CPG Industry SolutionDairy Evaporator Control Application

The ChallengeManufacturers of milk and other food ingredient powders recognize the constant need to operate their processes more effi ciently. The goal is to increase throughput while simultaneously reducing costs in order to be competitive globally. Many manufacturers are also shifting more production towards higher value specialty products that require higher quality standards (such as low-fat, no-fat, protein-enhanced, etc.) In order to produce these diff erent products, plant operations must perform within narrower, more consistent, product specifi cations.

In the dairy industry, a variety of evaporators are critical in the production of powdered products to achieve cost eff ective moisture removal from concentrated liquids. Evaporators are one of the most energy intensive units used in the dairy processing industries. Optimal operation of this process is essential to reduce costs and help meet fi nal product quality specifi cations.

Rockwell Automation recognizes these challenges and off ers an application focused on delivering valuable evaporator control for optimization and performance.

Features and Benefi tsRealize faster time-to-value benefi ts, lower life cycle costs and higher lifetime business value

• Increase throughput up to 10%

• Reduce energy use up to 9%

• Reduce solids variability up to 60%

• Improve the consistency of dryer feed milk solids

Our solutions leverage 100+ years of Rockwell Automation innovation, experience and global support. Industry best practices are incorporated into every application, which is built upon a composite application framework that leverages a Service Oriented Architecture (SOA). This scalable solution, when combined with library-based content, off ers personalization options that promote faster user adoption and time-to-value.

TICSIC SIC

TIC

PIC

CW

FIC

TI TI TI DI

Steam

Steam

Condensate

VacuumPumps

FeedSilo

Surge Tk

Feed FlowFeed Solids MVR Speed(s)

Stage Temps TVR Steam Pressure

Condenser Valve

Concentrate %Solids

FeMV MVMMV

Steam

TVTMV

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CV

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Dairy Evaporator Control ApplicationThe Rockwell Automation Dairy Evaporator Model Predictive Control (MPC) Application assists in controlling and optimizing the evaporation process during the production of powdered dairy products. Powered by our patented technology, this application is tailored to the individual confi guration of each unit and specifi c site objectives. It may be a stand-alone option or combined with the Rockwell Automation Dryer Control Application for a complete drying solution.

Application Scope

This application works with single and multiple eff ect evaporators and can optimize energy usage by including mechanical and thermal vapor recompression loops if they exist. It has also been successfully applied in the most complex evaporator confi gurations, including rising-fi lm, falling-fi lm, wiped fi lm and units with pre-evaporation or fi nisher.

Milk Solids Management

This application reduces the variability of the milk solids concentrate, allowing the average production target to be shifted upward without compromising the downstream

drying process. Variations in milk feed temperature and solids content are automatically compensated for by the MPC controller. This provides a more consistent milk solids concentrate feed to the dryers, helping to improve the consistency in product quality.

Capacity Management

Capacity management is achieved by improving the thermal effi ciency of the evaporator and increasing the average milk solids concentrate coming out of the evaporator. When this improvement is combined with better product consistency, the result is an increase in plant capacity and improvements in the cost of energy per ton of fi nished product.

Performance Metrics and Visualization

Real-time visualization in a browser-based interface presents metrics that allow operators and management to monitor the performance measures of production, quality and energy. These dashboards allow current and predicted plant performances to be viewed and managed to realize and sustain the lifetime business value of MPC investment.

Real-time control and optimization of the process to improve effi ciencies and reduce costs

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Publication RSAPCP-AP002A-EN-P – March 2012 Copyright © 2012 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.