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Bradshaw Consulting has developed an effluent monitoring and analysis system incorporating the Micronics SLT32 ultrasonic non-contact open-channel flow measurement system for Dairy Crest.

Dairy Crest operates a large dairy processing site near Stroud in Gloucestershire.

The purchase of the new turnkey system and meters was driven by a need to provide online product wastage information from the various departments and further reduce milk wastage from the site.

Having considered various measurement alternatives, ultrasonic non-contact meters were selected because of their simple installation and the maintenance/service benefits associated with the technology.

Three Micronics SLT32 meters were purchased as a package.

The meters have the capability to measure and log effluent flow and totalised flow; however, in this application, they are providing flow data via a 4-20mA signal to the system’s separate control system.

The meters have been installed at three known process discharge points to assess effluent discharge rates assuming flume characteristics.

The Bradshaw system also analyses the effluent milk content to identify the milk wastage using a volume x turbidity (~ COD mg/l) calculation, which is further analysed in terms of real-time and day total data within the site SCADA system.

Site staff members are able to monitor live effluent discharge rates, initiate action to investigate potential reductions in process milk wastage and view the results in real time or daily values.

In doing so, they are able to identify and drive down milk wastage and effluent costs using MandT techniques in line with best practices.

Improved measurement and visibility have enabled Dairy Crest to improve the plant’s performance and, as a consequence, less product is being wasted and less effluent is being discharged.

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