October 2019

FOOD AND BEVERAGE n Cheesemaker turns to PLCs to expand G arstang-based Dewlay Cheesemakers was founded in 1957 by George Kenyon and is now run by his grandchildren. Over the years, the company has earned a reputation for its award-winning Lancashire cheeses, while its recently developed red Leicester, Caerphilly, Cheshire and Derby cheeses won prizes at the 2018 International Cheese & Dairy Awards Cheesemaking relies on a detailed understanding of the mechanisms governing changes in the curd as it is processed. Being able to monitor these key process parameters simultaneously for multiple batches and modify them promptly when needed, was crucial to moving Dewlay’s business forward. It needed a responsive, but easy-to-use, automation platform that would allow the subtleties of the cheesemaking process to be retained, while introducing the adjustments needed to deliver a consistent end-result. Dewlay’s production teammonitors the various cheese vats where pasteurised milk is processed by starter cultures. The milk goes through a cycle of stirring, cooking, setting, cutting and whey removal. This induces coagulation and syneresis to produce the curd, which is then processed until it achieves the required consistency and pH value. Next, it is sent downstream for further whey removal, before being formed or moulded and packaged ready for the maturation process. The composition of the milk and the bacterial activity are influenced by environmental factors such as weather patterns, feedstocks, plus the cows’genetics and physiological make-up. Given all of these variables, producing dairy products of a consistent high quality is a huge challenge. “We believe cheesemaking is a mix of art and science as it relies on living organisms,” explains Dewlay’s operations director, Richard Jones.“We need to be able to address this variability by having access to key process parameters and curd quality attributes, as well as by responding quickly to optimise the reactions taking place within the vats. “We see increasing the varieties of cheese we offer, while maintaining our artisan qualities, as an ideal way to expand the business,”he adds.“However, it makes the tracking and monitoring of each vat even more challenging. In fact, the family-owned business uses 20 different cheesemaking recipes, which can vary in the ingredients used and in the processing sequences. “Ours is a fast-paced production environment simply because we have so many cheese vats at different stages of the production cycle, following individual recipes,” Jones continues.“Our cheesemakers had been doing their best to keep track of timing and procedures manually for all of the active vats by relying on their memory, continuously looking at the clock, and making notes. However, this approach is not optimal and doesn’t support continuing growth.” To address these issues and ensure consistent quality throughout the year, Dewlay decided to install an automated control system. One that would help it to monitor its vats by providing live, accurate, actionable data, without limiting their ability to intervene and modify the curd production process. To develop a suitable system, the company contacted a local system integrator, Tritec Developments, which worked with Mitsubishi to help create a bespoke control system. The components were supplied by LC Automation. “This was not a straightforward automation solution, but rather an implementation mindful of the cheesemaking art,”says Richard Jones.“To define our needs and deliver the right solution, Mitsubishi Electric worked closely with us to add all the relevant information on the cheesemaking process into its project management software and was able to test the software and its corresponding hardware off-line and then quickly refine the program on-line.” The resulting system now allows Dewlay’s cheesemakers to monitor different cheese vats simultaneously, receive alarms, and adjust the process parameters in real time. Their primary interface is a Mitsubishi GOT2000 touchscreen HMI, which is networked to a Melsec FX3 PLC. The PLC collects the process data from in-line temperature sensors, indirectly monitoring coagulation and syneresis, and thus determining progress in the cheese vats. The control system quickly met Dewlay’s expectations by ensuring flexible operation and simple process tracking. It has allowed the cheesemaker to expand by increasing the number of vats that it can monitor, as well as the number of recipes in use. This allows existing products to be produced more efficiently, as well as perfecting new ones that can then be added to the production schedule. The upgrade has also resulted in increased productivity and efficiency. n Dewlay’s cheesemaking operations are now controlled and monitored via a PLC linked to touchscreen HMIs ® www.acorn-ind.co.uk T: 0800 8766 441 E: enquiries@acorn-ind.co.uk PROACTIVE FOOD SAFETY prevent the harbouring and ingress of bacteria with SKF Food Line Square 4-bolt Flanged Unit Pillow Block Unit Oval 2-bolt Flanged Unit Your authorised SKF distributor

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