DAL GROUP

DAL FOOD INDUSTRY

MILK & GUM ARABIC SPRAY DRYING
FACTORY

A REPORT OF MY TRAINING IN DAL

FACTORY OF MILK & GUM ARABIC:

BY : Alzubair Babiker Fadl Almoula Hussein

EMAIL : zebrajaali98@gmail.com

TEL. NO. : 0901239363

SUPERVISORS: Mr. Ahmed Alsafi

Mr.Adel Mohammed
Mrs. Sara Hatim
Eng. Mohanned moawia
Eng. Mohammed Alkhalifa

FIRSTLY: PRODUCTION OF GUM ARABIC POWDER:

 Dissolving

Filtration Area

Pasteurization

Spray Drying
Tower

Fluid Bed
Dryer

Packgaing

Dissolving:
In dissolving we dissolve the gum with water only if we are using
HASHAB GUM, but if we used SEYAL GUM we have to make bleaching by
adding caustic soda (NaOH) to increase the PH of the solution then when
add hydrogen peroxide (H2O2) this process is done in dissolving tank,
after the dissolving finished we take the solution to the filtration area.

Filtration Area:
In filtration area we have to remove most of the impurities we have:
1.Sieves:
that remove large impurities with (500-200µ) meshes size, after that we
take the solution to the pre-decanting tank to be ready for decantation.
2. Decanting tank:
In the decanting tank we can separate more impurities by using the
method of separation between two solution .
3. Centrifugation :
we receive the solution from the decanting tank in centrifugal we
separate the impurities from the solution by the different in their density .
4. From the centrifugal we carry the solution through pipes to balance
tank to store the solution
5. From balance tank we carry the solution to the last step of filtration
in this step we have two filter Gap filter(50µ size) and Cartridge
filter(20µ)
In this step the filtration will finished then we can move to the next
process .

Pasteurization:
In the pasteurizer we heat the solution of the gum till it reach (90oc) by
plate heat exchanger we use water (which is heated by steam) to heat
the solution to kill the microorganism. After that the solution is ready to
move it to the buffer tank.
Near the buffer tank we have small tank with sensor to make sure the
tank is full then we can take it to the high pressure pump to increase the
pressure of the solution till 200 bar then it will be ready to take it for
spray dryer .

Spray Dryer:
The spray dryer is a method of production a dry powder from a liquid
solution by using hot air and it works under vacuum pressure about (-
0.05- -0.07 bar)
We have two type of spray dryer:
1.Atomizer
2. Spray nozzle.
In the Gum Arabic Factory they use the spray nozzle which nozzles the
solution in the dryer and met the hot air and immediately dries the
solution, the source of the hot air is the atmospheric air, first the
atmospheric air have to pass the air filter for filtration the air and heat
exchanger to rise it temperature about (180-220 oC).
After the dries is finished , the product will come out about 10%
moisture and the outlet temperature about(75-80oc) pass through the
fluid bed dryer , and the air comes out with some fine powder so we
have transfer it to three cyclone .
The method of cyclone is to separate the fine powder from the hot air by
the different in their densities and then the powder goes back to the
spray dryer to re-enters with the gum feed. And the air is exhaust.

Fluid Bed Dryer:

In the fluid bed dryer we reduce the moisture of the powder to be less
than 10% we have three section in it:

:section1 :section 2 :section 3

hot air hot air cold air
temp (75- temp (75- temp(20±5
80 oc) 80oc) o
c)

the powder first pass through section 1 , then section 2, after that it pass
through section 3 to cold it then will be ready for the packaging . The air
comes out with some fine powder so we have transfer it to the cyclones .
Packaging:
Powder
Silo

Vibration Mesh size 0.2mm any

particle greater than it
transfer back to the
Sifter dissolving tank

Filling
Machine

Folding
Machine

Metal
Detector

Printing
Machine

Gum Analysis:
We make tests for the receiving gums, the solution in the dissolving
tank, after filtration, after pasteurization, for the final product (gum
powder) and in the packing area to make sure everything in our
standards. The tests are:
Tests Device Used Standard Range
pH pH meter 4-4.8
Moisture Moisture Analyzer Not more than 10%
Viscosity Viscometer 60-160 CPS
Color Colorimeter Maximum 6
Size of particle Sifter -
Brix Refractometer 28-32 Brix
Temp Thermometer Not more than 65oc
Black Particles Filtration Not more than 10
Total Ash Muffle furans Not more than 4.0%
Acid Insoluble Ash Filtration Not more than 0.5%
Acid Insoluble Filtration Not more than 0.5%
Matters

SECONDLY: Production of Milk Powder:

A- Processes:
We have three types of milk powder differs in their contained of fat:
1. Instant whole milk powder (3.2-3.3% fat)
2. Whole milk powder (3.2-3.3% fat)
3. Skim milk powder<0.1%
There is no difference in the processes for this types of milk powder
except in the fluid bed dryer as I will explain it.
First we receive the milk from capo at 4oC and concentration
between(12-13%) and we store it in an isolated tanks(two tanks) the
capcity of each one of them is 100,000Ton, this tanks are isolated that it
temperatures increase one degrees in a day. Before our processes start
we have to heat the milk in an pre heater first and in a heater second
until it reach 78oC then we can start our processes.
 Evaporators

Condenser

Buffer Tanks

Tubular
Heater

High Pressure
Pump

Spray dryer
tower

Fluid Bed
Dryer

Packing Area

1.Evaporators:
The method of evaporator is to increase the concentration of the milk
until it reach 45-50% by using steam as a heating medium , it consists of
four clandria the product from the first clandria enters the second
clandria ,the third one and the fourth until it reach the concentration
we wont and the product comes out from the third clandria and transfer
to the buffer tanks,they are some difference between the four
evaporators in their size the third one is the biggest one. The steam from
each calandria enter the second one as a heating medium same for the
third and the fourth one and then transfer to condser.

2.Condenser:
come from the main silo tank in the condenser th heat it and the same
time to condensate the steam as a type of energy The method of
condenser is to ccondensate the steam into water, we use the coled milk
that saving, the water comes out to drainage.

3. Buffer Tanks:
From evaporators we transfer the concentrated milk into two buffer
tank (8000L) to store the milk in it, untill the tank is get full and ready to
transfer the concentrated milk to the tublar heater

4. Tublar Heater :
In the tubular heater we heat the concentrated milk again until it reach
68oC by using steam, because it loss some of it heat in the buffer tank
then it travel to concentrate tank (500L) (2 tanks)

5. High Pressure Pump:

We receive the concentrated milk from the concentrate tank and we
have to increase it pressure and temperature by using high pressure
pump, we increase the pressure until it reach 200bar so that it can be
ready to take to the spray dryer.

6. Spray Dryer Tower:

As we mentioned they are two types of spray dryer and we use the
nozzle one, the concentrated milk enters the tower from the top and get
sprays through three nozzles and also get a sudden dries by hot air
which is heated in a plate heat exchanger by steam, the products comes
out at the bottom of the tower and enters the fluid bed dryer with
temperatures between (75-80oC), the air comes out with some fine
powder so it have to pass it through three cyclones to get rid of the fine
powder by the method of separating in deference between their
densities, the fine powder enters the tower again with the concentrated
milk and the air is exhausted( the same principle that is done for the
gum).

7. Fluid Bed Dryer:

The milk powder enters the fluid bed dryer to decrease it moisture to be
less than 4% and as we mentioned they are three sections in the fluid
bed dryer (hot air ,hot air, cold air ) , after that the milk powder is ready
to transfer it to the packaging area, but if we are using whole milk
powder we have to add lecithin which make powder more soluble.

8. Packaging Area:
Also the packaging is the same like the one for the gums and also the
same steps, but it differ that for milk powder we mix it with another milk
powder .And we have to add nitrogen for saving the milk.

B- Laboratory Analysis:
We make several analysis for the receiving milk and also for the milk
powder (the milk powder have more analysis than the milk), and we
have to take samples from each process to make sure everything is okay.

Milk Analysis:
Tests Standard Range
pH 6.60-6.80
Fat% Min 3.1%
Temp Not more the 4oC
SNF% Min 8.5%
Specific gravity 1.028-1.0360
Total solid % Min 11.5%

Milk Powder Analysis:

We make the same tests for the milk to the milk powder with some
additional tests which it:
Tests Standard Range
Moisture Max 4%
Ash contain 5.80% Max
Scorched Particles Disk B max
Lactose 34.0-39.40%
Protein 24.2-27.5%
Titratable Acidity Max 0.15%

-They are some microbiological tests make for both milk and milk
powder which are:
1. Coliform.
2. T.V.C.
3. Yeast and Mould.
4. Thermophilic Spore Formers.
5. Mesophilic Spore Formers.

SENSORY EVALUATION:
There are two standards which used for testing milk:
A.The result will be one of these:
1.Acceptable.
2.Not acceptable.
3.Standard
B.Or one of these:
1.Like very much.
2.Like moderately.
3.Like slightly.
4.Neither like nor dislike.
5.Dislike slightly.
6.Dislike moderately.
7.Dislike very much.

CIP (cleaning inside place):

The CIP units contains five tank three of them contains water, the fourth
one contain caustic soda and the fifth one contain HNO3.
We have two types of CIP:
1.Intermediate cleaning:
First we wash all the equipment's with water at 60 oC, second we wash it
with caustic soda (NaOH) with concentration (1.5-2%) and temperature
between (70-75oC) the third steps we wash it with water again at the
same temperature.
2. Full cleaning:
Is the same like the intermediate cleaning but we have more extra two
steps, that after the third steps finish we wash all the equipment's with
(HNO3) with concentration (0.8-1.2%)and temperature about 60 oC, the
last step is wash it with water again.

Utilities
The utilities unit supply the factory with the hot steam and the cold
water for condensation unit and also for air conditioners. In utilities unit
we have three units:
1. Water Treatment Unit:
We receive the raw water from the wells with some dirty so we have to
treat it until we get rid of this dirty, the water treatment unit consisting
of many small units:

Raw Semi
Sand Micro
water Pumps Softeners Treated UV Tubes
Filters Filters
wells Tanks

When we receive the water from the wells we transfer it through the
pumps to sand filters so that we can get rid of the large dirty and
impurities from the water, after that we transfer it to the softeners to
remove the minerals that cause the water to be hard, then we transfer it
to the semi treated tanks after that we take it to the UV tubes
2. Boiler:
Is a device used to create steam by applying heat energy to water .We
receive the water from water treatment units and we make another
treat for her in this unit by softening it by adding chemicals, then we
move it to the boiler that consists of many small tubes, we use it to boil
the water using the burners of gasoline or benzene until it reach 10 bar
and all the water convert to steam.
3. Chiller:
The chiller consist of refrigeration cycle that consists of:
1. Compressor: to compress ammonia.
2. Condenser: condenses the ammonia using water and fans (the
ammonia changes into liquid)
3. Expansion valve to reduce pressure and temperature
4. Evaporator: plate heat exchanger the ammonia is used to cool water,
the water inter the evaporator between (10-12oC) and comes out at 4oC.

Condenser

Expansion
Compressor
valve

Evaporator