DirectFlow

DirectFlow integrates group milking systems with milk pasteurization, filling, and sorting in a fully-automatic process
Summary
DirectFlow™ production cycle at a glance
DirectFlow™ is a plug-and-play prefab system ready for production of packaged milk from day one. Designed within a standard 40-feet shipping container, DirectFlow™ system integrates directly into any group milking system (herringbone, parallel parlor, carousel, etc.) with a capacity of up to 150 animals per hour. Our fully-automatic process accepts raw mixed milk directly from your milking system at one end with consumer-ready packages of pasteurized milk sorted to the crates in the cooling cell at its other end. The full process from milking to a sorted package takes just 15 minutes.
Alternatively, DirectFlow™ system can take mixed milk from a cooling tank and/or milk tankers shuttling between several farms.
While in operational mode, DirectFlow™ needs just one operator who transports finished products from our cooling cell to a higher capacity cold room, adds empty packages and spouts to the filler, and switches the system to CIP mode and back.
For farms or farm pools with 70 to 750 milking cows.
Turn-Key Set for Easy Start
DirectFlow™ hardware is supplied as integrated prefab system ready for production from day one.
Filler
We chose to fill our milk into stand-up pouches with sealed caps for two major reasons.
#1. This type of packages has the lowest carbon footprint compared to carton boxes, plastic or glass bottles.
#2. This is the only type of packaging that allows small-scale filling, labeling, and sorting of milk without manual operations.
The filler is coupled with a smart printer that prints variable data on each package. This feature makes every package label unique.
An optional extra filling head allows production of flavored milk or coffee latte.
Automated Sorting to Cold Storage
Milk packages are automatically sorted to crates in the buffer cold storage incorporated into DirectFlow™ container. The total capacity of the cold room is 60 crates (700-1000 liters). The system operator needs to move the trolleys with the filled crates to a bigger cold warehouse every 30-40 minutes.
Flow Pasteurizer
This is the first principal part of DirectFlow™ system designed from scratch by our engineers and protected by patent applications and know-how. Depending on their group milking capacity, farmers can opt for pasteurizers of 500, 1000 or 1500 liters per hour. A 1000 L/H pasteurizer requires less than 10 KWt of power supply and no ice-water for the milk chilling.
Changing room
Our production area is built with GMP standards. The system operator needs to wash hands and put on a disposable gown and shoe covers before entering the production area. The changing room also stores buffer volumes of some production items (CIP and cleaning chemicals, daily supply of empty packages, etc.).
Fermented Products (Optional)
Our standard DirectFlow™ facility can be expanded for production of fermented products. Farmers can expand their product list by adding liquid products like drinking yogurt, kefir, etc. from pasteurized milk. The standard DirectFlow™ hardware will fill and sort these products along with premium milk. Flavored additives and blended fruits can be mixed into your fermented products and filled into packages in a standard way.
CIP Unit and Air Sterilizer
CIP unit cleans our milk lines in coordination with the milking system to optimize the production cycle.
Air sterilizer prevents milk contamination in the processing room. The technology that sterilizes air on International Space Station upgrades our production room to GMP level of air cleanliness.
Deaerator (optional)
Homogenizer (optional)
Flow Pasteurizer
This is the first principal part of DirectFlow™ system designed from scratch by our engineers and protected by patent applications and know-how. Depending on their group milking capacity, farmers can opt for pasteurizers of 500, 1000 or 1500 liters per hour. A 1000 L/H pasteurizer requires less than 10 KWt of power supply and no ice-water for the milk chilling.
Filler
We chose to fill our milk into stand-up pouches with sealed caps for two major reasons. #1. This type of packages has the lowest carbon footprint compared to carton boxes, plastic or glass bottles. #2. This is the only type of packaging that allows small-scale filling, labeling, and sorting of milk without manual operations.
The filler is coupled with a smart printer that prints variable data on each package. This feature makes every package label unique.
An optional extra filling head allows production of flavored milk, fermented products or coffee latte.
CIP Unit and Air Sterilizer
CIP unit integrated with the pasteurizer cleans our milk lines in coordination with the milking system to optimize the production cycle.
Air sterilizer prevents milk contamination in the processing room. The technology that sterilizes air on International Space Station upgrades our production room to GMP level of air cleanliness.
Automated Sorting to Cold Storage
Milk packages are automatically sorted to crates in the buffer cold storage incorporated into DirectFlow™ container. The total capacity of the cold room is 60 crates (700-1000 liters). The system operator needs to move the trolleys with the filled crates to a bigger cold warehouse every 30-40 minutes.
Smooth Expandable Supply
Direct Dairy Holding BV supplies farmers with packages, spouts, filters, detergents, and other disposable items. Farmers can order farm-specific packages with different levels of customization.
Full-time Technical Support and Regular Service
Our technical personnel is available 24/7 for online consultations. Technical service intervals are monthly in the first three months upon installation and bi-monthly after this initial period. Standard or expanded set of spare parts goes together with every DirectFlow™ System.
Fermented Products (Optional)
Our standard DirectFlow™ facility can be expanded for production of fermented products. Farmers can expand their product list by adding liquid products like drinking yogurt, kefir, etc. from pasteurized milk. The standard DirectFlow™ hardware will fill and sort these products along with premium milk. Flavored additives and blended fruits can be mixed into your fermented products and filled into packages in a standard way.


Build your own brand!
DDH provides farmers with a contemporary interactive milk packages. Farmers can choose between different package volumes: 720, 1000 and 1250 ml. Farmers will build their own dairy brands.
An interactive QR code printed on each package will lead consumers to the farm's internet page with farmer addressing consumers with a welcoming speech, videos, pictures, news and promo hints.
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