AI for Evaporator Optimization: Enhancing Whey Permeate Evaporation Optimization
Executive Summary
Process Point successfully implemented an advanced optimization solution for a large multinational Dairy company’s lactose processing plant. By enhancing the whey permeate evaporator throughput, we significantly improved operational efficiency and product quality.
Client Profile
- Industry: Dairy Processing (Nutritional and Healthcare Products)
- Location: North America
- Production Capacity: 240 KT per annum of Whey permeate processing, 30 KT of Lactose production per annum
The Challenge
Optimize the whey permeate evaporator throughput in the lactose processing plant to improve efficiency and product quality.
Solution
Process Point developed and implemented a data-driven optimization strategy:
- Model Development: Created and tested multiple models on the plant floor
- Strategy Optimization: Identified "Strategy 4" as the most effective approach
- Performance Improvement: Focused on enhancing evaporator performance
- Throughput Increase: Optimized dry basis throughput of the permeate evaporator
Key Features
- Plant floor testing of developed models
- Implementation of the most effective strategy (Strategy 4)
- Focus on maintaining product quality while increasing throughput
Results and Impact
Our AI-driven solutions have led to remarkable improvements in operational efficiency and cost savings. By optimizing the permeate evaporator, we have achieved substantial gains in throughput and performance.
- Increased dry basis throughput of the permeate evaporator by over 15%
- Maintained solid content between 60-65% (w/w)
- Significant improvement in evaporator performance
- Projected savings of over 10 million dollars per year when deployed across all 4 plants
Conclusion
- Data-Driven Optimization – Implemented advanced analytics to enhance lactose processing efficiency.
- Increased Throughput – Boosted evaporator throughput by 15% without compromising quality.
- Maintained Product Quality – Ensured consistent standards while optimizing operations.
- Dairy Industry Impact – Demonstrated measurable value in improving efficiency and sustainability.
