Case Study

OBJECTIVES

• Adding milk receiving and storage capacity to eventually improve operational efficiency and yield across the entire milk processing systems.
• Greatly reduce the dependence on operator control by incorporating automation.
• Eliminate reliance on paper records for PMO compliance via implementing a new computerized data collection, storage, and reporting system.
• Put in place an electronic data and records system compliant with PMO Appendix H. Pasteurization Equipment and Procedures and Other Equipment – V. Criteria for the Evaluation of Electronic Data Collection Storage and Reporting.
• Reduce troubleshooting time by having in place more thorough and accurate system documentation as well as having in place an operator interface system that ‘leads’ the operator to the likely source of a problem.
• Architected a PMO compliant solution for CIP Records and Silo Storage Monitoring
• Meet aggressive project schedule and tight budget.

CHALLENGES

• Very aggressive project schedule.
• Client provided high-level guidance on process controls and reporting requirements. Malisko then leveraged their dairy process knowledge to program the operation from high level functional descriptions.
• Coordination of activities with multiple trades and engineering disciplines.
• Project took place during the 2020 – 2021 COVID-19 Pandemic.
• Phased approach on startups. Had to bring on processes in phases so that plant production was not adversely affected.
• New process required a new robust and secure network with design considerations of tying into the antiquated legacy network.
• No existing remote support capabilities for the automation system.
• Designing a fully automated system on a limited capital budget.

RESULTS

• Greatly improved system for milk receiving and storage.
• Reduced shrinkage/product loss with tighter process controls, visualization, and alarming.
• System met the documented specifications and functional requirements referenced above.
• Successfully implemented e-records meeting PMO compliance.
• Improvements to the CIP processes:
• Reductions in cleaning cycle times
• Reductions in chemical usage
• Effective equipment and process line cleaning
• Faster troubleshooting by plant maintenance as a result of:
• More intuitive messaging and notifications on the system HMIs
• Having comprehensive system documentation matching the programming code and functionality
• Automated and Ad Hoc process and CIP report providing timely data and information to supervisors and plant management enhancing time critical and pro-active decision processes
• Provided a secure network system including secure access via web portal
• As an outcome of meeting the project results and deliverables, client is asking Malisko to assist them with making additional operational improvements through enhancing and expanding their manufacturing automation systems

FOOTNOTES

PMO

The local State Health Inspector met with Malisko’s PMO Subject Matter Expert for a complete review and verification testing of the new system meeting Appendix H Section V of the code for Electronic Data Collection, Storage and Reporting for CIP and Silo Storage. The local State Health Inspector commented how impressed he was with Malisko’s implementation to meet PMO compliance.

CIP Data Logging and E-Reporting

Malisko deployed its CIP Logging and E-Reporting system developed over the past several years. The CIP logging and reporting is system-agnostic and can be applied to CIP systems of various configurations.