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Key words: Commercial dairy plant, Critical control points (CCPs), Dairy products, Data Energy consumption, Utilities.
Flow measurement is an important parameter for Water: Water is mostly used for cleaning purposes like
the calculation of milk, cold water and hot water for the cleaning of equipments, storage tanks, cans, crates etc. in the
various operations. Various techniques and methods were used various sections. The consumed water was calculated by
to determine the flow rate of milk, cold and hot water. Any of multiplying the water flow rate and time required for cleaning.
the following two methods may be used. Steam properties: Steam consumption in the khoa, paneer
and ice-cream mixing was determined by the condensate
Bucket method: In this method the flow rate was measured weighing method.The steam pressure at various heating points
by collecting a quantity of liquid in a container in specified of the equipments and the pipeline was taken from the steam
time. In each, two or threereplications were made and the gauge fitted with equipments. Considering steam used in the
average was taken from the result for calculation. This method dairy
was used to measure the flow rate of water in can washing TABLE 1: Correction factor for flash steam
operations, in milk and cream pasteurizer.
Pressure Flash Pressure Flash
Tank level method: In this method, the basic principle (kgf/cm2) (kg/kg of (kgf/cm2) (kg/kg of
involved is the change in the level of the tank was noted in condensate) condensate)
afixed time. The mass flow rate was calculated from tank 0.3518 0.0161 3.165 0.0918
diameter or cross sectional area and density. 0.7025 0.0294 3.510 0.0987
1.0530 0.0410 4.220 0.1109
Steam measurement:The following two methods were 1.4050 0.0512 4.925 0.1226
employed to measure the steam rate in various sections. 1.7580 0.0607 5.625 0.1334
2.1190 0.0692 6.325 0.1436
Enthalpy balanced method:The method was used to 2.4650 0.0772 7.040 0.1530
determine the steam consumption in the direct steam injection 2.8150 0.0843 - -
100 ASIAN JOURNAL OF DAIRY AND FOOD RESEARCH
plant is saturated. Thus, the temperature, enthalpy, and latent HP rating and time of operation of drive motors of pump,
heat of saturated steam at its absolute pressure Ps (Pa) would conveyers, agitators, blowers, and fans. And the technique
be calculated by following empirical equations developed can be used for lighting devices.
from the data given in the steam table Consumed energy, unit of kWh=
wattrating of the devices*no of hours used
----------------------------------------------------------- (8)
(2) 1000
RESULTS AND DISCUSSION
(3)
The results of the study carried out for the
consumption of water, steam, refrigeration and electricity in
(4)
the manufacturing of peda, dahi, ghee, ice-cream, lassi, butter,
pasteurized milk, and paneer in a commercial dairy plant are
Where, Ts is temperature of saturated steam at Ps
o presented and discussed. On the basis of the product
( C), Ls is latent heat of saturated steam (kJ/kg), Hs is enthalpy
technology of aforesaid products, the required utilities
of saturated steam at Ps (oC) and Ps is saturation steam pressure
consumptions were checked and calculated. After examining
(kgf/cm2)
and analyzing the data, the possible recommended
Refrigeration: The refrigeration of product in cold storage conservation techniques were presented.
is done by direct expansion of air chillers employed in the
Water consumption: The water consumption in different
dairy industry. Refrigeration load, in this case is calculated
operations and sections such as cleaning purpose, products
by:
section, different storage and processing section was
calculated and discussed separately. The calculated value and
(5)
major findings of water consumption has been presented in
Table 2 and 3 respectively. In milk reception section,
Where, M = Refrigerant mass flow rate (kg/h), D =
maximum water consumption was found in case of crate
compressor bore diameter (m), L is compressor stroke (m),N
washing while minimum in tanker washing.
is the rpm of compressor, n is the number of cylinder; Vg is
specific volume of refrigerant at suction (m3/kg). The net The water consumption study was done on daily
refrigerant effect was calculated by the formula (Gear, 1977) average no. of cans, tanker and crates. It is clear from the
table 2 and result that the amount of water used per can
(6) washing was found to be more compared to the previous
study (Gedam, 1966). Water consumed in the tanker and crate
Where, Q is a net refrigeration effect (kJ/kg), Hf is washing was found less compared to data presented by
enthalpy at the discharge of expansion valve (kJ/kg),Hg is Gedam, 1996, which can be improved by implementing a
enthalpy at the suction of the compressor (kJ/kg) and total complete mechanized washing process. The quantity of water
refrigeration effect (kJ/h) is given by M*Q. Chilling of raw used for washing the cans after caustic washing is the major
milk and pasteurized milk by using chilled water and the cause for high consumption, so it requires significantly good
worker efficiency, optimal number of flushing, control on
refrigeration load are calculated by:
water flow rate during flushing and timing.
f (7) Table 3 indicates that the water consumed in
pasteurizer cleaning in the plant was found 9920 liter per
Where, Q is refrigeration load(MJ/kg),Mis chilled cleaning where as 5548 litres in the case of cream pasteurizer.
water mass flow rate (kg/h), Cp is the specific heat of chilled
TABLE 2: Water consumption in milk reception section.
water, a T1 is the initial temperature of chilled water (oC), T2
Particulars Water Water
= final temperature of chilled water (oC) and f is a factor
consumption consumption
which relates the heat loss in the chilled water pipeline while (l/day) (l/per entity)
conveying it from the chilled water tank to the equipment
Can washing 8814.00 7.98
(the value is taken as 1.1) (1105 cans per day)
Electricity: The energy meter is an instrument which can Tanker washing 5378.66 316.39
(17 tankers per day)
directly measure electrical energy consumption. However,
Crate washing 11467.00 3.08
the electrical consumption may be calculated from watt or (3723 crates per day)
Volume 34, Issue 1, 2015 101
TABLE 3: Water consumption in processing section and TABLE 4: Steam and thermal energy consumption milk
storage tank cleaning reception section for cleaning and sanitizing.
Particulars No ofcleaning Water consumption Particulars No. of Steam Thermal
(l/cleaning) entities consumption Energy
Milk pasteurizer cleaning 2 9920.00 kg/entity (kJ/entity)
Cream pasteurizer cleaning 2 5548.00 Can sanitization 1105 0.351 943.24
Water required for cleaning 4 1240.00 Tanker 17 3.210 8626.27
of RMTs Crate 3723 0.234 628.83
Cream tank cleaning 1 2347.00
Pre pack 2 6717.60
Lassi culturing tank 1 1600.00
Flavoring tank 1 43.66
Aging tank 1 906.00
TABLE 6: Refrigeration load for milk processing and cold storage · Proper matching of temperature and pressure of fuel to the
Particulars Refrigeration load (MJ/day) burner.
Milk pasteurization 9831.41 · Boiler blow down should be done in optimal time.
Cream pasteurization 159.091 · Periodical checking of water softening plant to avoid the
Raw milk chilling 7716.48 scaling
Market milk chilling 1583.93 · Proper control of fuel gas temperature.
Paneer making 851.1183
Ice cream making 587.872 Besides these, the most important recommendation on dairy
Cold storage 32990.491 operations and equipment are:
TABLE 7: Electrical energy consumption in the different · Most effective instrumentation and control system should
section of dairy plant. be installed.
Particulars Electrical energy (kWh) · Condensate should be utilized for heating or as feed water
to the boiler.
Product section 1428.00
Processing section 849.43 · Continuous manufacturing of peda and ghee can save
Utilities generation (Engg. Section) 9289.58 thermal energy losses.
RMRD (Raw milk reception dock) 103.31 · Heat losses from product surface can be minimized by
heating the product in suitable scraped heat exchangers till
Energy conservation methods on water consumption- The
the products attain boiling temperature.
following suggestions are given optimal and efficient use of · There should an optimal gap between the cold, hot and steam
utilities. In the plant, it has been found that water is flowing pipelines
continuously throughout the day from hosepipes irrespective · Minimizing reprocessing of milk
of whether water is used or not. Some ways for improving Energy conservation method on refrigeration consumption
the utilization of water are given below. · Quick maintenance of leakage as soon as possible.
· Dairy staff should be instructed for judicious use of water.
· Cold storage should not be left open.
· Concerned man power must be trained in effective and · The chilled water pipeline should be monitored to ensure
optimal use. the insulation.
· The end diameter and shut off valve of hose pipe should be · Keep insure about the refrigerant leakage.
a central point for users. · Selecting right temperature for storing the products.
· There should a periodical examination of consumption and · Through educating man’s power about the proper use and
also be compared withearlier data.
handling of cold storageand freezer.
· A water recovery system should be installed at various · Recirculation of chilled water.
feasible points. Energy conservation methods of electrical energy:
Energy conservation methods on steam consumption- The · To ensure the proper matching of motor and machinery.
most effective use of steam starts from the boiler, because · Unnecessarily lighting should be avoided.
the boiler is the source for producing the steam. · Efficient pump should be installed.
· Steam traps must be used and kept in best condition.
Volume 34, Issue 1, 2015 103
· Solar lighting plant must be installed. operation.The main features of this study to find out the energy
· Machinery and conveying should be lubricated regularly. consumption for various operations and equipments and to
CONCLUSIONS suggest ways and means for the improvement. The data of
In these days, the cost of milk and milk based this case study was compared with previous study and found
products is going up due to the cost of raw materials and that the energy conserving status is declining. It is, therefore,
energy required for processing. The cost of milk depends essential that existing plant is instrumented well and at a
upon utilities consumption, such as water, steam, refrigeration significant level. Plant manufactures should be encouraged
and electricity. Thus, a case study was done to examine the to give more accurate service consumption figures for the
status for the further improvement in the energy conservation desire.
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