Sunday 16 December 2012

Success Story of Amul



Dairy Automation Pvt Ltd (formerly edoodh solutions pvt. ltd)   Plant intelligence solution helps Amul Satellite Dairy for Delivering Fresh Milk Products in Region of Maharashtra

This dairy was refurbished and upgraded to a fully automatic (Integrated) plant from a manual dairy. It was done with an Integrated Computerization Automation solution using a plant-wide network of PLCs and PCs over 10/100 mbps fast Ethernet. This plant intelligence system provides full integration, trace ability and visibility into actionable plant data.

The complete automation is done on turnkey basis by M/S Dairy Automation Pvt. Ltd. (Formerly edoodh solutions pvt. ltd.), which is an Indian company with the technical base in Houston (USA), with mutual support of technical and engineering staff of Amul Satellite Dairy.

This plant belongs to Kaira District Co-operative Milk Producers' Union Limited which was the First Co-operative Milk Producers' Union started in Gujarat, formed in Kheda district.



Its success, also known as Anand Pattern led to creation of District Co-operative Milk Producers' Union at each district, created Amul (Anand Milk Union Limited) in 1946. And AMUL is biggest dairy brand in Asia and also the largest exporter of dairy products in the country
Dairy Automation has successfully introduced the automation and computerization of entire milk processing. Right from reception of Milk in Tankers to operation of chillers, pasteurizers, standardization, and dispatch for packing. All milk processing operation are controlled and closely monitored by operator sitting in air-conditioned centralized control room.

The Milk Process







Every evening, raw milk is delivered from the farms to the dairy and milk processing begins. At each stage of the process, critical information — such as pasteurization temperatures and flow data from the cleaning process Must be tracked and recorded. Automating data collection has significantly increased the amount of control managers have over the day-to-day operation of the dairy.
“The previous dairy systems were not automated,” Joshi (Plant Manager) said. “The PLCs were not connected, there was no reporting, and there was no traceability. It was also possible to overfill a tank, leading to unnecessary waste and, because the process was highly manual, it was time-consuming And in-efficient. “Previously, in order to access vital process information,
We had to go through piles of reports. But the new system automates everything, and we can now provide critical process information to the people who need it to make important business decisions.”



“Traceability is mandatory and has been for many years. But, when you use a paper-based system, it takes a lot of time, slowing response time,” Joshi said. “With the previous system, it would take hours to locate the appropriate data to resolve a customer complaint.

Dairy Automation’s plant intelligence system has enabled Amul Satellite Dairy to enhance its reporting capabilities to more quickly address customer complaints. We are now able to access reports more quickly, which allows us to identify any errors in the manufacturing process that
Necessitate a product recall. “In addition to faster response times, this new level of trace ability actually reduces the risk of having to recall a large amount of milk processing information because we have detailed information of each shift. All we need is a date and shift to know exactly what time a given product was produced and what ingredients were used to make the product. We can then create a report and see exactly what was going on at that time and then implement a limited recall if necessary.

The One Amul Strategy

One of the drivers behind the adoption of an effective plant intelligence system was a directive from Amul corporate headquarter in Anand, which wanted better visibility into the performance of all its diverse plants. This

Strategy is called “One Amul”.
All the extracted reports are sent to headquarter on daily basis, this make it easier for our corporate headquarter to follow up on business operations on a regular basis — be that daily, weekly or monthly.

Implementing the Dairy Automation plant intelligence solution has also helped Amul Satellite Dairy improve its ability to follow up on quality issues. The organization now has documentation for the cleaning and filling processes as well as a variety of temperatures, enhancing the dairy’s ability to monitor the manufacturing process and ensure high product quality.





Dairy Automation Pvt. Ltd. 
www.dairyautomation.net





Saturday 15 December 2012

Success Story of Gokul


Dairy Automation Pvt Ltd's (formerly edoodh solutions pvt ltd)  Fully Computerized CIP and Plant wide automation system has enabled us to closely monitor and control our critical

‘GOKUL’ one of the biggest brand of quality Milk and Milk products in India is  having their Milk processing and packaging unit Vashi (Navi Mumbai) to cater Mumbai region. Handling capacity of this plant is appox 5.5 lac litres/day.

 Dairy Automation Pvt. Ltd. (Formerly edoodh solutions pvt. ltd.) has provided ‘Fully computerized CIP System’ having 04 Tanks and 03 running circuits. Along with this entire plant has been upgraded to semi automation; which includes milk reception, chillers and storage tank automation using a plant-wide network of PLCs and PCs over GIGABIT Ethernet. This plant intelligence system provides traceability and visibility into actionable plant data and CIP parameters.

The complete project of ‘Fully computerized CIP system’ and ‘semi-automation’  is done on turnkey basis by M/S 
 Dairy Automation Pvt. Ltd., which is an Indian company having technical base in Houston,TX (USA), with mutual support of technical and engineering staff of Amul Satellite Dairy.
Dairy Automation has implemented unique CIP system which takes care of their plant specific hygiene  it includes CIP of packing machine through injection tubes in re-circulation and recovery of cleaning agents back to CIP unit. This system also takes care of CIP needs for reception line, chillers and road tanker etc. All operations related to CIP and other processes are controlled and closely monitored by operator sitting in air-conditioned centralized control room.


Fully Computerized CIP (Cleaning in Place)


Complete CIP system includes tanks, valves, PHE’s, pipelines, dosing system, packing machine CIP through injection tube and road tanker CIP has been provided by Dairy Automation Pvt. Ltd. on turn-key basis.

This State-of-the-art CIP system is having 04 Nos. of tanks and 03 circuits which mean simultaneously CIP of 03 destinations can be done at a time. All operations of this CIP system can be done through computer screen like configuration of CIP recipe kitchen, start and stop operations, auto-dosing, chemical recovery settings, CIP supply flow control, operation of return pumps, level control of each tanks etc.

CIP system is capable of generating miscellaneous tabulated and graphical reports related to CIP traceability, effectiveness, recipe formation, recovery settings and usage of water and chemical done for conducting a specific CIP.


INTEGRATED CIP CONTROL SYSTEM – THE PROCESS


All CIP operations can be performed from the computer screen and it also displays the real-time status of complete CIP operations including valve positions, pumps, level, concentrations, temperature, destinations etc.

By utilizing high-tech, high-quality instrumentation in CIP, valves, pneumatics and process automation services. It facilitates all the CIP related requirements to formulate into Recipes to fulfill all the cleaning requirements.
The operation of CIP system is very easy and user-friendly only minimal training is required for existing operators. User has to only select the pre-defined recipe and click on START button to initiate cleaning operation.
The computer also records operating data that can be reviewed. For example, if operator wants to review CIP cycles, the system will display previous records for CIP conducted like CIP circuit, cycle duration, minimum wash time, temperature, concentration, destination cleaned etc.

Dairy Automation Pvt. Ltd. 

www.dairyautomation.net


Thursday 13 December 2012

Success Story of Mahanand Dairy

Mahanand adopt Dairy Automation


The modernization was done by the implementation of an Integrated Computerization/Automation solution using a plant-wide network of PLCs and PCs over GIGABIT Ethernet
The complete project is done on turnkey basis by M/S Dairy Automation Pvt. Ltd. (Formerly edoodh solutions pvt. ltd.) which is an Indian company with the technical base in Houston (USA), with mutual support of technical and engineering staff at Mahanand.

Mahanand is the first dairy in the country to be computerized with the existing facility and equipment's Dairy Automation has successfully introduced full scale automation of all critical processes like Milk reception, chilling, storage in raw milk silos, operation of pasteurizer, separator, homogenizer, milk dispatch to Packing section and Tanker, batch formation and CIP with modernization of equipment.

Maharashtra Rajya Sahakari Dudh Mahasangh, Maryadit (MSRSDMM) is an apex federation of District/Taluka milk unions in the state of Maharashtra. Since its establishment it has gained the reputation of a federation dedicated to quality of milk and development of milk farmers from each and every corner of Maharashtra state. At present MRSDMM has 81 member unions with 24,000 primary milk societies. Total members registered are 24 lakh, which include approximately 25,000 women members.



How does it work?



With this the entire processing operations are carried out from an air-conditioned control room. Information of milk at various stages are closely monitored, recorded and controlled by the computers and PLCs. On top of this there is an umbrella MIS (Management Information system) to maintain the record and communication to the laboratory for quality assurance. Automation is introduced at various stages like milk storage in silos; centralized monitoring and control of all pasteurizers (maintained exactly at required levels and ensures proper pasteurization). Milk silos are connected with the quality control laboratory for on-line approval process.

Cleaning of one lakh litre capacity silos is also done by computer. In ordinary systems, it is difficult to monitor cleaning and maintain quality standards. At Mahanand, all parameters such as concentration of cleaning agents and temperature of water to be used for rinsing are stored in the system with no room for error. In totality complete system offers qualitative benefits and apart from this increased working efficiency, saving in energy, water and recovery of cleaning solutions.

“It’s critical that technology solutions control critical Milk processing activities, gather information, provide analysis, notifications and reports, and communicates to plant management.” 

Entire Plant is now working on Full Scale Automation. Right from Reception of Milk in Tankers à Pre-chilling of Milk through chillers à Storage of Raw Milk à compete milk processing line i.e. Pasteurizer, Separator / clarifier, Homogenizer etc. à Storage of processed Milk à Batch / lot preparation à Dispatch of Milk to Pre-pack section and Tanker, all CIP related activities etc.


Communication Infrastructure -







Dairy Automation Pvt. Ltd. 
www.dairyautomation.net

 

Tuesday 27 November 2012

Who are we

DAPL (formerly e-Doodh Solutions Pvt.Ltd) has emerged as a leading innovator and implementor of cost-effective cutting-edge technology based solutions for the Dairy industry.


Dairy Automation Pvt. Ltd. 

http://dairyautomation.net

CIP

 Cleaning Solutions from Dairy Automation

Significant features of our CIP systems

DAPL being a leader in offering and implementing total automation solutions for the dairy/brewery and beverage industries, has also innovated cleaning solutions for the cleaning of process equipments,tanks,lines,filling lines etc.This fully computerized CIP system is called the CLEAN MASTER and is available in 4 skid mounted models. The CLEAN MASTER performs all the tasks assigned to it with speed and accuracy and at the same time proves to be cost-effective.

DAPL offers the fully computerized CIP system on a turnkey basis which includes design,supply, installation and commissioning.This also includes supply of tanks, valves, pipeline assemblies, instrumentation, control panels and ethernet-linked computer display. The entire system is offered as skid-mounted units along with total integrationof your existing plant to facilitate very effective cleaning.


Various skid-mounted CIP systems

Single Tank System

This is a simple and low cost unit which is specially suitable for plants with low budgetary requirements and simple technical operations. It's simple and skid-mounting feature offers a space-saving option with the facility of portability.

Two Tank System

This skid-mounted unit is for dairies, breweries and beverage plants with a medium budgetary allocation and slightly complex processing facilities.

Three Tank System

This skid-mounted is for slightly high budget allocation plant. Depending upon the technical challenges of the plant ,this system offers wide options in terms of CIP circuits (1,2,3 circuit) to meet the day to day operations.

Four Tank System

This amazing cleaning solution fulfills all requirements of heavy load of CIP operations through a 4 circuit system making it easy for the CIP's of 4 different destinations to be performed simultaneously. It's significant features include speed, accuracy,cost-effective,chemical-r ecovery, operational ease, upgradable, energy efficient etc.


Dairy Automation Pvt. Ltd. 

http://dairyautomation.net




Our Automation Services

Processing Solutions
DAPL is credited in innovating and designing a novel concept in total computerization in the dairy industry. Rightly called 'Dairy Dashboard' it performs all the routine and complex operations of a dairy at the click of a mouse from a centralized process control room making the right move every time in ' cost-driven operational excellence'.Similar solutions are also available for brewery and beverage industries.

Processing and Cleaning Solutions
At DAPL we have complete integrated software solutions for the smooth running of plants- Be it in the areas of product processing or in the CIP's of various lines,tanks concerned with production.Also, we offer to upgrade and/or expand your plant operations with the existing equipments set up by incorporating the latest solutions to provide a cost-effective automated plant with an emphasis on energy savings.We are working continually to innovate new products based on need-based ideas and plan to come up with new,unique and cost-driven solutions for the dairy/brewery and beverage industries.

Cleaning Solutions
DAPL presents an amazing cleaning-solution-based- equipment system that performs all the tasks with speed and accuracyand at the same time proves to be cost-effective too.This system is called the 'Clean Master' and is available in 4 skid-mounted models depending on the technical and budgetary requirements of the plant.

Automation upgradation
This service is for plants with an installed base of exixting old/ obsolete equipments which are not in synchronization with the present processing needs.

MES Applications
The Manufacturing Execution System is suitable for manufacturing and equipment performance,production execution,quality and tracking.

ERP Integration Services
This is for automation equipment offering maintenance and support programs,spare parts etc maintaining and improving conditions to maximize plant up-time.

Automation Services
This is to link plant floor automation systems to customer's enterprise.

Automation Systems
This system consists of PLC and HMI for plant-wide automation.


Dairy Automation Pvt. Ltd. 




Why a fully computerized CIP system ???


The fully computerized CIP system offered by DAPL is a future-proof investment, offering short payback time with significant savings in operation costs and it gives the opportunity to reconfigure,expand and upgrade if needed.
This system helps to keep your entire plant clean and hygienic through centralized and integrated CIP software with ease of operational cost cleaning programs make economical use of cleaning agents and water and allows you to restart the production as quickly as possible.


Dairy Automation Pvt. Ltd.