Located in the city of Salzburg, company SalzburgMilch GmbH was founded in 2013 and emerged from fusion of Alpen-milch Salzburg and Käsehof. The company employs 289 people and processed 214 million kilograms of milk in 2012, 119 million kilograms of which came from special varieties of milk (organic milk, silo-free milk ("hay milk") and organic hay milk) that need to be processed without being mixed. The range of products comprises roughly 600 different milks, cheeses and flavored products including organic and long-life products.

Project description:

Company SalzburgMilch (former Alpenmilch Salzburg) has been using electrical systems and control technology from Siemens Industry Automation since 2002. The main plant construction partner is company Bertsch Foodtec GmbH (process section – stainless steel). The core of the automation solution at SalzburgMilch is the higher- level process control system SIMATIC PCS 7, which is used for all expansion and modern-ization processes.

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This is the largest PCS 7 application in the Austrian food and beverage industry, with over 14,000 I/Os.

The following sections were converted to SIMATIC PCS 7:

• Milk pasteurization with all the related tanks (28 tanks, volume of approximately 560,000 liters) • Soured milk production with all the related tanks (30 tanks for 7 filling systems, volume of approximately 400,000 liters) • Sterile production for all milk products processed at high temperatures with special pressure-proof sterile tanks (4 tanks, volume of approximately 70,000 liters) • Two fruit mixing systems each with a capacity of approximately 5,000 liters per hour • Milk reception for 6 raw milk varieties with all related tanks (8 tanks, volume of approximately 492,000 liters), including milk acquisition and shipment • Ice water preparation system • Well water system

Food & Beverage

SIMATIC PCS 7 control system at SalzburgMilch GmbH, SalzburgIncreased efficiency in the manufacturing process

Your contact:

Siegmund Scherney Tel. +43 (0)5 1707 65378 siegmund.scherney@siemens.com

In addition, new storage tanks, filling systems and external installations were incorporated into the SIMATIC PCS 7 control system:

• Upgrading of 10 double stock tanks in the pasteurized milk section and two raw milk tanks • Expansion of the soured milk department to include 6 large incubation tanks • Expansion of sterile production to include a sterile tank and a second high-temperature heating system by company GEA TDS GmbH • Feed and residual milk discharge • Connection of filling machines that have their own controls: Data coupled with filling machines from various manu- facturers (Elopak, SIG, Miromatic, Ampack), allowing for production archiving on the SIMATIC PCS 7 control system. • Connection to other sections of the dairy, such as whey concentration, the new high-bay warehouse, the NH3 system, the palletizing system and concentrate storage • Programming and incorporation of machine controls for two fruit mixing systems for the filling of drinkable yogurt, cups and tubs (in cooperation with company Bertsch Foodtec GmbH) • Conversion of milk reception to SIMATIC PCS 7 with a connection to the tanker system ARS Compact from company Schwarte Jansky for recording data about the accepted volumes and varieties of milk • CIP system with 7 cleaning circuits

Currently being implemented:

• More efficient use of energy

An analysis is being performed about the entire area of energy consumption at the Salzburg location. The result will be handed over to management in the form of a detailed concept for the efficient use of energy.

• SITUS maintenance software

A major part of the decision in favor of this system was the comprehensive incorporation of the system data contained in the SIMATIC PCS 7 process control system, which will lead

to a reduction in the time spent on entry and administration for maintenance.

• Connection to resource management system

The FELIX® resource management system by company GKC will be connected to the SIMATIC PCS 7 process control system. The data interface, which had to be administered manually before, will therefore be extremely secure, high-performance and above all else, include a wide variety of material and production data. The beta version was presented at the ANUGA 2012 trade fair.

Customer benefits:

• The SIMATIC PCS 7 process control system and the soft-ware components that were specially developed for dairy plant operation – which will also be used at SalzburgMilch – make the operation of the plant more flexible and more efficient. The production volume and the product mix width and depth have continuously increased since the process control system went into operation.

• Due to the high level of production growth that SalzburgMilch has strived for years, Siemens employees work from an engineering office that is located directly at SalzburgMilch. This ongoing service on site allows for quick responses to the customer’s wishes, ensures successful con-versions during regular operations and drastically shortens the channels of communication and the time it takes to communicate with SalzburgMilch and the plant builders.

Implementation period: 2002 – 2012

SalzburgMilch GmbH New CIP system

Siemens AG ÖsterreichIndustry SectorIndustry AutomationWolfgang-Pauli-Strasse 24020 Linz, Austria

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