Optimizing Clean-in-place cycle time
Benefits
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| Reduce CIP cycle times | Reduce machine downtime | Reduce water consumption |
Project Goal
As part of their corporate philosophy, Emmi Roth believes cutting waste, emissions, and water consumption are part of their responsibility to act as stewards of sustainable growth and a healthy planet. They want to provide a positive impact on the cheese industry to balance sustainable practices with cheese production. They set a corporate goal to reduce their water usage by 15% by 2027. This initiative drove the research into how they could gain insight into where water usage was occurring, so they could identify inefficiencies to optimize in production processes.
As of October 2022, Emmi Roth surpassed that goal and decreased water consumption per pound of cheese by 57%.
Results
- Reduced 14-minute cleaning cycles to 10 minutes
- Reduced 12-minute cleaning cycles to 9 minutes
- Reduced downtime by 25%
- 1.2-1.5 million gallons of water saved per year
The significant time and water savings helped Emmi Roth meet corporate sustainability goals ahead of schedule.
Analyzing the cleaning process
The Plant Manager at the Emmi Roth Wisconsin facility identified the clean-in-place (CIP) cycle as a significant source of their water consumption. Each step of the CIP cycle was set for a specific time to ensure it was effective in washing, sanitizing, and rinsing. The cycle length was determined with extra time built-in as a measure to ensure that no residual chemicals were left behind after a cycle, and to ensure that the cleaning process was fully completed between batches. Reducing any risk of contamination was important to ensuring batch quality and food safety.
However, a time-based interval meant that inefficiency was accepted as part of the process. With the robust performance and affordable per-instrument price, ifm conductivity sensors were installed at multiple points along the process. Conducitivty measurements provided data that each step of the cycle had completed and that only clean rinse water was flowing through the line. This allowed Emmi Roth to reduce each cycle time by 3-4 minutes. This reduced water consumption while also bringing an additional layer of verification that all chemicals had been safely removed from the line at the end of the cycle. This meant that they could change from a time-based interval cleaning cycle to a performance-based cycle.
Digital data with IO-Link
This application was made possible using the IO-Link technology embedded in the sensor to provide data in real-time. In addition to providing more accuracy with purely digital signals, the IO-Link conductivity readings allowed Emmi Roth to verify that the rinse cycles had fully completed and the water flowing through would not risk any contamination. The real-time access to data ensured food safety, highlighting the potential of using data to make more informed decisions.
ifm IO-Link masters come with a separate IIoT port with a dedicated IP address for the IT infrastructure. This works in any number of dairy processing applications without affecting the machine control side of the system. This unique approach allows you to send process data directly to higher level software systems while bypassing any interference with the PLC.
Getting started
Dairy companies can reduce their carbon emissions by analyzing how even small process changes can increase efficiency and reduce consumption of resources. With increased access to process data, facilities can make the switch from time-based monitoring to instrument-based monitoring, saving resources and reducing their environmental impact. At ifm we are committed to helping dairy producers embrace sustainability while maintaining product safety and quality above all else. By leveraging the power of our automation solutions, dairy facilities can make informed decisions, optimize processes, and contribute to a more sustainable future.
