Facing challenges such as fluctuating milk prices, evolving consumer preferences and regulatory shifts, dairy farmers have been compelled to adapt to survive in an increasingly competitive market. One dairy industry systems integrator, Technidrive collaborated with an agricultural equipment supplier to optimise the milk pumping system at a dairy farm in Rocklittle, Ireland.

Having worked with Technidrive for around five years, it was only natural for the agricultural equipment supplier to reach out to its longstanding partner to find a solution to optimise the parlour’s milking processes. The farm had previously installed Technidrive’s Technivac vacuum pumping system in 2020 and three years later upgraded from a fixed-speed pumping system to a variable-speed control system to further optimise its milking operations, improve efficiency and reduce energy consumption.

To meet these objectives, the agricultural equipment supplier chose the Techniflow system from Technidrive to ensure that the farm could benefit from increased product quality and decreased refrigeration energy requirements. Consisting of the Techniflow panel, a level probe and control switch box, this variable speed control system stood out as a cutting-edge control solution meticulously engineered to integrate into all dairy parlour systems equipped with milk pumps and plate coolers.

Variable speed control

Before the system was installed, the farm was using a fixed speed system that was continually running at 50 Herz (Hz) regardless of system demand. The pumps were powered by a 1.1 kilowatt (kW) WEG motor with 230/400 dual voltage. The parlour could accommodate 18 units at any one time, but demand was significantly higher in the morning than in the evening, meaning that the farm could significantly benefit from variable speed control. The Techniflow system was retrofitted onto the existing system seamlessly.

Techniflow is compatible with a wide array of milk receivers, automatic washer systems and various milk pump types. Offering efficiency, its variable speed control ensures a consistent and smooth milk flow while automatically managing the cooling water, therefore optimising the performance of the plate cooler.

“Through the Techniflow controller, milk pump speed adjusts dynamically based on the receiver’s inflow, monitored by a level probe included in the kit,” explains Andrew Ritchie, technical sales manager at Technidrive. “By reducing the flow from the receiver to the plate cooler, the cooling process is intensified, leading to decreased refrigeration energy requirements and improved product quality.

“Engineered to fit into the majority of parlour setups, the system is fully customisable and programmable to suit specific needs. It optimises efficiency for milk pumps, substantially minimising milk damage and can be installed in less than six hours in 95 per cent of current systems.”

Milk quality

The new system led to an enhancement in milk quality compared to the conventional fixed speed milk pump system that was previously operating. By eliminating the need for a start and stop process, through the precise control of the milk flow, it minimises agitation and maintains a consistent temperature. This results in better milk quality that meets stringent industry standards. 

Furthermore, the system significantly improves milk cooling efficiency. Its intelligent design allows for precise regulation of the cooling process, ensuring rapid and thorough cooling of the milk, which not only enhances its freshness but also extends its shelf life. Enhanced milk cooling also impedes bacterial growth, thus protecting the quality and flavour of the milk.

In addition to improving milk quality and cooling efficiency, the Techniflow system delivers tangible cost savings by reducing energy consumption related to refrigeration. With its variable speed control mechanism, it optimises energy usage, resulting in lower operational expenses without compromising performance.

Moreover, the system has contributed to increased pump longevity. By operating at variable speeds and reducing unnecessary wear and tear, it has prolonged the lifespan of the milk pump, minimising maintenance costs and downtime.

For example, the pump now runs proportionally to the inflow of milk while controlling the water inlet valve on the plate cooler. These features ensure the milk gets cooled quickly as the heat is transferred from the milk to the water. The water is then reused elsewhere.  Instead of the milk entering the cooling tank at 30 °C this is now typically dropped to below 10º Celsius, subject to water temperature. In turn the cost of refrigeration can be reduced equating to a substantial reduction in energy consumption.

Operational benefits

Another benefit of the system is its ability to reduce noise levels in the dairy environment. Its advanced control features ensure smooth and quiet operation, creating a more comfortable working environment for dairy workers. The system’s versatility is further underscored by its compatibility with single-phase 230V power supply and multiple control voltage options, making it adaptable to various setups and configurations.

Furthermore, the Techniflow system comes equipped with a built-in supply for automatic control of the plate cooler water solenoid valve, enabling integration and automation capabilities. The inclusion of features such as remote starting, stopping and draining of the system, as well as the provision of a level sensor, further enhances the system’s usability, convenience and overall effectiveness in dairy operations.

Installation

Following the commissioning phase, the order was delivered to the farm in two to three weeks. The agricultural equipment supplier completed the installation in collaboration with a local electrician, in line with Technidrive’s installation manual. Its installation process ensures a hassle-free implementation experience for dairy farmers and operators, the company says.

Engineers visited the site prior to installation to ensure there was enough wall space for the panel enclosure and that it could be mounted in an accessible location as close to the pump as possible and not too far from the fuse board.

The switch box which was prewired with ten metres of cable was positioned in the parlour. Proper installation of the probe following the manual guidelines and programming during initial startup was also crucial for optimal performance. Finally, the panel was connected to the WEG motor using screened cable along with EMC glanding.

Multiple Techniflow and Technivac systems have been installed across various farms, with Technidrive consistently providing strong technical support throughout these projects. At the farm in CountyWicklow, the installation of the Techniflow system required only a single minor adjustment after commissioning.

Initially the milk setpoint, measured as a percentage of the probe which maintains the level of milk in the receiver, was set to 65 per cent. Following a few weeks of testing, engineers returned to the site to reconfigure the level to 45 per cent of the probe. The optimal setpoint is always set according to the preferred level in the receiver and will vary depending on each manufacturer’s The system has now delivered benefits for the farm in terms of improved milk quality, energy efficiency, equipment longevity and operational convenience.