Non Contact Open Channel Flow Measurement for Dairy Processing Site

Bradshaw Consulting specialises in Energy and Process loss reduction in the Food and Drink sector. Their client Dairy Crest operate a large Dairy Processing site near Stroud in Gloucestershire and with the help of the Dairy Crest Improvement team (Chemical Engineers) Bradshaw have
developed and installed a unique Effluent Monitoring and Analysis system incorporating the Micronics SLT32 - Ultrasonic Non Contact open
channel flow measurement system.
The purchase of the new turnkey system and meters was driven by a need to provide online product wastage information from the various
departments and hence, further reduce milk wastage from the site.
Having considered various measurement alternatives Ultrasonic Non Contact meters were selected due to the ease of installation and
maintenance/service benefits associated with the non-contact technology. Micronics were selected as the supplier due to a combination of their experience with open channel flow measurement
technology and their competitive pricing in comparison to alternative similar technology solutions or alternatives requiring considerable civil construction work. Three Micronics SLT32 meters were purchased as a package. The meters have the capability to measure and log effluent flow and totalised flow; however, in this application they are
providing flow data via a 4 to 20mA signal to the system\\\'s separate control system.
The meters have been installed at three known process discharge points to assess effluent discharge rates assuming flume characteristics.
The Bradshaw system also analyses the effluent milk content to identify the milk wastage using a volume x turbidity (- COD mg/l) calculation,
which is further, analysed in terms of real time and day total data within the site SCADA system.
Site staff are able to monitor live effluent discharge rates, initiate action to investigate potential reductions in process milk wastage and
view the results in real time or daily values. And in doing so they are able to identify and drive down milk wastage and effluent costs using M&T techniques in line with Best Practice.
Bradshaw\\\'s Will Todd has managed the project and he believes the project has developed an industry-leading tool for the management of
process waste and effluent within the Dairy Processing industry. The Micronics products have performed well, service has been good and the
installation has been an environmental and financial success. Improved measurement and visibility has enabled Dairy Crest to improve the
plant\\\'s performance and as a consequence less product is being wasted and therefore less effluent is being discharged!