AU2MATE

Butter Standardization Unit

Au2mate’s Butter Standardization Unit automates moisture and fat control, improving butter quality, consistency, and profitability. With real-time monitoring and seamless integration, it reduces waste and offers a fast payback period.

Automatic butter standardization

Application

Looking to maximize efficiency and profitability in your butter production? Au2mate, in collaboration with FOSS, offers an innovative solution tailored for producers who demand precision and sustainability.


Description

The system integrates a PLC with Au2mate’s standardization software and a ProFoss in-line sensor for continuous monitoring of moisture and SNF levels, as well as automatic speed control of dosing pumps.

Developed in collaboration with FOSS, the unit offers precise in-line process control for butter standardization. It is designed to seamlessly integrate into both new and existing installations and is adaptable as a standalone unit with an operator panel or as a fully integrated component of a central PLC and SCADA system. This combination of expertise ensures consistent, high-quality butter production with minimal downtime and rapid commissioning.

Challenges in butter production

Moisture standardization in a butter churn is often performed manually, with operators conducting lab tests at regular intervals and adjusting dosing pump speeds based on the results. This manual approach tends to result in a conservative operation of the churn, with moisture content typically well below 16% to prevent quality issues. Consequently, butter is often produced at around 15.6% moisture, leading to high cream giveaway and missed profitability.

With Au2mate’s Butter Standardization Unit and ProFoss sensor, producers can reliably achieve higher moisture levels, such as 15.85% or even 15.9%, significantly boosting profitability, product consistency, and operational efficiency.


Standardization unit

key features

  • In-Line Analysis: Real-time monitoring of moisture, fat, salt, and SNF levels using ProFoss 2 for complete butter blend analysis.

  • Advanced Automatic Regulation: Dynamic control of moisture and fat levels to meet precise production targets.

  • Self-Learning Functionality: Stores and optimizes regulator outputs during production for faster startup and reduced settling times.

  • Configurable Recipes: Customize the process to specific production requirements with flexible recipe management.


Benifits

Enhanced Automation and Efficiency

  • Automates processes, significantly reducing operator workload.

  • Ensures robust performance during restarts after production pauses, such as downstream stops on butter silos or packaging lines.

  • Achieves steady moisture levels quickly and efficiently.

Fat Standardization

  • Achieve higher quality and yield by moving closer to target fat levels.

  • Reduce average fat content by 0.20% – 0.30%, leading to substantial cost savings.

Moisture Standardization

  • Decrease process variation from 0.26% to as low as 0.05%–0.10%, ensuring consistent moisture content.

  • Move moisture targets closer to specifications (e.g., 15.75%–15.90%), boosting product quality and profitability.

Results

  • Significant increase in yield and profit, with a typical payback period of just 4–8 months.

Easy maintainable

  • PLCs and HMI parts can quickly be sourced locally, reducing risc for unnecessary downtime should disaster strike.

  • Technologies that maintenance technicians are able to troubleshoot.

  • No propriety technologies used except FOSS instrument, reducing dependency on exotic manufacturing.

  • 24/7 Support is offered for extended support, including support for the complete Churn.


Base configuration

The Au2mate Butter Standardization Unit is pre-mounted, wired, and tested, ensuring easy installation. Standard components include:

  • Stainless steel electrical cabinet.

  • Rittal HD Compact enclosure (WHD: 810x650x821 mm).

  • Siemens Control System.

  • Analog and digital I/O.

  • Siemens Unified HMI panel (12″).

  • 24 V DC power supply.

Optional features 

  • Rockwell or Schneider Electric control systems.

  • Additional network cards for dedicated factory LAN.

  • Larger cabinets accommodating up to two frequency inverters for dosing pumps.

  • Seamless MES system integration.

  • 24/7 support agreements for uninterrupted operations.


Fully integrated solution

For facilities seeking full integration into their butter churn control system, Au2mate provides:

  • Standardization software embedded in existing PLC systems.

  • Communication with ProFoss instruments for real-time data.

  • ProFoss results displayed on SCADA systems for enhanced monitoring.

  • Recipe management system for tailored production processes.

  • Dynamic production backups and daily reporting for operational insights.

By integrating Au2mate’s Butter Standardization Unit, you’ll achieve superior butter quality, reduced waste, and improved profitability. Contact us today to discover how this cutting-edge solution can transform your butter production process.


Analytical advantages

Some systems attempt to achieve moisture optimization using conductivity sensors. However, this approach is inferior for several reasons. Below are the key advantages of the Au2mate solution with ProFoss compared to competitors:

  • Superior Accuracy: ProFoss’s ability to control SnF content ensures consistent quality and yield improvement, reducing operational costs and increasing profitability. A German study demonstrated daily moisture averages of 15.97% with ProFoss.

  • Faster Startup: Reduces startup time from 45 minutes to 15 minutes, increasing both quality and yield.

  • Scalability and Integration: Au2mate’s scalable design ensures compatibility with evolving production technologies.

     


FAQ

Can you deliver the panel with cUL certification?

The panel can be cUL marked. Any CSA-related inspections will need to be arranged by the end user.

I would like some kind of reporting or data aggregation to my MES for quality and traceability. Does this solution support that?

Yes, the solution supports OPC UA by default. Au2mate can provide an interface specification for your integrator or handle the integration task for you. We have extensive experience with MES integration and data aggregation for quality and traceability.

I already have a ProFoss 1. Can we use this instead of upgrading to a ProFoss 2?

Yes, a ProFoss 1 can be used for moisture control. However, for SnF (Solids-not-Fat) measurements, a ProFoss 2 is required. Let’s evaluate the numbers together to determine if upgrading to a ProFoss 2 is a viable option for your business case.

I don’t like the idea of coordinating both FOSS and Au2mate during the project.

We’ll streamline everything for you. Au2mate will act as your single point of contact, ensuring you don’t need to take on any extra project management responsibilities.

I’ve heard promises of huge savings before, only for the results to be marginal. Why should I trust this?

We understand your concerns. That’s why we’re open to KPI-based agreements. We’re confident the solution works and consistently delivers measurable results. Let’s discuss your specific needs in a sales meeting and explore the potential savings for your operation.

Should I integrate the solution into the existing pasteurizer control system or use a standalone setup?

At Au2mate, we are integrators at heart. We always recommend integrating the solution into your existing system. The benefits—such as reduced maintenance, improved safety, and a better operator experience—often outweigh the costs.


CONTACT OR DOWNLOAD PDF

Contact Au2mate for a demonstration or download this solution as a data sheet.


Want more insight?

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INFORMATION

Au2mate A/S
Frichsvej 11
DK-8600 Silkeborg
Tel. +45 8720 5050
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