Rugged measurement technology for the dairy industry: The new V-Line
In 2016, one of the major dairies approached us in search of a competent partner for the plant’s measurement technology. The reason for contacting us was that some measurement points in the plant had proved extremely problematic, as the severe temperature fluctuations caused by the cooling and ultra-high-temperature pasteurisation of the milk regularly overwhelmed the measurement technology in use. After just a few weeks, most of the devices had to be replaced, as weld seams or diaphragms, for example, were failing. The extreme temperature fluctuations quickly led to material fatigue and put all the components used to the test.
The test quickly proved its worth
As experts in bespoke customer solutions and hygienic measurement technology, we took on the challenge and initially supplied the PASCAL Ci4 diaphragm seal with a clamp-type diaphragm seal for testing purposes: this combination is characterised not only by its hygienic design and extremely robust construction, but also by a particularly intuitive 4-button user interface. The diaphragms and welded joints are designed for the specific conditions in the dairy and can easily withstand significant temperature fluctuations. The device quickly proved its worth: weeks, months and eventually over a year passed without the need to replace the units. This success soon paved the way for a more extensive collaboration. A total of 1,000 flow measurement points were in place at one of the plants, all meticulously monitored by additional temperature and pressure gauges. For only strict monitoring and adherence to all process data can ensure consistently high quality when dealing with large production volumes. The plant in question has an average capacity of 100,000 litres of milk per hour – an enormous volume that must be continuously and precisely monitored. Following the positive experience with our devices at the critical measuring points, the pressure and temperature measuring devices at the flow measurement points were now also to be gradually replaced by devices from Labom.
Compact design – large display
In addition to the tried-and-tested PASCAL Ci4, we also had the opportunity to use the brand-new V-Line: this new range of instruments offers the same benefits and performance as the PASCAL Ci4 series – but in a significantly more compact design. Whilst the Ci4 still weighs approx. 1.4 kg (with threaded connection) and has a housing diameter of approx. 74 mm, the PASCAL CV4 pressure transmitter and the PASCAL GV4 temperature transmitter impress with a weight of approx. 0.7 kg and a diameter of just 59 mm. The V-Line devices combine a very compact design with a maximised display area. The intuitive 4-button user interface guides the user via a dialogue box displayed in various languages on the high-resolution, well-lit dot-matrix display. A special quick-setup feature makes it easy to get started and configure the devices. Furthermore, the temperature and pressure transmitters are visually identical: from the outside, the devices look exactly the same, which was important to the plant operator as well as the technical specifications. This ensures a uniform appearance. Unlike the critical measuring points we had previously equipped, however, there was no standard connection available for the flow measuring points. We therefore first had to design a new process connection tailored to this application. Once this hurdle had been overcome, a continuous replacement of the existing devices with ours began, a process that continues to this day: whenever a device fails, it is now replaced by one from Labom. Based on their previous excellent experience with the PASCAL Ci4, the dairy trusts our devices so much that they ordered the newly developed V-Line devices before a finished prototype even existed.
Continuous product optimisation
Today, around 1,000 of our devices are already in use across various plants at the dairy, and more are being added all the time. They are not only located at critical measurement points and flow measurement points, but also at the lactose filter systems, where continuous pressure measurements are used to monitor the condition and degree of contamination of the filters. All the measuring instruments used impress with their hygienic design, high-quality and hygienic surfaces, and ease of cleaning. Despite the customer’s high level of satisfaction, we are constantly optimising the products and adapting them even more specifically to the on-site production conditions. By using ventilation filters, the PASCAL CV4 pressure transmitter can, for example, be supplied with the improved IP 69K enclosure protection rating. This option is currently under discussion: the filters inside the measuring instrument, which compensate for pressure differences with the environment and thus prevent measurement errors, would then also be protected against splash water, such as that generated during high-pressure cleaning of the systems.
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