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Dairy

Case Study    

Hygienic Plant Upgrade Boosts Dairy Capacity by 50%

The Client

Our client is a major international dairy firm north of St Petersburg, Russia. The company specialises in the production of whole milk, sour cream and yoghurt food products, processed using a full suite of Alfa Laval technologies. 

The Challenge

To increase capacity, improve efficiency and comply with safety and hygiene requirements, Moloko, one of the largest producers of dairy products in the Nizhny Novgorod region, planned to upgrade its 50-year-old dairy plant located in the town of Gorodets.

To optimize plant operations, Moloko turned to Alfa Laval to plan, design and implement a plant upgrade to achieve more sustainable operations, reduce waste and drive more effective utilisation.

Operate Sustainably

Operate
Sustainably 

Reduce Waste

Reduce
Waste 

More Effective Utilisation

More Effective
Utilisation

The Solution

Alfa Laval provided Moloko with a broad range of dairy plant solutions to improve efficiency, reduce water and energy consumption, and reduce waste. This included hygienic Alfa Laval LKH centrifugal pumps to transport dairy products throughout the plant. Moreover, to reduce product waste, Alfa Laval Unique Mixproof valves equipped with ThinkTop control units were used in various piping systems. 

Before the upgrade, the plant processed approximately 70 tons of raw milk per day. Today plant capacity is up 50%. With more raw milk available, production of whole milk, sour cream, yoghurt and ryazhenka, a baked cultured milk that is a popular Russian breakfast drink, has increased substantially as a result. Significant reduction in utilities and raw material Upgrading the Gorodets Dairy delivers significant savings on water consumption and increased the utilization efficiency of both raw materials and electricity.

Alfa Laval LKH Centrifugal Pumps

Alfa Laval LKH Centrifugal Pumps

The LKH pump is a highly efficient and economical centrifugal pump, which meets the requirements of sanitary and gentle product treatment and chemical resistance.
Alfa Laval Unique Mixproof Valve

Unique Mixproof

Alfa Laval Unique Mixproof valves enable simultaneous flow of two products or fluids through the same valve without risk of cross-contamination. Their exceptional spillage free operation is compliant with most hygienic standards.
Wash Station
Alfa Laval EnSaFoil Agitators

Alfa Laval EnSaFoil Agitators

The Alfa Laval EnSaFoil agitator solution brings a modular tank mounted agitator system to the process industry. The agitator range is specifically designed to bring the maximum mixing effect through gentle controlled rotation yet the minimum of energy requirement.

ThinkTop Control Units

ThinkTop Control Units

The ThinkTop® is designed to ensure optimum valve control in conjunction with Alfa Laval butterfly, single-seat and Mixproof valves and it is compatible with all major PLC systems.

Wash Station

The Results

Water savings from the new process design and equipment add up to approximately 15%. More raw milk is put to better use, reducing waste and raising product yields. Electrical energy savings also amount to a significant 20%, thanks to energy-efficient equipment such as Alfa Laval EnSaFoil agitators, which deliver energy savings of up to 80%, and Alfa Laval LKH centrifugal pumps, which offer up to 30% or more energy savings compared to similar mid-range pumps.
Water Saving
0 %
Energy Savings from EnsaFoil Agitators
0 %
Energy Savings from LKH Centrifugal
0 %