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The importance of measurement in the dairy industry

Our daily lives are characterised by dairy products that are produced and manufactured according to strictly controlled quality standards and conditions - ELPRO LEPENIK makes these conditions a reality with precision equipment from our and our partners' dairy solutions programme.

The dairy industry plays an important role in the food sector, processing a variety of dairy products such as milk, cheese, butter and yoghurt. The processes that take place in dairies are complex and their success depends on a combination of factors. These include: the quality of raw milk, efficient production processes and, above all, the correct choice and use of measuring equipment.

In this article, we will explore the importance of measuring equipment in the dairy industry and its impact on the smooth running of dairies. We will also present some examples of good practice in the dairy industry.

Precision pasteurisation: ensuring the safety and quality of dairy products

Pasteurisation is a critical process in the dairy industry that ensures the safety and quality of milk and dairy products by removing harmful bacteria, thus extending shelf life. To achieve the desired results, it is essential to use appropriate instrumentation and control equipment that contributes to the efficiency and safety of the pasteurisation process.

Equipment for trouble-free pasteurisation

Regulators play a key role in pasteurisation by controlling the temperature of the steam or hot water that heats the milk to the desired temperature. They are usually installed in control cabinets and ensure a constant temperature during the pasteurisation process. The controllers can be manually operated or equipped with an automatic time and temperature control system that adjusts the temperature as needed. This ensures that the milk is heated to the right temperature and is at the correct pasteurisation temperature, the time needed to kill harmful bacteria.

Our customers in the dairy industry rely on Shinko temperature controllers , who diligently ensure a smooth pasteurisation process and the best end products.

Figure: Example of a Shinko controller in a dairy

ON SITE hygienic temperature sensors read the temperature of the milk in real time during the pasteurisation process and ensure that the temperature is constant within the desired range. They can be installed in different locations during the process, allowing operators to monitor and adjust the process as needed. This is particularly important in the case of temperature deviations, where operators can quickly take corrective action and ensure that the milk is safe to consume. These sensors, with their calibration port, allow a precise control measurement to be made quickly at the very centre of the temperature sensor, the temperature correction to be determined, and any problems that may arise during the pasteurisation process to be identified and corrected, thus increasing efficiency and reducing downtime.

As part of our production of temperature sensors, we offer ON SITE hygienic temperature sensors for the dairy industry, specially designed for the pasteurisation process. These sensors are manufactured in a hygienic design with different process connection versions (Clamp, VARINLINE®, BioControl®, Welding ball, Ingold and DIN 11851/DIN 11864). These can withstand strong cleaning agents commonly used in the dairy industry. With ELPRO ON SITE temperature sensors, there is no need to shut down the system, dismantle or carry out time-consuming and costly sensor calibration or replacement.

Figure: Hygienic temperature sensor and available connections

Accredited sensor calibration is another key tool in pasteurisation to ensure the accuracy of temperature measurement during the process. Calibration is essential to check the long-term accuracy and stability of temperature sensors used to measure the temperature of milk during pasteurisation. This ensures that the milk is heated to the correct temperature and kept there for the right amount of time, killing any harmful bacteria.

In our company we offer accredited calibration of sensors used in the pasteurisation process in the dairy industry.

Calibrations can be performed at the customer’s site (ON SITE) or in our calibration laboratory. Our calibration services are carried out by qualified experts using state-of-the-art measurement equipment and following strict calibration procedures. This ensures accuracy and traceability.

Figure: Example of calibration in a dairy at the customer’s site

The importance of manometers in homogenisation

Homogenisation is a process often used in the dairy industry to improve the quality of milk and other dairy products. The process involves pushing the milk through a homogeniser, which breaks up the fat globules and creates a more even distribution of fat throughout the product. Maintaining the correct pressure during the homogenisation process is crucial to achieve the desired results.

Pressure gauges are devices commonly used in the dairy industry to measure the pressure of a liquid, in this case milk. They are available in different versions, as digital or analogue pressure gauges. They are often calibrated to specific pressure ranges. Using a pressure gauge, operators can monitor and adjust the pressure to ensure it is at the correct level throughout the homogenisation process.

We offer a wide range of pressure gauges from our partner WIKA for sanitary applications, which are essential for correct pressure measurement in the pasteurisation process of the dairy industry. These gauges are designed to withstand high operating pressures. They are made of materials that resist corrosion and wear. They are available in different sizes and ranges, ensuring the right solution for all your specific needs. Our team of experts can help you with installation and calibration to ensure the accuracy and reliability of your pressure gauge.

Image: PG43SA-S diaphragm pressure gauge for WIKA sanitary applications
Image: PG43SA-D diaphragm pressure gauge for WIKA sanitary applications
Image: PG43SA-C diaphragm pressure gauge for WIKA sanitary applications

Milk storage: ensuring quality and freshness

Maintaining the quality of the milk in the tanks is crucial to producing high-quality dairy products. Two essential factors to consider in milk storage tanks are the level of the milk and its temperature.

Level gauges provide an accurate reading of the amount of milk in the tank, allowing operators to monitor the quantity and prevent overfilling or underfilling. Overfilling can cause milk spillage, which is not only a big waste but also a hygiene risk. On the other hand, underfilling can cause air pockets, which can cause spoilage and reduce the shelf life of the milk.

Our company offers high-quality WIKA level gauges , which are of fundamental importance in the dairy industry, more specifically during the pasteurisation process. These meters are designed to accurately measure and display the level of milk in the containers. They are made of high-quality materials. Their resistance to corrosive environments makes them ideal for use in milk processing plants. Their easy installation requires minimal maintenance, which affects the smooth and efficient process.

Image: WIKA FLR-F Reed Level Converter (HACCP)

Temperature gauges, on the other hand, allow operators to monitor the temperature of the milk in the tank to ensure that it is stored at the correct temperature. This is essential to prevent bacterial growth and to maintain the quality and freshness of the milk. Milk can spoil if the temperature is too high, and too low a temperature wastes energy unnecessarily.

In our product range you can find WIKA temperature gauges which are essential for maintaining the correct temperature during pasteurisation in the dairy industry. Temperature gauges accurately monitor and display the temperature in tanks and pipes, ensuring that milk is pasteurised at the required temperature to remove harmful bacteria.

Image: TG58SA WIKA bimetallic thermometer

Efficient cheese and cottage cheese production with remote temperature control

Cheese curd making is a complex process that requires precise temperature control to achieve the desired texture and flavour.

In small dairies, dairy farmers often have multiple tasks during the production process, which can make consistent temperature monitoring difficult. This is where remote data loggers or remote memory units.

Using data loggers, small dairies can monitor the temperature when heating milk. They are also consistently reminded of the temperature reached by SMS.

Users can monitor the temperature and humidity in the production room without the need for manual checks and readings. This information is sent to the user remotely, by SMS or email, via smartphone or computer. This allows them to monitor temperature values and make the necessary adjustments from anywhere, continuously and reliably.

Data loggers warn of any significant temperature variations, which helps them to react quickly and prevent any problems with the final product.

Image: U0141M IoT wireless data logger for four Pt1000 external temperature sensors (probes) with built-in GSM modem

GOOD PRACTICE: ELPRO solutions in the dairy industry

At our company, we prioritise providing the highest quality products and services to our customers, which means finding solutions to any challenge that arises.

We were recently contacted by a customer in the dairy industry whose sensor had broken due to an incorrect choice of sensor material and mounting position.

It was found that the sensor was not able to cope with the cleaning agents required in the dairy industry, which caused the malfunction.

To solve this problem, together with the customer, we decided to install an ELPRO hygienic temperature sensor.

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Image:Customer sensor failure due to improper choice of material
Image: replacement with an ELPRO sensor TTU-HIG-050

We also successfully tackled a challenge from a customer who needed to measure and display the temperature locally on their milk pasteurisation exchanger.

Our team of experts recommended a temperature sensor TTU-GLA-LED as the perfect solution for their needs.

The sensor has been designed to provide accurate and reliable temperature readings in real time. The local display is designed for easy monitoring of the user’s temperature.

The analogue output function makes it easy to integrate with a control and regulation system. This app offers optimal temperature control throughout the pasteurisation process.

Our client was satisfied with our solution, which allows them to better and faster control the process and take appropriate action.

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Figure: Installing a temperature sensor at a customer’s site.

Conclusion

The dairy industry requires careful monitoring of temperature and other critical parameters. This is the only way to ensure that milk and milk products are safe to consume. With the right tools and equipment, dairy companies can ensure that their products meet legal requirements and quality standards.

It is very important that companies in the dairy processing industry work with qualified and experienced suppliers. This is the only way they can get the right equipment, services and support they need to operate efficiently and safely.

☏ Call us: +386 2 62 96 720

They are always available for opinions and explanations:

Aleksandra Lepenik, expert in temperature measurements

Measurement expert Zoran Lepenik

Authors Zoran Lepenik and Mojca Kugler
May 2023

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