NAPCON Controller maximizes whey powder production

Goal: To increase the capacity of the spray dryer with no increase in energy consumption

Valio Oy is the largest producer of dairy products in Finland. At Valio’s dairy complex in Lapinlahti, eastern Finland, demineralized whey powder is produced in large quantities. The moisture content of the final product is adjusted by a spray dryer. This is an energyintensive and demanding process because excessive water content makes the powder sticky. This causes disturbances and might even result in shutdowns. Excessively dry whey powder generates dust, which has a negative effect on product properties and uses excess energy.

By controlling the spray dryer capacity and hot air streams in an optimal way using MPC (model predictive control) at a 30-second interval, it is possible to keep the moisture content of the final product very close to its target value in all process conditions and under multiple dynamically changing process constraints. This leads to a significant increase of production without any increase of total energy used for heating the drying air. Moreover, the risk for shutdowns due to bag filter clogging is also significantly reduced.

The average capacity of the spray dryer increased by 10% with no increase in energy consumption.

Aleksi Ylitalo,
Process Expert, powder technology at Valio