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
A high-tech industrial evaporator in operation, showcasing advanced AI-driven optimizations with steam and bright lights.

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.

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