The 24-month project substantially increased plant production, provided “value added” products capability, reduced energy and operating costs, and improved efficiency of production—all without interrupting existing plant production. Additionally, Shambaugh achieved the following:
- Improved production flexibility through new product transfer systems.
- Maximized condensing capacity with installation of 2 new MVR preconcentrators to improve thermal efficiency and increase infeed capacity by more than 50%.
- Maximized drying capacity with installation of a new spray dryer capable of producing NFDM, WMP, and agglomerated powders with minimum NOx levels in powder.
- Modification and redesign of the existing plant process flow to achieve an increase of 100% in plant milk powder production capacity.
- Modification and redesign of the existing plant process flow to achieve an increase of 50% raw product intake and condensing capacity.
- Water recovery and re-use was vastly improved by elevating the evaporated water to Category I status. This allowed water to be used for final rinses and sanitizing. Recovered water is also used for CIP, hose stations, and boiler make-up.
- Provided more efficient energy infrastructure to reduce plant-operating costs.
- Product recovery was improved through automated water flush technology.
The Michigan Milk Producers Association wanted to expand the capabilities of their Ovid, MI plant to allow for the future installation of processing and packaging equipment.
Additionally, they wanted to increase efficiency and volume, and continue efforts of environmental awareness and conservation by expanding in the location where the product is most available.
Scope of Services
The expansion included the following:
- $27 million tower dryer
- $7 million in mechanical vapor recompression (MVR)
- $28 million in receiving, processing, utility and warehousing improvements and additions
- $4 million for three backup generators and diesel fuel storage. The 6 megawatts of emergency power click on within 15 seconds of an outage and allow the plant to operate off the grid for 24 hours before refueling
- Modification and redesign of the existing plant process flow to achieve an increase of 100% in plant milk powder production capacity
- Modification and redesign of the existing plant process flow to achieve an increase of 50% raw product intake and condensing capacity
- Improved production flexibility through new product transfer systems
- Maximize condensing capacity with installation of two new MVR preconcentrators to improve thermal efficiency and increase infeed capacity by more than 50%
- Maximize drying capacity with installation of a new spray dryer capable of producing NFDM, WMP and agglomerated powders with minimum NOx levels in powder
- Expanded Ammonia Refrigeration System including new 480HP compressor
The expansion provided a solution to Michigan Milk Producers Association by adding capacity and flexibility to help with production balancing swings. It also empowered MMPA to more effectively meet the needs of their growing dairy manufacturing customers by allowing its members to increase production with the confidence that they will have a secure home for the milk.
Modifications to the existing plant utility systems support the plant’s increased capacity, including 100% electrical generation back-up and a new boiler house with 4600B HP. Good Manufacturing Practice (GMP) was incorporated to ensure food safety included stringent control of the room’s red zones, temperature, and air flows. Product recovery was improved through automation.
Shambaugh is proud of its 25-year partnership with MMPA. The Ovid, Michigan facility is currently 241,000 sf on 7.5 acres. Products made by its 100 employees include butter, nonfat dry milk powder, cream, condensed skim milk, and specialty blends.