Large-scale dairy operations require high standards of hygiene, consistency, and efficiency in cream handling. Traditional manual or semi-automatic processes often lead to variability in quality, higher labor dependency, and increased risk of contamination. Upgrading to automated cream-handling systems ensures uniform processing, minimizes product losses, and enhances overall operational reliability.

1. Objective of Automation Upgradation

The primary objective of this automation upgradation is to streamline all stages of cream reception, separation, standardization, chilling, storage, and transfer. Automation aims to reduce manual intervention, improve process accuracy, and strengthen product traceability while ensuring compliance with food safety standards.

2. Scope of Automation

This upgrade covers the integration of automated control systems, sensors, CIP-enabled pipelines, flow management equipment, and SCADA connectivity across the following cream-handling areas:

  • Cream separators
  • Cream pasteurization units
  • Cream silos and buffer tanks
    • Maintain cream storage temperature at ___°C (typically 4–6°C).
    • Agitators run automatically in intermittent mode:
      • Example: 5 minutes ON / 30 minutes OFF
  • Daily check through SCADA:
    • Temperature trend
    • Agitator status
    • CIP status
  • Quality sampling frequency:
    • Fat %
    • Microbiological tests (as per QA plan
  • Cream cooling systems
  • Cream transfer pumps and automated transfer valves
    • Select destination line on SCADA (butter plant, ice cream mix area, fat standardization etc.).
    • Confirm tank selection and line availability.
    • Start automated cream transfer pump.
    • System will automatically:
      • Route product via sanitary automated valves
      • Maintain flow rate as per recipe
      • Log batch volumes
    • After dispatch, verify line clearance via conductivity probe or air-blow sequence as applicable.
  • CIP system integration
  • Quality monitoring and data logging

3. Need for Upgradation

Due to increased production volumes and stringent quality requirements, existing manual systems show limitations such as inconsistent fat levels, temperature deviations, product losses, and longer processing times. Automation will eliminate these inefficiencies through precise control, real-time monitoring, and improved operational safety.

4. System Features

The system will include:

  • Automated flow-meter-based cream dosing
  • Online fat analysis using NIR or ultrasonic technology
  • Temperature-controlled cream storage with automated chilling
  • PLC-controlled pump and valve sequencing
  • SCADA interface for real-time visualization and alarms
  • Hygienic, SS-316 PHE and pipelines with automated CIP
  • Data logging for batch-wise tracking and regulatory reporting
  • Alarm Handling

Common alarms & actions:

  • High fat deviation: Check separator performance
  • Low-temperature alarm: Check chiller flow or PHE
  • Pump fault: Inform maintenance, switch to standby pump
  • Valve position mismatch: Inspect actuator or sensor. All alarms must be acknowledged and recorded in the shift log

5. Expected Benefits

Upgrading to a fully automated cream-handling system will deliver:

  • Consistent cream quality and stable fat content
  • Reduction in human error and manual handling risks
  • Improved hygiene and minimised contamination
  • Real-time tracking of critical process parameters
  • Reduction in product wastage and energy consumption
  • Enhanced equipment life through optimized CIP cycles
  • Better production planning and traceability

6. Implementation Plan

The implementation will be executed in phases:

  • Assessment & Design: Evaluation of existing infrastructure and preparation of automation layout.
  • Procurement: Selection of sensors, PLCs, SCADA systems, pumps, and hygienic pipelines
  • Installation & Integration: Equipment installation, process interconnection, and automation logic development.
  • Testing & Validation: FAT, SAT, and trial runs to ensure accuracy and reliability.
  • Training & Handover: Operator training, documentation, and final handover.

About Team EIPL

At Team EIPL, we bring extensive expertise in fully automated cream handling systems for large-scale dairies. Our team, led by Mr. Manoj Sharma, a renowned instrumentation specialist, and supported by skilled Instrumentation Engineers and Dairy Experts, has successfully implemented automation projects, including at Bhole Baba Group, Kanpur, achieving 100% client satisfaction and excellent operational results.

We specialize in analyzing existing systems and transforming them into state-of-the-art automated solutions that enhance operational efficiency, ensure consistent product quality, maintain regulatory compliance, and provide a reliable, scalable platform for future growth. Partnering with us ensures that your dairy operations remain competitive, modern, and optimized for the challenges of tomorrow.