The BlueMilk project, led by Zott SE & Co. KG, set out to raise the energy efficiency of the dairy industry while simultaneously increasing its flexibility to accommodate the variable supply of renewable electricity. The programme combined two complementary approaches: a pinch‑analysis based optimisation of heat flows and a dynamic simulation of the entire cold chain. The goal was to develop a technically and economically viable system that could be transferred to other dairy plants and even to related sectors such as beer and fruit‑sauce production.
On the technical side, the project produced a detailed model of the high‑rack cold storage facility. By adding complexity layers the model captured the spatial temperature distribution and the thermal inertia of the stored products. Additional temperature sensors were installed throughout the warehouse, enabling a fine‑grained comparison between simulated and measured temperature profiles. The same modelling framework was extended to the transport leg, the cooling tunnels, the picking area and the truck loading process. For each segment the simulation could calculate the energy demand and the temperature change of the products, allowing the team to identify critical points where energy savings or flexibility could be introduced.
The dynamic simulation of the cold chain was validated against real‑time measurements. The team installed flow meters, temperature probes and conductivity sensors in the cooling plant, and built an intelligent energy meter that combined these signals with the control‑system logs. The resulting data set was used to calibrate the simulation, improving its accuracy and giving confidence that the model could predict the impact of different operating strategies. With the validated model the project carried out a greenhouse‑gas analysis of a flexible operating mode, quantifying the potential CO₂ reductions. An accompanying economic assessment evaluated the cost implications for the company and its logistics partners, leading to a set of recommendations that balance technical feasibility with financial viability.
The project also addressed the broader implications of temperature fluctuations on food quality. A dedicated discussion highlighted how deviations from the optimal temperature range can affect product shelf life and safety, reinforcing the need for precise control in the cold chain.
Collaboration was central to BlueMilk’s success. The consortium comprised Zott SE & Co. KG, the Technical University of Ingolstadt, the industry association DLG e.V., and the media partner Deutsche Molkerei Zeitung. Regular workshops were held across several regions, and the project’s findings were disseminated through national and international journal publications and an online closing event. The funding, provided as a grant, covered personnel costs, the procurement and installation of measurement equipment, and the development of the simulation tools. Travel expenses were incurred for meetings in 2018, 2019 and 2020, although some in‑person sessions were cancelled due to the COVID‑19 pandemic.
In summary, BlueMilk delivered a validated, high‑resolution simulation of the dairy cold chain, integrated energy‑efficiency and flexibility measures, quantified environmental and economic benefits, and established a framework that can be replicated across the dairy sector and beyond. The project’s outcomes were shared with academia and industry, ensuring that the knowledge gained will inform future energy‑management strategies in the food‑processing sector.