Optimizing Whey Permeate Evaporator Throughput in Dairy Processing
Executive Summary
Process Point successfully implemented an advanced optimization solution for a large multinational Dairy company’s lactose processing plant. By enhancing the whey permeate evaporator throughput, we significantly improved operational efficiency and product quality.
Client Profile
- Industry: Dairy Processing (Nutritional and Healthcare Products)
- Location: North America
- Production Capacity:240 KT per annum of Whey permeate processing30 KT of Lactose production per annum
- 240 KT per annum of Whey permeate processing
- 30 KT of Lactose production per annum
Challenge
Optimize the whey permeate evaporator throughput in the lactose processing plant to improve efficiency and product quality.
Solution
Process Point developed and implemented a data-driven optimization strategy:
- Model Development: Created and tested multiple models on the plant floor
- Strategy Optimization: Identified "Strategy 4" as the most effective approach
- Performance Improvement: Focused on enhancing evaporator performance
- Throughput Increase: Optimized dry basis throughput of the permeate evaporator
Key Features
- Plant floor testing of developed models
- Implementation of the most effective strategy (Strategy 4)
- Focus on maintaining product quality while increasing throughput
Results and Impact
Our AI-driven solutions have led to remarkable improvements in operational efficiency and cost savings. By optimizing the permeate evaporator, we have achieved substantial gains in throughput and performance.
- Increased dry basis throughput of the permeate evaporator by over 15%
- Maintained solid content between 60-65% (w/w)
- Significant improvement in evaporator performance
- Projected savings of over 10 million dollars per year when deployed across all 4 plants
Conclusion
Process Point’s data-driven solution significantly enhanced the client’s lactose processing efficiency, increasing evaporator throughput by 15% while maintaining product quality. This optimization showcases our ability to deliver substantial value in dairy industry operations.
