wheyco takes an important step towards condition-based maintenance

In the food industry, productivity, reliability and availability are always high on the agenda. That includes wheyco, which processes whey into protein and permeate powder. The numerous motors for pumps, fans and agitators, among others, are equipped with soft starters to minimise mechanical stress on equipment. A new generation of softstarters was recently introduced with ABB’s PSTX and PSE series. itsme served as the vital link between ABB and wheyco.

Near Hoogeveen, in beautiful Drenthe, is the Zuivelpark [Dairy Park]. This is where wheyco and DOC Kaas are located, two parts of the DMK Group representing several links in the cheese chain. The whey released from cheese production by DOC Kaas goes through a pipe system to the wheyco whey factory. Here, it is made into protein and permeate powder; important ingredients for sports, dietary and senior nutrition, for example, but also for bakery products, chocolate and pet food. As the two production sites are “neighbours”, no freight transport is required for transporting the whey. This contributes to a sustainable production process.
 

A complex process

Whey processing is a complex process consisting of several stages. After pasteurisation, the whey is split by ultrafiltration. In this process, protein molecules (whey protein concentrate) are separated from smaller molecules, such as lactose and minerals (whey permeate concentrate). The whey permeate is then further thickened by evaporation and finally dried into a powder by the spray dryer. The whey protein concentrate is immediately dried on the spray dryer. Throughout the pasteurisation process, filtering, drying and cooling, pumps, fans and agitators are indispensable “ingredients”.

Downtime costs us a lot of money. As whey has to be processed almost immediately, downtime not only results in production losses but also requires the whey to be processed elsewhere.

Productivity, reliability and equipment availability play a vital role in the process. As an E&I engineer and installation manager within wheyco, Jeroen Meijer is closely involved in all electrical engineering issues. “When whey is released from DOC Kaas’ production process, we have a purchase obligation. You’re talking about large amounts of whey coming in. That means our equipment and production capacity must always be available. Downtime costs us a lot of money. As whey has to be processed almost immediately, downtime not only results in production losses but also requires the whey to be processed elsewhere. You want to avoid such headaches at all costs.”

Sustainable and reliable production

Regarding the rotating equipment within wheyco, Meijer continues: “The motors used for the pumps, fans and agitators are not only major energy consumers but are actually the beating heart of production. To reduce the mechanical stress on the motors, we started fitting them with softstarters between 2002 and 2003. Less mechanical stress also means less wear and tear, less maintenance and lower costs.” Thus, the knife cuts four ways. 

After 20 years, however, it was high time for renewal. wheyco wanted to take advantage of this renewal not only to reduce the mechanical stress on equipment, but also to keep the voltage and current quality as high as possible. “If you do that properly, you save energy,” Jeroen Meijer explains. In consultation with ABB and itsme, ABB’s PSTX and PSE series were chosen. 
 

We are increasingly deploying data for condition-based maintenance. We therefore want to reduce the probability of downtime even further.

When selecting the softstarters, the version with bus communication was deliberately chosen. “That way, we can use data from softstarters better and more easily. We are increasingly deploying that data for condition-based maintenance. We therefore want to reduce the probability of downtime even further.” Asked whether the purchase actually led to the desired result, Meijer replies: “There are indeed fewer malfunctions. For the effects on condition-based maintenance, we will have to be patient. These become visible only after a somewhat longer time. The smooth transition to the new generation is remarkable, though.” The softstarters are set up in a conditioned central switch room. “Previously, we inventoried all the motors. itsme then delivered the ABB softstarters with the right settings. As a result, the integration was flawless. I have sometimes likened it to a pit stop: old soft starter out, new one in and running.”

Smooth collaboration

The wheyco project is a fine example of successful cooperation between wheyco, itsme and ABB. “By tackling the project in this way, we were able to move very quickly,” says Arthur Cooke, senior account manager at itsme. Jeroen Meijer adds: “Switching to a new generation of softstarters requires essential preparations. It is good to be able to fall back on an expert partner like itsme for this. In the relationship between wheyco and itsme, our permanent contact at the itsme back-office is very important. They work with us and remind us what extras are needed when ordering a product.”

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