 Actively Shipping with
Standard 10 day Lead
Times
 Get 2 day shipping with North
America Quick Ship Program
 Transmitters
 Flow Meters
 Gas Analyzers
 Liquid Analyzers
 Data Acquisition Recorders
 Controllers
 Most process instruments are
assembled in the United States.

Q & A
pH, ORP, Conductivity, and Gas
Analyzers
Coriolis and Magnetic Flow Meters
Data Recorders, Controllers,
and Systems
Hygienic Pressure and Level
Transmitters
• Clean-in-place (CIP)
• Receiving tank level
• Balance tank level
• Heat exchangers
• pH in breweries, sugar refineries,
and fish farms
• Oil and fat processing
• Water treatment and purification
• Mixing and blending
• Concentration control
• Batch recording
• Audit trail
• Pasteurized Milk Ordinance
• Air Cleanliness Monitoring
• Particle analysis
• Temperature control for package
sealing
• Bottling
• Fermentation
• Product quality control
• Pump and compressor vibration
monitoring
• Feed mills
• Essential oils
Questions?

The names of corporations, organizations, products and logos herein are either registered trademarks or
trademarks of Yokogawa Electric Corporation and their respective holders.
41

Dare We Discuss Dairy Webinar Slides

Recommended

Recommended

More Related Content

Similar to Dare We Discuss Dairy Webinar Slides

Similar to Dare We Discuss Dairy Webinar Slides (20)

More from Yokogawa1

More from Yokogawa1 (20)

Recently uploaded

Recently uploaded (20)

Dare We Discuss Dairy Webinar Slides