Smart software optimises production of whey and milk powder

Finland’s biggest dairy company, Valio, recently boosted the production of its Lapinlahti whey powder plant by over 10% by implementing the NAPCON Controller solution (Advanced Process Control) from Neste Jacobs. The results were so convincing that Valio is now optimising a milk powder plant in Seinäjoki, Finland, in a similar way.

Since whey and milk powder production is about drying fluids, the process is very energy consuming. NAPCON balances the need of energy within the desired product specifications so that the energy consumption is minimised.

“Valio ships over 60 million kg of milk and whey powders annually,” said Antero Ylitalo, production manager of Valio Powder Production. “That means we are talking big money when the productivity boosts by more than 10% without higher energy consumption or costly hardware investments.”

NAPCON can also predict the moisture content and in real time adjust the water balance, even adapting to changes in outdoor humidity. Moisture content is a critical factor — especially at the final stages of the production line, where a spray dryer removes the last part of the water while still keeping the valuable properties of the milk or whey.

“Too large water content makes the powder sticky and disturbs the process,” Vesa Strand, production manager of the Seinäjoki plant, explained. “On the other hand, if the powder is too dry it generates dust and uses excess energy. With NAPCON, we can allow an increase in the average moisture content in the process and still keep the moisture content of the final powder product very close to its target value under all circumstances.”

The NAPCON solution in Valio’s two production plants consists of two tools: a NAPCON Indicator that calculates the material and energy balance information; and a NAPCON Controller that controls the process using multivariable model-predictive control (MMPC).

In addition to the MMPC solution, Valio also utilises an OPC UA (Open Process Control Unified Architecture) connection between NAPCON and Valio’s process control system.

Image caption: The APC solution from Neste Jacobs is integrated into the plant’s process control system. Image credit: Neste Jacobs.