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Milk Collector CONTENTS :

Collects milk
Rural Milk Collection Centre from Cooperative
Cools Milk for Collection and  REFRIGERATION LOAD IN DAIRIES
Societies
Processing Refrigerated
Milk Processing and
“Energy Efficient Refrigeration system for Dairy Plant” Farmers Transport Transportation
Storage Centre;
 TYPES OF CHILLED WATER GENERATION SYSTEM
Milk by Small Vehicle/
DAIRY PLANT
By Motorcycle/Walk Process Milk into Milk
 ENERGY EFFICIENT COMBINATION OF CHILLED WATER
Products
GENERATION SYSTEM
Farms (Cheese, Butter, Yoghurt,
Fresh & Hygiene Milk Powder, Sweets etc.)  USE OF PRE CHILLER ( PHE & FALLING FILM CHILLERS)
P. SUDHIR KUMAR Collection Points Refrigerated
Transportation  SELECTION OF EQUIPMENTS
(PAST PRESIDENT – AAR) of Milk and Milk
( DIRECTOR MARKETING – FRICK INDIA LTD ) Products to  USE OF ENERGY EFFICIENT MOTORS, VFD STARTERS AND
Consumers
sudhir@frickmail.com AUTOMATION
+91 9819704968 Retail Centre/Consumers
Utilize the Milk And Milk
Fresh & Hygienic Products as Nutritious Food THE AVERAGE ENERGY CONSUMPTION OF
Milk By Animals REFRIGERATION SYSTEM IN A DAIRY
PLANT OF SIZE 5 TO 30 LAKHS LTR/DAY IS
60 TO 65 %
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DIRECT REFRIGERATION LOAD HEAT LOAD

MAIN REFRIGERATION LOAD IN DAIRIES
Heat Load Sheet
CALCULATION OF REFRIGERATION LOAD IN Refrigeration load will
DAIRIES BASED ON VARIOUS MILK be sum of the
PROCESSES AND COLD STORAGES PLAYS A following for Cold
KEY ROLE IN SELECTION OF EQUIPMENTS Room such as
Storage, Blast, Deep
TYPES OF LOADS MILK COLD ROOMS (3 TO 4 DEG C) BUTTER ,CHEESE AND ICECREAM
Freezer etc.,
COLD ROOMS (-18 TO -22 DEG C)

 Wall heat load

CHILLED WATER LOAD  Air change load
 Product load and
 Supplementary
DIRECT REFRIGERATION LOAD load or
Miscellaneous load
DAHI COLD ROOM ( 3-4 DEG C) DAHI BLAST ROOMS ( 2-4 DEG C)
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COLD ROOMS DESIGN COLD ROOMS DESIGN CHILLED WATER LOAD

MILK CHILLER

 RAW MILK CHILLER :

1. OPTIMUM ROOM HEIGHT OF COLD 34 Deg C to 4 Deg C
ROOMS TO REDUCE HEAT LOAD
 TANKER MILK CHILLER
2. ANTE ROOMS IS A MUST FOR 10 Deg C to 4 Deg C
NEGATIVE TEMPERATURE COLD
ROOM.  MILK PASTEURIZATION :
PUF PANELS & LED ENERGY SLIDING DOORS 14 Deg C to 4 Deg C
3. SIZING OF ACU WITH DRAIN PAN SAVING LIGHTING
HEATER AND HEAT TRACING OF  BUTTER MILK CHILLER :
DRAIN PIPES. 45 Deg C to 4 Deg C

4. PROPER HOT GAS DEFROSTING  AGEING TANKS :

CONTROLS 8 Deg C to 4 Deg C

COLD ROOM STRIP CURTAINS

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CHILLED WATER LOAD CHILLED WATER LOAD- CALCULATION

CHILLED WATER LOAD- GRAPH
Tanker Milk Butter Milk Rinse Milk Milk Chilling Cream Cream CBBM Butter Pow der airconditioni
Chiller Chiller Chiller Chilling Aging jacket spray w ash conveying ng
Tim e w ater air de- Total Load

40000 2000 5000 20000 2500 50000 1875 20000

humidif icatio
n
17000
Load distribution
FLOW LPH
( 12-4 ) ( 18-4) ( 34-4 ) ( 12-4 ) ( 34-4 ) - ( 8-2 ) ( 34-8 ) ( 7-2 )

Calculation of refrigeration capacity

IN/OUT TEMP

 Sp.Gravity
Sp.Heat
1.03
0.935
1.03
0.935
1.03
0.935
1.03
0.935
1.03
0.935
1
1
1
1
1
1
1
1 600.00
DELTA T 8 14 30 8 30 1 6 26 5
PER HOUR LOAD 101.91 8.92 47.77 50.96 23.89 16.53 3.72 171.96 28.11 16.00
15% safety 117.20 10.25 54.94 58.60 27.47 19.01 4.28 197.75 32.32 18.40
7 to 8 A.M 10.25 58.60 27.47 19.01 4.28 32.32 18.40 170.34
500.00
8 to 9 A.M 117.20 10.25 58.60 27.47 19.01 4.28 32.32 18.40 287.54

 Plotting a Histogram 9 to 10 A.M 117.20 10.25 58.60 27.47 19.01 4.28 32.32 18.40 287.54

Capacity (TR)
10 to 11 A.M 117.20 10.25 54.94 58.60 27.47 19.01 4.28 32.32 18.40 342.47
11 to 12noon 117.20 10.25 58.60 23.89 19.01 4.28 197.75 32.32 18.40 481.70
400.00
12 to 1 P.M 117.20 10.25 58.60 27.47 19.01 4.28 32.32 18.40 287.54
1 to 2 P.M 117.20 10.25 58.60 27.47 19.01 4.28 32.32 18.40 287.54
2 to 3 P.M 117.20 10.25 58.60 27.47 19.01 4.28 32.32 18.40 287.54
3 to 4 P.M 117.20 10.25 54.94 58.60 27.47 19.01 4.28 32.32 18.40 342.47
300.00
Process load
Decide a base load for the refrigeration
4 to 5 P.M 117.20 10.25 58.60 27.47 19.01 4.28 32.32 18.40 287.54

 5 to 6 P.M
6 to 7 P.M
117.20 10.25
10.25
58.60
58.60
27.47
27.47
19.01
19.01
4.28
4.28
197.75 32.32
32.32
18.40
18.40
485.29
170.34
7 to 8 P.M 10.25 58.60 27.47 19.01 4.28 32.32 18.40 170.34
200.00
8 to 9 P.M 10.25 54.94 58.60 27.47 19.01 4.28 32.32 206.87
9 to 10 P.M 10.25 4.28 32.32 46.86
10 to 11 P.M 32.32 32.32
11 to 12MidNight 0.00
100.00

 Design a optimum system 12 to 1 A.M

1 to 2 A.M
58.60
58.60
27.47
27.47
19.01
19.01
105.08
105.08
2 to 3 A.M 54.94 58.60 27.47 19.01 160.02
58.60 27.47 19.01 32.32
0.00
3 to 4 A.M 137.41
4 to 5 A.M 58.60 27.47 19.01 32.32 137.41 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
5 to 6 A.M 58.60 27.47 19.01 197.75 32.32 335.16
6 to 7 A.M 10.25 58.60 27.47 19.01 4.28 32.32 151.94
Daily Load
Ave rage
5306.30 Time
Load/Hr
Running
10 16 4 21 21 21 16 3 20 12
Hours
TOTAL
5291.48 1171.97 164.08 219.74 1230.56 576.83 399.31 68.45 593.25 646.49 220.80
LOAD TR
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Average Load/Hr
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CHILLED WATER LOAD- LOAD SUMMARY TYPES OF CHILLED WATER GENERATION

CHILLED WATER LOAD- PLOTTING HISTOGRAM

HISTOGRAM
airconditioning • Total Load = 5, 292 TR / day  IBT SYSTEM :
500.00
Powder conveying air
de- humidification
This is conventional system
450.00
Butter wash water
400.00
CBBM jacket spray
• Average Load / 20 Hrs = 264.6 TR  ICE SILO :
350.00
Cream Aging

 IBT + PRE CHILLER SYSTEM (PHE / FFC)

C A P A C IT Y ( T R )

300.00

250.00
Cream Chilling
• Peak load = 483.38 TR A combination of IBT And Pre Chiller depending upon load
Milk Chilling
200.00 histogram.
Rinse Milk Chiller
150.00

100.00
Butter Milk Chiller
 PHE Chiller / Falling Film Chiller :
50.00
Tanker Milk Chiller
i. Chilled Water PHE/ FFC
ii. Chilled Glycol System for Deep Chilling
0.00
7 to 8 A.M 10 to 11 1 to 2 P.M 4 to 5 P.M 7 to 8 P.M 10 to 11 1 to 2 A.M 4 to 5 A.M
A.M P.M
TIME

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IBT SYSTEM : This is conventional system PHE / FALLING FILM CHILLER WITH IBT SYSTEM
PHE / FALLING FILM CHILLER WITH IBT SYSTEM
The concept of Pre (PHE/ FFC) Chiller and IBT combination i.e. return water
from process will be pre chilled in the PHE/Falling film chiller and fed into In a 1 Lakhs Ltr/ Day Dairy, 60,000 liters of milk will be processed in 4 Hours in
ADVANTAGES OF IBT SYSTEM : IBT for further chilling. the morning and 40,000 liters of milk will be processed in 2–½ Hours in the
In the above system, power saving will be substantial evening.
 THERMAL STORAGE OF ENERGY For a 15,000 LPH milk process PHE chilled water flow of 30,000 LPH shall be
AVAILABLE circulated with a temp range of 12 to 0.5 C. 12 Deg C return water shall be pre
RETURN FROM PROCESS chilled to 2 Deg C in a PHE chiller and fed into IBT for further
 REFRIGERATION PLANT CAPACITY SMALLER ( 12 Deg C)
chilling down to 0.5 C.
 LATENT HEAT AVAILABLE Falling Film Chiller /
PHE chiller To Milk
 SAFE DURING POWER CUTS/ BREAK DOWNS ( 12 to 2 / 0.5 Deg C) Process
( 0.5 Deg C)
DISADVANTAGES

 MORE SPACE REQUIRED

IBT ( 2 to 0.5 Deg C)
 LOW SUCTION ( -10 DEG C) INCREASES POWER CONSUMPTION

Chilled
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POWER COMPARISON ONLY PHE CHILLERS WITH HOT AND COLD WELL TANK

PHE / FFC Chiller System

Total handling of milk
No of compressor
Comp. connected motor
working
Suction/ Discharge temp.
System Details
Liq. pump system
Condenser Type
Refrigeration Capacity
IBT SYSTEM IBT CUM PRE CHILLER • The concept of only (PHE) Chiller has also been introduced without ice For the PHE / FFC chilling, heat load works out to 135 TR (approximately), a screw
2.00 Lakhs 2.00 Lakhs
bank tank but with a hot and cold well or buffer tank compressor selected @ –2 C SST & 40 C SDT delivers refrigeration capacity of
• The compressor size increases 137.6 TR which consumes 103.3 BkW
2 Nos Screw (1w+1S) 2 Nos Screw ( 1 w + 1 s) • Better for peak loads and chilling centers. BkW / TR = 0.75
Power Consumption in a day 137.6 TR x 0.75 BkW/ TR x 6.5 Hrs = 671 Units
1nos. x 160 kW 1 no. x 132 Kw
Equivalent IBT System
-10 0 C / 38 0 C -5 0 C / 38 0 C The BkW/TR of a SCREW compressor for an IBT application at –10 C SST & 40 C
SDT will be 1.00
IBT Pre chiller with IBT
Total Refrigeration capacity required 137.6 TR x 6.5 Hrs = 894 TR Per Day
Yes Yes Considering 20 Hours of Operation 894 TR / 20 Hours = 44.7 TR
BkW/ TR @-10 SST and 40 Deg C SDT will be = 1.00
Evaporative Condenser Evaporative Condenser
Power Consumption 44.7 TR x 20 Hours x 1.0 BkW/TR = 894 Units
150 TR 150 TR

Screw Comp. BkW/ TR 0.93 0.77 From saving of approx. 25 to 30 % with the above , you will notice a unit (power)
Pre-Chiller system
Recip Comp. BkW/ TR 1.02 0.86
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SELECTION OF REFRIGERANT RECIPROCATING COMPRESSORS

Ammonia – A Natural Refrigerants HEART OF THE REFRIGERATION SYSTEM Reciprocating Comp are selected if the refrigeration capacity is
Ammonia is a colourless gas that liquefies under pressure and COMPRESSORS
has a pungent odour. less than 350 kW (100 TR).

Ammonia is considered a natural refrigerant because it occurs

TYPES OF COMPRESSORS IN AMMONIA Latest developments for energy optimization in reciprocating
in nature’s material cycles.
compressors
Ammonia is also an ideal refrigerant from a climate protection
point of view RECIPROCATING • High speed compressors

It contributes neither to ozone depletion nor to global warming . OR • Direct drive.

Ammonia has no ozone depletion potential (ODP = 0) and no SCREW COMPRESSORS • PLC control panel
direct greenhouse effect (GWP = 0).

Ammonia is combustible only to a limited degree; its ignition

energy is 50 times higher than that of natural gas

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Parts of Screw Compressor Block ADVANTAGES OF EVAPORATIVE CONDENSER OVER

SCREW COMPRESSORS OPEN TYPE CONDENSERS

SPECIAL FEATURES OF SCREW COMPRESSOR Capacity

Control Cylinder Inlet casing INLET
• Less Space for big plants (Number of compressors less) FOR 6 NOS. PHE CONDENSER ( 300 TR EACH ) + COOLING
TOWER + PUMPS

• Adapts better for power saving in large plants running at part Kw Total Kw
Condenser water pump 6.00 19.00 114.00
Radial
load. Bearing Rotors
Cooling Tower Fan 6.00 7.50
26.50
45.00
159.00

• Dual capacity control system monitors volume as well as FOR 6 NOS. EVAPORATIVE CONDENSER

compression control. Capacity Fan Motor 6.00 9.00 54.00

control Valve Pump Motor 6.00 3.70 22.20

• Total installed horsepower 12.70 76.20

Shaft seal • Evaporative condenser is a water conservation

reduces.
Diff. in Kw 82.80
Considering Motor Efficiency 85% 97.41
Housing Therefore Kw difference 97.41 device and in effect, a condenser and a cooling
• Easy to automate No. of hrs running
No. of days
20.00
300.00
tower combined into a single unit.
Unit Rate (Rs.) 8.00 • Most of the refrigeration plants in dairies are
• Very low maintenance. Total Saving/ year 46,75,764.71
having open type atmospheric condensers, which
Rotor casing DISCHARGE Apart from above the Compressor will run at 38 Deg C mean indirectly getting affected by power
Discharge Condensing Temp., so that there will be further power saving in penalty.
Thrust bearing Casing
compressor power.
• Power penalty by way of running the make-up
water pump continuously due to water wastage
by splashing, high wind velocity etc.
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Ammonia Pumping Re-circulation System

Difference to run at Low Condensing temp at -10 Deg SST Screw
Desuperheater System
• Superb refrigerant distribution

• Lower inlet liquid temperature

For 100 TR
Condensing Difference • To cool down the
superheated discharge gas • Cut down capital costs
Temp Deg C Capacity & BkW BkW/ TR (BkW/TR)
from the compressor • High system efficiency
36 104.1 TR/92.4 BkW 0.88 before entry into the
condenser • Reduced operating expenses
38 103.1TR/97 BkW 0.94 0.06 • It is usually used in heat
recovery to generate hot • Low maintenance
40 101.9 TR/ 101.9 BkW 1.00 0.12 water ( 50 to 60 DegC ) • Protection of compressors from liquid
which can used in crate slugs
• If run with 38 = 0.06 x 100 TR x 18 Hr x 365 x Rs 7 = Rs. 2.75 Lakhs washing and floor
cleaning. • Tremendous power saving in operation.
• If run with 40 = 0.12 x 100 TR x 18 Hr x 365 x Rs 7 = Rs. 5.50Lakhs
• Temperature range: 0°C to
• Reduce Equipment size
150°C
• Eliminate individual accumulator

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Compressor Motor & its Drives.

Priority Vessel And Thermosiphon Oil Cooler
SELECTION OF EQUIPMENTS

ADVANTAGES OF THERMOSIPHON OIL Motor should select based on the efficiency.

COLLING SYSTEM
The efficiency of an electric motor is defined as the ratio of usable
• There is no possibility of contamination of
the cooling water circuit shaft power to electric input power.
• The water in the cooling circuit does not
require to be diverted to produce free Motor efficiency [%] = shaft Power [kW] / electrical input [kW]
cooling
• The free cooling is produced by evaporation Based on the Efficiency level, Motor are classified as Eff1, IE1, IE2,
of a relatively small flow of refrigerant.
Thus a IE3/ IE4 Motors.
• Thermosiphon system might require 80 mm
refrigerant piping and valves whereas a free
cooling
• system, in which the water to be cooled is
circulated directly through an ambient
cooler, might require 150mm piping and
valves.

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TYPES OF DRIVES
Compressor Motor & its Drives.
VFD & Vertical in line pump for chilled water circulation
Soft Starter
Variable frequency drive (VFD)
• Installed HP of pump A variable frequency drive (VFD) is a motor control device
will be reduced that protects and controls the speed of an AC induction motor.
VFD can control the speed of the motor during the
• Speed will vary
depending upon load start and stop cycle, as well as throughout the run cycle.
means reduce power
cost.

• Increase overall
efficiency.

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DATA LOGGING / SCADA DCS SYSTEM

LATEST TRENDS

• PHE/ Falling Film chiller + IBT

• Screw Compressors
• Evaporative Condensers
• Liquid Ammonia pumping system
• Thermosiphon Oil Cooling system
• Introduction of VFD for compressors.
• Chilled water pump automation with VFD
Total Plant Control. • Energy efficient motors ( IE3)
centralized temperature
recorder and interlocking • Automation of the complete plant
electric circuit for various
process controls can be
interlocked to your PC/PLC

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NEW INNOVATIONS/CHALLENGES

• LOW CHARGE AMMONIA REFRIGERATION THANK YOU

SYSTEM

• CO2 REFRIGERATION SYSTEMS YOU CAN MAIL YOUR QUERIES TO

ammoniaindia@gmail.com
• AMMONIA REFRERATION CHILLER SYSTEMS sudhir@frickmail.com
FOR COMMERCIAL AIRONDITIONING.

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