The enterprise friction point
Lactalis over-dosed expensive butterfat and milk solids by 0.12% across its standardized milk and cheese vats to prevent falling below mandatory FDA minimum label claims. Across 4.2 million daily liters, this raw ingredient giveaway cost $1.6M annually in unrecovered dairy fats.
Transformation objectives
- Connect laboratory LIMS raw milk chromatography analyzers with standardization blending PLC valves.
- Dynamically calibrate cream dosing setpoints based on incoming raw tanker composition assays.
- Guarantee 100% FDA regulatory compliance while eliminating ingredient over-dosing.
Discovery & architectural audit
Plant audit revealed that batch standardization operators deliberately over-fortified cream because static standardization tables did not update when incoming tanker fat percentages fluctuated throughout the day.
The Fortiv AI architecture
- 01
FOSS MilkoScan LIMS Ingestion Connectors: Streams incoming raw tanker fat, protein, and solids-non-fat assays in real time.
- 02
Non-Linear Fluid Milk Standardization Solvers: Mass-balance algorithms calculate exact cream and skim milk valve trim setpoints.
- 03
Rockwell FactoryTalk & Wonderware Batch Data Bridges: Sends verified dosing offsets to automated standardization blending valves.
- 04
Control Room Dynamic Dosing Advisory Console: Displays real-time margin cost per ingredient addition with operator verification checkpoints.
Verified audit outcomes
Post-deployment impact
- -82% Fat Giveaway
- Excess butterfat over-dosing trimmed to within 0.02% of target nutritional label specifications
- $1.6M Annual Savings
- In unrecovered cream and dairy solids saved across fluid milk and cheese vats
- 99.8% Claim Precision
- Full legal compliance with FDA nutritional label claims across all SKUs
- 0 Re-Batching Runs
- Eliminated batch standardization re-blending and holding tank bottlenecks
Architectural lessons learned
Real-time tanker assay ingestion allows standardization valves to adjust dynamically before mixing begins.
Operator buy-in was achieved by displaying real-time dollar savings per batch directly on the control booth screen.
Future scale roadmap
Expanding the mass-balance optimization model to cheddar cheese curd moisture and salt dosing.
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