Professional Documents
Culture Documents
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
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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. .
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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.
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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.
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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.
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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.
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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.
Air-conditioning Unit design: Multiple-zone system, which is ideal for
multiple room space conditioning requirements, multi-control systems
consisting of separate conditioners and heaters are used to distribute
variable air conditions to multiple rooms.
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.
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.
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 )
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.
j. Cooling Load:
a) Transmission load: Q = A(𝑇𝑓 – 𝑇𝑖 ) / R; 𝑇𝑖𝑛 = 20°C.
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 )
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.
j. Cooling Load:
a) Transmission load: Q = A(𝑇𝑓 – 𝑇𝑖 ) / R; 𝑇𝑖𝑛 = 20°C.
B. Ceiling Conduction
1) Outside airfilm 0.029
2) Sheating fiber
board,13mm 0.232
3) Gypsum 0.080
board,10mm 0.120
4) Inside airfilm 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 )
Cooled Area
68.46 kW
4°C, chilled
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.
MILK TRUCK
The milk truck delivers the raw
material (the raw milk) from the
source bound to the plant.
MILK SEPARATOR
Milk separator is a device that
removes cream from whole milk.
As a result, the whole milk is
divided into a cream and skim milk
after separation.
CHURNER
A butter churn is a device used to
convert cream into butter. This is
done through a mechanical
process, frequently via a pole
inserted through the lid of
the churn, or via a crank used to
turn a rotating device inside
the churn.
PROCESSING & LABORATORY PPE
Since butter is part of the diet of the consumers, it is produced with the utmost care. To avoid
contamination and to maintain hygiene, workers in the processing area and in the laboratory area are
required to wear Personal Protective Equipment (PPE).