1. Operator Training Simulator for Milk Powder Production Processes
The Virtual Powder Plant
Operator Training Simulator for Milk Powder Production Processes
Michael Robinson – Manager, NCDEA Gilbert Chandler Centre

2. Project sponsors

3. The Victorian Dairy Industry: Milk Powder Production
Dairy based powders account for over 36% of Australian dairy industry manufacturing
Milk powders contribute over $1 billion in export income to Victoria
Reference: Dairy Australia; ABARE

4. Powder Manufacturing Systems
Large, complex and diverse operations
Difficult for new staff to master
Offer challenges in process optimisation
Highly automated, with hidden sequencing steps
Equipment is remote from operator terminals

5. Skilled operators for industry

6. The Simulator
The development of an Operator Training Simulator to provide operational staff with:
training and competency development
a tool for observing the changes in both manufacturing operations and product parameters in an interactive system
a guide for operational changes in manufacturing

7. The typical Operator interface – Murray Goulburn Cooperative Ltd Rochester site

8. Focus: Operations & Supervisory Staff
Improved understanding of the plant activities
Analysis of signs and signals
Early recognition of problems
Fine-tuning tools
Plant optimisation capacity
Problem prevention and problem solving capability

9. Outcomes: The Simulator
The Package
Modelled on Murray Goulburn Coop Ltd Rochester
Fidelity
Operating Manuals
Engineering tools
Data capacity
Process Trend Charts
Remote Connection
Networked VPN access (dongle activated)

13. Learner interface – evaporator simulator and operation procedure

14. Learner interface – dryer simulator and operation procedure

16. Outcomes: Delivery Class Usage Remote access
Diploma & Grad Cert programs – blended delivery
Certificate II & III – Food Processing
Remote access
Elluminate on-line usage
Remote access from workplaces
Control room access
Firewalls, ownership & licensing

17. Implementation - Outcomes for the Dairy Industry
For operator training the Simulator will facilitate:
Improved operator performance
Reduced wastage and rework
Improved product quality and plant performance
Reduced plant downtime
Reduced operational costs
Improved profitability

18. Future developments Interface simplification
Parent plant layout with core information and buttons
Overlay of scripted scenarios
CadSimPlus direct HTML linkage of Operating Manuals
Further development of knowledge base linkages to HTML Operating Manuals

19. Project Contributors
Clean Technology Solutions Pty Ltd