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Precision and Purity – Remote Dairy Pipeline Monitoring
The Challenge: Maintaining Purity and Efficiency Across Dairy Operations
One of our customers is a prominent producer of fresh milk and dairy products, operates a complex network of pipelines across its processing facility. These pipelines transport various dairy products (raw milk, pasteurized milk, yogurt, cream) at different stages of production, demanding absolute precision in flow rates and meticulous adherence to hygiene standards.
The challenge was clear: manual monitoring of these distributed RS485-enabled flow meters was inefficient and risked compromising product integrity. Operators had to physically check meters, leading to delayed data, inconsistent readings, and a fragmented view of the entire production flow. This lack of real-time dairy flow monitoring made it difficult to:
- Precisely control pasteurization times.
- Optimize filling processes for consistent product volumes.
- Detect leaks or blockages quickly, preventing costly product loss.
- Ensure efficient and thorough Clean-in-Place (CIP) cycles. This manual approach hampered customer’s efforts towards holistic dairy process optimization, leading to potential spoilage, wasted resources, and increased operational costs.
The Solution: Seamless Integration with Precisol’s RS485 Serial to IoT Edge Gateway
To overcome these critical limitations and achieve centralized, real-time visibility, our customer partnered with an automation specialist. The recommended solution involved strategically deploying Precisol’s RS485 Serial to IoT Edge Gateway throughout their facility. These industrial communication gateways were chosen for their proven ability to reliably convert RS485 based serial Modbus RTU data into MQTT packets, supporting remote monitoring via our cloud dashboard “PreciCloud”.
The implementation was designed for speed and minimal disruption to ongoing production. Our gateways were installed at each critical section of the pipeline network, directly connected to the existing RS485 enabled flow meters. Using our intuitive configuration software PreciCON, their engineers efficiently mapped the flow meter’s RS485 registers (e.g., liters per minute, totalized volume) to corresponding MQTT tags. This seamless industrial communication solution meant that the valuable data from every legacy flow meter became instantly accessible to the cloud dashboard, appearing as native wireless devices. This approach preserved customer’s investment in existing, functional equipment while modernizing their data acquisition capabilities.
Results: Enhanced Purity, Efficiency, and Cost Savings
The integration of Precisol’s RS485 Serial to IoT Edge Gateway transformed customer’s operations, delivering significant and immediate benefits:
- Real-time Process Control & Quality Assurance: Operators gained immediate, precise flow data across all product lines. This allowed for dynamic adjustments to pump speeds and valve positions, ensuring optimal flow rates for pasteurization, homogenization, and filling, directly contributing to consistent product quality and reduced batch variations.
- Reduced Product Loss: Instantaneous detection of abnormal flow rates or sudden drops signalled potential leaks or blockages. This enabled rapid intervention, significantly minimizing product spillage and spoilage, which directly impacted the bottom line.
- Optimized CIP Cycles: By monitoring flow during cleaning processes, customer ensured that cleaning agents circulated effectively and rinse cycles were perfectly timed, improving sanitation efficacy while reducing water and chemical consumption.
- Enhanced Operational Efficiency: The elimination of manual data collection freed up personnel for more critical tasks, while automated data logging simplified record-keeping and compliance audits. Overall energy consumption was reduced through optimized pump operation based on actual flow demand.
- Scalable and Future-Proof System: The successful integration demonstrated the scalability of the Precisol solution, providing a clear path for incorporating future sensors and expanding monitoring capabilities as the plant evolves towards full smart dairy production.
In conclusion, the strategic adoption of Precisol’s RS485 Serial to IoT Edge Gateway was a pivotal step for the customer. By cost-effectively integrating their legacy RS485 flow meters into a modern industrial network, Precisol unlocked critical real-time water data, enhancing operational precision, ensuring product purity, and driving substantial efficiencies across their complex dairy processing pipelines.
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Arima Leonardo
Electrician
Alex Piter
Designer
Mariya Komola
Developer
David Malan
Developer
Arima Leonardo
Electrician
Alex Piter
Designer
Mariya Komola
Developer
David Malan
Developer
