IoT for Bulk Milk Chiller (BMC)

Efficient Cooling for Quality Milk, Always Fresh

Maintaining milk quality in the dairy industry requires a robust monitoring system for both milk temperature and chiller temperature, humidity levels and motor statuses (stirrer and chiller motors).

While milk temperature ensures direct quality control, chiller temperature indicates the efficiency of the cooling system. Humidity monitoring prevents condensation and microbial growth. The stirrer motor plays a critical role in preventing milk layer separation by ensuring uniform mixing and uniform cooling. An IoT-based solution integrates these parameters, providing real-time insights and operational control.

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Dairy - Bulk Milk Chiller (BMC)

Quality Assurance: Milk must remain between 4 to 6°C to prevent spoilage.

Chiller Efficiency Monitoring: Faulty chillers may cause temperature inconsistencies.

Humidity Control:High humidity leads to condensation and microbial risks.

Stirrer Motor Status: Stirrer motor failure can lead to uneven cooling and localized spoilage.

Chiller Motor Status: Chiller motor malfunction may compromise refrigeration efficiency.

Manual Monitoring Gaps: Periodic checks are prone to delays and errors.

Remote Accessibility: Many chillers operate in rural locations, complicating monitoring.

Regulatory Requirements: Accurate logs for milk temperature, chiller performance, and environmental conditions are required for compliance.

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IoT-Based Solution

A smart monitoring system was implemented using IoT-enabled sensors, cloud platforms, and remote dashboards.

  • Milk and Chiller Temperature Sensor: DS18B20 sensor (Fig a) used for precise milk and chiller temperature measurement inside the storage tank.
  • Humidity Sensor: DHT22 (Fig b) to monitor humidity inside the chiller room.
  • Motor Monitoring: Voltage sensors are used to monitor stirrer and chiller motor status.
  • Lid Status Monitoring: Door sensors are used to monitor lid status.

ESP32 microcontroller for data acquisition, data transmission, and wireless communication.

  • Wi-Fi for areas with network availability.
  • GSM/LTE for remote locations.

AWS IoT, Azure IoT, or ThingsBoard for data storage, visualization, and analytics.

  • Real-time temperature and humidity data visualization.
  • Alert notifications for deviations.
  • Display Type:
    • 16x2 or 20x4 LCD for basic setups.
    • 2.4" or larger TFT touchscreen for advanced setups.
  • Display Data:
    • Milk temperature, chiller temperature, and humidity levels in real-time.
    • System status (e.g., "Normal," "Alert: Temperature High").
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Data visualisation

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Temperature and Humidity

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Dashboard

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Status

Benefits

Enhanced Quality Assurance

Ensures milk stays at optimal temperatures and meets regulatory standards.

Predictive Maintenance

Chiller temperature monitoring helps detect cooling system inefficiencies early.

Humidity Control

Reduces microbial growth and equipment wear.

Real-Time Insights

Continuous monitoring prevents spoilage and reduces manual interventions.

Cost Savings

Early fault detection minimizes maintenance costs and operational disruptions.

Regulatory Compliance

Automated logs streamline compliance with food safety standards.

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Results

Smart BMC - IoT Device

Category Details
Operating System FreeRTOS
Processor ESPRESSIF-ESP32 240MHz Xtensa® single-/dual-core 32-bit LX6 microprocessor
Memory 520KB SRAM
Storage 4MB ROM
Power USB-C Power Adapter: 5V DC, 2A | Input: 100-240V AC | Rechargeable Battery (optional): 3.6V Li-Ion, 4200 mAh
Wireless Connectivity Wi-Fi: IEEE802.11 b/g/n | Bluetooth: V4.2 BR/EDR and Bluetooth LE | 2G/4G GPRS
Sensors Temperature Sensor | Lid Sensor | Humidity Sensor | Voltage Sensor
Actuators OLED Display | Buzzer | RGB LED | Relays
Package Contents BMC Monitoring Board | Power Adapter | Wi-Fi Antenna | Quick Setup Guide

An IoT-based solution for monitoring milk temperature, chiller temperature, and humidity ensures comprehensive quality control in bulk milk chillers. This system enhances milk quality, operational efficiency, and regulatory compliance, making it an essential tool for the dairy industry.