ProSpect- Inline Dairy Process Control

ProSpect Inline Process ControlThe ProSpect inline analyser has been specifically designed for the dairy industry by Ametek Mocon. Uniquely, the ProSpect inline analyser brings real-time control of production and testing to milk-based process lines utilising the strengths of Transmission based Near-Infrared Analysis. With Real-time product composition information and control manufacturer.s can optimise production, quality and formula management in milk and dairy. With immediate milk analysis and accurate information about your dairy product blending and product composition you can adjust your processes to maintain your product consistency, reducing product giveaway, out-of-spec products and safety margins.

Better Process Control Equates to Increased Profit

 

 

About

ProSpect Inline NIR AnalyserIn-line Testing and Standardisation

ProSpect in-line process control has been designed with the dairy industry in mind. The ProSpect analyser delivers you a level of speed and precision in product testing unachievable with traditional laboratory testing. The ProSpect inline analyser is calibrated to the laboratory method, ensuring accuracy, but removing the representative sample issues, delays and costs associated with post-batch standardisation. With it's inline position, the ProSpect analyser automatically and continuously controls your correct milk and dairy product composition/ recipe.

Optimum Uptime, Thanks to Easy Maintenance 

Unlike alternative solutions, the ProSpect inline process analyser requires very little maintenance. The sanitary flow cell is integrated into CIP routines and doesn't need to be removed for inspection or calibration. Since the ProSpect analyser operates in-line there is no product waste during sampling and it is cleaned with the same chemicals as your process system.

The ProSpect inline process control requires very little routine maintenance ensuring your continual process control and giving you very high uptime. Scheduled Preventative Maintenance is only required annually.

ProSpect Inline Process ControlEasy to Install

The ProSpect in-line analyser is easily installed adjacent to your process system and with little downtime. Fibre optic cables are installed directly into your process line in a specifically designed hygienic stainless steel flow cell.

The ProSpect in-line analyser also seamlessly integrates into existing PLC/ Control Platforms in operation throughout the plant. Speedy implementation is easily achieved thanks to the pre-loaded calibrations that require only a small amount of localisation.

Robust Design

Specifically designed for the milk and dairy process environment, the ProSpect in-line analyser is enclosed in a hygienic stainless steel NEMA 4 sealed cabinet. With the manufacturer's company history steeped in process system design and manufacture they have been sure to design an analyser that tolerates everything a harsh process environment can throw at it including: vibrations, humidity and temperature fluctuations.

 

Simple to Operate

The completely automated in-line process control continuously compares multiple constituents and their concentration against production parameters, feeding required information to the Process Operator and to the integrated process control.

True Transmission Based Near Infrared Analysis for Unsurpassed Accuracy

At the heart of the ProSpect in-line analyser is the Near-infrared Spectrometer using an ultra high resolution diode array detector to deliver continuous, accurate analysis in transmittance mode. Transmission NIR has long been recognised as superior for in-line liquid analysis requiring high accuracy.

Calibrations

Calibrations have been developed for a wide range of milk and dairy products such as: MPC, WPC, skim milk, butter, cheese milk and cheese. To ensure a speedy implementation the ProSpect in-line analyser is pre-calibrated for multiple constituents including Fat, Protein, Lactose and Total Solids.

 

Model Options

ProSpect Inline Process ControlTransmission based analytical control solutions are recognised as providing superior analysis and precise measurement of liquids and slurries because the probes are placed within the constituent flow. Alternative solutions may measure only incoming or finished product or a smaller surface sample. ProSpect offers 3 different transmission analytical control solutions:

ProSpect TS1 - Single transmission spectrometer monitoring one process flow

ProSpect TM1 - Single transmission spectrometer monitoring two process flows for specific applications

ProSpect TD1 -Two transmission spectrometers monitoring two process flows

 

Milk Standardisation

inline milk standardisationMilk Protein Concentrate; Whey Protein Concentrate; Whey Protein Isolate. The ProSpect tests the milk for the Total Solids, Protein and Fat composition in the concentrate stream updating the PLC every 30 seconds.

The PLC uses the information from the ProSpect analyser to make continuous adjustments to the Ultrafiltration machine's ratio and diafiltration set points. By using the information supplied by the ProSpect analyser and manipulating the critical set points on the UF machine you can control the Protein and Total Solid Levels.

 

In-line Milk Testing

The ProSpect milk analyser delivers you a level of speed and accuracy in standardisation unachievable with traditional laboratory testing. The ProSpect milk analyser is calibrated to the laboratory method, ensuring milk testing accuracy, but removing the representative sample issues, delays and costs associated with post-batch standardisation. With it's in-line position, the ProSpect analyser automatically and continuously controls your correct product composition/ recipe.

Calibrations

Calibrations have been developed for a wide range of milk and dairy products such as: MPC, WPC, skim milk, butter and cheese. To ensure a speedy implementation the ProSpect is pre-calibrated for multiple constituents including Fat, Protein, Lactose and Total Solids.

Better Process Control Equates to Increased Profit

With immediate, accurate information about your blending and product composition you can adjust your processes to maintain your product consistency, reducing product giveaway, out-of-spec products and safety margins.

Optimum Uptime, Thanks to Easy Maintenance

Unlike alternative solutions, the ProSpect analyser requires very little maintenance. The sanitary flow cell is integrated into CIP routines and doesn't need to be removed for inspection or calibration. Since the ProSpect analyser operates in-line there is no product waste during sampling and it is cleaned with the same chemicals as your process system.

The ProSpect analyser requires very little routine maintenance ensuring your continual process control and giving you very high uptime. Scheduled Preventative Maintenance is only required annually.

Easy to Install

The ProSpect analyser is easily installed adjacent to your process system and with little downtime. Fibre optic cables are installed directly into your process line in a specifically designed hygienic stainless steel flow cell.

The ProSpect analyser also seamlessly integrates into existing PLC/ Control Platforms in operation throughout the plant. Speedy implementation is easily achieved thanks to the pre-loaded calibrations that require only a small amount of localisation.

Robust Design

Specifically designed for the process environment, the ProSpect analyser is enclosed in a hygienic stainless steel NEMA 4 sealed cabinet. With the manufacturer's company history steeped in process system design and manufacture they have been sure to design an analyser that tolerates everything a harsh process environment can throw at it including: vibrations, humidity and temperature fluctuations.

Simple to Operate

The completely automated analyser continuously compares multiple constituents and their concentration against production parameters, feeding required information to the Process Operator and to the integrated process control.

True Transmission Based Near Infrared Analysis for Unsurpassed Accuracy

At the heart of the ProSpect Analyser is the Near-infrared Spectrometer using an ultra high resolution diode array detector to deliver continuous, accurate analysis in transmittance mode. Transmission NIR has long been recognised as superior for in-line liquid analysis requiring high accuracy.

Butter Process Control

Inline Butter process controlSalted Butter

The ProSpect in-line process control is the ideal butter analyser computing the Fat, Moisture and Salt composition in the butter stream, supplying updates to the PLC every 30 seconds. The PLC uses this information to make continuous  adjustments to the moisture and salt addition in the butter churn. Using the information supplied by the ProSpect in-line process controller and manipulating the critical set points on the churn butter manufacturers can control the fat and salt levels.

Unsalted Butter

The ProSpect in-line process controller  is also effective for unsalted butter. The ProSpect is an in-line process controller that computes the Fat, Moisture and Salt composition in the butter stream, allowing updates to the PLC every 30 seconds.  The PLC uses the information to make continuous adjustments to the moisture addition in the butter churn. Using the information supplied by the ProSpect in-line process controller and manipulating the critical set points on the churn butter manufacturers can control the fat levels in the butter stream.

Cheese & Cheese Milk

Cheese and Cheese Milk inline analysis

The ProSpect analyser is an in-line process controller ideal for cheese and cheese milk analysis. After computing the Total Solids, Protein and Fat composition in recombined milk stream, the PLC  is updated every 30 seconds. The PLC uses this information to make continuous adjustments to the cheese milk process system's ration valve and cream additional valve. By using the information supplied by the ProSpect in-line process controller and manipulating the critical set points, cheese and cheese milk manufacturers can control the Protein and Total Solid levels in the cheese milk and manage the cheese quality.

 

 

 

Mozzarella Cheese Process ControlMozzarella Cheese

The ProSpect in-line process controller ideal for mozzarella cheese analsyis. The ProSpect determines the Fat, Moisture and Salt composition of the cheese milk updating the PLC every 30 seconds. The PLC uses the information to make continuous adjustments to the process set points, and by doing so allows mozzarella cheese producers to control the final mozzarella product to tighter variances.