Butter is as old as history.

Records show that the

use of butter is as early as 2000 years before Christ.
In nutrition, butter has its distinguishing qualities
and characteristics that explain its pre-eminence as
a food fat. It has a pleasing aroma with along with
its pleasing flavour.

Butter has long been recognized as a rich source of the

fat-soluble vitamin A and its precursor, carotene,
from where vitamin A originates. It also contains vitamin
D, which is significant to human nutrition.

Butter is a semi-solid fat-rich product, principally

in the form of an emulsion of the water-in-oil type
with complex rheological properties, and its structure
and consistency are determined by numerous factors. It
also contains more than 80% milk fat, 16% moisture, 0.3%
salt and 1-1.5% curd which exerts a decisive influence on its
properties(Wright & Marangoni, 2006). This proportion is
largely controlled by the method of manufacture and
regulated to conform to the standards of butter prescribed
by regulatory authorities such as codex and FSSAI.
FLOOR AND SPACE REQUIREMENT

Overall layout – 30 m x 25 m = 750 sq.m

ZONE A:
Milk reception and washing unit – 55 sq.m
Utility and maintenance area – 24 sq.m
Processing area – 240 sq. m

ZONE B:
Refrigeration room – 40 sq.m
Laboratory – 16 sq.m
Storage area – 72 sq.m
Packaging area – 56 sq.m

ZONE C:
Office – 60 sq.m
Toilet – 24 sq.m
Canteen – 50 sq.m

___________________________________________________________________________________________

MARK ET DISPOSAL SCHEDULE

Since this is a large scale butter manufacturing facility, a large amount of solid
waste will be generated day by day, therefore, market disposal schedule will be
during Mondays, Wednesdays, and Fridays.
 1. MILK RECEIPT 5. COOLING AND
The milk as soon as it is received at AGEING(7-9°C)
plant, is weighed, dumped into the
Cooling and ageing are processes
dump tank (weigh tank) and has to
which prepare the cream for
be chilled before it is stored for
subsequent operation of churning
processing. .
. .
. .
. .
. .
.
6. RIPENING
2. CREAM SEPARATION It refers to the process of
fermentation of cream with the
1. Centrifuges can be used to separate
help of suitable starter culture
the cream from the skim milk.
.
. .
. .
. .
. .
.
7. CHURNING
3. STANDARDIZATION It is the process of converting cream
It refers to adjustment of fat to into butter through appropriate
desired level. It is done by adding mechanical manipulations leading to
calculated quantity of skim milk or the conversion of oil-in-water (O/W)
butter milk. emulsion of cream into water-in-oil
. (W/O) emulsion desired in butter.
. .
. .
. .
. .
.
4. PASTEURIZATION
It destroys pathogenic microorganisms 8. WASHING & DRAINNG
in cream so as to make it, and the Washing of butter means removal of
resultant butter, safe for human remnants of curd adhered to surface
consumption. It also destroys bacteria, of butter grains.
yeast, mould, enzymes and other
biochemical agents that may lower
keeping quality.
 9. INITIAL WORKING & FINAL
WORKING
During initial working, excess moisture and
buttermilk is removed. This is followed by salt
and make-up water addition and
the butter granules are worked again. This is
called as final working and the purpose of this
is to properly incorporate salt
and moisture in butter to form a compact
mass.
.
.
.
.
.

10. PACKAGING
The primary purpose of packaging is to offer
butter to the trade and to the consumer in
packages of such size, material,
form and appearance, as will best meet the
requirements and satisfy the preferences of
the buyer.
.
.
.
.
.

11. STORAGE
For the sake of consistency and appearance,
butter should be placed in cold store as soon
as possible after wrapping and
should be chilled to 4°C for 24 to 48 h
 Specific heat: 2.04 kJ/kg-°C
 Bulk density: 911 kg/𝑚3
 Thermal Conductivity: 0.2 W/m-K
 Average ambient air temperature: 18 °C
 Ceiling height w/ 50% space allowance: 6 m
 6535 kg per day will be produced
 Operation schedule is Monday to Friday, and
delivery is done every 48 hours.
 Butter is placed in cold sore after wrapping and chilled
to at 4°C for 24-48 hours.
 Packaging material used is moisture and grease
proof, specifically, lacquered tin cans.
 Fully automatic units are used in packaging.
Zone A. Processing Area
1. Before Re-heat part:
a. Air supply; 𝑇1 = 12°C, 𝑅𝐻1 = 30%.
b. Read; 𝑝𝑑1 = 1.4014 kPa, ℎ𝑔1 = 2523.6 kJ/kg, 𝑣𝑔1 = 93.84m3/kg.

c. Solve: 𝑝𝑠1 = 𝑝𝑑1 𝑅𝐻1 = 1.4014(0.30) = 0.42042 kPa.

0.622∗ 𝑃𝑠1 0.622∗ 0.42042
d. Solve; 𝑊1 = = 101.3−0.42042 = 0.002592 kg/kg
𝑃𝑡 −𝑃𝑠1

e. Solve: ℎ1 = 𝑐𝑝 𝑇1 + 𝑊1 ℎ𝑔1 = 1.0062(12) + 0.002592(2523.6) = 18.6156 kJ/kg

2. After Reheat to Zone-A;

a. Supply temperature: 𝑇𝑠2 = 16°C
b. Read: 𝑝𝑑𝑠2 = 1.1818 kPa, ℎ𝑔𝑠2 = 2530.8 kJ/kg, 𝑣𝑔𝑠2 = 73.33 m3 /kg

c. Solve: 𝑅𝐻𝑠2 , 𝑊𝑠2 = 𝑊1 = 0.002592 kg/kg; 𝑝𝑠2 = 𝑝𝑠1 = 0.42042 kPa.

𝑝𝑠2 0.42042
𝑅𝐻𝑠2 = = = 0.3557 (35.57%)
𝑝𝑑𝑠2 1.1818
d. Solve: ℎ𝑠2 = 𝑐𝑝 𝑇𝑠2 + 𝑊𝑠2 ℎ𝑔𝑠2 = 1.0062(16) + 0.002592(2530.8) = 22.6593 kJ/kg

e. Design room conditions: 𝑇2 = 20°C; 𝑅𝐻2 = 60%; u, air velocity = 0.25 m/s.
f. Read; 𝑝𝑑2 = 2.337 kPa, ℎ𝑔2 = 2538.2 kJ/kg, 𝑣𝑔2 = 57.84 m3 /kg.

g. Solve; 𝑝𝑠2 = 𝑝𝑑2 (𝑅𝐻2 ) = 2.337(0.60) = 1.4022 kPa.

0.622∗ 𝑃𝑠2 0.622∗ 1.402
h. Solve: 𝑊2 = = 101.3−1.402 = 0.008729
𝑃𝑡 −𝑃𝑠2

i. Solve: ℎ2 = 𝑐𝑝 𝑇2 + 𝑊2 ℎ𝑔2 = 1.0062(20) + 0.008729 (2538.2) = 42.2803 kJ/kg.

j. Cooling Load:
a) Transmission load: Q = A(𝑇𝑓 – 𝑇𝑖 ) / R; 𝑇𝑖𝑛 = 20°C.

Material R, therm. Area 𝑇𝑓 – 𝑇𝑖 𝑄1

Resistance 𝑚2 °C kJ/s
m2 -K/W
 A. Wall Conduction
1) Outside air film 0.029
2) Face brick, 50 mm 0.038
3) Concrete,120 mm 0.066
4) Gypsum board, 0.080
10mm 0.120
5) Inside airfilm 0.333 240 8 5.765

B. Ceiling Conduction
1) Outside airfilm 0.029
2) Sheating fiber
board,13mm 0.232
3) Gypsum
board,10mm 0.080
4) Inside airfilm 0.120
0.461 120 8 2.082
Sub-total 7.847

b) Infiltration load: Heat gain due to the entry of outdoor air through door
opening/closing is assumed 8% of the transmission load.
𝑄2 = 0.08 (7.847) = 0.62992 kJ/s
c) Internal load:
1) Lights: Lighting requirement is 10 watts/m2, 12 hrs per day, for a total floor
area, 200 m2:
10 ∗ 240 ∗ 12
𝑄𝑎 = = 1.2 𝑘𝐽/𝑠
24 ∗ 1000
2) Conveyor motors: 5-units 3 hp each, 8% radiation/kW.
𝑄𝑏 = 5 ∗ 3 ∗ 0.746 ∗ 0.08 = 0.895 𝑘𝐽/𝑠
3) Workers: 12 laborers to stay 8 hrs/day. Activity- standing and working.
𝑄𝑐 = 305 𝐽/𝑠 − 𝑝𝑒𝑟𝑠𝑜𝑛 ∗ 12 𝑝𝑒𝑟𝑠𝑜𝑛𝑠 ∗ 8/24/1000 = 1.220 𝑘𝐽/𝑠
𝑄3 = 1.2 + 0.895 + 1.220 = 3.315 𝑘𝐽/𝑠
d) Solar Load: Minimal effect due to complete shading at all wall-sides.
e) Sensible heat load of the product:
𝑄5 = 𝑚𝑝 𝑐𝑝 (𝑇𝑝 – 𝑇𝑖 )

= 150,000 kg * 3.95 kJ/kg°C (22 – 20) °C/6/3600

= 54.8611 kJ/s
f) Latent heat load of the product:
Heat gain due to respiration rate of protein and fats–15% of
𝑄6 = 0.15 (54.8611) = 8.2292 kJ/s
g) Total Load
𝑄𝑡 = 𝑄1 + 𝑄2 + 𝑄3 + 𝑄5 + 𝑄6 = 74.8822 𝑘𝐽/𝑠
For 50 % safety factor;
Refrigeration load: QL2 = 1.5 (74.8822) = 112.3233 kJ/s.
k. Needed mass of air: 𝑚𝑎2
Energy balance about the meat packing area:
ma2(h2 – hs2) = QL2 … (Total heat load)
𝑄𝐿2 112.3233
ma2 = (ℎ = (42.2803−22.6593) = 5.7246 𝑘𝑔/𝑠
2 −ℎ𝑠2 )

l. Volume of air; Va2

Va2 = ma vgs2 = 5.7246 kg/s(73.33 m3/kg)
= 419.788 m3/s (25187 m3/min)
Use 25,000 m3/min blower capacity.
3. Main duct area; us2 = 75 m/s.
𝑉 419.788.3527
Va2 = A2us2; A2 = 𝑢𝑎2 = = 5.5971 𝑚2
𝑠2 75

4. Heating Load at the Reheat:

Qr2 = ma2 (hs2 – h1) = 3.6434 kg/s(22.6593 – 18.6156) kJ/kg
= 14.7328 kJ/s
5. Moisture Removed in this Zone:
Mr2 = ma2 (W2 – Ws2) = 3.6434 kg/s(0.008729 – 0.002592) = 0.02236
kg/s (22.36 gm/s)

Zone B. Packaging & Storage Area

1. After Reheat to Zone-B;
a. Supply temperature: 𝑇𝑠3 = 16°C
b. Read: 𝑝𝑑𝑠3 = 1.1818 kPa, ℎ𝑔𝑠3 = 2530.8 kJ/kg, 𝑣𝑔𝑠3 = 73.33 m3 /kg

c. Solve: 𝑅𝐻𝑠3 , 𝑊𝑠3 = 𝑊1 = 0.002592 kg/kg; 𝑝𝑠2 = 𝑝𝑠1 = 0.42042 kPa.

𝑝𝑠3 0.42042
𝑅𝐻𝑠3 = = = 0.3557 (35.57%)
𝑝𝑑𝑠3 1.1818
d. Solve: ℎ𝑠3 = 𝑐𝑝 𝑇𝑠3 + 𝑊𝑠3 ℎ𝑔𝑠3 = 1.0062(16) + 0.002592(2530.8) = 22.6593 kJ/kg
e. Design room conditions: 𝑇3 = 18°C; 𝑅𝐻3 = 60%; u, air velocity = 0.25 m/s.
f. Read; 𝑝𝑑3 = 2.064 kPa, ℎ𝑔3 = 2534.4 kJ/kg, 𝑣𝑔3 = 65.038 m3/kg.

g. Solve; 𝑝𝑠3 = 𝑝𝑑3 (𝑅𝐻3 ) = 2.064 (0.60) = 1.2384 kPa.

0.622∗ 𝑃𝑠2 0.622∗ 1.2384
h. Solve: 𝑊3 = = 101.3−1.2384 = 0.007698𝑘𝑔/𝑘𝑔
𝑃𝑡 −𝑃𝑠2

i. Solve: ℎ3 = 𝑐𝑝 𝑇3 + 𝑊3 ℎ𝑔3 = 1.0062(18) + 0.007698 (2534.4) = 37.62 kJ/kg.

j. Cooling Load:
a) Transmission load: Q = A(𝑇𝑓 – 𝑇𝑖 ) / R; 𝑇𝑖𝑛 = 20°C.

Material R, therm. Area 𝑇𝑓 – 𝑇𝑖 𝑄1

Resistance 𝑚2 °C kJ/s
m2 -K/W
A. Wall Conduction
1) Outside air film 0.029
2) Face brick, 50 mm 0.038
3) Concrete,120 mm 0.066
4) Gypsum board, 0.080
10mm 0.120
5) Inside airfilm 0.333 128 8 3.075

B. Ceiling Conduction
1) Outside airfilm 0.029
2) Sheating fiber
board,13mm 0.232
3) Gypsum
board,10mm 0.080
4) Inside airfilm 0.120
0.461 120 11 2.863
Sub-total 5.938

b) Infiltration load: Heat gain due to the entry of outdoor air through door
opening/closing is assumed 8% of the transmission load.
𝑄2 = 0.08 (5.938) = 0.47504 kJ/s
c) Internal load:
1) Lights: Lighting requirement is 10 watts/m2, 12 hrs per day, for a total floor
area, 128 m2:
10 ∗ 128 ∗ 12
𝑄𝑎 = = 0.64 𝑘𝐽/𝑠
24 ∗ 1000
2) Conveyor motors: 5-units 3 hp each, 8% radiation/kW.
𝑄𝑏 = 5 ∗ 3 ∗ 0.746 ∗ 0.08 = 0.895 𝑘𝐽/𝑠
 3) Workers: 12 laborers to stay 8 hrs/day. Activity- standing and working.
𝑄𝑐 = 305 𝐽/𝑠 − 𝑝𝑒𝑟𝑠𝑜𝑛 ∗ 20 𝑝𝑒𝑟𝑠𝑜𝑛𝑠 ∗ 8/24/1000 = 2.0333 𝑘𝐽/𝑠
𝑄3 = 0.64 + 0.895 + 2.0333 = 3.5683 𝑘𝐽/𝑠
d) Solar Load: Minimal effect due to complete shading at all wall-sides.
e) Sensible heat load of the product:
𝑄5 = 𝑚𝑝 𝑐𝑝 (𝑇𝑝 – 𝑇𝑖 )

= 150,000 kg * 3.95 kJ/kg°C (22 – 18) °C/24/3600

= 27.43 kJ/s
f) Latent heat load of the product:
Heat gain due to respiration rate of protein and fats–15% of
𝑄6 = 0.15 (54.8611) = 8.229165 kJ/s
g) Total Load
𝑄𝑡 = 𝑄1 + 𝑄2 + 𝑄3 + 𝑄5 + 𝑄6 = 45.6405 𝑘𝐽/𝑠
For 50 % safety factor;
Refrigeration load: QL3 = 1.5 (45.6405) = 68.46075 kJ/s.
k. Needed mass of air: 𝑚𝑎2
Energy balance about the meat packing area:
Ma3(h3 – hs3) = QL3 … (Total heat load)
𝑄𝐿3 68.46075
ma3 = (ℎ = (37.62 −22.6593) = 4.5760 𝑘𝑔/𝑠
3 −ℎ𝑠3 )

l. Volume of air; Va3

Va3 = ma vgs3 = 4.5760 kg/s(73.33 m3/kg)
= 335.5609 m3/s (20133.66 m3/min)
Use 20,000 m3/min blower capacity.
3. Main duct area; us3 = 65 m/s.
𝑉 335.5609
Va3 = A3us3; A2 = 𝑢𝑎2 = = 5.1625 𝑚2
𝑠2 65

4. Heating Load at the Reheat:

Qr3 = ma3 (hs3 – h1) = 4.5760 kg/s(22.6593 – 18.6156) kJ/kg
= 18.504 kJ/s
5. Moisture Removed in this Zone:
 Mr3 = ma3 (W3 – Ws3) = 4.5760 kg/s(0.007698– 0.002592) = 0.02236
kg/s (22.36 gm/s)

Zone C. Administration Building

1. After Reheat to Zone-B;
a. Supply temperature: 𝑇𝑠4 = 20°C
b. Read: 𝑝𝑑𝑠4 = 2.339 kPa, ℎ𝑔𝑠4 = 2538.1 kJ/kg, 𝑣𝑔𝑠4 = 57.791 m3 /kg

c. Solve: 𝑅𝐻𝑠4 , 𝑊𝑠4 = 𝑊1 = 0.002592 kg/kg; 𝑝𝑠4 = 𝑝𝑠1 = 0.42042 kPa.

𝑝𝑠4 0.42042
𝑅𝐻𝑠4 = = = 0.1797 (17.97%)
𝑝𝑑𝑠4 2.339
d. Solve: ℎ𝑠4 = 𝑐𝑝 𝑇𝑠4 + 𝑊𝑠4 ℎ𝑔𝑠4 = 1.0062(20) + 0.002592(2538.1) = 26.7068 kJ/kg

e. Design room conditions: 𝑇4 = 23°C; 𝑅𝐻4 = 40%; u, air velocity = 0.25 m/s.
f. Read; 𝑝𝑑4 = 2.81 kPa, ℎ𝑔4 = 2543.5 kJ/kg, 𝑣𝑔4 = 48.574 m3/kg.

g. Solve; 𝑝𝑠4 = 𝑝𝑑4 (𝑅𝐻4 ) = 2.81(0.40) = 1.124 kPa.

0.622∗ 𝑃𝑠4 0.622∗ 1.124
h. Solve: 𝑊4 = = = 0.006979 𝑘𝑔/𝑘𝑔
𝑃𝑡 −𝑃𝑠4 101.3− 1.124

i. Solve: ℎ4 = 𝑐𝑝 𝑇4 + 𝑊4 ℎ𝑔4 = 1.0062(23) + 0.006979 (2543.5) = 40.8937 kJ/kg.

j. Cooling Load:
a) Transmission load: Q = A(𝑇𝑓 – 𝑇𝑖 ) / R; 𝑇𝑖𝑛 = 20°C.

Material R, therm. Area 𝑇𝑓 – 𝑇𝑖 𝑄1

Resistance 𝑚2 °C kJ/s
m2 -K/W
A. Wall Conduction
1) Outside air film 0.029
2) Face brick, 50 mm 0.038
3) Concrete,120 mm 0.066
4) Gypsum board, 0.080
10mm 0.120
5) Inside airfilm 0.333 134 8 3.129

B. Ceiling Conduction
1) Outside airfilm 0.029
2) Sheating fiber
board,13mm 0.232
3) Gypsum
board,10mm 0.080
4) Inside airfilm 0.120
0.461 120 11 2.863
 Sub-total 5.992

b) Infiltration load: Heat gain due to the entry of outdoor air through door
opening/closing is assumed 15% of the transmission load.
𝑄2 = 0.15 (5.992) = 0.8988 kJ/s
c) Internal load:
1) Lights: Lighting requirement is 10 watts/m2, 8 hrs per day, for a total floor
area, 134 m2:
10 ∗ 134 ∗ 8
𝑄𝑎 = = 0.4467 𝑘𝐽/𝑠
24 ∗ 1000
2) Office Equipment: A total of 5 hp, 8% radiation/kW.
𝑄𝑏 = 5 ∗ 3 ∗ 0.746 ∗ 0.08 = 0.298 𝑘𝐽/𝑠
3) Workers: 10 laborers to stay 8 hrs/day. Activity- standing and working.
𝑄𝑐 = 150 𝐽/𝑠 − 𝑝𝑒𝑟𝑠𝑜𝑛 ∗ 10 𝑝𝑒𝑟𝑠𝑜𝑛𝑠 ∗ 8/24/1000 = 5 𝑘𝐽/𝑠
𝑄3 = 0.4467 + 0.298 + 5 = 5.7447 𝑘𝐽/𝑠
d) Solar Load: Minimal effect due to complete shading at all wall-sides.
e) Sensible and latent heat load of the occupants is included in internal
loads
g) Total Load
𝑄𝑡 = 𝑄1 + 𝑄2 + 𝑄3 = 12.6355 𝑘𝐽/𝑠
For 50 % safety factor;
Refrigeration load: QL3 = 1.5 (12.6355 ) = 18.95325 kJ/s.
k. Needed mass of air: 𝑚𝑎4
Energy balance about the meat packing area:
Ma4(h4 – hs4) = QL4 … (Total heat load)
𝑄𝐿4 18.95325
ma4 = (ℎ = (40.8937 −26.7068) = 1.336 𝑘𝑔/𝑠
4 −ℎ𝑠4 )

l. Volume of air; Va4

Va4 = mavgs4 = 1.336 kg/s(57.791 m3/kg)
= 77.2069 m3/s (4632.417 m3/min)
Use 5,000 m3/min blower capacity.
3. Main duct area; us4 = 40 m/s.
𝑉 77.2069
Va4 = A4us4; A4 = 𝑢𝑎4 = = 1.9302 𝑚2
𝑠4 40

4. Heating Load at the Reheat:

Qr4 = ma4 (hs4 – h1) = 1.336 kg/s(26.7068 – 18.6156) kJ/kg
= 10.8098 kJ/s
5. Moisture Removed in this Zone:
Mr4 = ma4 (W4 – Ws4) = 1.336 kg/s(0.006979 – 0.002592) = 0.005861
kg/s (5.86 gm/s)
Refrigerating Unit design: Vacuum Refrigeration System

Cooled Area
68.46 kW

4°C, chilled

From Steam Table:

h1 = hf at 4°C = 16.78 kJ/kg
h2 = hf at 10°C = 42.01 kJ/kg
h3 = hg at 4°C = 2508.7 kJ/kg
v3 = vg at 4°C = 157.232 m3/kg
h4 = hf at 21°C = 88.14 kJ/kg
Let z = vapor removed from the evaporator, carried by nozzle steam.
Let m = mass flow rate of chilled water.
There are required 1.27 kg of nozzle steam per kg of vapor removed from the
evaporator.
System Requirement
1. Energy balance about the whole system, neglecting pump work,
zh4 + 68.46 = zh3
88.14z + 68.46 = 2508.7z
z = 0.0283 kg vapors/s
Volume of vapor removed = zv3 =0.0283 (157.232) = 4.4497 m3/s
Quantity of nozzle steam = 1.27 kg steam/kg vapor * 0.0283 kg vapor/s = 0.035941kg
steam/s
2. Energy balance about the cooled area, solve water flow rate.
 mh1 + 68.46 = mh2
16.78m + 68.46 = 42.01m
m = 2.7134 kg/s chilled water
Other important data:
Ti = 13°C, RH = 85-90%,
Thermostat regulated refrigeration, converter type system run.
Air velocity = 3.35 m/s.
Product load = 6525 kg
Cooler unit:
T1, chilled water temp. = 4°C
T2, warm return water = 10°C
T4, make-up water = 21°C
T3, vapor = 5°C
3. Refrigeration capacity: Tons of refrigeration
68.46 𝑘𝑊
𝑄= = 19.45 𝑇𝑅
3.52 𝑘𝑊/𝑇𝑅
20 tonner Steam-jet refrigeration System
4. A humidifier unit has to be installed inside the Bunker room to maintain
relative humidity at 85-90%.
_____________________________________________________________________________________________________
WASTE DISPOSAL SYSTEM
Approximately 65% of dairy factory losses enter waste water discharge streams and these can
have a major impact on the environment.
Main sources of dairy processing plant waste water are:
1. Raw materials (predominantly milk) and product losses;
2. Equipment overflows and malfunctions; and
3. By-products.

MEMBRANE FILTRATION: This process has the potential for acid and alkali recovery and
recycling. Best quality wastewater is obtained by pumping effluent through porous media
containing millions of tiny pores. The media area is regularly cleaned by high pressure backwash
using water and/or air. The removal of dissolved solids is best achieved by the passage of water
through a semi-permeable membrane that restricts the movement of salts. This process for the
desalination of wastewater is based on the osmotic pressures on either side of the membrane.