Getting a measure of milk wastage
November 1st 2007 An ultrasonic, non-contact open channel flow measurement system from Micronics is providing a cost-effective solution for a dairy processing site in Gloucestershire, helping it to reduce both milk wastage and costs Bradshaw Consulting specialises in energy and process loss reduction in the food and drink sector. One of its clients, Dairy Crest, operates a large Dairy Processing site near Stroud in Gloucestershire and, with the help of the Dairy Crest Improvement team (Chemical Engineers), Bradshaw has developed and installed an effluent monitoring and analysis system incorporating a Micronics SLT32 - Ultrasonic Non Contact open channel flow measurement system. The purchase of the new turnkey system and meters was driven by a need to provide online product wastage information from the various departments and hence, further reduce milk wastage from the site. Ease of installation Having considered various measurement alternatives ultrasonic non-contact meters were selected due to the ease of installation and maintenance and service benefits associated with the technology. Micronics was selected as the supplier due to a combination of the company's experience with open channel flow measurement technology and its competitive pricing in comparison to some alternative similar technology solutions or alternatives requiring considerable civil construction work. Three Micronics SLT32 meters were purchased as a package. The meters have the capability to measure and log effluent flow and totalised flow; however, in this application they are providing flow data via a 4 to 20mA signal to the system's separate control system. The meters have been installed at three known process discharge points to assess effluent discharge rates assuming flume characteristics. The Bradshaw system also analyses the effluent milk content to identify the milk wastage using a volume x turbidity (~ COD mg/L) calculation, which is further analysed in terms of real time and day total data within the site SCADA system. Driving down milk wastage Site staff are able to monitor live effluent discharge rates, initiate action to investigate potential reductions in process milk wastage and view the results in real time or daily values. And in doing so they are able to identify and drive down milk wastage and effluent costs using M&T techniques in line with Best Practice. Bradshaw's Will Todd has managed the project and he believes the project has developed an industry-leading tool for the management of process waste and effluent within the Dairy Processing industry. The Micronics products have performed well, service has been good and the installation has been an environmental and financial success. Improved measurement and visibility has enabled Dairy Crest to improve the plant's performance and as a consequence less product is being wasted and therefore less effluent is being discharged! The potential for system expansion onsite is circa 50% and there is significant potential for replication on other sites across the Dairy Processing industry. More articles from Micronics Ltd: | 
