Dairy Industry

The Dairy Industry can be challenging: a constant pressure to decrease conversion costs and improve yield, with strict food safety regulations and varying milk composition. Nevertheless you need to produce the expected volumes and – even more challenging – a consistent end-product quality. Whether you produce cheese, milk powder, infant nutrition, whey products, yoghurt, deserts, or any type of fresh or long-life milk, the production process conditions are demanding and require full control at all times.

Meanwhile you’re focused on getting the most out of your installations: trying to increase your volumes and dealing with unplanned downtimes. And what about optimizing yield, moisture content, end-product weight control, and improving your product quality performance?

Yes! It is a challenging game. And to perform as the best in this game you need to have a perfect insight into the characteristics of your incoming milk, processing conditions within your factory, operator observations, and in the end your product quality performance. Dealing with kilograms and liters in parallel, calculating fat- and protein- content at all times, and – in the end – knowing exactly your actual cost-price per product and batch.

The HAI smart4industries software collects and calculates all these data. It supports operators with real-time dashboards, trends and early warning systems. It supports production and quality staff with real-time dashboards and reports and in-depth analyses for trouble shooting and optimization. Whilst reducing complexity, it improves and speeds up batch-release.

The reactions from the field are laudatory

Cheese technologist

We have substantially improved our yield in our cheese factory. How? With the HAI software we collect and monitor in-line measurements on cheese before brine. This helps us to identify at an early stage if we need to make adjustments to our processes. We have improved our capacity to produce close to target on moisture content. This is an immediate and substantial saving.

Plant manager

I need reliable plant performance reports, which give me a clear understanding of what happens in production. We used to make decisions largely based on experience and intuition. The real-time HAI dashboards and reports help us to make more data-driven decisions.

What you’ll have

One central factory database with production & quality data from multiple sources. It collects data in real-time from SCADA/PLC/Historian and ERP-systems (from SAP, Infor, Microsoft, etc.). It also includes data from LIMS, and In-line inspection equipment (like weighing scales, vision systems, metal detection, etc.). And don’t forget to include the External lab results (microbiology, product composition, …..), etc.
A paperless plant or digital factory. Include in the HAI-database all your current paper-based records for operator quality control, operator start-up checklists, operator cleaning records, energy monitoring, and other excel sheets. Also replace your current lab excel sheets by a data-entry screen in the HAI software (organoleptic tests, visual inspections, QA inspections, etc.)
Real-time Trending Dashboards, correlations and other SPC analyses for operator early warning, trouble shooting, process improvement opportunities, etc.
Dashboards that combine manual operator entry with data that is collected in real-time from other sources, such as: the lab or SCADA (this enables the operator to monitor data from other sources whilst entering hourly operator control checks in the same dashboard)
Operator dashboards that combine operator data with lab test results
Dashboards that include real-time reporting through real-time calculations of data that is collected in the database (like cumulatives per shift, product, run, or automatic calculation of duration of process steps,or caclulation of % out of spec/in-spec, from ltrs to kgs., etc.)
Use your in-line product quality measurements (like NIR, pH, moisture weights, etc.) for real-time predictive analytics on your end-product moisture, pH, weights, etc.
Connections to collect data from your lab instruments, like Milkoscan, Lactoscope, Foodscan, etc.
Automatic handling of QLIP sample requests, and analysis results
OEE on your process & downtime analyses
Real-time compliance display for process conditions & quality
Early warning system to prevent out-of-spec
Tracking & Tracing, exceptions reports, cost-price validation, etc.
A Plant BI-Tool for all your plant reports and dashboards

Your benefits

In case of any questions, quality issues or complaints: no more extensive searching in operator control records, SCADA, ERP, Excel and lab systems. All the information you need immediately available in one database: one mouse click away!
Real-time dashboards which help production and quality staff to immediately identify compliance and anomalies
Reduce rejected batches (wrong protein/fat ratio, visco, moisture, etc.)
Find optimum process settings for fast and stable production
Improve product quality consistency
Minimize downtimes/maximize speed/improve OEE
Reduce energy consumption
Optimize your CIP process and your maintenance strategy
Unparalleled insight into the performance of your production units for sterilisation, pasteurisation, coagulation, mixing, homogenization, (spray)drying, processing, cooling, cheese production, treatment, ripening and slicing, filling, packing, etc.

Simple, yet powerful

Avoiding complexity is one of HAI’s secrets for success. It’s easy to understand, easy to implement, easy to maintain and easy to extend to other production units and sites. Once the key-user has received a short training, the key-user is capable of managing the system with little or no support from the HAI experts.
Yet, the HAI software is very powerful: its generic features allow to have dashboards for multiple purposes: to monitor product quality, process compliance, production, OEE, utilities, cleaning and sanitation, transport, etc.
Analytics, correlation and trending becomes even more powerful once the data has been contexted

Simply available in the Cloud …. No capital investment …. Subscription-based

Smart Factory Cloud Computing Paperless Plant Lab HAIQPM

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