Case Study — Dairy Processing
Achieving 3-A Dairy Sanitation Standards at a Multi-Line Cheese Plant
A regional cheese manufacturer needed 3-A Dairy-compliant washdown equipment that could survive daily CIP chemical cycles while maintaining precise temperature control.
The Challenge
The cheese plant operated six production lines processing 400,000 lbs of milk per day. State dairy inspectors required all washdown equipment to meet 3-A Dairy Sanitary Standards — a certification that mandates specific material grades, surface finishes, and design features to prevent bacterial harborage.
The facility's existing bronze mixing stations failed 3-A compliance requirements due to material composition. Additionally, the daily CIP (Clean-In-Place) cycle used caustic soda and peracetic acid sanitizers that were corroding internal components, causing leaks and requiring replacement every 12–18 months.
The plant needed a complete replacement program that would achieve 3-A certification, survive the aggressive chemical environment, and reduce the maintenance burden on their engineering team.
The Solution
Northeast Controls specified the SuperKlean Model 3600M-S — the stainless steel version of the 3600 Series mixing station — for all 24 wash points. The 3600M-S is constructed from 316 stainless steel throughout, meeting 3-A Dairy Sanitary Standards for material composition and surface finish requirements.
Each station was paired with the DuraFlow DH150D Dairy Nozzle, specifically engineered for dairy applications with a smooth-bore stainless steel body, no crevices or threads exposed to product contact surfaces, and a design that meets 3-A Standard 74-07 for spray devices.
The thermostatic mixing valve was set to 145°F — above the minimum required for dairy sanitation while remaining safe for operators. Temperature validation was performed at each station and documented for the state dairy inspector's records.
The Results
Switching to the 3600M-S and DH150D dairy nozzles solved our 3-A compliance problem and eliminated the corrosion failures we were dealing with every year. The stainless steel construction holds up to our CIP chemicals without any issues.
— Engineering Manager, Northeast Cheese Manufacturing Plant