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Within large dairy manufacturing sites, there are a multitude of processes that require heated water from a single source (eg. Single boiler supply). These processes can experience significant temperature fluctuations as a result of pressure fluctuations from rapid changes in process demands. Emech Control Limited have identified applications in the dairy industry where precise control of water temperature is required. The pastuerization and butter conditioning processes are two areas where flow control and temperature control is critical. Pasteurization Control: Current pasteurization methods require a minimum of 72º treatment of milk for 20 seconds. In the cheese making process, the performance of control valves is essential. Temperature fluctuations in the hot water loop for the pasteurizers causes temperature variance. A pasteurization temperature above a specified temperature can affect the whey protein binding quality and ultimately cheese making. The installation of precision control valves on the hot water loop into the heat exchanger system will ultimately improve the precision of pasteurisation temperatures. An Emech 2 port ceramic disc valve could provide a possible solution that could reduce the variance significantly above a traditional butterfly valve system.  Cheese Pasteurization Objective:
To improve yield and quality of cheese. This can be achieved by lowering pasteuriser temperatures resulting in less denatured whey protein binding to casein and thus allowing more rennet activity. The goal is to improve the setting in vats and synersis, as well as improving the whey yield. Solution: Installation of an Emech system – comprising 2 port ( See 2 port Valve) ceramic disc valve and electronic actuator at the secondary flow of the heat exchanger unit provides precise placement of the disc and accurate control. The result is a responsive control system to enable tight control of flow through the heat exchanger enabling higher product yield.  Butter conditioning:
The blending and processing of butter or similar yellow fats (eg margarine) require tight operating temperatures. Typical blending / processing requires a water-jacket vessel in which the product can be warmed to a specific working temperature. If the temperature fluctuation is too high the product will liquefy and conversely if the working temperature is too low the appropriate blending cannot be achieved. Butter Conditioning Objective: To maintain correct viscosity of fats and oils to ensure the correct blending and processing. Solution: The installation of an Emech F5 Steam-water heater ( See F5 Steam-water mixer ) can be used to provide accurate heated water to the water-jacket blender. This heater ensures that the correct amount of steam energy is introduced to the heated water to maintain correct  temperatures. The system can be used in a total loss, or circulating steam-injection system. Case Study : Heinz Watties Limited, Hastings, New Zealand  In early 2004, Heinz Watties Limited reported production difficulties in their yellow fats processing area.
This site experienced water and steam pressure fluctuations and had difficulties achieving water temperatures required for the water jacket blender. The engineering team were faced with installing a boiler system dedicated to this application which was costly and expensive to operate. Greg Crofskey, Project Engineer at Heinz Watties Limited contacted Emech Control Limited to supply a solution. "We experienced steam and water pressure fluctuations which led to temperature variation on our water-jacket blender. The Emech Steam-Water heater provided a simple solution whereby we can set our process to specific operating temperatures, yet maintain tight temperature accuracy" “This system has been operating for over 8 months in our butter-blending operation and we now enjoy increased productivity" 
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