Milk data, from collection through to processing all the way to utilisation for logistical purposes

Data recorded on milk tankers as a standard consists of the following information:
• automatic identification of the supplier
• identification of the driver
• officially determined quantity of milk
• temperature of the milk, including limit value monitoring
• identification of the sampling bottle
• date/time
• monitoring of the metering equipment (service/maintenance)
• tanker and engine data (for maintenance or servicing intervals)
• logging of faults and errors, e.g. with documentation of manual interventions

ZEVODAT-M data acquisition unit with a variety of peripheral devices

In modern tanker fleets, many additional functions are integrated:

• control of the metering equipment (pump, sampler control etc.)
• control of tanker logistics (valve control for the compartments, trailers etc.) at reception and possibly also at discharge (e.g. in the case of partial discharge)
• transmission of information to the supplier (laboratory results, comments etc.) which can be printed out directly at the tanker
• routing through navigational support for the driver
• monitoring of sample cooling
• monitoring of tank content

Years ago already, GEA Diessel designed an “open” system consisting of a modular ZEVODAT concept based on its own developed CS3 electronics platform. This offers the advantage that new, innovative functions can be added to existing equipment at a later date. In this way, ZEVODAT always remains state-of-the-art, and the lifetime of the generation of devices is extended from development stage to development stage.

It is quite normal nowadays for road tankers to be equipped with modern communications and satellite technology. GPS positioning as a method of supplier identification is common practice. The data records that are created can be transmitted via GSM or GPRS without any delay and for immediate processing. In this way, the supervisor is in a position to monitor and optimise the current milk collection, and if necessary to modify it.

Official printed vouchers, semiconductor cassettes as intermediate storage media and traditional cable transmission are being used less frequently. Wireless transmission technologies such as infrared or Bluetooth still continue to be used.

Fleet management is supported by intelligent logistics programmes, according to the mottos “optimisation of tanker deployment” and “uninterrupted flow of goods”.

The dairy must always be in a position to be able to react to any parameter deviations immediately.

One declared aim of trip planning is to reach 100% of tanker capacity wherever possible. Some of the important aspects that have to be taken into account are:

• compliance with weight limits, e.g. on bridges
• the danger of exceeding the permitted filling level in the tank, e.g. on gradients
• other restrictions on collection times (noise nuisance at night, prohibitions on Sunday driving etc.) or road use (diversions at certain times near schools)
• monitoring of the driver’s working time (including maximum annual working time)

Officially approved metering apparatus with control unit and ZEVODAT-M data acquisition unit

Milk payment accounting remains an important aspect of data capture on milk collection tankers. For this purpose, the milk quantity has to be linked to the analysis data determined in the laboratory. It is of extreme importance that sampling bottles should be reliably attributed to the correct suppliers; this can be double-checked, for example, by reading the barcode number into the data capture system again before the start of the intake process. If any additional information is required for the sampling, it is advisable to use RFID tags. The data from the laboratory and the tanker are linked automatically in the operating system and form the basis for milk payment accounting.

It is a declared aim of the industry federations and of the dairies to achieve the standardisation of data formats and common regulations for the collection of milk; only then will it be possible to use tankers across national boundaries within the EU.

It is utterly essential that reliable metering, approved by the weights and measures authorities, should be guaranteed. Although the individual devices have been type-tested and approved, and are thus to a large extent self-monitoring, provision is nevertheless frequently made for an official stationary measurement device (using volumetric or mass flow metering technology) to be used for counterchecking purposes, ensuring adequate redundancy and thus enhancing the reliability of the measurements taken.

Communication with the tanker
Bilateral data exchange between the tanker and the base station has now been replaced by “multiple” exchanges between all the tankers of a fleet. The reporting back of the previous day’s quantity data (“quantity memory”) supports the function of controlling the tanker-mounted sampler, ensuring the consistency of samples. At the same time, the quantities provide the basis for dynamic route planning.

Any changes to the route or any unforeseen events can be communicated individually to the tankers at any time; the drivers can receive or call up the necessary instructions on special terminals in their cabs, or even through a function integrated into normal, commercially available navigation systems.

The GPRS service is particularly suitable for this constant communication; since 2002 GEA Diessel has been retrofitting fleets’ existing ZEVODAT systems with this function.

Data security

Reliable access to data should already be adequately ensured in the individual data capture unit, e.g. through the long-term memory. In addition, the security of the data channels against unauthorised access and manipulation is an important aspect. Right from the basic design phase, GEA Diessel has taken into account all modern security techniques at the various points of the overall transmission chain from the tanker all the way to the server via the internet. Thus the data is always protected against both external and internal attack.

The author:
Hermann Hartmann, Dipl.Phys., Head of metering and data technology at GEA Diessel

Published in: European Dairy Magazine 1/2006

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