Liquids & Drinks · Dairy & Cultured

HTST Pasteurization Yield & Energy

Lift HTST pasteurizer yield over 2 points while cutting steam per hectoliter through tighter holding-tube control and predictive plate-fouling alerts.

+2.1 pts

Pasteurizer Yield

From 96.8% to 98.9% average, fewer diversion events and tighter flow control on the holding tube

−14%

Steam per Hectoliter

Holding-tube tightening and heat-regeneration optimization cut steam consumption across the line

−66%

Plate-Fouling Stops

Predictive fouling alerts on rising PHE ΔP triggered planned cleans before forced diversion, with 3 unplanned stops eliminated in 8-week pilot

How Allie Works Here

From signal to action in real time.

Process ControlQuality ControlEnergy OptimizationPredictive Maintenance

The Process Control agent monitors holding-tube temperature at 1-second resolution against the certified process schedule and adjusts the steam regulator setpoint via Siemens S7 OPC-UA writes before the flow diversion valve trips. The Quality Control agent computes per-tank product yield from raw milk receiving meters and downstream flow tags, attributing yield loss events to specific causes: diversion, foaming, or homogenizer pressure drift. The Predictive Maintenance agent tracks plate heat exchanger ΔP trajectory and homogenizer piston wear signatures, alerting the maintenance lead 24–48 hours before a planned clean would normally be scheduled. The Energy Optimization agent reduces preheat steam setpoints during regeneration-favored conditions without compromising pasteurization safety margins.

Machines & Connectivity

OT-connected, protocol-native.

SPX FLOW APV Plate Pasteurizer

SPX FLOW

Modbus TCP

HTST plate pasteurizer for milk and cream: heat-regeneration, holding tube, and cooling sections

Tetra Pak Homogenizer 250

Tetra Pak

OPC-UA

Two-stage homogenizer downstream of preheater; pressure setpoint critical for fat globule size distribution

Siemens S7-1500 PLC

Siemens

Pasteurizer control loop owner; manages flow diversion valve and CIP permissives

Process Variables

The signals Allie monitors and moves.

Signal Name	Historian Tag	Unit	Baseline	Optimized	Target
Holding Tube Temperature	`DPAST01.HOLD.TMP`	°C	72–76	72.5–73.5	Tighter
Homogenizer Pressure (Stage 1)	`DPAST01.HOMO.P1`	bar	165–200	180–190	Tighter
Plate Heat Exchanger ΔP (Fouling Indicator)	`DPAST01.PHE.DP`	kPa	40–95 (run-end)	40–62 (run-end)	Lower
Product Yield	`DPAST01.YIELD`	%	96.2–97.4	98.3–98.9	Higher

Holding Tube TemperatureTighter

DPAST01.HOLD.TMP

Baseline: 72–76 °C→ 72.5–73.5 °C

Homogenizer Pressure (Stage 1)Tighter

DPAST01.HOMO.P1

Baseline: 165–200 bar→ 180–190 bar

Plate Heat Exchanger ΔP (Fouling Indicator)Lower

DPAST01.PHE.DP

Baseline: 40–95 (run-end) kPa→ 40–62 (run-end) kPa

Product YieldHigher

DPAST01.YIELD

Baseline: 96.2–97.4 %→ 98.3–98.9 %

In the Field

"a Latin American dairy processor running multiple HTST pasteurizer lines across two plants with combined throughput exceeding 800,000 liters per day"

Deployed at a Latin American dairy processor running multiple HTST pasteurizer lines across two plants with combined throughput exceeding 800,000 liters per day. The results above reflect production data from the 60–90 day period following full deployment.

+2.1 ptspasteurizer yield

−14%steam per hectoliter

−66%plate-fouling stops

Next Step

See what your lines are actually capable of.

A 30-minute operational assessment. We review your OT/IT setup, identify the highest-ROI deployment, and deliver a scoped pilot proposal.

Schedule a Plant Assessment