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. DUTTA SAISTA ANJUM (5th Semester) FOOD TECHNOLOGY

CONTENTS

SNO. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

TOPIC INTRODUCTION PRODUCTION SECTION PLANT ACTIVITIES PROCESS SECTION MILK PROCESSING PACKING SECTION PRODUCT SECTION BOILER SECTION REFRIGERATION SECTION QUALITY CONTROL

PAGE No. 3-4 5-10 11-13 14-20 21-29 30-32 33-48 49-54 55-59 60-62

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 Total Number of Chilling Centre Total Number of Dairy Cooperative Societies Total Milk Collected

: One : 5 (Hajipur, Ara, Sitamadhri, Vikram )

: 1492(Functioned)

: 1 lac/day

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 2. Milk Powder

100TLPD 10MT/day

50 TLPD 10MT/day In 25 kg bags

3. Table Butter

3.5MT/day

3.6MT/day/machine in 100gms pack or

18MT/day/machine 4. Ghee 6MT/day

in 500gms pack 15MT/dayinpolypack

PRODUCTS:

 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

 Misti dahi Flavored Milk desserts

Brand Name for the entire product is SUDHA Total number of employee Installed Capacity of Plant Present Capacity Capacity of Drying Plant - 630 - 1, 00,000 LPD Milk - 1, 50,000 LPD Milk - 10MT/day The plant is spread in approx 24 acre area land

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.

PRODUCTION EQUIPMENTS

Particulars

Numbers

Capacity

Can milk reception dock Can washer (st.through type) Processing section Milk pasteurizer Cream separators Homogenizers

Two

600 cans per hr.

Two

10,000LPH Four Two One 10,000LPH 10,000LPH 2,000LPH

Cream Pasteurizer

Milk Packing section Form-fill-seal machine Crate washer Butter &Ghee section One 15heads 2,500pouches/hr 800crates/hr

Butter Churn One (Top Shape) Ghee kettle

10,000Ltr. Two One 1,000/1500Ltr 800kg butter/hr

CBM

Powder Plant (Spray dried) Condensing unit (Triple effect) Drying unit One 10TPD One 4,040kg/hr

Product Section

Cultural Propagation Machine

One One 50 kg/hr

Mawa Machine

10

11

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 FLOWCHART
Milk

Chilling/Processing

Standardized milk

Skimmed milk

Cream

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S.M.P. butter Toned milk Double Toned Std. Milk FCM milk Send to APS Milk for indigenous products

White butter

Table

Ghee Paneer 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 to milk 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
a) Pre-rinse b) Detergent c) Final rinse d) Hot air

Temperature
Ambient 750C 850C >1000C

Detergent Strength
Nil 2.25% Nil Nil

15

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 Type Make Capacity Number b) Weighing bowl Make Capacity Number c) Balance(Electronic) Make Avery L 105A Avery 300kg 2 SW-8 Straight through Swastick 10-12 cans per minute. 2

16

Range Number d) Dump tank Make Capacity e) Milk Pump Make Capacity f) Can Scrubber Make Capacity Number

0-500kg 2 Alfa laval 1,500Lt (for good milk) 1,000Lt (for sour milk) Alfa Laval 20,000LPH Alfa Laval 250Lt. 2

The detergent solution is heated by Electrical coils and steam.

RMRD Operating Parameters CAN WASHER

Steam pressure Pre rinse temp. Detergent temp. Strength 2kg/cm2 Ambient temp. 750C 1.25%

Washing soda:TSP 70:30 by wt.

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Final rinse temp Hot air temp Washer speed

850C 100-1100C 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 Washer speed schedule Mixture 0.5%by weight 600cans/hr

Scrubbed cans re-cleaned in can washer and sterilized as per

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 Temperature Neutralizer test MBRT : : : : less than 0.17% 5-70C Negative >30 minutes

RAW MILK SILOS

Temp of milk Agitators : : 5-70C in working condition

RECEIVING PASTEURIZED MILK FROM MEMBER UNION AND OTHER DAIRIES

Temp Acidity Neutralizer : : : <50C >0.135%LA Negative

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Phosphatase test

Negative

DISPATCH OF PASTEURIZED MILK

Temp Acidity MBRT Composition : : : : <50C <0.135%LA >4.0hrs as per agreement

CHILLING
Chilled milk temp Chilled water temp Chiller no.1 flow rate Chiller no.2 flow rate : : : : 5-60C 1-20C 2000LPH (can milk) 20,000LPH 5-60C

Temperature of chiller1&2 :

20

PROCESSING OF MILK

21

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 (Plate heat exchanger parallel flow type) 2. Milk chiller for pasteurized milk 20,000 LPH 10,000 LPH 3. Milk pasteurizer(continuous, HTST type) 20,000 LPH

Milk pasteurizer comprises of different sections such as : a) First regeneration b) 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

22

Past. Milk Temp. Chilled milk temp Chilled water inlet temp Hot water inlet temp Steam pressure

75to780C 5+/-10C 1to 1.50C 85to900C 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 Chilled cream temp Chilled water temp. Steam pressure : : : : 90+/-20c 9+/-10C 1to1.50C 3kg/cm2

MILK AND CREAM STORAGE FACILITY

For storage purposes eight insulated, vertical milk storage silos (Six30, 000ltr & Two-60, 000ltr capacity) and five insulated horizontal storage milk tank of 15,000ltr each. Four jacketed vertical cream storage tanks one

23

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 Toned milk Double Toned Standard milk Full cream milk Skim milk for powder Making Fat% (Min) 3.10 1.60 4.60 6.10 0.05to0.07 SNF% (Min) 8.64 9.10 8.60 9.10 7.8to8.7

MIXED CREAM FOR CHURNING

Table butter 38to40%fat

PROCESSING PARAMETERS
Milk pasteurizer no. 1&no.2 Past milk temp Chilled milk temp 75to780C 5+/-10C

24

Chilled water inlet temp 1.5+/-10C Hot water inlet temp Steam pressure Flow rate Plant capacity 85to 900C 3.5kg/cm2 7500to8000LPH 10,000LPH

CREAM PASTEURIZER
90+/-20C 9+/-10C 2000LPH 3.5kg/cm2 working

Past. Temp Chilled temperature Flow rate Steam pressure Vaccum gauge

Chilled water inlet temp 0.5to1.50C

SEPARATORS
Separation temp %fat in skim milk for drying 42+/-20C 0.05%

TEMPERATURES
Milk storage temperature In tanks/silo 5-60C

25

Cream storage temp. Intakes

8-100C

SPECIFICATION OF EQUIPMENTS PROCESSING SECTION

CREAM SEPERATOR
Make Capacity Number RPMof bowl RPM of motor Motor power (HP) Alfa-Laval 10,000 LPH Two 71-75(speed) 1450 15

MILK PASTEURIZERS
Make Capacity Heating medium Larsen& Turbo 10,000 LPH Hot water

No. of plates in: Regeneration 1st Regeneration 2nd Regeneration 3rd Heating section Chilling section 85 25 13 25 22

26

Width of holding section Holding time Ratio of hot water to Milk Ratio of chilled water to milk Calculated pressures of:Whole milk Skim milk Hot water Chilled water Numbers

275mm 20sec. 4:1 temp850C 3:1 temp1.50C 0.8kg/cm2 2.2kg/cm2 0.4kg/cm2 0.3kh/cm2 Two

HOMOGENIZER (Not in working )

Make Capacity H.P.of motor Gaulin 10,000 LPH 150 1st stage1700 PSI 2nd stage 500 PSI Numbers Two

Pressure

CREAM PASTEURIZER
Make Capacity Alfa-Laval 2,000 LPH

27

CREAM TANKS
Make Capacity Number Position Vulcan Laval Three-10,000lit & One-5000lit 4 Vertical

Accessories: Agitator, Temperature gauge, Chilled water line & return line, Sampling Cock, watch glass and man hole.

MILK SILOS
Make Capacity Number Position Larsen & Turbo Six-30,000 lit & Two-60,000lit 8 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

28

Capacity Number Position

15,000 lit 5 Horizontal

Raw milk tanks are insulated and mounted with temperature gauge, sampling cock, agitator, watch glass, illumination glass and manhole.

PLATE CHILLER
Make Capacity Number Number of plates Vulcan Laval 20,000 lit 3 99&54 Plates

POWDER MIXING HOPPER

Make Shape Vulcan Laval Conical from Bottom

29

30

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 of the same.

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MILK PACKING AND DISPATCH

Volume Weight Pouch length Yield/kg film 500+/-5ml 518-520g 145-150mm 410 1000+/-5ml 1035-1040g 220-230mm 55-60 micron 200

Pouch film thickness 50-55 micron

Note: - Compressed air pressure is to be maintained at 7kg/cm2

32

33

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.

34

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: -

35

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

36

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 (temp8to100c)

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.

37

(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), Temp8100C, 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.

38

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.

39

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 and storage area.

RESULTS ACHIEVED 1. moisture 2. Salt 3. Curd 4. Fat 5. Coliform count 6. Yeast& Mold 7. SPC : : : : : : : 15.6to15.8% 2.3to2.4% 0.50to0.06% 81.20to81060% Nil Nil 1000average.

LIST OF EQUIPMENTS

40

 BUTTERN CHURN Larson & Turbo Ltd. Cylindrical cum Conical 5000ltr of cream in a batch. Single speed, 1440 rpm 25

Make

Type Capacity Motor H. P. of motor BUTTER TROLLEY Make Capacity Number

Vulcan Laval 600kg Five

BUTTER PACKING MACHINE Make Capacity VACUUM PUMP Type H. P. Capacity Water ring type, motor driven 5 Corresponding to the arrangement of churn. SIG Swiss industrial co. Switzerland. 32 packs/min (100,200,500gms)

41

BUTTER MILK PUMP Make H.P. Capacity Larson & Turbo Ltd. 2 15000LPH

CREAM PUMP Make Capacity Alfa-Laval 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

42

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.

43

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 CG01 HMT Capacity (LPH) 900 (water equivalent) 7200 RPM

Type Make Max Bowel Speed

CODE PRINTER

Make Type GHEE BOILER Make Capacity Make Capacity

Nimach AU-2

Vulcan Laval 1000lts Bansal Industries 1500

44

 GHEE SETTLING TANK

Make Number Capacity

Chemical vessel fabricators Two type cylindrical vertical 100 lit each

BY PRODUCTSAND PANEER SECTION

In this section following products are manufactured 1. Paneer

2. lassi 3. ice cream mix

45

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

46

 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

47

 ICE CREAM MIX

For 40 kg mix

6 kg milk 12kg cream (40%) 6kg sugar 60 gm emulsifier 100 gm stabilizer

48

49

BOILER SECTION Oil Fired Boiler

Model Capacity Name Working Pressure Made Number of passes Maximum Working Pressure

RJ813 Oil Fired Boiler 5Tons/hr Wester work fire tube 18kg/cm2 Network Engg. Ltd. Bombay 3 20kg/cm2

50

Technical Specifications :
Details Unit RT-01 RT-02 RT-03 RT-04 RT-05 RT-06 RT-08 RT-10 OPERATING PARAMETERS Steam output Kgs/hr 100 200 300 400 500 600 800 1000 F & A 100oC. Steam Kgs/cm2 15 15 15 15 15 15 15 15 pressure Fuel Oil Consumption Kgs/hr 6 12 18 24 30 36 48 60 LDO Kgs/hr --19.1 25.4 31.8 38.1 50.8 63.6 FO Efficiency % -----------------------> 88 + 2 <--------------------------------(NCV) Start up Minutes 3 3 3 3 5 5 5 5 Burner -----------------------> ON/OFF <--------------------------------control Pressure OUTSIDE THE PURVIEW OF INDIAN BOILER REGULATIONS parts Electric AC - 3 - PHASE : 415 V - 6% ; 50 Hz = 3%; 4 wire Supply Connected Electrical Load Feed water HP 0.5 0.5 1 1 1 1 2 3 pump motor Blower + Fuel pump HP 1.5 1.5 2 2 2 2 3 5 motor Fuel oil preheater KW --3 3 3 3 6 6 (For F O fired units only) Total electrical load for : LDO Fired 3 HP 3 HP 3 HP 3 HP 3 HP 5 HP 8 HP 2 HP Units 3 3 3 3 3 5 8 FO Fired HP+3KW HP+3KW HP+3KW HP+3KW HP+3KW HP+6KW HP+6KW Units Flue Gas mm 150 150 200 200 200 250 300 300 outlet

INITIAL FIRING ARRANGEMENTS

51

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.

52

53

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.

54

55

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.

56

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 after cooling 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.

57

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 Frick India 4 Heavy duty industrial type, double cylindered reciprocating

Make No.of compressors Type of compressors ammonia

Compressors. Capacity HP of compressor motor Type of motor Suction pressure Discharge pressure Oil pressure 50 tons 125 HP/150HP induction 30-35 psi 180-200psi 50-60psi

58

Dimension of liq receiver No. of chilled water tanks Capacity

600mmdia x 5.5 meter 4 30,000ltr each

BOOSTER COMPRESSOR Frick India Two 25 tones each 15 HP

Make Number Capacity Motor HP

59

QUALITY CONTROL LABORATORY

60

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.

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