In recent years, with the continuous improvement of consumers' requirements for dairy product quality, dairy production enterprises have also set higher standards for the performance of production equipment. The ultrafiltration equipment produced by [Company Name] has been successfully applied in many dairy enterprises with its advanced technology and excellent performance, providing strong support for the improvement of industry production efficiency and product quality. The following takes the actual project of a large - scale dairy enterprise as an example to introduce the application of our company's ultrafiltration equipment in detail.
I. Project Background
A large - scale dairy enterprise mainly produces liquid milk, yogurt and other products, with an annual output of 500,000 tons. The original dairy filtration process combined traditional centrifugal separation and diatomite filtration, which had many problems. In terms of product quality, it was difficult to effectively remove bacteria, colloids and other impurities in whey, resulting in sedimentation and deterioration of some products during the shelf life; the retention of nutrients was insufficient. For example, the loss rate of active ingredients such as lactoferrin during the filtration process was as high as 30%. In terms of production efficiency, the traditional equipment had a low processing capacity, often encountering production bottlenecks during peak production periods. Moreover, the equipment required frequent maintenance, and the cost of consumable replacement was high. The annual cost of diatomite consumables alone was as high as 5 million yuan. To solve the above problems and enhance product market competitiveness, the enterprise decided to introduce advanced ultrafiltration equipment to upgrade the production process. After extensive investigation, it finally chose the ultrafiltration equipment of our company.
II. Application and Implementation of Our Company's Ultrafiltration Equipment
(I) Equipment Selection and Customization
The technical team of our company customized a set of ultrafiltration equipment system for the enterprise according to its production scale, dairy product type and quality requirements. The core ultrafiltration membrane module adopted the self - developed polyvinylidene fluoride (PVDF) hollow fiber membrane, with the membrane pore size precisely controlled at 0.01 microns. It has the characteristics of high strength, anti - pollution and strong hydrophilicity. It can not only efficiently intercept impurities such as bacteria, colloids and macromolecular proteins, but also ensure that low - molecular nutrients in whey can pass through smoothly, retaining the nutrition of dairy products to the greatest extent. The designed processing capacity of the entire set of equipment is 100 tons per hour, meeting the large - scale production needs of the enterprise.
(II) System Installation and Debugging
Pretreatment System: A pretreatment system was built in front of the ultrafiltration equipment, including multi - media filters, activated carbon filters and fine filters. The multi - media filter removes large - particle suspended solids in raw milk through filter materials such as quartz sand and anthracite of different particle sizes; the activated carbon filter adsorbs odors, pigments and some organic substances in raw milk; the fine filter uses 5 - micron filter elements to further filter tiny particles, reducing the turbidity of raw milk and providing good inlet water conditions for the ultrafiltration membrane.
Ultrafiltration Main Unit: The ultrafiltration main unit is composed of multiple membrane module units and adopts the cross - flow filtration method, effectively reducing the deposition of pollutants on the membrane surface. The equipment is equipped with an intelligent control system, which can real - time monitor and adjust parameters such as filtration pressure, flow rate and temperature to ensure stable operation.
Cleaning and Maintenance System: A fully automatic chemical cleaning system was designed. According to the membrane pollution situation, appropriate cleaning agents (such as alkaline protease cleaning agent and acidic citric acid cleaning agent) can be automatically selected for cleaning. The cleaning process includes steps such as water flushing, chemical soaking and circulating cleaning, effectively restoring the membrane flux and extending the membrane service life.
After the equipment installation was completed, the professional technicians of our company carried out a one - week debugging work, optimized the system parameters to ensure that the equipment reached the best operating state, and provided comprehensive operation training and maintenance guidance for the enterprise's operators.
III. Application Effects
Effect Category | Specific Performance |
Significant Improvement in Product Quality | - The bacteria removal rate is as high as 99.9%, effectively reducing the risk of product microbial exceeding the standard and extending the product shelf life. The shelf life of liquid milk has been extended from the original 30 days to 45 days- The interception rate of colloids and other impurities exceeds 98%, enhancing product stability and basically eliminating quality problems such as sedimentation and delamination- The loss rate of active nutrients such as lactoferrin is reduced to less than 5%, greatly improving the nutritional value of the product and winning wide acclaim from consumers |
Substantial Increase in Production Efficiency | - The unit - time processing capacity has increased by 60% compared with traditional equipment, meeting the production capacity requirements during peak production periods. The annual output value can be increased by about 80 million yuan- High degree of automation reduces manual operation links, reduces labor intensity, and saves about 2 million yuan in labor costs annually- The equipment operates stably, and the maintenance cycle has been extended from once a month to once a quarter. The maintenance time has been greatly shortened, and production continuity is guaranteed |
Significant Cost Reduction | - The service life of the ultrafiltration membrane is as long as 3 - 5 years. Compared with traditional diatomite filtration consumables, about 4 million yuan in consumable costs can be saved annually- Energy consumption has been reduced. Through the optimization of the filtration process and the energy - saving design of the equipment, 20% of electricity can be saved for every ton of dairy products produced, saving about 1.5 million yuan in electricity bills annually |
IV. Summary of Application Experience
1.Accurate Selection is the Foundation
There are differences in product types, production scales and quality requirements among different dairy production enterprises. Our company provides customized equipment selection solutions by deeply understanding customer needs and combining our own technical advantages, ensuring a perfect match between equipment performance and production needs.
2.A Complete Pretreatment is Crucial
A good pretreatment system can effectively reduce the pollution load of the ultrafiltration membrane, extend the membrane service life and improve the operational stability of the equipment. In dairy filtration, it is particularly important to reasonably configure the pretreatment equipment and process parameters according to the characteristics of raw milk.
3.Professional After - Sales Service Guarantee
Our company provides comprehensive after - sales services for customers, including equipment installation and debugging, personnel training, regular maintenance inspections, etc., timely solving problems encountered by customers during the use process and ensuring the continuous and stable operation of the equipment.
The successful application of our company's ultrafiltration equipment in this dairy enterprise fully demonstrates the reliability and advancement of the product. In the future, [Company Name] will continue to be committed to the research and innovation of ultrafiltration technology, providing higher - quality and more efficient filtration solutions for the dairy industry and more fields.
