XDS Process Analytics is the newest generation of FOSS NIR process analysers for the dairy industry. It allows efficient, in-line analysis and real-time control of Butter, Powders, Whey Protein Concentrate, Milk Protein Concentrate, Processed Cheese, Cream Cheese, Quark/Fromage Frais, Mozzarella and other dairy products. Product quality, yield and raw material savings (for example fat and protein) can be improved significantly.
The XDS Process Analytics™ solutions for in-line measurement and process control of dairy production can be installed directly in dairy environments. It is standard NEMA / IP65 rated. It comes with start-up calibrations for all major dairy applications.
The analyser concept combines a high-energy, full-scanning NIR monochromator with high-quality fibre optics and sample probes. The probes are installed in the process flow line for either transmission, reflectance, transflectance or direct light measurement. The sensors are made of food grade materials and they resist high temperature, high pressure and CIP liquids.
Configured, standard solutions for the common dairy applications are available with application-dedicated probes. The choice is easy. Length of the fibres, environmental temperature and physical vibrations as well as communication options between the analyser and the PC (and between the PC and the process PLC) are discussed individually. For new applications, the analyser configuration is defined according to laboratory studies and/or feasibility studies in the field.
Applications and parameters
Application
Most commonly
Other
Butter
WPC
Mozzarella
Cream cheese
Powder
Processed cheese
Quark (fromage frais)
Moisture, Fat, SnF, Salt
Protein/TS
TS, Salt
Moisture
Moisture
Moisture
Moisture
pH
Ash
pH
Fat
Fat, Protein
Fat
Fat, Protein
Repeatability The repeatability of measurements with XDS Process Analytics™ is to the hundreths of a percentage, i.e. much better than duplicates in standard reference (primary) methods. Process conditions will affect achievable repeatability for in-line applications.
Accuracy Expected performance accuracy is ≤ 1½ (to 2) times the reproducibility of the reference (primary) method.
Payback on investment Calculation of pay back time varies from customer to customer and from application to application. But in general, it is easy to calculate the tangible benefit of a FOSS process control solution. In many instances, profit improvement (opportunity to reduce safety margins and production costs or simply increase yield) results in pay back periods of less than a year.
Generally, the larger the size of the dairy, the larger the advantage to be gained with XDS Process Analytics. However, mid-sized dairies may also gain from the system.
Profit improvement example - Butter In-line control in butter means more moisture and possibly also more salt and SnF. Yearly production profit increases by > Euro 105,000 if the said component can be controlled at a 0.10% higher level (price of 1 kg butter, 1 kg of brine (50% suspension) and 1 kg SNF is Euro 0.25, 1.80 and 3.50 respectively).
Profit improvement example - Quark 10 million kg quark production requires a minimum of 17.5% solids after the quark separator and costs of processed, fermented skim milk per kg is Euro 0.15. With a Process Analytics™ solution, moisture can be controlled automatically 0.2% lower than daily average today and additional yearly profit can be calculated to > Euro 90,000.
Profit improvement example - Powder In powder production, product composition can be controlled continuously in-line and moisture could be increased by e.g. 0.2% in 20 million kg of whole milk powder per year. With a price of Euro 2.30 per kg powder, extra profit can be calculated between Euro 95,000 and 78,000 per year depending on fat adjustment in the milk standardisation.
The newest generation of NIR process analysers for the dairy industry
