A growing middle class in India has created a growing market demand and increased consumption of dairy products.
This dairy, one of Asia’s largest, has a processing capacity of 50,00 lac liters of milk a day. With the increasing demand for quality milk throughout India, the plant is challenged to increase production for various dairy products. To meet demand, they need an integrated liquid milk plant.
The goal of the expansion was process optimization, manpower reduction (doing more through automation) and faster time to market. The dairy also focused on maintaining low operating margins.
In addition, the control systems of various plants would need to integrate with the systems in the dairy. The plant required greater visibility and productivity, while optimizing resources including water, air, gas, electric and steam (WAGES).
The goals of the plant included reducing batch cycle time to increase productivity of plant, and creating a flexible storage matrix for raw materials to improve operations.
Given the scope and complexity of the project, the dairy recognized they needed a single vendor to manage the design and implementation of the control system. Choosing a company with the right set of skills and experience was critical.
The dairy selected Rockwell Automation due to its extensive experience in automation and global reach. With a local sales office and distributor located close to the project site, Rockwell Automation had the required expertise and partnerships to manage the entire project from initial design through engineering and implementation.
Effective solutions included seamless integration on a single EtherNet/IP network; process optimization by deploying controller-based modular predictive control (MPC) on the pasteurizer; real-time energy monitoring; scalable engineering practices and standardization.