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CPG Industry Solution

Dairy Dryer/Evaporator Balance Application

Features and Benefits


Realize faster time-to-value benefits,
lower life cycle costs and higher
lifetime business value

• Increase throughput up to 15%


• Increase outlet air relative
humidity up to 16%
• Reduce energy use up to 12%
• Reduce off-spec product up
to 75%
• Increase moisture yield up to 1%
• Reduce moisture variability
up to 60%
• Improve the consistency of
dryer feed milk solids The Challenge
Manufacturers of milk and other food ingredient powders recognize the
constant need to operate their processes more efficiently. The goal is to
Our solutions leverage 100+ increase throughput while simultaneously reducing costs in order to
be competitive globally. Many manufacturers are also shifting more
years of Rockwell Automation production towards higher value specialty products that require higher
innovation, experience and quality standards (such as low-fat, no-fat, protein-enhanced, etc.) In order
to produce these different products, plant operations must perform
global support. Industry best within narrower, more consistent, product specifications.
practices are incorporated
In the dairy industry, a variety of dryers and evaporators are common in
into every application, which the production of powdered products to achieve cost-effective moisture
is built upon a composite removal from concentrated liquids. Dryers and evaporators are the most
application framework that energy intensive units used in the dairy processing industries. Optimal
operation of this process is essential to reduce costs and help meet final
leverages a Service Oriented product quality specifications.
Architecture (SOA). This scalable
Rockwell Automation recognizes these challenges and offers an
solution, when combined with application focused on delivering valuable dryer and evaporator balance
library-based content, offers control for optimization and performance.
personalization options that
promote faster user adoption
and time-to-value.
Real-time control and optimization of the process to improve efficiencies and reduce costs

DV Evaporator Feed % Solids Steam


MV Dryer
Dr Exhaust Temp
MV DDryer Inlet Temp
TIC Feed CV Dryer Feed Rate
Feed MV Fe
Feed Flow
MV Ev
Evaporator Silo CV Evaporator Stage Temps Air
TIC PVC
Fe
Feed Flow

Surge Tk
Steam
TIC
SIC
MV DDryer Inlet Air Flow
FIC
Dryer
CV Dryer Feed
Pump Speed
CV Concentrate %Solids
Steam
TIC

CV Evaporator Condenser Valve Steam


TIC

Air DV Dryer Feed


CV Sticky Point Moisture
%Solids
Air
CV Product Moisture

Dairy Dryer/Evaporator Balance Application Energy Balancing


This Rockwell Automation Model Predictive Control (MPC) Implementing this dual application solution offers a
and Optimization Application assists in controlling and unique thermal energy balancing opportunity between
optimizing the drying process during the production the evaporator and the dryer. Optimal energy use and cost
of powdered dairy products. Powered by our patented control can be achieved.
technology, this application is tailored to the individual
configuration of each unit and specific site objectives. It Early Engagement and Capacity Management
combines Rockwell Automation Dryer and Evaporator This application also includes early engagement control,
Balance Control Applications for a complete solution which sees the dryer under MPC and optimization. This
which incorporates full thermal control and optimization. helps in achieving optimal quality and thermal efficiency
within minutes of the dryer commencing powder
Application Scope production.
This application works with single and multi-stage spray
Capacity management is achieved by improving the
drying processes as well as flash dryers and processes with
thermal efficiency of the dryer and controlling chamber
fluidized beds. It controls product average moisture to a
temperatures and airflows to achieve the capacity target.
desired target, while reducing overall moisture variability,
At the same time, the absolute chamber relative humidity
and manages relative humidity and capacity to achieve
constraint and product quality are optimized.
optimal performance.
Performance Metrics and Visualization
Moisture Management
Real-time visualization in a browser based interface
The MPC controller compensates for variations in the milk
presents metrics that allow operators and management
solids concentrate as well as inlet air relative humidity
to monitor the performance measures of production,
and other disturbances that affect drying efficiency. By
quality and energy. These dashboards allow current and
reducing moisture variability, the average moisture target
predicted plant performances to be viewed and managed
can be increased without compromising product quality.
to realize and sustain the lifetime business value of MPC
This increase in moisture target can also produce higher
investment.
yields from the same milk solids. Dryer capacity can be
increased and product re-works and energy use per ton
of finished product can be reduced.
X, Y and Z are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.

Publication RSAPCP-AP003B-EN-P – July 2012 Copyright © 2012 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

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