GEA launches digital condition monitoring solution for dairy processing
GEA has introduced GEA InsightPartner EvoHDry, a new digital condition monitoring system designed to enhance production reliability and operational efficiency in dairy and beverage manufacturing facilities. The solution targets complex industrial environments where continuous operation is critical for producing high-quality products including infant formula, cream, evaporated milk, condensed milk, and cheese.
Real-time monitoring prevents equipment failures
The GEA InsightPartner® EvoHDry system employs real-time condition monitoring through continuous data collection and analysis to identify early warning signs of equipment degradation. The technology tracks parameters including temperature, pressure, vibration, and flow rates, providing operators with comprehensive system performance visibility through both mobile applications and web-based interfaces.
The system specifically addresses a common cause of unplanned downtime in dairy operations: gradual suction pressure loss in vacuum pumps within evaporation systems. This condition reduces evaporator efficiency and can force unplanned shutdowns. The monitoring solution uses predictive analytics to recognise failure patterns early and generates pre-alarm notifications for preventive intervention.
Technical architecture ensures security and accuracy
The technical setup incorporates market-leading sensors for vibration, flow, and pressure monitoring, connected through an edge gateway that processes data locally before cloud transmission. This local processing approach ensures rapid response times whilst reducing external network dependence. The system operates independently of customer IT infrastructure, eliminating direct plant network access requirements and minimising cybersecurity risks.
Data is securely transferred to the GEA Cloud and GEA Portal, where proprietary modelling algorithms evaluate equipment condition. Certified vibration specialists validate the automated diagnostics, combining human expertise with algorithmic analysis.
Addressing industry maintenance challenges
Modern dairy processing plants often struggle with alarm management, as SCADA systems can generate overwhelming numbers of alerts that operators find difficult to prioritise. Combined with skilled technician shortages, this creates challenges for effective maintenance management.
“Unplanned downtime remains the biggest challenge for dairy processors,” said Angela Yeung, Digital Portfolio and Strategy Lead for Liquid & Powder Technologies at GEA.
“By using predictive insights, customers can intervene before failures occur, reducing costs and improving efficiency. With GEA InsightPartner EvoHDry, operators gain clear insight into machine health. Instead of reacting to unexpected shutdowns, they can plan maintenance based on reliable diagnostics – keeping production stable and output consistent.”
OEM expertise integration
The solution leverages GEA’s original equipment manufacturer expertise, incorporating decades of equipment and process knowledge into its digital services. GEA InsightPartner EvoHDry has been specifically developed for evaporators, spray dryers, pumps, and rotating equipment, with monitoring coverage extending from vacuum stages through Clean-in-Place cycles.
The system forms part of GEA’s broader Service Performance Partnership programme, which integrates digital tools with service expertise to support plant operators in improving availability, productivity, and sustainability.
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