Modernization of the UHT Processing Line and Aseptic Tank Based on Siemens PLC and ISA-88 Standards at a Dairy Plant in Belarus

UHT Automation Modernization Without Production Downtime

UHT Automation Modernization Without Production Downtime
Modernization of the UHT Processing Line and Aseptic Tank Based on Siemens PLC and ISA-88 Standards at a Dairy Plant in Belarus

Belarus
Branch:

Dairy production
Year:

2025
About the project:

Modernization of the UHT Automation System Without Production Downtime

Aprotec Engineering successfully delivered a modernization project for the UHT (Ultra-High Temperature) processing line and aseptic tank at the dairy production facility “Molochny Mir” in Grodno, Belarus.

The key challenge — and the core achievement of this project — was a complete replacement of the control software and SCADA system on a live production line, without stopping production and without access to the source code or documentation from the previous vendor.

Our engineering team reconstructed and rethought the control logic by analyzing the actual behavior of the equipment, resulting in a new, stable and scalable automation system based on Siemens PLC and an industrial PC with SCADA.

Modernization “on the fly” — without production risk and without dependency on the previous system integrator.

Why Investing in Standardized Automation Pays Off

This project delivers measurable operational and long-term business value:

Zero production downtime — modernization was performed on a running line without stopping milk processing.
Vendor independence — the new control system is no longer tied to a single supplier or proprietary logic.
Operational flexibility — support for multiple capacity modes: 8, 6, or 4 tons per hour.
Improved reliability — stable control of heating up to 137°C and precise cooling processes.
Integrated control — seamless coordination between UHT processing, aseptic tank and packaging machines.
Future-ready architecture — the system is prepared for expansion and further integration.

The control system is developed in accordance with ISA-88 principles, ensuring modularity, standardization and long-term maintainability across the entire system lifecycle.

Results for the Customer

Stable and reliable operation of the UHT line and aseptic tank
Full replacement of legacy automation without production interruption
Clear and intuitive SCADA interface for operators and maintenance staff
Reduced operational risks and simplified system support
Compliance with international automation standards (ISA-88)
Readiness for future upgrades, replication and scaling

Automation built for the full lifecycle — not just for project delivery

By using Siemens platforms and ISA-88-based software architecture, Aprotec Engineering delivers automation systems that remain understandable, supportable and expandable for decades.