Milking more from every pump

Efficiency isn’t just a buzzword in dairy plants, it’s a daily necessity — and it starts with the pumps.

In Australia’s highly competitive dairy sector, utility operations are under growing pressure to deliver more with fewer resources. Operational teams are expected to meet ambitious sustainability targets while reducing costs and maintaining compliance with increasingly strict wastewater regulations. For most plants, water and energy use remain key challenges, and pumps are central to both.

Across all stages of dairy processing, from raw milk transfer to cleaning-in-place (CIP) systems, pumps are vital. But the conversation is shifting. Selection based on capacity or brand is no longer enough. What matters now is how well a pump performs as part of a larger system, and how efficiently that system can respond to demand.

That’s why many operators are moving away from stand-alone equipment upgrades and adopting a systems-based approach. Performance gains are no longer limited to the pump itself but extend across drives, sensors, piping, valves, and controllers. This shift toward integration and automation is enabling greater control of flow, pressure and energy use throughout the utility network.

Grundfos has seen this transformation firsthand in its work with dairy operators both locally and globally. Through ongoing consultation, it has become clear that optimising dairy pump system efficiency requires more than new hardware. It requires intelligent, responsive systems that adapt in real time to changing production demands.

For most dairy plants, the core priorities driving this change include improving overall equipment effectiveness (OEE) to maximise uptime, stability and product quality; integrating water reuse strategies to reduce freshwater consumption and reclaim process water for non-critical use; capturing energy from condensate and cleaning cycles to ease the load on boilers and heating systems; and enhancing chemical efficiency by reusing cleaning agents and limiting reliance on fresh chemical inputs. Each of these priorities becomes more achievable with intelligent pumping systems that communicate, adapt, and optimise performance in real time.

Grundfos offers two solutions designed specifically for this kind of systems optimisation. Grundfos iSOLUTIONS integrates pumps, frequency drives, sensors, and controllers to deliver precise, coordinated performance. Rather than operating independently, each component works in harmony, adjusting speed, flow and pressure dynamically to reduce energy use and extend equipment life. Grundfos E-pumps, which combine the motor, pump, and drive into a single unit, deliver additional energy savings by constantly matching pump output to actual demand.

This combination of intelligent control and modular integration is proving effective across a wide range of dairy applications, from CIP processes to wastewater treatment. By reducing overpumping, avoiding pressure surges and stabilising system performance, operators can reduce downtime, avoid maintenance disruptions, and meet stricter discharge conditions.

Advanced milk processing also relies heavily on precision control, particularly in membrane separation systems and reuse loops. Pumps that respond predictively and consistently ensure these systems remain stable and efficient, preserving product quality while conserving resources.

As dairies grow in scale and complexity, system-wide optimisation is no longer optional. It is a strategic investment that supports both operational resilience and long-term sustainability. Grundfos’ approach, focused on dairy pump system efficiency through integrated design, reflects a broader shift across the sector. Smart, connected pumping systems are not just add-ons. They are key enablers of innovation, efficiency and compliance.

For more information, visit Dairies | Grundfos

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