The study was conducted with an optical sensor from the Finnish company SATRON Instruments, for the improvement and optimization of resources associated with the maturation / pasteurization line, complementing the existing control by conductivity.
The results obtained extrapolated to one year were the following:
Savings of more than:
- 744 m3 of water
- 2,868 liters of ice cream mix
- 62 hours
The amortization of the sensor, only based on the cost of ice cream mix, was 6 days.
DETAILS OF THE PROCESS:
- Pasteurization phase: The ice cream mix is conducted to the pasteurizer, using a centrifugal pump, to reduce the presence of pathogens (such as certain bacteria, protozoa, molds, yeasts, etc.) that it may contain. Later it is accumulated in a tank for the maturation process.
- Maturation phase: It consists of leaving the ice cream mixture in a cold place, between 2ºC and 5ºC, during a certain time so that it rests and some ingredients are hydrated. Slow agitation should be applied at intervals, so that the solids that are in suspension do not precipitate. You can not have more than 72 hours. It can be done in the same pasteurizer, or in a maturing tub.
- Transport phase: After the necessary time the mix is conducted to the different process lines such as the chilling or packaging. The mix thrusts are made with water.
- End of the cycle: Immediately after finishing the production cycle, it is rinsed with water, since, otherwise, the milk residues dry and stick to the surfaces quickly, which makes it more difficult to clean. Next, a wash is made with an alkaline solution and a final rinse. This is done with drinking water for a sufficient time to eliminate any traces of NaOH, since otherwise the milk processed later could be contaminated. The correct operation of this phase is essential for the product to meet the necessary hygienic characteristics.
Characteristics of the optical sensor used:
- Measurement by light scattering.
- Measuring range: 0-1,000 up to 5,000 NTU or FNU
- Accuracy: 0.1% of the calibrated range
- Integrated temperature measurement.
- Temperature measurement of the electronics.
- Simple calibration (from 2 to 16 points).
- Analysis damping: from every 60 “to 100 seconds
- Memorisable up to 4 calibrations. Allows remote calibration change (relay contact).
- Output: 2 output 4-20mA (turbidity + temperature) + HART.
- EHEDG and 3A certificate
- Phase separation
- Discharge to a water treatment plant
- Control in exchangers
- Milk fat monitoring
- Color control
For more information contact MATELCO, S.A tel. 184.108.40.2063, or email us from the contact section.
In Matelco we believe that the turbidity measurement is essential to ensure optimum quality and control of industrial processes in the water analysis, the wastewater treatment or detection of loss of product in the dairy industry.
Our optical sensor VO-m Satron is a suitable technological solution for the measurement of liquids and also turbidity, to measure colors and suspended solid content in fluids.
Optical turbidity sensor VO-m Satron detects tips pouring of product as milks or creams at the entrance of the purification of industrial waste water (EDARI). At this location, a rapid response in the case of dumping of the product, can save significant costs to your company in seconds .
How our VO-m optical sensors work?
In the specific case of the dumping of milk, the measure of our associated optical sensor to chemical oxygen demand, COD , correlated to the turbidity of the sample. The optical sensor also measures the temperature, so that an accidental spillage of milk cold state involves a sudden drop in the same.
The following graph our optical sensor is calibrated with samples of 6 clients 0-20000 ppm (4 to 20mA) COD and installed in line at the entrance of the EDARI . When our sensor Satron detects a value less than 6,000 ppm alarm is activated and this signal allows corrective actions.
This chart reflects the behavior registered our optical sensor VO-m Satron during a single day.
In the above graph the peak where there is an increase of COD and decreasing the process temperature is clearly observed. This measurement determines the tips pouring milk product without installing any temperature gauge, because our sensor already has it in its standard installation and can be monitored with a second analog output.
The key advantages of our optical sensor
In addition to being a key to the advantage savings product loss , with this technological solution your company will have the full assurance of a spill according to local environmental regulations, avoiding an increase in treatment costs which can cause failure legal.
The main technical characteristics of our optical sensor for determining turbidity of suspended solids and / or liquids colors:
1 # Use the operating principle backscatter or scattered light measurement.
2 # The configuration and calibration can be performed through the same sensor interface which can be connected via a PC or using the HART protocol .
3 # For the sensor supply an operating voltage 24VDC and 3 wires is necessary.
4 # The output signal is 4-20 mA (3 wire) with HART protocol signal.
5 # The maximum pressure recorded is 20 bar (tested up to 30 bar).
6 # The measuring range is 0-1.000-5.000 FTU.
7 # Has Certificate EHDEG toilet and A3.
8 #It allows simple user calibration (from 2 to 16 points) and you can save up to 4 different calibrations on the same computer.
9 # has Datalogger with integrated clock (one measurement / min = 2 months).
Then you can view this video in a graphic example of connecting our optical sensor VO-m Satron :
To learn more about our optical sensor VO-m Satron you can consult our experts in the section contact so that we can propose the most appropriate solution.