Monitoring systems for dairy production facilities
Viravix Engineering provides a service for the implementation of a remote monitoring system for production lines in the dairy industry. The customer receives an expert technical solution for controlling process parameters in 24 / 7 mode, without personal presence at the plant. We connect the best process engineers with dairy plant owners.
Why dairies need monitoring systems
There are several reasons why a customer would benefit from such a technical solution. And they all come together in one group - the benefits of using online production monitoring.
You will get:
You will get:
Product quality and bacobbin control
The system monitors important process parameters, such as storage or heat treatment temperatures, twenty-four hours a day. The operator can monitor and change these remotely according to the situation.
Stable product quality ensures less product loss, fewer returns from point-of-sale and protects against commercial and reputational losses.
Stable product quality ensures less product loss, fewer returns from point-of-sale and protects against commercial and reputational losses.
Increased productivity
Remote monitoring of production processes objectively identifies bottlenecks and shows clearly where they can be optimised. We have had a project where we used this system to find bottlenecks and increase the productivity of a production line by 15% without costly upgrades.
Cost savings
Online monitoring of production lines will show the sources of leaks and energy losses within a short time. The experts at Viravix Engineering know effective solutions to reduce energy and water consumption, the implementation of which will save the dairy money.
Also, monitoring of equipment operation parameters helps to efficiently plan the repair and investment programme. The dairy plant owner can see which devices need to be replaced or serviced before a breakdown occurs, allowing money to be spent for the intended purpose. Any engineer knows that emergency repairs are several times more expensive than preventive maintenance.
Also, monitoring of equipment operation parameters helps to efficiently plan the repair and investment programme. The dairy plant owner can see which devices need to be replaced or serviced before a breakdown occurs, allowing money to be spent for the intended purpose. Any engineer knows that emergency repairs are several times more expensive than preventive maintenance.
Early detection of problems
The monitoring system will warn you in advance of any unusual situations or deviations from normal process parameters. Responding quickly reduces downtime due to accidents and helps avoid product spoilage.
Investing in a remote process monitoring system for production lines pays off in terms of results. You get rid of 'hidden' accidents and incidents, you can effectively plan your repair and investment programme, you see ways to optimise processes and save energy.
Monitor your production around the clock, from anywhere in the world, and minimise the risks of "manual management by situation".
Monitor your production around the clock, from anywhere in the world, and minimise the risks of "manual management by situation".
Which processes can be monitored
The system monitors basic parameters: temperature, pressure, time, flow rate, volume, microbiology and others, depending on the process. On packaging and labelling, it can be configured to monitor consistency and quality.
Remote monitoring of production parameters is applicable to most processes in a dairy plant, including:
- Raw material preparation - cleaning, cooling, normalising, pasteurising;
- Application of stabilizers;
- Heat treatment and centrifugal cleaning
- Deaeration;
- Homogenisation;
- Ultrapasteurisation;
- Cooling;
- Bottling, packaging, labelling;
- CIP washing of equipment.
The sensors can be installed on almost any equipment, and setting up the system is no more complicated than setting up a Wi-Fi router. Plus, we'll send your technicians detailed instructions on how to install the software and debug the communications.
You'll protect your business by reducing the risks posed by human error.
You'll protect your business by reducing the risks posed by human error.
Examples of monitoring systems for various equipment
QiVisor applicable to a lot of equipment in a dairy, including CIP washers, tank equipment, pasteurisers
What the system can do:
- Monitors the status of events on the production line.
- Controls the consumption of utilities: water, steam, electricity, oxygen etc.
- Shows process performance history for any period (hour, day, week, year).
- Analysis of the efficiency (OEE) and productivity of the line.
- Displays reports in Excel format.
Developer: META SYSTEMS LLC — The company specialises in the development of process monitoring systems for food production and FMCG.
Product applications
Keeps track of water, steam and electricity consumption. Additional utilities can be added.
- Monitors capacity equipment load.
- Monitors CIP washing of equipment.
- Monitors the pasteurisation process.
Advantages
- Ability to add parameters and events.
- Easy set-up, without the need for external specialists.
- User training and video tutorials.
- A cloud-based product that does not require servers, workstations.
Safety
- Data is stored in the cloud in encrypted form - Encryption-at-Rest.
- The information is sent over a secure HTTPS connection.
- Backups are made every day.
Koeebox Suitable for monitoring the operation of mains-connected equipment, including filters, pumps, heat exchangers and pasteurisers
What the system can do:
- Monitors operating parameters.
- Sends warnings when parameters are out of specification.
- Provides data to help identify trends and optimise production processes.
Developer: Koeebox
Product applications
Measures:
- power consumption;
- operating time;
- temperature;
- vibration level;
- mass;
- pressure.
- Recognises operating modes.
- Records energy consumption.
- Displays current process status.
- Tracks operating time.
- Sends instant notification.
Advantages
- Requires no infrastructure and no dedicated staff.
- Can be installed in 15 minutes.
- Works on any equipment where electricity is available.
Safety
- Cloud storage.
- It is up to the client to decide to who they give access to the data.
PLC Analyzer pro 6 it is a programme for analysing PLC systems used to automate equipment in dairies
Possibilities PLC-Analyzer features:
Developer: AUTEM — PLC-ANALYZER pro 6 simplifies the acquisition, presentation and evaluation of PLC signals such as input, output, flags, timer, counter, data block data.
- Monitors PLCs from different manufacturers and analyses PLC data to identify potential problems, optimise performance.
- Simulates PLCs for testing and troubleshooting.
Developer: AUTEM — PLC-ANALYZER pro 6 simplifies the acquisition, presentation and evaluation of PLC signals such as input, output, flags, timer, counter, data block data.
Product applications
- Diagnoses faults.
- Eliminates random errors.
- Optimises cycle time.
- Keeps a permanent record of measured parameters.
Advantages
- The Virtual HMI module assists in accident investigation.
- The subsequent visualisation of the HMI based on the recorded process data facilitates the detection of possible operating errors.
- The HMI visualisation can also take place live during recording.
Safety
- Compliant with TPM/OEE, EU Machinery Directive.
- Stored on workstations.
Clarify it is a quality control and process monitoring system
Features:
Developer:Clarify
Product applicatio
Integrates and visualises data from different sources. Suitable for the systematisation and analysis of the performance of industrial equipment and utility systems, PLC systems and SCADA systems.
Advantages
Safety
The customer provides access to the data himself.
- Monitors temperature, pressure, flow and pH.
- Provides real-time data visualisation and reporting.
- Monitors filling lines to ensure efficient and accurate filling of containers.
Developer:Clarify
Product applicatio
Integrates and visualises data from different sources. Suitable for the systematisation and analysis of the performance of industrial equipment and utility systems, PLC systems and SCADA systems.
Advantages
- User-friendly interface for data integration, visualisation and organisation.
- Streaming timeline technology for fast navigation.
- Search and filter functions.
- Time selector to get statistics and comparative analysis.
- Addition of multimedia: videos and photos.
- Search and view previous transactions.
- Proprietary mobile app.
- Quick data export.
- @-remembering function for collaborative work.
- Support for Node-RED, OPC UA, Azure IoT, MQTT, Ignition and Google Sheets add-on.
Safety
The customer provides access to the data himself.
«Виравикс инжиниринг» использует индивидуальный подход. Мы подберем систему удаленного мониторинга параметров производственных линий под потребности вашего молокозавода. Наши программисты доработают и настроят ее под конкретные пожелания заказчика и условия эксплуатации.»