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Learn some options to help you with efficient use of water during the plant washing process.
The volume of water required to clean the plant varies with the size of the dairy. Larger dairies (over 60 sets of clusters) use up to 5,000L while even smaller dairies use around 2,000L daily.
This is not a place to skimp on water because getting a hygienic clean is vitally important for our industry. However, many farmers use a range of strategies to make sure they are using water wisely in the plant washing process.
The links below show some options.
Reviewing your cleaning program can often lead to water savings. Excessive water volumes mean higher water heating and chemical costs.
Jetter systems are by far the most water efficient way to clean the milking machine. Typically 6-8 litres per cluster are needed for each wash cycle. An easy way to check that enough water is being used is by ensuring the wash drum does not empty during recirculation. If it does, more water is required.
Some automatic cleaning units can further reduce the amount of water required for effective cleaning.
Reverse flow systems use a lot more water than jetter systems and are expensive to run, so consider installing a jetter system.
Use a warm pre-rinse to warm pipework and remove most of the residue. Fully drain out pipework between milkings.
Check manufacturer's specifications and take advice from your technician / chemical re-seller.
Better cleaning protects milk quality, reduces power and chemical costs. Lower volumes can mean quicker drops in temperature so monitoring is needed.
Nil unless requires manual cleaning.
Protecting milk quality is the primary concern and must not be put at risk.
Using less water means less waste to effluent.
Cleaning the vat is not a place to skimp on water but it may be worth checking that your current cleaning regime matches the manufacturer's recommendations.
As a general guide, the amount of hot water required for effective cleaning is 1-3% of the milk vat's storage capacity, although the design of the vat makes a big difference and there is a poor relationship between size and water use. The number of cycles per wash and the temperature of each cycle will also affect the total volume of water required.
The newer spray heads ($150-$400) and pumps ($1,000 - $2,000) increase kinetic energy and can sometimes reduce water use.
Systems that re-use the detergent wash fluids are available but the costs of maintaining their temperature can be high.
Check and clean spray heads periodically. Use correct chemicals. Retro-fitting vats with new spray heads can be tricky - seek professional advice.
New spray head systems can usually be retrofitted to vats with sealed lids, older vat designs may leak.
Nil unless requires manual cleaning. Significant OH&S risk with entering confined spaces.
Nil unless inadequate cleaning.
Air injectors (also called and flushing pulsators) increase turbulence and improve cleaning - making it less likely that additional cleaning of the plant will be required.
Air injectors are usually located on the milk line. They periodically (2-3 cycles per minute) admit air, creating a large slug of wash fluids to increase mechanical scrubbing down the milk line. They are standard issue on newer installations but some older dairies with milk lines of 50mm or more may benefit from a retrofit if cleaning is less than ideal.
Should be fitted professionally and filters checked periodically. Easy to see if working by watching action of wash fluids through face plate of receiver.
Permanent fix.
Reduce power and chemical costs and may improve milk quality.
Will reduce the temperature of the wash solutions more quickly.
Should improve effectiveness of clean.
Acid detergent solutions designed for use in cold water are well suited for re-use. Capturing and storing the solutions for re-use requires minor changes to the pipework and an extra sealed wash barrel.
Capturing and storing the alkali solution is more problematic as the solution needs to be hot when used (at least 65oC). This means that the storage barrel needs to have a heating element and good insulation.
Regular monitoring of pH and top-ups are required and the solutions need replacing every 2 - 6 weeks (although some farmers do it less frequently).
Commercial re-use systems are available but most examples in Australia have been put together by farmers and chemical supply companies on a case-specific basis.
Permanent water and chemical savings (and power too). Can use the best quality of water available for plant wash.
Difficult to automate and / or integrate into existing automated systems. Heating costs for keeping alkali hot can be substantial.
Manual labour required, OH&S issues with storage of wash chemicals.
Nil - may improve this.
The last hot (sterilising) rinse from plant washing can be saved and re-used as the first pre-rinse at next milking - saving 200-800 litres per day.
It is important that the pre-rinse water is warm (around 38oC) so the wash barrel should be covered and well insulated.
Insulation is important to prevent heat loss during storage. Ensure the milking machine drains well after the each cycle to minimise contamination with detergents and milk residue.
Relatively easy to do as equipment is already in place. At present it is difficult to automate this or configure automated systems to save hot sanitising rinse.
Manual labour required to divert wash fluids. OH&S issues with storage of hot water.
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