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Dairy Processing Plant and Equipment
Considerations
Eric Goan Dairy Processing Specialist
Department of Food Science Technology University of Tennessee
• Considerations – Are you sure this is something you want to do? – Talk to other producers
• Visit their facility – Would they change anything? – Keep in mind you may not be approved for the exact same set up.
• Commitment to the dairy • Advantages and disadvantages • How hard and competitive is marketing the product? • If they had to do over would they begin processing? • What does it cost to process a gallon/pound of product?
Processing Considerations
First Talk with Inspection Service (Tennessee Department of Agriculture) or UT Extension (Department of Food Science & Technology)
Processing Construction Requiremnets
• Bill Thompson Food Manufacturing Administrator Tennessee Department of Agriculture 440 Hogan Road Nashville, TN 37220 Phone: (615) 837-5534 Fax: (615) 837-5335 Email: [email protected]
• Eric C. Goan Director Center for Food Processing Extension Specialist Dairy Processing The University of Tennessee Department of Food Science & Technology 2510 River Drive Knoxville, TN 37996 Phone: 865-974-7287 Fax: 865-974-7332 Email: [email protected]
• First Talk with Inspection Service (Tennessee Department of Agriculture) or UT Extension (Department of Food Science & Technology)
• Order of Approval Process – Site Approval (TDA) – Facility Approval (TDA)
• Waste Water (TDEC) • Potable Water (TDEC) • Septic Tank (Health Department) • Direction of all facility Drains (TDA)
– Equipment Approval (TDA) • Prior to Purchase and Installation • After Installation
– Plant Layout and Design Approved (TDA) – Approved Lab (TDA) – Special License (TDA)
• Plant Permit • Hauler/Sampler License
– Chemical Approval (TDA)
Processing Construction Requiremnets
• First Talk with Inspection Service Tennessee Department of Agriculture (TDA) or UT Extension, Department of Food Science & Technology (UTFST)
• Order of Approval Process – Site Approval (TDA) – Facility Approval (TDA)
• Waste Water (TDEC) • Potable Water (TDEC) • Septic Tank (Health Department) • Direction of all facility Drains (TDA)
– Equipment Approval (TDA) • Prior to Purchase and Installation • After Installation
– Plant Layout and Design Approved (TDA) – Approved Lab (TDA) – Special License (TDA)
• Plant Permit • Hauler/Sampler License
– Chemical Approval (TDA)
Processing Construction Requiremnets
• First Talk with Inspection Service (Tennessee Department of Agriculture) or UT Extension (Department of Food Science & Technology)
• Order of Approval Process – Site Approval (TDA) – Facility Approval (TDA)
• Waste Water (TDEC) • Potable Water (TDEC) • Septic Tank (Health Department) • Direction of all facility Drains (TDA)
– Equipment Approval (TDA) • Prior to Purchase and Installation • After Installation
– Plant Layout and Design Approved (TDA) – Approved Lab (TDA) – Special License (TDA)
• Plant Permit • Hauler/Sampler License
– Chemical Approval (TDA)
Processing Construction Requiremnets
• First Talk with Inspection Service (Tennessee Department of Agriculture) or UT Extension (Department of Food Science & Technology)
• Order of Approval Process – Site Approval (TDA) – Facility Approval (TDA)
• Waste Water (TDEC) • Potable Water (TDEC) • Septic Tank (Health Department) • Direction of all facility Drains (TDA)
– Equipment Approval (TDA) • Prior to Purchase and Installation • After Installation
– Plant Layout and Design Approved (TDA) – Approved Lab (TDA) – Special License (TDA)
• Plant Permit • Hauler/Sampler License
– Chemical Approval (TDA)
Processing Construction Requiremnets
• Grade “A” Pasteurize Milk Ordinance (PMO) – All Federal and State of Tennessee Rules for producing and processing grade A
milk – State rules vary state to state
• Interstate Milk Shippers List (IMS) – Allows products to be sold across state lines – Three tiered inspection program on dairy plant and dairy farm for IMS
• 1) Area inspector inspects plant every 3 months • 2) State rating officer conducts state survey every 2 years • 3) Federal rating officer conducts federal survey every 3 years
• Good Manufacturing Practices (GMPs) – Cornell online course
• Standard Operating Procedures (SOPs) • Standard Sanitation Operating Procedures (SSOPs) • Hazard Analysis Critical Control Points (HACCP)
– Certification course offered through UTFST
Processing Regulations
• Considerations – Processing Classes
• Learn processing and lab techniques • Sensory properties
– Co-Packers • Starting Point
Processing Considerations
Sources of Milk
Table 1. Gross Composition (%) of Milk from Domesticated mammals
Species Fat Protein Lactose Ash Total Solids
Cow
Ayshire 4.1 3.6 4.7 0.7 13.1
Brown Swiss 4.0 3.6 5.0 0.7 13.3
Guernsey 5.0 3.8 4.9 0.7 14.4
Holstein 3.5 3.1 4.9 0.7 12.2
Jersey 5.5 3.9 4.9 0.7 15.0
Goat 3.5 3.1 4.6 0.8 12.1
Sheep 5.3 5.5 4.6 0.9 16.3
Park, YW and Haenlein, GFW. Handbook of Milk of Non-bovine Mammals. Blackwell Publishing.
Different Dairy Products
http://commons.wikimedia.org/wiki/File:Milkproducts.svg
• Test Milk • Separate Fat • Mix Ingredients • Pasteurize Milk • Bottled or Further
Processed (i.e. Cultured Products)
Processing Plant
• Milk Tests – Smell & Taste – Receiving Temperature – Titratable Acidity – Direct Microscopic Count (DMC) – Standard Plate Count – Somatic Cell Count – Drug Residue (Inhibitor Testing) – Lab Pasteurize Test – Freezing Point of Milk – Butterfat
Processing Plant
DCQI Services http://www.dqci.com/milk-microbiology-analyses.html
• Milk Storage – Refrigerated Farm Bulk Tanks
• Pasteurize Milk • Raw Milk • Cream Storage
• Separator • Blend/Mix Tanks • CIP and COP Systems
Processing Equipment
Processing Equipment
• Pasteurization – High Temperature Short Time (HTST)
• 161.5°F (72°C) for 15s
– Vat or Batch Pasteurization • 145°F (63°C) for 30m
www.shiercompany.com
www.dairyagendatoday.com
• HSTS Pasteurizer Heat Exchangers – Plate Heat Exchanger – Tube in Tube Heat Exchanger
Processing Equipment
• Homogenizer – Breaks down fat globules
• Jug Filler – Product must be mechanically
filled and sealed
• Fermentation Vat – Allows Yogurt to
ferment
Processing Equipment
• Excess Cream – Butter
• Utilizes more cream • Churn
– Ice Cream • Limitations
– Seasonal – Varieties
• Uses less cream • Ice Cream Maker • Storage freezer
Processing Equipment
• Cheese Making – Make Sheet – Vat – Drain Table
• Waste Material (Whey)
– Press
http://www.wsu.edu/creamery/phototours/phototourschz.htm
Processing Equipment
• Dairy Plant with Batch Pasteurization
Dock
Up
Dock
Up
Casing Area
Jug Filler
3'x10' C.O.P.
Vat
Homogenizer Platecooler
500 Gallon PasteurizedFarm Bulk
TankRefrigerated
500 Gallon PasteurizedFarm Bulk
TankRefrigerated
800 Gallon Pasteurized
Farm Bulk TankRefrigerated
800 Gallon Pasteurized
Farm Bulk TankRefrigerated
Butter Making
1500 Gallon Raw Milk Tank
1500 Gallon Raw Milk Tank
390 Seperator
800 Raw Skim Blend
800 Raw Skim Blend
500 Mix Tank
300 Mix Tank
600 Gallon Pasteurization
Vat
600 Gallon Pasteurization
Vat
Sales RoomSecretary’s
Office
Manager’s Office
Raw Milk Storage
Raw C.I.P.
Women’s Locker Room
Men’s Locker Room
Chemical Storage
Mechanical
3'x10' C.O.P VatHand Wash Sink
Han
d W
ash
Sin
k
Hand Wash Sink
Hand/Eye Wash Sink
Hand W
ash Sink
Men’s Public Restroom
Women’s Public
Restroom
Finish Product Storage Cooler
Empty 25Jug Storage
Dry Storage
Dock anteroom with three 8 ft. wide unloading doors with dock
seals.
12 ½’
60'
12 ½’ 12 ½’
12 ½
’
10’10’
10’
10’ Sliding Door
10’
10’10’
10’
10’
6’
25’
25’
25’
25’
20’20’
34’
4’
4’ 4’
4’4’
4’
4’4’
4’4’
4’6’
8’
4’4’
4’
4’4’4’
6’ 6’
10’
10’
8’ Overhead
Roll U
p Door
8’ Overhead
Roll U
p Door
8’ Overhead
InsulatedR
oll Up D
oor
30'
85'
12’
10’
20’
19'
19'
19'
19'
19'
19'
19'
24'17'
12'
19'
24'
20'
40'
12' Overhead Roll Up Door
20'
12 ½
’17
½’
24’
24’
70'
70'
70'
70'
46'
46'
20'
12’
11’
120'
120'
120'
120'
4’12’
6’ 6’
6’6’
8’ Overhead
Roll U
p Door
With D
ock Seal
8’ Overhead
Roll U
p Door
With D
ock Seal
8’ Overhead
Roll U
p Door
With D
ock Seal
Up
Up
6’6’
12 ½’
12 ½’
12 ½’
4’
72'
10’
20’
Break Room
4’
Dairy Processing Plant Fluid Milk & Butter Floor Plan
Prepared by Eric Goan and Tommy Burch (University of Tennessee) and Hugh Wilson and Terry Kinser (Tennessee Department of Agriculture)
1" = 17.14'
19'
ChillerBoiler 2
Boiler 1
1
Work Bench
2
Hand Wash Sink
1 2
Hand/Eye Wash Sink
4’3'
Sales Counter
Sales Cooler 1 Sales Cooler 2
Sal
es C
oole
r 3
Sal
es S
helv
ing
500 Gallon Pasteurization
Vat
300 Gallon Pasteurization
Vat
200 GallonRaw Cream Vat
Refrigerated
50 Gallon Pasteurization
Vat
Air Compressors
3'x8' C.O.P
Vat
Drain
Drain
Drain
Drain
Drain
Drain
Drain
Drain
Drain
Drain
Drain
Drain
Drain
Drain to Safety Box
DrainDrain
Drain
Drain
Drain
Drain
17'
Drain
Drain
Hand/Eye Wash Sink
19'
19'
Labratory
Pasteurization C.I.P. Drain
Hand/Eye Wash Sink
4’
Drain
20'
300 Gallon Pasteurization
Vat
Commercial Hot Water Heater
Hand W
ash Sink
Han
d W
ash
Sin
k
10’ Overhead Roll Up Door
12' Overhead Roll Up Door
Up
Milk Receiving
3'
10'
Plant Considerations
• Dairy Plant with HTST Pasteurization
Dock
Up
Dock
Up
Casing Area
Jug Filler
3'x10' C.O.P.
Vat
HTST Pasteurizing Unit With Homogenizer
500 Gallon PasteurizedFarm Bulk
TankRefrigerated
500 Gallon PasteurizedFarm Bulk
TankRefrigerated
800 Gallon Pasteurized
Farm Bulk TankRefrigerated
800 Gallon Pasteurized
Farm Bulk TankRefrigerated
Butter Making
1500 Gallon Raw Milk Tank
1500 Gallon Raw Milk Tank
390 Seperator
800 Raw Skim Blend
800 Raw Skim Blend
500 Mix Tank
300 Mix Tank
600 Gallon Pasteurization
Vat
Sales RoomSecretary’s
Office
Manager’s Office
Raw Milk Storage
Raw C.I.P.
Women’s Locker Room
Men’s Locker Room
Chemical Storage
Mechanical
3'x10' C.O.P VatHand Wash Sink
Han
d W
ash
Sin
k
Hand Wash Sink
Hand/Eye Wash Sink
Hand W
ash Sink
Men’s Public Restroom
Women’s Public
Restroom
Finish Product Storage Cooler
Empty 25Jug Storage
Dry Storage
Dock anteroom with three 8 ft. wide unloading doors with dock
seals.
12 ½’
60'
12 ½’ 12 ½’
12 ½
’
10’10’
10’
10’ Sliding Door
10’
10’10’
10’
10’
6’
25’
25’
25’
25’
20’20’
34’
4’
4’ 4’
4’4’
4’
4’4’
4’4’
4’6’
8’
4’4’
4’4’
4’4’
6’ 6’
10’
10’
8’ Overhead
Roll U
p Door
8’ Overhead
Roll U
p Door
8’ Overhead
InsulatedR
oll Up D
oor
30'
85'
12’
10’
20’
19'
19'
19'
19'
19'
19'
19'
24'17'
12'
19'
24'
20'
40'
12' Overhead Roll Up Door
20'
12 ½
’17
½’
24’
24’
70'
70'
70'
70'
46'
46'
20'
12’
11’
120'
120'
120'
120'
4’12’
6’ 6’
6’6’
8’ Overhead
Roll U
p Door
With D
ock Seal
8’ Overhead
Roll U
p Door
With D
ock Seal
8’ Overhead
Roll U
p Door
With D
ock Seal
Up
Up
6’6’
12 ½’
12 ½’
12 ½’
4’
72'
10’
20’
Break Room
4’
Dairy Processing Plant Fluid Milk & Butter Floor Plan
Prepared by Eric Goan and Tommy Burch (University of Tennessee) and Hugh Wilson and Terry Kinser (Tennessee Department of Agriculture)
1" = 17.14'
19'
ChillerBoiler 2
Boiler 1
1
Work Bench
2
Hand Wash Sink
1 2
Hand/Eye Wash Sink
4’3'
Sales Counter
Sales Cooler 1 Sales Cooler 2
Sal
es C
oole
r 3
Sal
es S
helv
ing
200 GallonRaw Cream Vat
Refrigerated
Air Compressors
3'x8' C.O.P
Vat
Drain
Drain
Drain
Drain
Drain
Drain
Drain
Drain
Drain
Drain
Drain
Drain
Drain
Drain to Safety Box
DrainDrain
Drain
Drain
Drain
Drain
17'
Drain
Drain
Hand/Eye Wash Sink
19'
19'
Labratory
Pasteurization C.I.P. Drain
Hand/Eye Wash Sink
4’
Drain
20'
Commercial Hot Water Heater
Hand W
ash Sink
Han
d W
ash
Sin
k
10’ Overhead Roll Up Door
300 Gallon
Past Vat
12' Overhead Roll Up Door
Up
Milk Receiving
3'
10'
Plant Considerations
• Milking Parlor with Plant Attached
Drain
Water Heater
IceBuilder
Bulk Milk Tank 100 or 200 Gallon
Air Compressor
100 or 50 GallonVat Pasteurizer
Cheese Vat Cheese Press
COP Vat
Up
Laboratory
Mechanical Room
Dry Storage Crate Storage
Chemical Room
Manager’s Office
Office
Refrigerator
Store Bathrooms
Milking Parlor
Tank Room
Milk Processing
Drain Table
Casing Area
Viewing Hallway
Anteroom
Locker Room
Crate Washer
Vacu
um
Seal
er
COP Vat
Plate Cooler andHomogenizer
Drain
DrainDrain
Drain
Drain
Drain
Drain
Drain
Jug Filler
Drain
Drain
Drain
Drain
Drain
Drain
Drain
Plant Considerations
• Goat/Sheep Processing Facility
Plant Considerations
Up
200 gallonVat Past.
Jug Filler
Drain
Drain
Drain
200 Gallon Cheese Vat
Crate Washer
Lab/Locker Room
Tank RoomMilk ParlorBathrooms
Processing
Cooler
Cooler/ Dry Storage
Shipping/ReceivingDry Storage
Mechanical
Office
Loading Dock
Hot Water HeaterBoiler
Air Compressor
Chemical Storage
Bulk Tank
Drain
DrainDrain
3'x8' COP Vat
Chill Water Tank