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ACKNOWLEDGEMENT
I avail the opportunity to express our heart felt gratification to Mr. RAHUL
AGARWAL (Lect. , Dept. of Food Tech. , J.N.U. Jaipur) for extending
hand of co-operation to every occasion.
I really thank to Mr. D.K. SHRIVASTAV Manager (Dairy) at Patna Dairy
for availing us the golden opportunity to complete our In-Plant training in
the esteemed organization, under his valuable guidance.
During my training I was indeed fortunate to get the co-operation of the staff
. we would like to extend thanks to all employees and apprentice for the
friendly and cordial atmosphere.
At the end we thank one and all that have contributed directly and indirectly
in successful completion of the training.
Date:- RISHABH KR. DUTTASAISTA ANJUM
(5th Semester)
FOOD TECHNOLOGY
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CONTENTS
SNO. TOPIC PAGE No.
1. INTRODUCTION 3-4
2. PRODUCTION SECTION 5-10
3. PLANT ACTIVITIES 11-13
4. PROCESS SECTION 14-20
5. MILK PROCESSING 21-29
6. PACKING SECTION 30-32
7. PRODUCT SECTION 33-48
8. BOILER SECTION 49-54
9. REFRIGERATION SECTION 55-59
10. QUALITY CONTROL 60-62
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INTRODUCTION
Name of organization : Vaishal Patliputra Dugdha Utpad Sahakari
Sangh Ltd.
Location of plant : VPDUSS Ltd
Feeder Balancing Dairy
P.O- Phulwarisharif , Patna- 801505
Total Number of Plants : One
Total Number of Chilling : 5 (Hajipur, Ara, Sitamadhri, Vikram )
Centre
Total Number of Dairy : 1492(Functioned)
Cooperative Societies
Total Milk Collected : 1 lac/day
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PRODUCTION SECTION
The Patna Dairy plant was commissioned on 1st October 1981 under OFI
with the different capacities as under:
Particulars Handling capacity Packing capacity
Sections
1. Liquid Milk 100TLPD 50 TLPD
2. Milk Powder 10MT/day 10MT/day
In 25 kg bags
3. Table Butter 3.5MT/day 3.6MT/day/machine
in 100gms pack or
18MT/day/machine in 500gms pack
4. Ghee 6MT/day 15MT/dayinpolypack
PRODUCTS:
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Fluid Milk
(a) Toned Milk
(b) Standard Milk
(c) Full Cream Milk
(d) Double toned milk
(e) Cow Milk
Ghee
Butter
White butter
Paneer
Lassi
Ice Cream
(a) Candy
(b) Ice Cream
Skim Milk Powder
Mawa
Dahi
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Misti dahi
Flavored Milk
desserts
Brand Name for the entire product is SUDHA
Total number of employee - 630
The plant is spread in approx 24 acre area land
Installed Capacity of Plant - 1, 00,000 LPD Milk
Present Capacity - 1, 50,000 LPD Milk
Capacity of Drying Plant - 10MT/day
This Milk Plant feed milk to the city consumer of Patna by milk
Booths in polythene packs. In addition to this surplus milk is sent to Delhi,
to meet the demand of fluid milk in Delhi. In flush season part of the surplus
milk, left after supplying milk to city, is separated and excess of fat is
converted into Butter, Ghee and Skim Milk is used in making powder
(SMP). Chhach, Lassi, Srikhand, Paneer and UHT milk also produced at this
plant.
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PRODUCTION EQUIPMENTS
Particulars Numbers Capacity
Can milk reception dock
Can washer Two 600 cans per hr.
(st.through type)
Processing section
Milk pasteurizer Two 10,000LPH
Cream separators Four 10,000LPH
Homogenizers Two 10,000LPH
Cream Pasteurizer One 2,000LPH
Milk Packing section
Form-fill-seal machine 15heads 2,500pouches/hr
Crate washer One 800crates/hr
Butter &Ghee section
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Butter Churn One 10,000Ltr.
(Top Shape)
Ghee kettle Two 1,000/1500Ltr
CBM One 800kg butter/hr
Powder Plant
(Spray dried)
Condensing unit One 4,040kg/hr
(Triple effect)
Drying unit One 10TPD
Product Section
Cultural Propagation One
Machine
Mawa Machine One 50 kg/hr
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PLANT ACTIVITIES
Raw milk from DCSs is received at the raw milk reception dock
(RMRD) twice a day and immediately chilled and stored in raw milk silos.
Similarly, milk received from chilling centers and other unions is unloaded
in the silos (after chilling, if necessary) according to expected intake of the
day, daily utilization plan is made in the morning keeping the broad outlines
with respect to product mix plan in mind. (Though there is not much of
variation in the daily utilization plan).
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The process section takes care of chilling, pasteurization,
milk separation and standardization various other sections are then
issued/transferred the quantity of milk/cream/skimmed milk required by
them as per the products mix plan.
MILK FLOWCHARTMilk
Chilling/Processing
Standardized milk Skimmed milk Cream
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S.M.P. White butter Tablebutter
Toned milk Send to Milk for indigenous
Double Toned APS products
Std. Milk
FCM milk
GheePaneer
Pouch filling Chhach,lassi,srikhand
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PROCESS SECTION
RAW MILK RECEPTION DOCK (RMRD)
Raw milk in 40 liters cans is received through different milk routes
established all over the milk shed. The milk is graded, weighed and sampled
society wise, the empty cans are then diverted to straight through can washer
for cleaning and sanitation. Milk, after weighing and sampling, is poured
into the dump tank from the weighing bowl. From there, it is then pumped tomilk silos through chiller. The temperature range of milk received from
DCSs is from 250C to 370C, which is then chilled up to 50C.
The empty cans pass through different sections of can washer, namely
Section Temperature Detergent Strength
a) Pre-rinse Ambient Nil
b) Detergent 750C 2.25%
c) Final rinse 850C Nil
d) Hot air >1000C Nil
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Can scrubbers are also provided for manual cleaning of cans. The cleaned
and empty cans are then handed over to the route contractor for handling
back to respective DCSs. The samples taken are tested for fat (by Electronic
milko tester) and SNF (by Sp.gravity method). The computerized milk
payment bill, based on the quantity, and testing done as above are then
prepared on daily basis.
Apart from receiving milk in cans, chilled milk is also received through
insulated road milk tankers both from own milk chilling center and
regional milk grid pool. The tankers are directly decanted in silos.
LIST OF EQUIPMENTS AT RECEPTION DOCK
a) Can washer
Model SW-8
Type Straight through
Make Swastick
Capacity 10-12 cans per minute.
Number 2
b) Weighing bowl
Make Avery
Capacity 300kg
Number 2
c) Balance(Electronic)
Make Avery L 105A
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Range 0-500kg
Number 2
d) Dump tank
Make Alfa laval
Capacity 1,500Lt (for good milk)
1,000Lt (for sour milk)
e) Milk Pump
Make Alfa Laval
Capacity 20,000LPH
f) Can Scrubber
Make Alfa Laval
Capacity 250Lt.
Number 2
The detergent solution is heated by Electrical coils and steam.
RD Operating Parameters
CAN WASHER
Steam pressure 2kg/cm2
Pre rinse temp. Ambient temp.
Detergent temp. 750C
Washing soda:TSP 70:30 by wt.
Strength 1.25%
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Final rinse temp 850C
Hot air temp 100-1100C
Washer speed 600cans/hr
Change the detergent after one operation .
Dosing apparatus to monitor and adjust the strength of detergent every 1
hour operation.
CAN SCRUBBING
Detergent strength
Washing soda+teepol Mixture 0.5%by weight
Washer speed 600cans/hr
Scrubbed cans re-cleaned in can washer and sterilized as per
schedule
Handling of Failed Products
Raw milk found to have objectionable smells or flavors including kerosene,
diesel or containing rodents is to be immediately destroyed.
Sour milk Not to be mixed with good milk.
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Fat to be recovered for ghee making
TANKER MILK RECEPTION AND DESPATCH
Acidity : less than 0.17%
Temperature : 5-70C
Neutralizer test : Negative
MBRT : >30 minutes
RAW MILK SILOS
Temp of milk : 5-70C
Agitators : in working condition
RECEIVING PASTEURIZED MILK FROM MEMBER
UNION AND OTHER DAIRIES
Temp : 0.135%LA
Neutralizer : Negative
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Phosphatase test : Negative
DISPATCH OF PASTEURIZED MILK
Temp :
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PROCESSING OF MILK
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The raw chilled milk, so received (either of DCSs or from chilling
centers) is subjected to different processes like pasteurization,
separation/standardization. As per fine tuned planning, skimmed milk is
made available for powder plant for drying, good quality cream for table
butter/white butter, milk for by products, standardized (standard/toned) milk
for sachet packing for market.
The equipments available for aforesaid job is as below:
1. Milk chiller for raw milk 20,000 LPH
(Plate heat exchanger parallel flow type)
2. Milk chiller for pasteurized milk 20,000 LPH
3. Milk pasteurizer(continuous, HTST type) 10,000 LPH
Milk pasteurizer comprises of different sections such as :
a) First regenerationb) Second regeneration
c) Third regeneration
d) Heating
e) Holding
f) Chilling
Various automatic controls are provided with milk pasteurizer to
facilitate temperature control, temp recording, temp failure, and product
diversion with alarm.
Time-temp-pressure combinations are
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Past. Milk Temp. 75to780C
Chilled milk temp 5+/-10C
Chilled water inlet temp 1to 1.50C
Hot water inlet temp 85to900C
Steam pressure 25kg/cm2
Hot water flow rate 7.5 to 8,000LPH
CREAM SEPARATOR
The cream separators are centrifugal types, of 7,000rpm, milk is fed at a
temperature of 42+/-20C. The capacity of separator matches with that of
pasteurizers i.e.10, 000 LPH
CREAM PASTEURIZER
It comprises of regenerating, heating/holding, chilling sections.
The Time-Temp& pressure combinations are:
Past cream temp : 90+/-20c
Chilled cream temp : 9+/-10C
Chilled water temp. : 1to1.50C
Steam pressure : 3kg/cm2
LK AND CREAM STORAGE FACILITY
For storage purposes eight insulated, vertical milk storage silos (Six-
30, 000ltr & Two-60, 000ltr capacity) and five insulated horizontal storage
milk tank of 15,000ltr each. Four jacketed vertical cream storage tanks one
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of 10,000 ltr capacity and there of 5,000 ltr capacity each have been
provided.
Compositional Standards Required
{Milk for pouch and local dispatch)
Type Fat% SNF%
(Min) (Min)
Toned milk 3.10 8.64
Double Toned 1.60 9.10
Standard milk 4.60 8.60
Full cream milk 6.10 9.10
Skim milk for powder 0.05to0.07 7.8to8.7
Making
XED CREAM FOR CHURNING
Table butter 38to40%fat
PROCESSING PARAMETERS
Milk pasteurizer no. 1&no.2
Past milk temp 75to780C
Chilled milk temp 5+/-10C
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Chilled water inlet temp 1.5+/-10C
Hot water inlet temp 85to 900C
Steam pressure 3.5kg/cm2
Flow rate 7500to8000LPH
Plant capacity 10,000LPH
CREAM PASTEURIZER
Past. Temp 90+/-20C
Chilled temperature 9+/-10C
Chilled water inlet temp 0.5to1.50C
Flow rate 2000LPH
Steam pressure 3.5kg/cm2
Vaccum gauge working
SEPARATORS
Separation temp 42+/-20C
%fat in skim milk 0.05%
for drying
TEMPERATURES
Milk storage temperature 5-60C
In tanks/silo
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Cream storage temp. Intakes 8-100C
SPECIFICATION OF EQUIPMENTSPROCESSING SECTION
CREAM SEPERATOR
Make Alfa-Laval
Capacity 10,000 LPH
Number Two
RPMof bowl 71-75(speed)
RPM of motor 1450
Motor power (HP) 15
MILK PASTEURIZERS
Make Larsen& Turbo
Capacity 10,000 LPH
Heating medium Hot water
No. of plates in:
Regeneration 1st
85
Regeneration 2nd 25
Regeneration 3rd 13
Heating section 25
Chilling section 22
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Width of holding section 275mm
Holding time 20sec.
Ratio of hot water to Milk 4:1 temp850C
Ratio of chilled water to milk 3:1 temp1.50C
Calculated pressures of:-
Whole milk 0.8kg/cm2
Skim milk 2.2kg/cm2
Hot water 0.4kg/cm2
Chilled water 0.3kh/cm2
Numbers Two
HOMOGENIZER(Not in working )
Make GaulinCapacity 10,000 LPH
H.P.of motor 150
` Pressure 1st stage1700 PSI
2nd stage 500 PSI
Numbers Two
CREAM PASTEURIZER
Make Alfa-Laval
Capacity 2,000 LPH
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CREAM TANKS
Make Vulcan Laval
Capacity Three-10,000lit &
One-5000lit
Number 4
Position Vertical
Accessories: Agitator, Temperature gauge, Chilled water line & return
line, Sampling Cock, watch glass and man hole.
MILK SILOS
Make Larsen & Turbo
Capacity Six-30,000 lit &
Two-60,000lit
Number 8
Position Vertical
Accessories: Pneumatically operated receiver gauge which indicates
amount of milk,
Temp gauge, Agitator, Watch glass, Sampling cock, Man
hole.
CITY SUPPLY MILK TANKS
Make Unicomindustries,Secundrabad
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Capacity 15,000 lit
Number 5
Position Horizontal
Raw milk tanks are insulated and mounted with temperature gauge,
sampling cock, agitator, watch glass, illumination glass and manhole.
PLATE CHILLER
Make Vulcan Laval
Capacity 20,000 lit
Number 3
Number of plates 99&54 Plates
POWDER MIXING HOPPER
Make Vulcan Laval
Shape Conical from Bottom
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PACKING SECTION
The standardized milk (Toned, Double-Toned, Standardized, Sudha
gold) received from process section is packed by Form-fill and seal type of
packing machines. A total 15 packing heads are provided (7 double heads
and one single head). A single head and double head have a capacity of 2500
packs/hr and 5000packs/hr.
There are two chain conveyer passes through the lines of packing
machines. The filled pouches from the machines are manually set in tub-type
crates, as the crates pass by the machines. The filled crates enter into the
cold store at a point where they are checked and stacked manually (seven
stack height) in cold storage.
This section takes care of crate washing, milk packing, and storage in
milk cold store. Every prevention is taken to check weight of milk in
pouches and pouch length on half-hourly basis as this involves a
considerable cost area.
After every packing operation effective CIP and manual cleaning is
done on daily basis. A proper record of crate washer operation w. r. t. time
/temp / pressure is also maintained. The crate account is maintained to
monitor in the out position ofthe same.
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MILK PACKING AND DISPATCH
Volume 500+/-5ml 1000+/-5ml
Weight 518-520g 1035-1040g
Pouch length 145-150mm 220-230mm
Pouch film thickness 50-55 micron 55-60 micron
Yield/kg film 410 200
Note: - Compressed air pressure is to be maintained at 7kg/cm2
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PRODUCT SECTION
BUTTER SECTION
CONSTRUCTIONAL AND OPERATIONAL FEATURES
The butter churn is Top Type i.e. cylindrical cum conical type.
The max charge of the drum is 45-50% of its total capacity based on
maximum 40% fat in cream. The drum and working crossbars are
made of brine resistant stain less steel. The outside of the drum is
circled polished. Interior surface are treated to prevent butter from
sticking. All drums mountings are made of stainless steel. The drum is
furnished with buttermilk valve, air valve, air escape valve and sight
glass frame. A stainless steel guardrail is also included. There is one
large door for unloading the butter.
Driving gears can be adjusted for four speeds. All enclosed moving
parts are splash lubricated. It is fitted with precision cut gears wheels
of steel casting built in break and friction clutch built in to the pulling.
The speed can be changed by means of leavers and the direction of
rotation byreversing of the motor.
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VACUUM DESIGN
The churn can be supplied in vacuum design making of
possible to connect the drum with a vacuum pump so that the butter
can be worked under vacuum and the cream if desired sucked in to the
drum through the butter milk valve.
MOTOR
Churn requires 1440 rpm single speed motor or 1440/960RPM
two speed motor.
SPRINKLER SYSTEM
Stainless steel sprinkler for efficient control of the butter is
provided.
WHITE BUTTER MANUFACTURING PROCESS
White butter is used only for ghee manufacturing. The flow diagram
of the manufacturing process is as follows: -
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Cream From Cream Tank At 8-100C
(PUMP)
Butter Churn
Churning At 18 RPM till Breaking Stage
Draining Of Butter Milk
Working At 10-15 RPM for 20 min.
Unloading In Butter Trolleys
To Ghee Section
Ghee Boiler
Ghee
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Packing
STORAGE OF WHITE BUTTER
White butter is transferred in the trolley and taken in the hardening
chamber,. Next day trolley is taken out and blocks of 24kg are made. These
blocks are kept in the cold storage. it requires less space for storage.
CLEANSING AND STERILIZATION OF CREAM
TANK, BUTTER CHURN AND PACKING MACHINE
(A) CREAM TANK
Cleaning of cream tank and pasteurized chilled water tank.
Hot water rinsing of cream and pasteurized water tank. (Temp.
60to700c)
Caustic cleaning of cream tank strength 0.8%, temp800c
duration 20to30 minutes.
Hot water rinsing (temp60to700c)
Chilled water rinsing of cream tank (temp8to100
c)
Sanitation of cream tank with iodophor 75 ppm, circulation for
10-15 minutes.
Manual cleaning and sanitization of intermediate tank, cream
pasteurizer lines, cream tank valves.
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(B) BUTTER CHURN
Steaming of churn for removal of fat (melting)
Rotate churn with 200 ltr hot water + soda ash 5kg+1/2 kg teepol
at 800Cfor 30 min.
Hot water rinsing 600C after draining the above solution.
After closing all the outlet and manholes to be kept idle overnight.
Sanitization with iodophor 75 ppm for 10min(200ltr water
+1ltriodophore).
Flush the loading line with hot water and than with iodophor
solution from butter churn prior to loading of cream.
Take remaining iodophor solution in butter trolleys after cleaning
with steam, teepol and then hot water.
(C) BUTTER MANUFACTURING
Loading of cream [Fat 40+/-2%, Acidity0.09%, MBRT 5hrs(min), Temp8-
100C, volume 1/3drum capacity]
Add color@ 1.75ml/kg of fat to have color in between H1&H2 shade of
standard color curd. Start churning and after completing of churning removal of butter milk.
Add pasteurized chlorinated (10ppm) chilled water at 8-100C.
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Drain wash water after rotating (washing )10 min.and repeat step 4and 5 for
2nd washing.
Start pre working & operate until all the wash water is drained out and butter
stitching on the watch glass.
Add salt@ 2.4% in approximately 2time water.
Start salt working under vacuum (0.6kg/cm2) and continue until butter start
stitching on the watch glass.
Rotate churn at lowest speed to form lump of butter during the period of
moisture testing and sprinkle iodophor solution on the exterior of churn.
If require, add make up water to attain desired moisture and rotate churn for
working for 5 min and another 5min for lump formation.
Unload the butte and cover the butter with polythene sheets (dipped in
iodophor solution.)
Start packing Butter at temp 12-150C (packing room temp 20 to 240C)
TEST PERFORMED FOR QUALITY CONTROL
1. Pre moisture test.
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2. Final moisture test from trolleys and packet.
3. chemical analysis of packet Salt/ Moisture /Curd/Fat.
4. Sensory evaluation of each bath with respect to body
and texture, color & appearance, extraneous matter and
free moisture.
5. Coliform count/ SPC.
6. Air count of manufacturing, packing andstorage area.
RESULTS ACHIEVED
1. moisture : 15.6to15.8%
2. Salt : 2.3to2.4%
3. Curd : 0.50to0.06%
4. Fat : 81.20to81060%5. Coliform count : Nil
6. Yeast& Mold : Nil
7. SPC : 1000average.
LIST OF EQUIPMENTS
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BUTTERN CHURN
Make Larson & Turbo Ltd.
Type Cylindrical cum Conical
Capacity 5000ltr of cream in a batch.
Motor Single speed, 1440 rpm
H. P. of motor 25
BUTTER TROLLEY
Make Vulcan Laval
Capacity 600kg
Number Five
BUTTER PACKING MACHINE
Make SIG Swiss industrial co. Switzerland.
Capacity 32 packs/min (100,200,500gms)
VACUUM PUMP
Type Water ring type, motor driven
H. P. 5
Capacity Corresponding to the arrangement of churn.
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BUTTER MILK PUMP
Make Larson & Turbo Ltd.
H.P. 2
Capacity 15000LPH
CREAM PUMP
Make Alfa-Laval
Capacity 5,000LPH
GHEE SECTION
Ghee is prepared either from white butter or curd. Received sour milk
is transferred to the dump tank of sour milk, where it is brought to the cream
separators of ghee section separated cream is taken in cans and sour skim
milk is transferred to the drain.
CHURNING OF SOUR CREAM
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Churning of sour cream is carried at RMRD from there cream is manually
transferred to ghee section.
GHEE MANUFACTURING PROCESS
The butter is transferred to ghee boiler which consists of a double jacket pan
provided with a mechanical stirrer. A steam control valve, pressure and
temperature indicator etc. are also provided in the boiler.
The butter is heated in ghee boiler by opening the steam valve and
temperature of butter is brought to 80-85 0C for half an hour. It stratifies in
to three distinctly layers viz, a top layer of floating denatured particles of
curd, a middle layer of fat and a bottom layer of burnt milk. After half hour
butter milk which contain 60-70 % of solid not fat and 80% of moisture is
removed by opening the valve present at the bottom of ghee boiler, without
disturbing the top and middle layers.Afterwards the temp of the remaining two upper layers is raised and agitator
is stared. The boiling is continued till the ghee formed gives the appearance
of second effervescence, together with the browning of the curd particles. At
this stage ghee gives characteristics ghee flavor and golden yellow color.
Care is taken as not to allow the temperature to arise more than 1080C for
ten min.
When the residue is settled the ghee is taken to ghee settling tanks. Before
butter is taken to ghee boiler it is melted and passed through ghee clarifier.
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Ghee in the settling tank is kept at 800C for 24 hr. Residue ghee is taken out
from the bottom valve of ghee boiler in trolley ghee is filled directly in tins
of 15 kg or through FFS machine in poly packs.
EQUIPMENTS IN GHEE SECTION
GHEE CLARIFIER
Type CG01
Make HMT
Max Capacity (LPH) 900 (water equivalent)
Bowel Speed 7200 RPM
CODE PRINTER
Make Nimach
Type AU-2
GHEE BOILER
Make Vulcan Laval
Capacity 1000lts
Make Bansal Industries
Capacity 1500
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GHEE SETTLING TANK
Make Chemical vessel fabricators
Number Two type cylindrical vertical
Capacity 100 lit each
BY PRODUCTSAND PANEER SECTION
In this section following products are manufactured
1. Paneer
2. lassi
3. ice cream mix
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MANUFACTURING OF PANEER
Raw Milk (4.5% fat & 8.5% SNF)
Heating At 80-850C For 10min.
Cooling To 700C
Coagulation Using 0.2%Citric Acid Solution
Agitation
Whey Drainage
Pressing For 30 To 45min
Cooling 30 To 45 min To 5-100C
Cutting
Packing
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MANUFACTURING FLOW DIAGRAM OF LASSI
Pasteurize Milk(toned)
Heat To 370C And Culturing @0.2%
Incubation For 3hr.
Storage For 8hr. In Cold Store
Mixing Of Sugar @12% Of Curd
Standardized At 2 to 2.5% Fat
Packing
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BOILER SECTION
Oil Fired Boiler
Model RJ813 Oil Fired Boiler
Capacity 5Tons/hr
Name Wester work fire tubeWorking Pressure 18kg/cm2
Made Network Engg. Ltd. Bombay
Number of passes 3
Maximum Working Pressure 20kg/cm2
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Technical Specifications :
Details Unit RT-01 RT-02 RT-03 RT-04 RT-05 RT-06 RT-08 RT-10
OPERATING PARAMETERS
Steam outputF & A 100oC.
Kgs/hr 100 200 300 400 500 600 800 1000
Steampressure
Kgs/cm2 15 15 15 15 15 15 15 15
Fuel OilConsumptionLDOFO
Kgs/hrKgs/hr
6--
12--
1819.1
2425.4
3031.8
3638.1
4850.8
6063.6
Efficiency(NCV)
% -----------------------> 88 + 2 ON/OFF
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Initially oil is preheated using electrical heater and steam and high
temperature condensate up to 80-85C . This heated oil is passed through a
burner and sprayed in fine droplets. It is sparked and once it catches fire,
supply of oil in furnace is controlled and the furnace draught is also
accordingly increased.
Service requirements 3 phase , 440 volts, 50 Hz AC supply ,
4wire
Thickness of insulation 63.5mm mineral wool in the G.I. venner casing.
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STARTING OF THE BOILER
1. Confirm that the water level is up to the mark.
2. Feed the oil to the boiler with the help of oil pump.
3. Ignite the oil with the help of electrical spark.
4. As working pressure is achieved, check whether all the instruments and
mountings are working and check all joints
STOPPING OF THE PLANT
1. See that the water level is full
2. Stop oil feeding pump.
3. Stop the F.D. fan.
FEED AND BOILER WATER
CONDITIONING
In order to minimize deposits ,scale formation and corrosion ,not
only in the boiler but also in the feed lines , feed heaters , economisers ,
superheaters and prime movers , it is necessary to maintain certain chemical
conditions and to inject treatment chemicals into the feed system and into
the steam and water drum of the boiler.
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REFRIGERATION SECTION
Refrigeration in general is defined as any process of heat removal.
The rate at which heat must be removed from the refrigerated space or
material in order to maintain desired temperature is called refrigeration load.
The substance employed as heat absorber or cooling agent is called
refrigerant which is ammonia in case.
The refrigerant circulates through the system and passes through a
number of changes in state or condition each of which is called a process.
The refrigerant starts at some initial state and passes through process in a
definite sequences and returns to the initial condition. The series of process
is called a cycle which consists of :
1. Expansion
2. Evaporation
3. Compression
4. Condensation
OPEARTION OF THE REFRIGERATION PLANT
The plant includes 4 compressors of 50 tons capacity each and 2
booster compressors for maintain the temp of cold store, deep frieze and
butter cold stores in minus degree temp. The compressor run at a suction
pressure 35 psi and discharge pressure of 180 psi.
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Ammonia is charged in to the receiver directly by attaching the mouth
of the cylinder to the charging tube the receiver. The refrigerant first foes to
the expansion valve where the refrigerant than passes through the coils of
the evaporator immersed in water in the ice bank tanks. Here the low
pressure liquid refrigerant is converted to vapors.
The refrigerant vapors then go to the suction side of the compressor
(50tonnes) where the vapors are compressed to a high pressure (180-200psi).
These high pressures are than taken to the water cooled condenser coils
where the refrigerant vapors get condensed to a liquid form and from there
they are returned to the receiver thus completing the refrigeration cycle.
Low pressure and high pressure cut out are provided at the suction &
discharge ports respectively so that the machine is saved from any pressure
variation as the motor will be stopped automatically. Oil filters are provided
with each assembly of compressor so that the discharge vapors are oil free.
The compressors are cooled by water coming from the condenser and aftercooling goes back to the condenser.
START UP OF THE PLANT
At the start the blowers in the condensers are started and then the
water circulation pumps of the condensers are started. The inlet and
discharge valves to the receiver are open. The compressor inlet (suction)
valve is opened. All the necessary motors and pumps are started.
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SHUT OF THE PLANT
First vacuum is to be created in the plant. For this the out let or
discharge side of the receiver is closed. Thus the pressure on the suction side
of the compressors keeps on reducing. When this pressure has come down to
15 psi then the suction valve of the compressor is closed. With this the
compressor will be stopped.
Then the condenser blower and the water pumps may be shut off. All the
electric controls and switch are housed on the panel board provided by the
L&T switch gear.
SPECIFICATIONS OF THE REFRIGERATIONS PLANT
COMPRESSORS
Make Frick India
No.of compressors 4
Type of compressors Heavy duty industrial type, double
cylindered reciprocating
ammonia
Compressors.
Capacity 50 tons
HP of compressor motor 125 HP/150HP
Type of motor induction
Suction pressure 30-35 psi
Discharge pressure 180-200psi
Oil pressure 50-60psi
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Dimension of liq receiver 600mmdia x 5.5 meter
No. of chilled water tanks 4
Capacity 30,000ltr each
BOOSTER COMPRESSOR
Make Frick India
Number Two
Capacity 25 tones each
Motor HP 15 HP
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QUALITY CONTROL LABORATORY
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The quality control laboratory is an independent department working under
the general supervision of Dy. Manager (Q.C.). the various functions that are
carried out are:-
1. Raw milk grading at RMRD
2. Raw milk sampling and testing.
3. Controlling the quality, temp and stability of the milk received and
products manufactured.
4. Controlling the skimming efficiency of the cream separator.
5. Controlling the acidity, temp and stability of skim milk.
6. Analysis of cream and skim milk.
7. Analysis of butter and ghee.
8. Analysis of city supply milk.
9. Chemical analysis of SMP
10.Controlling the overall hygiene of the plant.11.Calibration the various equipments and apparatus against the
standards.
12.Testing and controlling the softness of water to milk plant as well
boiler.
13.Maintain the strength of detergent solution and tem of different
section of can washer.
The various tests that are carried out on the milk and milk products are
as follows:-
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1. RAW MILK Organoleptic test (at dock), Alcohol and COB test, Fat
test, SNF test, Adulterants and preservative detection, Acidity.
2. SKIM MILK Temperature of storage, Acidity, Stability (Alcohol
&COB), fat%, SNF%.
3. CREAM Fat%, Acidity.
4. BUTTER- Fat%, Moisture content, Curd content, Salt content,
Acidity, Yeast and mold count, coliform.
5. GHEE Flavor, Color, and texture, Moisture, FFA.
6. BUTTER MILK Fat test, Acidity, Stability.
7. LASSI-Fat test, flavor, taste, acidity, sugar content.
8. SMP- Bulk density, Moisture, Ash, Solubility index, Sediment,
Acidity, Fat test, Reconstitutability.
9. TM/RM/Std.MILK/GOLD- Organoleptic test, Fat test, SNF, Heat
stability, acidity.
Test carried out for the storage study of powder- Organoleptic, Moisture and
solubility test.