ProcesScan™ 2

ProcesScan™ 2 is a fully automated, on-line FTIR solution for standardization of milk and liquid dairy products with superior accuracy and speed.

Bringing FTIR technology directly into the production line gives dairy processors an accurate picture of what is going on inside the process. Fast, accurate and continuous measurements allow process adjustments to be made in real-time for optimal process control.

ProcesScan 2 offers a best-in-class solution for continuous and simultaneous analysis of milk composition parameters.

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ProcesScan™ 2 is a fully automated, on-line FTIR solution for standardization of milk and liquid dairy products with superior accuracy and speed. ProcesScan 2 offers a best-in-class solution for continuous and simultaneous analysis of milk composition parameters. Learn how to hit your targets continuously, ensure predictable performance and secure uptime.

Where you can analyze

In the production line: Close to the mixer, the blending unit or off the separator standardization.

What you can analyze

Milk and liquid dairy products

Parameters

Protein, fat, total solids, solids-non-fat (SNF), and lactose.

Analysis time

Continuous analysis with results every 10 seconds

Principle

FTIR

Value

Hit your targets with continuous, real-time results. Benefit from predictable performance made easy and ensure efficient operations supported by connected services.

Type sample

Milk and liquid dairy products.

Parameters

Protein, fat, total solids, solids non fat (SNF), and lactose.

Detect. React. Detect. React. That’s automated process control

Automated process control is the key to profitability. Reliable, real-time data about product composition every 10 seconds, combined with subsequent control, can reduce variation between batches considerably and help you bring your production even closer to target values.

Profit improvement graph

Move your targets closer to specification

Reduce the protein and fat variation in your standardized products and optimize the average value for increased yield and profit. On-line results integrated in intelligent PID loops will reduce your variation significantly and enable you to move your targets closer to specifications.

For instance, for a milk powder or cheese producer, keeping the variation of fat and protein content in milk as low as 0.01-0.02 %, makes it possible to reduce the give-away of expensive fat and protein by a factor of 10, depending on the starting point.

FOSS can provide dedicated savings and ROI calculations upon request.

Process drawing

Make every drop count

Bringing FTIR technology directly into the production line ensures reliable data giving dairy processors an accurate picture of what is going on inside the process. Fast, accurate and continuous measurements allow process adjustments to be made in real-time, thereby securing optimal process control. With ProcesScan™ 2 you can improve your product consistency and yield, reduce production variation, make the most of your raw materials, and reduce the risk of error. Simply hit your targets again and again to improve margins, streamline production and run a more profitable business.

On top of this, ProcesScan 2 is supported by state-of-the-art digital capabilities giving you unrivalled, automated process control. Instrument standardization combined with ready to use global calibrations means that ProcesScan 2 is up and running within a few days with only minor adjustments needed to get started, and going forward, calibration maintenance is minimal.

Streamline your production and get:

Consistent quality with best-in-class milk standardization for cheese, powder and consumer milk production
Unrivalled, automated process control with proven FTIR technology from MilkoScan™ FT3
Hit your targets every time with analysis results every 10 seconds (WPC/MPC 20 seconds)
Measurement performance at a superior level compared to other process solutions

Eliminate the risk of error with performance validation

Performance validation allows you to validate ProcesScan™ 2 predictions using a FOSS benchtop analyzer such as the MilkoScan™ FT3, without any manual entry of data.

Samples are measured and registered by the ProcesScan 2 and benchtop analyzer respectively to eliminate the risk of error and secure optimal performance. Using integration, connectivity and automation the results matched are saved via cloud and are ready for evaluation and reporting using digital services.

Get more value from your milk

Getting the composition of fat, protein, total solids, solids non fat and lactose as close to targets as possible has always been essential to make the most of raw materials and secure quality and profit. In this context, milk standardization is the backbone of process control for any dairy.

While standardizing closer to targets to ensure a profitable business is as critical as ever, the dairy industry is rapidly moving towards industry 4.0 with a focus on turning analytical data into actionable insights that give you automated control and full overview of your production. Automated and connected processes provide dairies with the data to make better decisions to optimize the process, meet targets, improve yield, and ensure final product composition. At the same time, automation enables a more sustainable production by making the most of valuable raw materials.

Hit your targets with continuous FTIR analysis

Detect changes in your production process in real-time.

Constant and representative sampling combined with high frequency, FTIR analysis ensures accurate and representative results and allows you to bring your milk standardization closer to specified targets.

Increasing the number of samples allows you to reduce the measurement uncertainty, reduce the variation in your process and produce closer to product specifications. At the same time, you can free up time for busy staff to do other tasks.

Predictable performance made easy

Get your ProcesScan™ 2 up and running in no time with ready-to-use global calibration models.

ProcesScan 2 has no drift and always delivers the same high level of measurement stability and ensures identical performance across multiple instruments.

Automatic clean and zero
Transferable calibrations for a wide range of products and parameters
Easy process integration with interface to all major PLCs and Scada systems
Performance is constantly monitored by built-in intelligent diagnostics
No interruptions with continuous zero reference - manual zero setting only after CIP
Easy to perform local validation and adjustment
Always standardized - no instrument drift and optimized transferability
Plug-and-play global product models (slope/intercept adjustments only at installation)

Efficient operations supported by connected services

ProcesScan™ 2 is supported by best-in-class digital capabilities ensuring optimal analytical performance and uptime. Get an overview of analytical data across individual or whole populations of instruments, using device management tools and protect your investment with a SmartCare™ service and support plan.

Assisted by device management tools you can monitor and manage your ProcesScan 2 units from a single desktop, for example, when making calibration adjustments or proactively planning maintenance cycles for optimal uptime. This can be done from anywhere in the world from any PC.

Technical specification

Specifications
Technology	Fourier transform infrared spectroscopy (FTIR)
Parameters	Fat, protein, lactose, total solids (TS), solids non fat (SNF)
Product types	Liquid milk for cheese, powder and consumer milk production, without solid particles or coagulated proteins in the product. Liquid dairy products with total solids concentration < 25% (WPC/MPC, high fat)
Accuracy*	Fat (0-10 %) Fat (10-20 %) Protein (0-10 %) Protein (10-20 %)	Guaranteed < 0.05 < 0.15 < 0.04 < 0.13	Typical 0.02 0.12 0.022 0.023	Lactose (0-7 %) TS (8-20 %) TS (20-25 %) SNF (4-20 %)	Guaranteed < 0.05 < 0.10 < 0.18 < 0.10	Typical 0.02 0.05 0.10 0.04
Repeatability**	Fat (0-10 %) Fat (10-20 %) Protein (0-10 %) Protein (10-20 %)	Guaranteed < 0.015 < 0.045 < 0.015 < 0.034	Typical 0.007 0.022 0.006 0.022	Lactose (0-7 %) TS (8-20 %) TS (20-25 %) SNF (4-20 %)	Guaranteed < 0.015 < 0.039 < 0.068 < 0.024	Typical 0.008 0.012 0.029 0.018
Result frequency	10 seconds (20 seconds for high viscous products)
Technical specifications and installation requirements
Protection degree	IP56
CIP and CIP temperature	Fully CIP compatible. Temperature maximum 95°C (203°F)
Product temperature	3-65°C (39-149°F)
Ambient conditions	Humidity: < 93% RH (45°C). Temperature: 5-45°C (41-113°F)
Process pressure	Maximum 10 bars (145 PSI) static. Pressure shocks maximum 20 bars (290 PSI).
Production line dimension	Minimum DN 40, OD 1 1/2", IPS 2" and ISO 42.4.
Varinline access unit	Ø68 (type N)
Water supply, cooling	Minimum flow rate 0,1 L/min. Temperature: 2-20°C (35.6-68°F)
De-mineralized water (Zero water)	Consumption: 9 litre/day ISO 3696 grade 3 or ASTM D1193-91 type IV. Conductivity (µS/cm) <5.0.
Main cabinet	304 Stainless steel
Dimensions, cabinet (W x D x H)	539 mm x 285 mm x 480 mm (21.1" x 11.2" x 18.9")
Weight, cabinet	39.5 kg (87 lb)
Interface to PLC/SCADA	Standard OPC UA server with the possibility to define specific FOSS tags. Alternative KEPServerEX supporting connection to other PLC protocols.
Network connections	LAN cable: Minimum category 5e STP LAN plug: RJ45 Maximum LAN cable distance to the net connection: 100 meters
Hygiene standards	3-A Sanitary standard EHEDG Guideline: Guideline 8 on hygienic design principles

*The accuracy of individual sets depend on the sampling handling uncertainty, reference method SE and product concentration range.
The example outlined should be regarded as a possible achievable target for the expected performance of new installations.

**60 seconds averaging.

ProcesScan™ 2

Value

Type sample

Parameters

Get more value from your milk

Hit your targets with continuous FTIR analysis

Predictable performance made easy

Efficient operations supported by connected services

Technical specification

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