Project Description
The client, a major dairy product manufacturer, needed a smarter and more consistent control system for their Ultrafiltration (UF) department. The existing system was manually operated and frequently caused inconsistent product quality and delayed output.
Timeline
Completed over 6 weeks, ensuring zero disruption to daily production.
Background
Milk filtration requires precise control over pressure, flow, and membrane cycles. Manual systems lacked precision and created inconsistencies in yield and concentration levels. We modernized the system using advanced PLC logic, HMI panels, and sensor-actuator networks to deliver automated batch control and consistent filtration parameters.
Process
We began with on-site evaluations of the existing UF system and filtration cycles. The solution evolved through custom PLC panel design, HMI interface creation, and multi-sensor integration. Each phase included real-time system simulations, safety logic testing, and operator training to ensure a smooth transition to automated control.
Audit & Requirements Gathering
Assessed membrane cycles, pump performance, and operator logs. Designed a feedback-based control system to improve accuracy and reliability.
Control Design & Panel Upgrade
Installed a new PLC panel (Fatek + LS) with optimized safety interlocks. HMI screens were configured for batch control, cycle management, and error detection.
Integration & Testing
Connected sensors (pressure, flow, level) and implemented programmable alarms, automatic backflushing, and recipe management.
Solution
The upgraded UF control system delivered consistent product quality, reduced manual errors, and improved cycle efficiency. With smart PLC logic, real-time sensor feedback, and user-friendly HMI panels, the dairy filtration process became fully automated and easier to monitor and maintain.
Fully automated filtration cycle control with alarm-based error handling
HMI-based batch tracking and remote reset/start functionality
Preventive maintenance alerts based on pressure trends and cycle counts
Results
The new control system led to a 35% improvement in product consistency and a significant drop in manual errors. Operators reported smoother workflows and easier system handling. Batch traceability and maintenance alerts added long-term reliability and oversight to the UF process.
Product consistency improved by 35%
Reduced operator workload and human error
Full traceability of each batch’s filtration cycle
