Global heat transfer, separation, and fluid handling specialist Alfa Laval has once again demonstrated the impact of smart engineering on operational efficiency. Through a trial installation by Alfa Laval at Molkerei Wiegert Dairy, the company’s side-mounted agitator proved its energy-saving claims, delivering tangible reductions in both electricity use and environmental footprint.
Agitators are indispensable in dairy processing, facilitating the mixing of ingredients, maintaining uniform consistency, and aiding in fermentation and temperature regulation. At its Velen site, Molkerei Wiegert operates close to 40 such units. When frequent mechanical seal failures plagued one of their aging lateral agitators, the company reached out to Alfa Laval’s sales partner, SKS GmbH, to explore alternatives.
The old agitator, used to homogenize skimmed milk concentrate with 35% dry matter, consumed 8.6 kilowatts during four hours of daily operation. Alfa Laval estimated that switching to their side-mounted agitator would reduce energy usage by over 75%. Despite initial skepticism, the dairy agreed to test the system for three months.
“We actually found it hard to believe Alfa Laval’s calculations,” explains Operations Manager Nicolas Becker. “Our old agitator was powered by a 15-kilowatt motor while the new agitator operates with just 2.2 kilowatts. We were sceptical but appreciated the chance to test the Alfa Laval agitator.”
Installation took just one day, and the new system immediately functioned seamlessly. After the trial period, the results confirmed Alfa Laval’s projections.
“We achieve the same consistent mixing quality but use significantly less electricity,” Becker confirms.
These energy savings translate into approximately EUR 1,200 in annual cost reductions and a 5.4-tonne decrease in carbon emissions. With a return on investment in just 2.8 years, the move also supports Wiegert Milch’s energy management goals aligned with DIN EN ISO 50001 standards.
Encouraged by the results, the dairy has ordered a second unit for a similar tank and plans a broader evaluation of all agitators on-site.
“We were unaware of the extent of the potential savings offered by replacing our agitators,” Becker reflects.