Case Study: How Valio's Joensuu plant achieved significant savings annually

Valio's Joensuu plant utilised Collo's technology and achieved significant cost savings on an annual basis by improving the efficiency of the cream production process

THE CHALLENGE

The Hidden Losses

Valio’s Joensuu plant had already made strides in reducing product losses through previous initiatives. However, after addressing the visible losses, the plant faced a new challenge: tackling the "invisible" losses inside the steel pipes of their cream production line. These hidden inefficiencies were difficult to identify using traditional methods.

The plant focused on analysing pushouts—instances where cream or whey is lost or diluted due to incorrect detection of the interface. The data from existing process sensors and instruments was deemed unreliable, which prompted to investigate more closely, focusing on the high-volume, high-value processes first.

“We were unable to detect waste with existing methods, when product goes down the drain, it's invisible—we only see the effect later  in the wastewater load."

says Olli Ruotsalainen, Process Specialist at Valio.

Using flow meters, the plant could not pinpoint the losses with precision. The random deviation of the actual value in volume made it extremely difficult to detect the interfaces and to control the process accurately.

THE SOLUTION

Accurate insights for optimisation

To address the challenge, Valio implemented Collo’s Insights solution to the cream line. Collo’s sensors provided precise data on where and when product loss or dilution occurred, enabling the plant to optimize processes in real time.

“With Collo, we were able to gain reliable insights into how our process actually works. This was critical for identifying the issues and implementing the necessary changes,”

explains Jari Pikkarainen, Development Manager at Valio Joensuu.  

Unlike traditional sensors, Collo’s sensors not only detect losses and dilution but also analyses the underlying causes and offers actionable insights. This comprehensive analysis empowered Valio to take corrective actions.

THE RESULTS

Significant financial and sustainability gains

Valio optimized its process, reducing unnecessary waste and preventing product dilution. This led to an immediate and substantial financial impact. 

Even a small mistake – just a few seconds in timing – can lead to a loss or dilution of 1-2%. Given the plant's high volumes and associated costs (product, wastewater treatment, transport and retreatment), these small errors resulted in significant annual savings.

Beyond financial savings, Collo’s solution also supported Valio’s sustainability efforts. By preventing the loss of valuable raw materials, money was saved, and emissions were reduced. Since raw milk contributes to 80% of Valio’s CO² emissions, the ability to preserve every drop is a crucial step toward achieving their sustainability goal.

“Our collaboration with Collo has made a remarkable difference in our margins. Their expertise helped us quickly identify and eliminate costly inefficiencies that would have otherwise gone unnoticed.” 

says Petri Liukka, Plant Director at Valio Joensuu.  

CONCLUSION

Valio’s partnership with Collo has not only led to substantial financial savings but has also contributed to the company’s environmental sustainability targets. By uncovering hidden losses, optimizing pushout processes, and improving overall efficiency, Valio is well on its way to achieving its goals in both operational excellence and sustainability.

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