Rajkot Dairy, India - The Indian dairy industry needs to rapidly expand to meet the demands of the world’s largest market, which continues to grow. Indian dairy plants already produce 132 million tons of milk per year but will need to produce 200 million tons by 2022. To achieve this huge leap, dairy farms throughout India are moving from traditional manual plants to plants using automation technology to increase speed, efficiency, and the quantity of milk produced. The enhanced performance achieved by automating manual tasks was quickly proven when Siemens integrated a state-of-the-art process control system into a dairy plant in Rajkot, India.
Food & Beverage
In India, demand for dairy products is rising steeply, and producers feel challenged to keep up with this growth. To help bridge the gap between demand and supply, Ashish C. Sinha, CEO of Rajkot Dairy, realized his vision of implementing a state-of-the-art dairy automation system based on Simatic PCS 7.
Rajkot Dairy’s first fully automated plant
The Rajkot District Co-operative Milk Producer’s Union Limited, known as Rajkot Dairy, part of the Gujarat Cooperative Milk Marketing Federation known as “AMUL,” produces a wide selection of dairy products. With assistance from the National Dairy Development Board, it wanted to open a state-of-the-art milk processing plant. Using machines imported from Germany, France, and Canada, the plant would be fully automated – the first of its kind in India. Creating a fully automated plant was a new concept for Rajkot Dairy. Project timelines were tight, and, to add to the project’s challenge, Rajkot Dairy set the ambitious target of producing 0.6 million l of milk per day with the option of expanding up to 1 million l. Having invested $15 million in this project, Rajkot Dairy did not want to risk working with an unproven or inexperienced process control technology partner. Siemens was already recognized as a leading provider of electrical systems and dairy-specific automation technology. This gave Rajkot Dairy the confidence that Siemens had the necessary expertise and proven systems to ensure a smooth and successful implementation.
Standards facilitate smooth integration
At the start of the project, Siemens and the OEM demonstrated the recommended standardized dairy automation system to Rajkot Dairy and explained how easy it would be to operate. Siemens also conducted a technology workshop for Rajkot Dairy on the standardized products and systems it had already provided to dairy plants worldwide.
Siemens then integrated the entire automation system into the dairy plant’s control room. At its core was Siemens’ state-of-the-art Simatic PCS 7 process control system, backed up by a standardized Dairy Library (Advanced Process Function technology package). This combination of technology provided Rajkot with automation and process control specifically optimized for dairy plants. Siemens also provided laboratory PC and weighbridge data integration along with all the necessary intelligent motor control center software applications and hardware for smooth, safe control of all operations.
Leading the industry
Siemens was the one-stop shop Rajkot Dairy needed, supplying all the technology in one package and integrating everything into the dairy plant’s control room. This eliminated the risks associated with trying to combine technology from multiple vendors.
Especially the standardized library for dairy plants proved highly beneficial. With its preexisting tool sets for dairy applications, Siemens was able to integrate Simatic PCS 7 and the additional hardware into Rajkot Dairy’s existing set-up quickly and easily. The new system also provided Rajkot with long-term cost savings thanks to its automated monitoring and control, which minimized manual interventions.
Ultimately, Rajkot Dairy succeeded in creating India’s first fully automated dairy farm on time and on budget. It was a prestigious project in an industry that is rapidly modernizing, and its positive results have marked Rajkot Dairy as an innovative technology leader. Additionally, Rajkot Dairy was able to achieve its ambitious production goals and make a significant contribution to satisfying the demand of the world’s fastest-growing market. The project’s success has triggered future ambitions for Rajkot Dairy envisioned by CEO Ashish C. Sinha. He now plans to build a fully automated chilling center alongside the dairy plant.