End-to-End Automation of Cottage Cheese Production
End-to-End Automation of Cottage Cheese Production
Process Control System (SCADA) for a Curd Production Line | Siemens S7-1500 PLC | Recipe Management
Belarus
Branch:
Food Industry
Year:
2025
About the project:
To create a unified automated control system for the cottage cheese preparation section, ensuring flawless product quality and eliminating the influence of the human factor.
The client faced the need to modernize production: ensure parameter stability, increase efficiency, and integrate disparate equipment into a single control loop.
We implemented a comprehensive solution that covered all stages:
1. Automation of Curd-Making Tanks:
Precise temperature maintenance in heating jackets and independent hot water circuits.
Complex algorithms for reverse-direction agitators to achieve the perfect curd structure.
Automatic whey cooling.
2. Intelligent Whey Separator Control:
Belt positioning for guaranteed, consistent product quality.
3. Deep Integration:
The client's equipment (pasteurization/cooling unit, CIP station, packaging equipment) became part of a single system.
Recipe management was implemented — the operator selects a recipe, and the system does the rest.
4. Technology Stack:
PLC: Siemens S7-1500 (maximum reliability and speed).
Operator Panels: Siemens HMI.
Field Network: Valves and sensors via AS-i protocol, frequency converters via Profinet. This ensured ease of installation and diagnostics.
5. SCADA System:
An intuitive visualization system was implemented for operational control and real-time parameter monitoring.
100% Consistency: Every batch of cottage cheese meets the quality standard.
Reduced Human Factor: The process is controlled by predefined algorithms.
Complete Transparency: Full control over all production parameters.
Scalability: The system is ready to connect new equipment.
This project is further proof: there is no such thing as "impossible to automate." There are only interesting challenges that we brilliantly solve.
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