INGREDIENTS

Dairy Balancing plants are challenged to effectively balance their production with seasonal demands and milk availability . Dairy Powder facilities tend to be large in scale with major investments in equipment and resources. Malisko Engineering, Inc. has proven to be a trusted partner for Class IV – Butter and Dry Products clients to maximize their capacity and increase efficiencies by leveraging PMO guidelines and ISA-S88 batching standards into the process controls. Malisko solutions provide efficient operation of the entire process from Intake/Receiving of raw milk through product transfer to packaging, including critical functions of HTST, Milk Separation, Fractionation, Evaporation, Drying and CIP processes. Malisko also partners with clients to ensure HACCP and SQF compliance through electronic record keeping capabilities. Product tracking and production data can be captured and leveraged to create “Real Time” analysis of an operations performance. Providing critical controls and monitoring features for power consumption, influent and effluent conditions, create additional cost saving opportunities for our clients.

Robust modern Industrial Control Systems allow operators to minimize unplanned downtime, by leveraging designated KPIs for “Predictive” and “Preventative” maintenance enhancements. Modern control systems also provide a stable foundation for Ingredient Manufacturers to leverage the implementation of IIoT technologies further enhance their capabilities, efficiencies and profitability.

For over 25 years, Malisko Engineering has been part of this ever-changing landscape and understands the challenges these balancing plants are facing. Quality standards are getting tighter and milk processing volumes are getting larger.

If you find yourself facing these challenges and need a little extra help, then please consider Malisko Engineering. Malisko can provide the following services to meet your needs.

CHEESE

Malisko Engineering, Inc. understands that the cheese market is a very competitive landscape in today’s economy. With high volatility in the marketplace, how do cheese producers maintain productivity at a profitable level? Proactive companies are integrating innovative technologies along with proven Automation Solutions. Malisko has the experience and know how to effectively facilitate cheese processors ability to achieve economies of scale more rapidly and with greater reliability all while maintaining or even improving their quality. Whether it be through a customized recipe handling system, which allows countless cheese making recipes at the plant to be stored and recalled quickly; or unique Digital Transformation offerings that provide insight into critical operations like your CIP process.

Our Engineering Department is staffed to provide the services you require. Malisko can automate a single piece of equipment such as a Cheddaring or CIP skid if needed. Malisko can provide “End-to-End” Process Control solutions to suit your needs from Curd Production through Ripening and Storage to fully optimize your entire facility. We can also provide integrations, upgrades, and expansions of your existing control system.

Turn to Malisko Engineering, Inc. if you need assistance or guidance to ensure FDA / USDA compliance by maintaining clean-in-place (CIP) processes that incorporate Electronic Record Keeping and high-temperature, short-time (HTST) controls with the Legal Interlocks. Malisko solutions comply with the ISA-88 batch control standard, ISA-95 enterprise control standard and the Pasteurized Milk Ordinance (PMO). We can also offer solutions to aid in the control of shrinkage by performing process audits to identify where unaccountable product and butterfat losses are occurring. From there Malisko can help implement process changes and plant loss control goals. Improving the efficiency of your dairy processing lines with integrated automation systems is our priority. Additional solutions provide dairy traceability and lot genealogy solutions for comprehensive product tracking. Our Frontedge® OT VITALS® allow you to visualize your facilities Operational Technology (OT) Network to eliminate OT Network downtime.

FLUID MILK

One challenge that Fluid Milk processors face is the diversity of their products, which can range from skim – 2% – whole milk to cottage cheese and sour cream. Fluid Milk Processors are facing many challenges with changing market dynamics which have thinned gross margins to critical levels for many operations.

Many Fluid Milk processors have aging process automation systems and infrastructure, which over the years becomes less reliable and more costly to maintain due to obsolescence. The lack of investment over the years has also created a shortfall of knowledge on emerging technologies and qualified vendor partners. Forward thinking Fluid Milk processors are making concerted efforts to invest in their aging process control systems and infrastructure to gain better operational efficiencies and production of higher margin products.

Whether your organization needs improvements in your Pasteurization, Heat Treating, CIP, Packaging or Record Keeping, Malisko Engineering is uniquely qualified to provide your systems while being attentive to maximize the return on your capital investment in manufacturing automation. Malisko offers unique process control solutions that lower your total cost of ownership.

CULTURED PRODUCTS

The growth in popularity of cultured dairy products has stretched the resources of existing production facilities. To meet production demands, many organizations are looking for partners to help them gain efficiencies in their process while maintaining regulatory compliance. Malisko Engineering has helped small- and large-scale yogurt plants meet the challenges of today’s markets.

Collaboration with your team is the secret to our success. Whether it is scaling up or advancing automation capabilities, Malisko will work to provide the right automation solution for your project, large or small. You can count on us to design and implement a fully automated control system for your yogurt facility. A control system that can easily capture material tracking data such as: raw milk/cream receiving information, critical temperatures at specific points in the process, ingredient amounts, batch cycle times, CIP tracking, and more. Malisko Engineering Automation Solutions allow your team to easily retrieve data to troubleshoot process issues, saving valuable time and money. Employees will no longer need to speculate about what could be going wrong. We are with you through the entire project from inception to commissioning and ongoing support both on site and remotely.

If your organization is looking for automation solutions, Malisko Engineering is the company to turn to.

ICE CREAM

The Ice Cream Market continues to grow year over year in the United States and abroad. Rapid growth in the market creates as many challenges as it does opportunities. One of the biggest challenges Ice Cream Makers are facing is capacity planning. Another common challenge is variety of product demand. Many ice cream manufacturers create several iterations of their product from multiple flavors and sizes to varied novelty added ingredients. There are multiple ways Malisko Engineering can assist your Ice Cream operation to increase productivity, improve quality and reduce overall costs.

Malisko solutions reduce labor costs through uncomplicated automated equipment solutions to provide reliable consistent quality. By working with your team to diagnose areas of your operation where deviations in quality or throughput are common, we can provide recommendations for improvement. Our experience has been that Batching, Flavour/Colour Addition, Freezing, Whipping, Packaging and Hardening are processes that typically create productivity challenges. Malisko can provide solutions to improve the Operations Equipment Efficiency (OEE) of these processes. If your production planning changes rapidly and when quick change-overs are necessary, you can count on our expert Dairy Team to provide a cost effective, reliable user-friendly solution to allow your organization to produce consistent high-quality products that your customers desire.