AUTOMATION JULY/AUGUST 2019
THE LAND OF
MILK & HONEY
Automation and dairy production:
Dewlay Cheesemakers and Mitsubishi
Electric show how the two are in no
way like chalk and cheese
BY AMY BEST
Dewlay Cheesemakers has commissioned
TRITEC Developments for a new
automation system to help apply the
expertise of its finest cheesemakers
to a wider range of cheeses.
Based in Garstang, Lancashire,
Dewlay Cheesemakers was founded in 1957
by George Kenyon and is now run by his
grandchildren, Nick and Richard, who are the
third generation of cheesemakers.
There must be a better whey
The challenge was to introduce new varieties
while continuing to deliver exceptional batch
quality and consistency. TRITEC Developments
provided a solution that incorporates hardware
from Mitsubishi Electric to develop an advanced
tracking and monitoring solution to help
supervise and manage the individual processes.
Traditional cheesemaking relies on a detailed
understanding of the mechanisms governing
quality changes in the curd as it is processed
in large batches. Being able
to monitor these key process
parameters simultaneously
for multiple batches, and
modify them promptly when
necessary, was deemed crucial
to moving Dewlay’s business
forward. A responsive but easy
to use automation platform
was needed that allowed
for the subtleties of the
cheesemaking process to be
retained while introducing the
right adjustments to deliver a
consistent end result.
Every day Dewlay monitors
the various cheese vats where
pasteurised milk is processed
by starter cultures. The milk
goes through a cycle of stirring,
cooking, setting, cutting and
whey removal. This induces
coagulation and syneresis,
resulting in the production
of curd. The curd is then
processed until it achieves
the required consistency
and pH value. Next, it is sent
downstream for further whey
removal, it is then formed or
moulded and packaged ready
for the maturation process.
A grate mix of art
and science
Dewlay says that milk
composition and bacterial
activity is influenced by several
environmental conditions
such as weather patterns and
seasons, feedstock, plus a cow’s
genetics and physiological
make up. As a result, producing
consistent high-quality dairy
products, given all the variables,
is the biggest challenge for
Dewlay’s cheesemakers.
Richard Jones, operations
director at Dewlay, explains:
“We believe cheesemaking is a
mix of art and science as it relies
on living organisms. As a result,
we need to be able to address
this variability by having access
to key process parameters and
curd quality attributes, as well
as by responding quickly to
optimise the reactions taking
place within the vats.
“We see increasing the
varieties of cheese we offer
while maintaining our artisan
qualities, as an ideal way to
expand the business. However,
it makes the tracking and
Garstangbased
Dewlay
Cheesemakers
was established
over 60 years ago
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