Copy of Rishabh Report

8/6/2019 Copy of Rishabh Report

1/62

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

1


2/62

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

2


3/62

3


4/62

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 : 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

4


5/62

5


6/62

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:

6


7/62

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

7


8/62

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.

8


9/62

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

9


10/62

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

10


11/62

11


12/62

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).

12


13/62

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

13


14/62

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

14


15/62

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

15


16/62

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

16


17/62

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%

17


18/62

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.

18


19/62

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

19


20/62

Phosphatase test : Negative

DISPATCH OF PASTEURIZED MILK

Temp :


21/62

PROCESSING OF MILK

21


22/62

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

22


23/62

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

23


24/62

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

24


25/62

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

25


26/62

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

26


27/62

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

27


28/62

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

28


29/62

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

29


30/62

30


31/62

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.

31


32/62

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

32


33/62

33


34/62

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


35/62

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


36/62

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


37/62

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.

37


38/62

(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.

38


39/62

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


40/62

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

40


41/62

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.

41


42/62

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

42


43/62

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


44/62

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

44


45/62

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

45


46/62

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


47/62

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


48/62


49/62

49


50/62

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

50


51/62

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


52/62

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


53/62

53


54/62

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


55/62

55


56/62

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


57/62

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.

57


58/62

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

58


59/62

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

59


60/62

QUALITY CONTROL LABORATORY

60


61/62

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:-

61


62/62

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.

Documents

Copy of Rishabh Report