Advanced process filtration for superior dairy quality
From milk processing to cheese and yogurt production, every step in dairy manufacturing requires stringent control over contaminants, bacteria, and particles to maintain purity and meet regulatory standards. Process filtration is essential part of the dairy industry and ensures product quality, safety, and consistency. Filtration systems remove impurities, extending shelf life, and preserve the natural taste and nutritional value of dairy products.
The problem
A medium sized dairy processing plant was experiencing frequent production slowdowns and quality inconsistencies in their milk and cheese products while trying to expand their production through introducing some new products. The root cause of these issues was found in their undersized filtration system, which led to premature clogging, increased maintenance downtime, and compromised product purity. The plant struggled to meet the growing demand for their products while maintaining high standards of hygiene and operational efficiency.
Additionally, their current pre filters were inefficient at capturing fine particulate matter, causing some contaminants to pass through and affect the final filtration stage. This resulted in increased waste through filter replacement and the need for more downtime, further reducing overall productivity.
The plant sought a solution that would improve filtration efficiency, reduce downtime, and ensure consistently high-quality products without driving up operational costs.
The solution
The dairy plant partnered with AC specialists in high-performance process filtration solutions. After conducting a comprehensive analysis of the plant’s processing lines, AC recommended and installed a customized filtration system designed specifically for dairy production. The solution was an Atlas Copco SLH liquid filter housing for each stage and the PFP-A pre filter series with a final stage using the Atlas Copco SME Polyethersulfone sterilizing grade membrane, for removal of microorganisms.
The advanced process filters provided by Atlas Copco offered:
- High-efficiency filtration to capture finer particles as pre filtration, protecting the final stage, ensuring product purity.
- Longer filter lifespan, reducing the frequency of filter changes and associated downtime due to increased housing size based on maximizing lifetime
- Low-pressure drop technology, enabling consistent flow rates and preventing system blockages from the increased filter surface area
- Easy-to-clean filter elements, minimizing maintenance time and simplifying compliance with the dairy industry's stringent hygiene regulations.
The new filters were integrated seamlessly into the plant’s existing processing lines with minimal disruption to daily operations. AC also provided on-site technical support to ensure optimal filter performance.
The benefits
- Improved Product Quality: The advanced filtration system effectively captured impurities, resulting in cleaner, fresher-tasting milk and cheese products. The plant experienced a significant reduction in rejected batches due to quality issues.
- Increased Operational Efficiency: With fewer filter changes and removal of premature blocking and longer-lasting filters, the dairy plant saw a marked decrease in unplanned downtime. This led to more consistent production schedules and higher overall output.
- Reduced Maintenance Costs: The new filtration system required less frequent filter changes and maintenance, saving both time and money for the plant’s operations team and reduced waste costs.
- Enhanced Compliance: The plant achieved full compliance with industry hygiene standards, thanks to the easy-to-clean filters and reduced risk of contamination.
- Collaboration with a trusted partner: The plant started working with experts that can take fast and accurate action when it comes to problems.
