Case Studies

Plains Dairy Shifts to Numeric Computer Systems State-of-the-Art DSD/Route Accounting Solutions

Nestled in the heart of Amarillo, Texas, sits a state-of-the-art dairy processing facility known as Plains Dairy. From its humble beginnings – run by a single owner and supported by only 70 cows – to operating today as a subsidiary of Affiliated Foods, Plains Dairy supplies hundreds of thousands of gallons of milk each day to customers in West Texas, New Mexico, Oklahoma, Colorado, Kansas and Arizona. The dairy’s product line also includes brewed Red Diamond tea, Tampico punch, Culligan water and fruit drinks.


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Partial demineralization and concentration of whey permeate by nanofiltration

DOW was invited to participate in a competitive field trial comparing five Dairy nanofiltration elements available on the market. The purpose was to determine which elements provide the best overall performance concentrating and demineralizing lactose over a period of 12 months. The results show that FILMTEC™ NF245 membrane consistently outperformed the other elements and maintained the highest lactose rejection and highest salt permeability. Additionally, FILMTEC NF245 had 16 percent higher permeate flow than the competition.


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Dairy processing

Delkor’s KwikCool unit accelerates chilling process for dairy products

The equipment cuts vents into shrink-wrapped bundles of cultured dairy products, allowing high-pressure refrigerated air to mix with the warm air emanating from the packaged product so the product cools quicker.

A new end-of-line piece of equipment developed by Delkor Systems shaves off as much as 30% of the time required for cultured dairy products to cool between packaging and shipping


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Alternative energy

Cheesemaker turns waste whey into energy

A Wisconsin cheese producer is utilizing a two-stage digestion process to convert its high-strength waste to biogas while reducing the cost and liability associated with using land application methods to handle its high-strength wastes.

Anaerobic treatment technologies are a cost-effective means of managing high-strength organic wastes, while avoiding expensive treatment costs imposed by municipalities and contending with increasingly strict environmental regulations


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Better than a crystal ball

Dannon analyzes data to optimize forecasting and get product on the shelf

The yogurt maker needs to ensure product availability at the shelf at the right time and minimize waste through optimized forecasting.

The yogurt business is a highly competitive $7 billion industry fueled in part by the dramatic surge in demand for Greek yogurt. Dannon is using predictive analytics and trade planning from IBM to analyze shopper behavior, leading to improved predictions on product volume and profitability.


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Production efficiencies

Cheesemaker's automated packaging line increases throughput by nearly 10%

MDS Foods implements Ossid’s labor saving packaging solution to increase throughput, improve accuracy, and save time.

MDS Foods’ goals were to increase the production line’s capacity and profitability as well as give the company the capability to bring more product categories, predominately packaging smaller chunks of cheese, into its facility.

MDS Foods and Ossid collaborated on developing an automated system to replace the manual operation. 


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Green energy

Pearl Valley Cheese goes green with GEM Energy power system

Pearl Valley Cheese Co. is going green with an energy-saving power system that runs on cheese manufacturing waste water.
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FFS technology

Synerlink is a Chobani partner in the yogurt maker's new Idaho plant

In less than one year the engineering team delivered the first complete packaging production line to Chobani’s new yogurt plant in Idaho.

Synerlink engineered the complete form-fill-seal packaging lines in Chobani's new Twin Falls, Idaho, plant. The yogurt maker produces its Bite and Flip cups here.


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Stretch wrapper’s integrated scale provides EZ path to more efficient, lower cost shipping

Patent-pending EZ Weigh stretch wrapper uses turntable scale to save time, labor and BOL adjustments.
Louisville, KY, February 2013 – Rising fuel costs and related surcharges continue to increase trucking costs, so the last thing a shipping manager needs is additional fees for improperly reporting the weight of shipments. On top of that, strict adherence to truck arrival and loading schedules has shippers looking for ways to streamline shipment processing, while balancing the needs of producing safe, secure loads and keeping labor costs down.
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Techniques

PBI finds a fluid bed processing system works most efficiently

A new food granulizing line fits a restricted space with circular fluid bed processor

Agglomeration required a third process line but the opportunity meant more business. PBI had to solve the challenge of fitting a new line that includes equipment to moisturize, agglomerate and dry the material in a plant of 27,000 square feet.


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Velvet Ice Cream Co., Utica, Ohio

Velvet Ice Cream built its reputation on making premium products that adhere to the standard of identity for ice cream. Its lines consist of premium, all natural, churned (low-fat), no sugar added, novelties, sherbet (in cups and in push-up tubes) and a controlled ice cream brand for grocery store customers.

BehindtheScenes

This photo gallery contains additional, unpublished photos of dairy processing facilities featured in Dairy Foods magazine. To view more Behind the Scenes galleries go to our archives page!

11/18/14 2:00 pm EST

Harness Your Product Inspection Program to Save Money, Ensure Quality and Drive Efficiencies

Consolidation in the dairy industry is raising the bar on innovation and driving efficiencies to ensure competitiveness. One area often overlooked is the role that the right product inspection program can play in supporting the organization’s overall business goals and protecting brand reputation. Drawing on best practices in metal detection, X-ray inspection and checkweighing, this session will cover criteria to help determine the right technologies to employ for a given product and packaging type for high-value, perishable dairy products.

Dairy Foods Magazine

dairy foods october

2014 October

A look inside 100-year-old Velvet Ice Cream; Plus we look at four cheese processors with award-winning artisan and farmstead cheeses.

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Tharp & Young on Ice Cream: An Encyclopedic Guide to Ice Cream Science and Technology

An at once an all-inclusive guide to the meaning of hundreds of technical terms and ideas needed for ice cream manufacturing, as well as a practical introduction to the ingredients, freezing methods, flavoring, and packaging of ice cream, sherbet, sorbet, gelato, frozen yogurts, novelties and many other kinds of frozen desserts.

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