Real-time inline measurement technology helping dairy producers improve quality, efficiency and sustainability
Hanley Controls is pleased to highlight the capabilities of the Vaisala Polaris™ Process Refractometer range, a proven inline measurement solution designed to help dairy processors achieve greater process control, product consistency and operational efficiency.
As dairy manufacturers face increasing pressure to improve yields, reduce energy consumption and maintain strict product quality standards, real-time process measurement has become a critical requirement across modern production facilities. Vaisala's Polaris™ refractometer technology provides continuous inline measurement of Brix, Total Solids (TS), Total Dissolved Solids (TDS) and concentration, enabling operators to make faster, data-driven decisions throughout the production process.
Why Inline Total Solids Measurement MattersThe concentration of dissolved solids directly impacts product quality, taste, consistency and regulatory compliance. Traditional laboratory sampling methods can create delays between measurement and corrective action.
The Vaisala Polaris™ refractometer measures refractive index in real time and converts this data into concentration readings, providing immediate visibility into process performance without the need for manual sampling or recalibration. The technology delivers drift-free measurement and remains unaffected by bubbles, foam, colour variations or vibration, making it ideal for demanding dairy applications.
Key Dairy Applications
Milk Standardisation and Ingredient Mixing Maintaining precise solids content is essential for products such as drinking milk, yoghurts, dairy beverages, ice cream and specialised nutrition products.
By continuously monitoring concentration during mixing and standardisation, the Polaris™ refractometer enables automated control of milk, cream, water and dry ingredient dosing. This helps ensure every batch meets specification while reducing ingredient waste and minimising manual intervention.
Evaporation and Spray Drying
Energy-intensive processes such as evaporation and spray drying can significantly benefit from accurate inline concentration measurement.
Real-time monitoring of solids concentration at evaporator outlets helps operators maintain target concentrations while optimising steam usage and reducing energy consumption. In spray drying applications, stable feed solids improve powder quality, particle consistency and shelf life while supporting efficient dryer operation.
Membrane Filtration Processes
In ultrafiltration (UF), reverse osmosis (RO), nanofiltration (NF) and microfiltration (MF) systems, accurate concentration monitoring is essential to maximise throughput and protect membrane performance.
The Polaris™ solution provides continuous visibility of separation efficiency, helping operators maintain target protein concentrations, identify fouling earlier and optimise membrane flux rates for improved productivity. [VIM-
Filling, Changeovers and CIP Optimisation
Process transitions and cleaning cycles often result in product losses, increased water consumption and unnecessary chemical usage.
The refractometer's ability to accurately detect interfaces between product, water and cleaning solutions allows dairy processors to optimise CIP (Clean-In-Place) operations, reduce waste and shorten changeover times.
Wastewater Monitoring and Water Recovery
Sustainability continues to be a major focus across the food and beverage sector. Inline measurement of dissolved solids in wastewater streams enables rapid identification of product losses, helping facilities reduce treatment costs, monitor discharge quality and improve water recovery strategies.
As dairy manufacturers face increasing pressure to improve yields, reduce energy consumption and maintain strict product quality standards, real-time process measurement has become a critical requirement across modern production facilities. Vaisala's Polaris™ refractometer technology provides continuous inline measurement of Brix, Total Solids (TS), Total Dissolved Solids (TDS) and concentration, enabling operators to make faster, data-driven decisions throughout the production process.
Why Inline Total Solids Measurement MattersThe concentration of dissolved solids directly impacts product quality, taste, consistency and regulatory compliance. Traditional laboratory sampling methods can create delays between measurement and corrective action.
The Vaisala Polaris™ refractometer measures refractive index in real time and converts this data into concentration readings, providing immediate visibility into process performance without the need for manual sampling or recalibration. The technology delivers drift-free measurement and remains unaffected by bubbles, foam, colour variations or vibration, making it ideal for demanding dairy applications.
Key Dairy Applications
Milk Standardisation and Ingredient Mixing Maintaining precise solids content is essential for products such as drinking milk, yoghurts, dairy beverages, ice cream and specialised nutrition products.
By continuously monitoring concentration during mixing and standardisation, the Polaris™ refractometer enables automated control of milk, cream, water and dry ingredient dosing. This helps ensure every batch meets specification while reducing ingredient waste and minimising manual intervention.
Evaporation and Spray Drying
Energy-intensive processes such as evaporation and spray drying can significantly benefit from accurate inline concentration measurement.
Real-time monitoring of solids concentration at evaporator outlets helps operators maintain target concentrations while optimising steam usage and reducing energy consumption. In spray drying applications, stable feed solids improve powder quality, particle consistency and shelf life while supporting efficient dryer operation.
Membrane Filtration Processes
In ultrafiltration (UF), reverse osmosis (RO), nanofiltration (NF) and microfiltration (MF) systems, accurate concentration monitoring is essential to maximise throughput and protect membrane performance.
The Polaris™ solution provides continuous visibility of separation efficiency, helping operators maintain target protein concentrations, identify fouling earlier and optimise membrane flux rates for improved productivity. [VIM-
Filling, Changeovers and CIP Optimisation
Process transitions and cleaning cycles often result in product losses, increased water consumption and unnecessary chemical usage.
The refractometer's ability to accurately detect interfaces between product, water and cleaning solutions allows dairy processors to optimise CIP (Clean-In-Place) operations, reduce waste and shorten changeover times.
Wastewater Monitoring and Water Recovery
Sustainability continues to be a major focus across the food and beverage sector. Inline measurement of dissolved solids in wastewater streams enables rapid identification of product losses, helping facilities reduce treatment costs, monitor discharge quality and improve water recovery strategies.
Built for Hygienic Dairy ProcessingThe Vaisala Polaris™ PR53 range is specifically designed for hygienic applications and offers:
- Hygienic 3-A and EHEDG certified designs
- Maintenance-free operation with no recalibration required
- CIP/SIP resistance
- Temperature-compensated measurement
- Fast response times
- Plug-and-play installation
- Advanced diagnostics including live optical imaging and Quality Factor monitoring
- Compatibility with the Vaisala Indigo520 transmitter platform for enhanced diagnostics, data logging and remote access.
Supporting Dairy Industry PerformanceBy providing accurate, real-time concentration measurement throughout the production process, Vaisala Polaris™ refractometers help dairy processors:
- Improve product consistency and quality
- Reduce ingredient losses
- Lower energy consumption
- Increase process efficiency
- Improve regulatory compliance
- Reduce water and chemical usage
- Support sustainability initiatives.
As Vaisala's trusted partner in Ireland, Hanley Controls works closely with dairy manufacturers to identify the most suitable measurement solutions for their applications, helping customers achieve greater reliability, efficiency and process visibility.
To learn more about Vaisala Polaris™ refractometers and how they can optimise your dairy processes, contact the Hanley Controls team today.
email [email protected]
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