INPLANTINDUSTRIAL TRAININGREPORT

NALANDA DAIRY,BIHARSHARIF

SUBMITTED BY-

NAME – RISHU RAJ

ROLL - 2004101032
 ACKNOWLEDGEMENT
The training opportunity I had with “NALANDA DAIRY(SUDHA DAIRY), BIHARSHARIF” was a great
chance for learning and professionaldevelopment. Therefore, I consider myself as a very lucky individual as I
was provided with an opportunity tobe a part of it. I am also grateful for having a chance to meet so many
wonderful people and professionals wholedmethroughthistrainingperiod.Iperceivethis
opportunityasabigmilestoneinmycareerdevelopment.

I am grateful to Dr. Ambrish kumar(Dean, CAET), Dr.Devendra kumar(Professor and Nodal

officer,Student READY Programme), fortheir kind help to avail my training at NALANDA DAIRY. I am also
thankful to all teaching and non-teachingstaffsfortheirguidanceineach&everystepofacquiringthis
opportunityofpracticalexperience.

Itismyradiantsentimenttoplaceonrecordmybestregards,deepestsenseofgratitudetoShri P K SINHA(CEO,
NALANDA DAIRY).I am sincerely thankful to Seemant sir( plant incharge ),Shukla sir(Inc.
Processing),Ashish kr singh (inc. Powder plant), Vkash sir( inc. Engineering section) for
theirguidancewhichwasextremelyvaluableformystudyboththeoreticallyandpractically.Iamalsothankfultoall the
deputy managers for their valuable guidance and support. I also thank all the operators and workers
whoreallyshowed co-operationand support.
Last but not the least I with due respect pay my regard to My Parents and Almighty God who have been
thesourceof motivation, strengthand support, whichled metoattain success.

NAME-RISHU RAJ
ROLL- 2004101032
B.Tech.(AGRICULTURA ENGINEERING),
 Contents

SR.NO CONTENT

1 INTRODUCTION

2 PRESENT STATUS OF PLANT

3 WEIGHT BRIDGE

4 RMRD

5 MILK PROCESSING SECTION

6 QUALITY CONTROL SECTION

7 ENGINEERING SECTION

8 UHT PLANT

9 POWDER PLANT

10 ICE CREAM PLANT

 INTRODUCTION

Bihar state milk cooperative federation limited also known as COMFED is

driving force behind white revolution in BIHAR founded in 1983 COMFED
market it’s product under the brand name SUDHA which literally translates to
Living water or nectar with 15000 dairy cooperatives procuring 1.8 million
litres of milk per day,8 milk union and 19 dairy plants.COMFED has a total
milk processing capacity of 3.1 million litre of milk each day and it’s capacity is
increasing each passing yearin continuation with it’s goal of providing superior
quality milk and milk products COMFED has built a 20 acre milk processing.
and packaging plant at Biharsharif in NALANDA District of bihar.
The plant is one of the eastern India’s largest milk and milk related production
facilities and 1st ULTRA HEAT TREATMENT and tetra packaging plant in
eastern India. The plant has processing capacity of 400000 liter per day. This
has made COMFED One of the pioneers of dairy industry. The state of art
facility is capableof nemerous milk related products like powder milk, white
butter, ghee, icecream UHT milk etc.
 PRESENTSTATUSOFPLANT

State BIHAR

District NALANDA

Address NALANDA DAIRY,

NH-31, BIHARSHARIF,
BIHAR-803101

Productprofile StandardizedMilk,FullCreamMilk,DoubleTone
dMilk,TonedMilk,SkimmedMilk,Ghee, Butter,
plain Lassi, aseptic
packing,,Dahi,Lassi,WhiteButter,Powder(SMP,
WMP), ICECREAM

ProductBrandName SUDHA

MarketedBy BIHAR STATE MILK COOPERATIVE

FEDERATIONS LIMITED (COMFED)

MilkHandlingCapacity 4LAKHLITRES of MILK and 30 ton POWDER

WEIGHT BRIDGE

A weighbridge is a large scale used to weigh vehicles and their

contents. It’s commonly employed in industries like logistics,
agriculture, and waste management to accurately measure the
weight of trucks, ensuring compliance with legal weight limits
and facilitating fair transactions based on weight.

In NALANDA dairy plant there is 2 weight each having

capicity of. 40 ton it is generally used for weight measuring of
Raw milk
The weight of Raw milk is calculated by = weight of tanker
filled with milk – weight of tanker after unloading
 Rawmilk receptiondock (RMRD)

As the quality of raw milk is the most important controlling factor for production of quality products,
separatespeciallydesigned dock isbuiltfor operation ofreception.

The Raw Milk Reception Dock (RMRD) is the primary intake point of liquid milk entry in
dairies/chillingcentres.ItisspecificallymeantforthereceptionofmilkbroughtintankersfromvillageBMC’Slocatedo
verawidearea.
The collection process starts from the village milk collection centres, groups of which are assigned to
distinctmilktruck routes.

Typeofmilkreceived
• Cowmilk

• Buffalomilk

• Mixedmilk

Receptionisdonebyfollowingway:

1. Firstly incoming tanker will be weighed on the weighbridge. Based on it, tanker id, receipt will
begeneratedwith vendor detailstankerno, date,timeetc.

2. Before starting the milk reception, quality control lab will take the sample of the milk from the
tankerand check the quality (fat, SNF, acidity etc) and after satisfactory lab result lab will clear QC of
thetankerfor reception.
3. Milk will be unloaded in the tanker reception bay area. Generally tanker unloaded done by local
HMIoperatorof thereception.

4. To start unloadingof the first tankerto the respective RMST, HMI operatorcommunicates withSCADA
operator. Then SCADA operator will open transfer popup from the reception screen and selectthe
RMST for reception after ensuring that all interlocks related to reception( destination, transfer)
arehealthyaswellasallprecondition(likesoftwaterpressure,chilledwaterpressure,temperatureetc)

5. If all the condition related to reception healthy, start button of the reception will be accessible to
thelocal HMI operator. After clicking the start button of the job, the drain valve (corresponding with
thatline) of RMST valve battery will open and followed by preceding valves of the transfer pump, then
thepumpwillstartwithreferenceofdeaeratorhighlevelswitch.

6. Product(Milk)PUSHwillstart(aspipeisfullyfilledwithwater)towardstheRMSTdrainvalve(which is
already in open condition) for a particular set time or set quantity and of water in the line willbedrained
out.

7. When product push will gained the set timer or set quantity (pump and related equipment will
considerthefirstachievedrunningtimerortransferquantity),transferpumpwillstopfor5secondsandthedrainv
alvewillclose, atthattimedestinationRMSTvalves willopen.
8. Then transfer pump will again startasa result product (milk) will go to the destination (selectedRMST)
safely without any mixing of water with milk. After emptying the tank, operator will starttankerflush
for 15sec.

9. After finishing of the total reception, one operator will connect the hosepipe with the soft water
linethrough flow plate (proximity should give healthy signal) to give water push in the line. Control
roomoperatorwillselectwaterpush inthereception pop-up followed byclicking startbutton.

10. After clicking the start button, transfer pump will start till dearator low level becomes dry then
softwatersupplyvalve (precedingflowplate)will openandagaintransferpumpwill start withthereference of
dearator low level switch as a result water moves forward in the line and pushing theproduct (milk)
remaining in the line for a particular set time or set quantity till the remaining portion
ofmilkentersintothedestination RMST.

11. When the water push will gained the set timer or set quantity, transfer pump will stop and water
supplyvalve will close and the dearator air release valve will open followed by drain valve of that line
opensfor20 second.

12. Once the tanker is empty it will processed to the tanker CIP bay for cleaning.Hose will be fitted
fromtanker outlet to CIP return. Operator will ensure that all interlocks related to tanker CIP are healthy
andthenstartCIP.
 Tankerreceivingprocess
Incomingtankerweight

Sampling plate-form (2 samples of 200 ml each

taken)Labtesting for qualityclearance

VisualcheckofcriticalequipmentclearanceTank

erpositioning

Hosefitting

Checking of all manual valve at proper

positionCheckingalltheequipment andtransferinterlock

Controlroomoperatoracknowledges thepup-
upon,selecttheRMSTfromreceptionandstartthejobbyclickingthestartbutton

Unloading tanker weighing and

washingDeareator

Transfer

pumpRawmilkchillier(

4ºC)Rawmilkstorageta

nk

Whenmilktankerisoutitscleaningisdone.Whentankeremptyitsweightistakenandnote
downtocalculateweightreceived fromtanker.
Cleaning isdoneinoldplant cleaningstation.Wherewater,caustic,watercleaningisdone.
SILO

Vertical storage tanks / silos

The vertical storage tanks are mainly used, when the floor space is less, and the roof of
processing hall is sufficiently high. Some of the high viscous products like cream or ghee are .
also preferably stored in this type of storage tanks.
Due to its shape, the manhole is at the top, and a ladder is provided for reaching on to the top.
The top is also conical to prevent any accumulation of water or dust. The sight and light glass
are also provided at the top. Due to its height, the agitator has to be long, and provided with .
more than two sets of blades for agitation. An internal ladder is provided to climb down for
manual cleaning. Other fixtures like CIP cleaning attachment or spray ball, thermo well,
sampling cock, lifting lugs or eye at the top, are provided as in horizontal storage tank. Both the
inlet and outlet will be at the side at the bottom level of the tank. The slope is 1:10 towards the
outlet so that there is free and complete drainage of liquid. The inner wall may be of Stainless
steel sheet of 3mm thickness while outside can be 2 mm. Some of the floors have greater
thickness of 5 mm. The tank is supported by four legs with SS ball feet and provision for height
adjustment. Silos are vertical storage tanks of large capacity, usually more than 30,000 to even
upto 1 lakh liters. The agitation is by compressed air in such case .

CAPACITY OF SILO IN NALANDA DAIRY

RMST-3 (100KL EACH)

. PMST-5. (3 OF 100KL AND 2 20KL EACH
Types Of Milk FAT SNF
SUDHA GOLD MILK. 6.0%. 9.1%
SUDHA SHAKTI. 4.5%. 8.5%
SUDHA HEALTHY MILK
(PASTEURIZED TONNED MILK). 3%. 8.5%
SUDHA COW MILK. 3.5%. 8.5%
MILK PROCESSING PLANT
 CIP SECTION
As it’s an automatic plant and so, it becomes more vital to ensure the cleaning of all equipment's,
tanks,pipelines and all related components in less time without dismantling the parts which are in direct contact
withthemilk and theproduct.

CIPkitchenbuildforthefollowingthreesectionswithoneconcentratechemicalstoragesection
1. ProcessCIPkitchen
2. FermentedCIPkitchen
3. TankerCIPkitchen
CONCENTRATECHEMICALSTORAGESECTIONCIP
1. This section comprises of two 15 KL tanks each for acid and lye bulk storage including one 2 KL
lyeflakedissolvingtank and one500 Lacid carbouytank.
2. To fill acid and lye to the CIP kitchen there is four overhead tanks including one 500L and 300L
foraciddosing and samecombination for lyedosingalso.
3. Concentrated bulk acid and lye are received in road tankers and for unloading there is flow
platearrangementforconnectinghosepipeand10KLPHcentrifugalpumpfortransferringchemical.
4. The chemical from 15 KL storage tank are transferred to overhead tanks with the help of four
airoperated diaphragm pumps (two for lye transfer and two for acid transfer), flow meter is fitted
tomeasuretheflowand transfer quantity.
Transferringofconcentratedchemicals
1. For transferring the acid or lye to overhead tanksfrom bulk storage tank, operator hasto open thepopup
of the acid/lye transfer in the concentrated chemical screen and start the transfer by clicking thestart
button, the transfer will continue till 300sec (Noted that transfer will be stop if high level isreached.)
2. Dosing of acid and lye to the CIP kitchen is automatic which works on conductivity, when
conductivityof the lye or acid tank is below; chemicals transferred automatically to achieve the set
concentrationvalueby commanding angleseatvalvefittedatthetop of respectivetank .

EQUIPMENTINCONCENTRATECHEMICALSTORAGE
EQUIPMENT TYPE MAKE QTY CAPACITY
ACIDUNLOA CENTRIFUGAL FRISTAM 1 10KLPH
DING
PUMP
LYE CENTRIFUGAL FRISTAM 1 10KLPH
UNLOADING
PUMP
ACIDTRANSFER DIAPHRAGM - 2 5KLPH
PUMP TO PUMP
DOSINGTANK

LYETRANSFERP DIAPHRAGM - 2 5KLPH

UMP PUMP

TODOSINGTAN
K
 QUALITYCONTROLLSECTION

Quality is the product and service of the total satisfaction of consumer in a continuous way for all
thesearethe assembly of all planned and systematic actionsnecessary to provide adequate confidence that a
product,process,or servicewillsatisfy given quality requirements.

Quality Assurance, in contrast to quality control is the implementation of quality checks and procedures
toimmediately correct any failure and mistake that is able to reduce the quality of interim products at
everyproductionstep.Thus thedesiredhigh qualityof finalproductisplannedand obtained.

HereQ.A.sectionensurestripleaspectofqualityofmilkandmilkproductsuptoconsumer
satisfaction level:

1) Organoleptic
2) Chemical
3) Microbiological

FUNCTIONSOFDIFFERENTLABSD
OCK LAB
1) Gradingofincomingrawmilk
2) Rawmilktesting
3) Testingofoutgoingpasteurisedmilk
4) Testingofprocessedmilkstoredinstoragetankorsilo
5) Creamtesting
6) Buttermilktesting
7) Standardisationoffluid milk
8) Checkingofstrengthofdetergentincratewasher

CHEMICALLAB
1) Sensoryevaluationofmilkandmilkproducts
2) Checkingthecompositionofmilkproducts
3) Hardnessofwater
4) Checkingthequalityofreagents,packagingmaterials,glasswaresfortesting
5) Checkingefficiencyofwastewatertreatment
6) Controllingthecleaningofdairyequipmentsaswellassanitationofplant.
 MICROBIOLOGICALLAB

1) Checkingthebacteriologicalqualityofvarioustypesofmilk&milkproducts.
2) Determinethetypesandnumberofmicroflorainair,water&variousdairyequipment'spipelines.
3) Testingof keepingofmilk&milk products.

TESTSFORRAWMILK
1) Organoleptictest
2) InDockLab
i) FatbyGerberorMilk-o-scan
ii) SNFbylactometerorMilk-o-scan
iii) Acidity
iv) Alcoholtest
v) COB(ClotonBoiling)
vi) Adulterants
vii) Sediments
viii) MBRT

3) MainLab
i) BRreading
ii) RMvalue
iii) PolanskiValue
iv) Sodiumioncontent
v) Maltose

PRODUCTANALYSIS
1) TESTSFORMILKANDPOUCHESOFPACKEDPASTEURISEDMILK
a) Weight
b) Leakage
c) Droptest
d) Length
e) Burstingstrength
f) Formilk:
i. Temperature
ii. Acidity
iii. Fat
iv. SNF
v. TotalSolids bygravimetricmethod
vi. Phosphatase
 vii. MBRT
2) TESTSFORCREAM
a) Acidity
b) Fat%
c) ORGANOLAPTIC
d) temperature
3) TESTSFORGHEE
a) Color
b) Flavour
c) FFA(Free FattyAcid)as%OleicAcid
d) RMValue
e) PolanskiValue
f) BRreading
g) Moisture
h) Adulterant–Baudouintest
4) TESTS FORBUTTER
a) Fat%
b) Moisture
c) Curd
d) Acidity
5) TESTSFOR SMP(SKIMMILKPOWDER)
a) TasteandFlavour
b) Color
c) %Moisture
d) %Fat
. TEST PERFORMED IN LABORATORY

METHYLENEBLUEREDUCTIONTEST(MBRTtest)

Itis indirectmethodofestimationoftotalbacterialcontentofmilk.Insteadofcountingbacteriadirectly,acorrelationis
madebetweenthetimerequired toreducedyetocolorless in milk.

Procedure

1. To 10 ml of milk in a sterilized test tube add 10 ml of methylene blue dye. Plug with a sterilized cork,
invertthetubeto mix thecontents.

2. Incubate at37°Cinawaterbath.

3. Note downthe time inwhichthecolour ofdye getsdisappearandthatwillgivethe MBRTtime.

TIME MILK

morethan orequalto 5 hrs VERYGOOD

3-4 hrs GOOD

1-2 hrs FAIR

lessthan halfhrs POOR

 Estimationoffatcontent
Fat canbedeterminedusingGerber’smethodorusingamilk-o-scanwhichissampleheated
at40ºC

Gerber Method:-
Principle:
When a definite quantity of sulphuric acid and amyl alcohol are added to a definite volume of milk,
theproteins will be dissolved and the fat will be set free which remains in liquid state due to heat produced
bytheacid.Theamylalcoholusedfacilitates
theseparationofaclearfatcolumn.Oncentrifugation,fatbeinglighterwillbeseparated ontop ofthesolution.

Procedureforestimation(milkandchhach)

• Takeabout10 mlof H2SO4(10% diluteformilk &20%for chhach)in Butyrometer.

• Addslowly10.75mlsample(canbechhachormilk)init.

• Add1mlIsoamylalcoholandadjustlevelwithdistilledwater.

• Capbutyrometerwithlockstopper.

• Centrifugeforabout5minutes.

• Takereading ofthe%fatbyreading thebutyrometer.

Procedureforestimation (PANEER,SHRIKHANDandCREAM)
• Takeabout10 mlof H2SO4(10% diluted) in Butyrometer.

• Addaknownamountofsample(notedown theweight) inthebutyrometer

• Add1mlIsoamylalcoholandadjustlevelwithdistilledwater.

• Capbutyrometerwithlockstopper.
• Centrifugeforabout5minutes.

• Takereading ofthe%fatbyreading thebutyrometer.

%Fat= 11.26×Fat% obtainedin Butyrometer

Weightof sampletaken
 EstimationofS.N.F.contentbyLactometer
S.N.F. % can also be estimated by using milk-o-scan before which the sample
isheatedto a temperature of40ºC

Principle:-

The method is based on the Archimedes Principle, which states that when a solid is immersed in a liquid it
issubjected to upward thrust equal to the weight of liquid displaced by it and acting vertically
upwards.Lactometers are variable immersion type hydrometers and calibrated beforehand with liquid of
knownspecificgravity.

Procedure:
• Warmmilkinlactometerjaratabout40˚Cthencoolat15.5˚C.

• Immerselactometer injarandtakeC.L.R.

%SNF=CLR/4+0.2×fat+0.40
TOTALSOLIDCONTENTOFMILKANDMILKPRODUCTS BYGRAVIMETRIC
METHOD:-

Formilk
Wholemilkcontainsabout84–87%waterandremaining13-16%aresolidscomprisingoffat,protein,carbohydrateand
minerals.
Byevaporatingwaterfromthemilkundercontrolledconditionsthetotalsolidcontentcanbedeterminedaccurately.
Weighaccuratelyacleananddryemptydish(W1).
1. Transfer1-2 mlofsampleinto dish andnotetheweight(W2).
2. Placethedishonboilingwaterbathorhotplatefor20-30minutes.Allow thewatertoevaporate.
3. Placedishinhotairovenat105±5°Cfor3hours.Transferdishtodesiccatorandallowcoolingfor30minutes.
4.Weighthecontentsandnotetheweight(W3).Repeatheatingandcoolinguntildifferenceintwosuccessivewei
ghtsdo notexceed 0.5mg.
• Calculate%TS =(B/A)x100

where,A=W2– W1, B=W3– W1

• %TotalSolidsprocedureforLassi,Dahi,issameasthatofmilk.
• %Moisturecanalsobecalculatedfromabovereadings

%Moisture=(B/A)x100Where,A= W2 – W1,B =W2 – W3

• %Moistureiscalculatedforpaneer

Estimationofbutter samplesformoisture%,curd%andfat%
Procedure

• Notetheemptyweightofdish as W1
• Nowtake10gmofbuttersamples andnotedowntheweightofdishwithsampleasW2
• Nowheatthebuttersamplesoastoevaporatemoisture.Whenbrownresiduesstartsformingthennotedown
theweightof dishasW3 after keeping itin desiccator.
• Now3washingshas tobedonewithpetroleumethersoas toextractfat.
• Heatthesamplesoastoremovethepetroleumetherresidues.
• Notedowntheweightofdishas W4afterkeepingitindesiccator.

%Moisture= W2-

W3×100

W2- W1

%Curd= W4-

W1×100W

2- W1

%Fat= 100-(%curd+%moisture)
 TESTINGSFOTPOWDER
1. MOSITER:-digitalandmanualbothmethodsusedmoistureshouldbelessthan4%

2. BULKDENSITY:-
a) 20gmpowderinmeasuringcylinder
b) 20timesupdownstork
c) Measurevolumetricreadingonvolumetriccylinder

3. Insolubilityindex:-
10gmpowder+100mlwaterFil

l in tube for

centrifugationCentrifuge(5mi

n/2600rpm)

DrainupperpartoftubesedimentremainintubeMix

water and again centrifuge (3

min)Sedimentsremainintubedrainupperportion

Sediment measureinpipetteandvolumeifislessthan1ml

4. scorchedparticle:-
(1) Dissolve10 gmofpowder dissolvein 100mlof water.
(2) Keepitsteady andcountno. Ofblack particles itvariesfrom7-8

5. Acidity:-
1. dissolvepowderinwater,
2. Addphenolphthaleinindicator
3. Titrateagainst0.1N NaOH
4. Itshould beNMT0.12%LA

Foreverytestingofpowderthisshould bedissolvedin inwaterinratioof1;10means1gmpowderin10gm

water.
 ENGINEERING SECTION
EngineeringDepartment isheadedbythe
ManagerEngineeringwhoisassistedbytechnicalofficer’sexpertinonebranchof engineeringorother.
EngineeringDepartmentisdividedintovarioussections viz
1. Boilersection
2. Refrigeration
3. Aircompressor
4. Electricalsection
5. Watertreatmentplant
6. Effluenttreatmentplant

BOILERSECTION:-
Sincesteamcanbetransportedthroughpipelines,veryconvenientlyfromitssourceofgenerationtoallplacesofutilizatio
n.
It is the most economical and common source of heat energy that is utilized in very large quantities in dairy
i.e.inproducts processingplantitis veryconvenientheatingmediacomparedwith othersourceofenergy.
Boileristheequipment thatproducessteam.
Therearetwoworkingboilersinthisdairyplant.Alltheheattreatments,heating,cleaningetcaredonewiththehelp of
steamin thedairy plant.

Typeofboiler
Horizontaltype Firetubeboilers
Number 2
Make Energyprocessequipment
Capacity 8toncapacity
Fuelused LDO
Pressureofsteam(sendtoplant) 12Kg/cm2
FuelConsumption 230kg/hr
Pressurerequiredby plant Normally-8-10Kg/cm2
pHoffeedwater 8.5-9.5
 BOILERMOUNTINGS
Thesearemountedonboiler’s bodyforitsproperandsafeworking.
1. Waterlevelindicator
2. Pressuregauge
3. Safetyvales:springloadedsafetyvalves,Steamstopvalve,Blowoffcock,Feedcheckvalve,Fusibleplug

BOILERACCESSORIES:
Theseareusedtoincreaseboilerefficiencyandtohelpintheirworking.
1. Feedpump
2. Superheater
3. Economiser
4. Airpre-heater

Boilerandsteam distribution
1. Steamissuppliedfromboilerhousehavingveryhighpressure@12kg/2.Thishighpressureisconvertedinto
desirablelowpressurebypressurereducing system.
2. Therearethreepressuresreducingstationeachforprocess(around3.5bar),CIP(around3.5bar),andcondensing
plant(around 9 bar).
3. Onevortexflowmeteris presentineachlineformeasurementofsteamflowandconsumption.
4. These all data are recorded in the MIS. Since the steam pressure is used as interlock for all process
andCIP, steam pressure should be at least 1.5bar less than that will hold any process/CIP i.e. will not
allowproceeding.
5. Low pressure steam is distributed in whole plant through a header from which tapping is provided
toindirecthotwater generator or directsteaminjectionsystem.
6. Allvalvesinbothhighpressureandlowpressurelinesarepistontype.

CONDENSATERECOVERYSYSTEM

1. Condensate recoveryisaveryefficient waytorecoverenergy.Steam convertedintocondensate

afterhotwatergeneration.
2. ThiscondensateisreturnedtothemainheaderthroughSteamOperatedPumpingTrap(SOPT).
3. Frommainheader,condensatereturnedtoPUMPandpumpdischargethecondensatetostoragetank(5KL).
4. CondensatefromthistankisutilizedinCIPkitchenashotwateraswellasinboiler.
 REFRIGERATIONSECTION:-

1. Refrigeration means process of absorbing undesirable heat from one substance & transporting this heat
toatmospherethrough thecoolingmedia.
2. Dairyproductsareseasonal&perishableinnaturerequiringpreservation.
3. Fortransportation,processingandstorageof milkandmilkproducts,refrigerationisessential.
4. Attheambienttemperature,micro-
organismsgrowwellandspoilthemilkandmilkproductseasily,soastoincreasetheshelflifeis
almostimportanttokeepthemilk&milkproductsataverylowtemperature.
5. Forproducingacoolingmedium(chilledwater)refrigerationsectionisessential.
6. In this plant there is a well – equipped & large refrigeration section, which meets the entire
refrigerationloadof theplant.

TYPE OF REFRIGERATION PLANT: - SCREW COMPRESSOR REFRIGERATION

SYSTEMCAPACITY OFREFRIGERATIONPLANT:-300 TR
REFRIGERANT USED:-LIQUID
AMMONIAVARIOUSPARTSOFREFRIGERATIO
NSYSTEM

1) COMPRESSOR:
Itsfunctionistoincreasethepressureandcorrespondingsaturationtemperatureofarefrigeranttoalevelenough to
condenseto ahigh pressurewarmliquid.
TYPE SCREWCOMPRESSOR
NUMBER 6
MAKE FRICKMICROTEK
MOTOR 335 HP
DESIGNPRESSURE(MPAG) 2.6
TESTPRESSURE(MPAG) 3.9
MAX. SWEPT VOLUME (CUBIC 1550
METERPERHOUR)
MAX.SPEED (1/MIN) 4500
OILUSED FORLUBRICATION SERVO-FRIZ68
TR OFEACHCOMPRESSOR 245

2) CONDENSOR:
Thisallows therefrigeranttocondensetoahighpressurewarmliquidbyremovingits heat.
TYPE AIRAND WATERCOOLED
NUMBER 5
MAKE EVAPCO
LOAD(TR) 300(EACH)
3) EVAPORATOR:
It isa typeofheatexchangerthatreceivescoldrefrigerant.Therefrigerantevaporatesfroma liquidtoalow
temperaturevapour.

4) EXPANSIONVALVE:whenliq.Passthroughthisvalve,itlowersitspressureandpressuredropalsolowers
thesaturation temptoapoint, wheretherefrigerantisreadyto entertheevaporator.

OTHERIMPORTANTEQUIPMENTSOFREFRIGRATIONSECTION
1) Oilseparator
2) Lowpressurereceiver
3) Highpressurereceiver:Itisequippedwitheconomisertoincreaseeconomyofprocessandsafetyvalveforsafety
purposes.
4) Nonreturnvalve
5) Suctionpressure(2.7-4.3BAR)
6) Dischargepressure(8.1BAR)
7) LOAD (113TR)
Components of Refrigeration sections
Toplayer,layer&firstlayerare madeup ofPolyethylene.
 Ultra-hightemperatureprocessing(UHT)

1. UHTmilkwasfirstdevelopedinthe1960sandbecamegenerallyavailableforconsumptioninthe1970s.
2. Sterilizesmilkbyheatingitabove138°C(275°F)–thetemperaturerequiredtokillsporesinmilk–for1 to 2
seconds.
3.
TheheatusedduringtheUHTprocesscancauseMaillardbrowningandchangethetasteandsmellofdairyproduc
ts.
4.
UHTmilkpackagedinasterilecontainer,ifnotopened,hasatypicalunrefrigeratedshelflifeofsixtoninemonths.

TetraPakMachine
 TetraPakMachine

1) Lowinvestment–Highperformance
2) Reliablemachine,simpletooperate&maintain
3) Lowoperationalcosts,high efficiency
4) Machinedesignedforeasyoperatoraccess
5) Stainlesssteelmachinebody
6) Spaceefficient
7) Capacity6000lt/hr

Hydrogen peroxides used for sterilizes the packaging material and maintain aseptic environment in
machine.Hydrogen peroxide is not an efficient when used at room temperature. Therefore, most aseptic
packagingsystems use hydrogen peroxide (at concentrations of 35-48%) as a sterility for packaging material
followedbyhotair (60 to 125°C) todissipateresidualhydrogen peroxide.
StripApplicatorusedforverticalsealingwithhelpofcellophane.
Sterilizationbyhotair(161°C)
Aftersterilizationmachinegivesignal(theyprepareforproduction)andproductionstart
Bvalveoperate:-means HotAir(161°C)providedbyjacketsinbetween3valve.
Sealing,cutting,coding,store

Milk Sterilization Machine:-

CIP
1. UseLye( caustic)for30 min.at80°C
2. WashwithWaterfor10min.
3. UseAcidfor20min.at61°C

FIG.:-CIPSECTION

Nutritiveeffects
CartonsofUHTmilk
 Calories:-UHTmilkcontainsthesamenumberofcaloriesaspasteurizedmilk.
 Calcium:-UHTandpasteurizedmilkcontainsthesameamountofcalcium.
 Protein:-
UHTmilk'sproteinstructureisdifferentfromthatofpasteurizedmilk,whichpreventsitfromseparatingin
cheesemaking.
 Vitamin:-B12,vitaminC andthiamininSomenutritionalloss canoccur inUHTmilk.
APS (ASEPTIC PACKING STATION)

Aseptic packaging:-

Process in which a food product, such as UHT (Ultra high temperature) milk and its package is sterilized
separately and then combined and sealed under sterilized atmosphere.

The first aseptic filling plant for milk was presented in Switzerland in1961. The Tetra Pak Company later became
one of the leading suppliers of processing and packaging equipment for dairies.

Type of Package Forms available in nalanda dairy

Tetra Brik Aseptic

Tetra Fino Aseptic

NALANDA dairy is major supplier of tetra pak milk to the armed force.

The aseptic packages are typically a mix of paper (70%), polyethylene (LDPE) (24%), and aluminum (6%), with a
tight polyethylene inside layer.
 weighing(200gm
manually)

Packing in
polythenesachets

Storageatbuttercoldsto
re

Dispatching
FlowDiagramofDahiPreparation
MilkistakeninvatforDahi
preparation

Standardization

Pasteurization(80-900C/15-30
min)

Cooling(370C)incan

Inoculationinwithlacticculture
(previousDayDahiAdded)

Fillingbypipefillerin
polystyrenecups

Sealingthecups

Putting12cups in each card

boardboxes

Incubation(370C/1.5-2hr)

Dahiprepared

Cooling&storage(50C)

Dispatch
 POWDERPLANT

Nalanda dairypowderplanthave

twopartscondensinganddrying.Condensing(evaporating plant)

4effect.

Evaporatewith5Calendria.(1,2,3,4,5)

Theyusethermalvapour recompressionsystemtomixsteamandvapour.

Flow

diagramMilk

siloBalancetan

FeedpumpseriesofpreheatersFl

ushvessel

DirectsteaminjectorHe

atingtube

Calendria1 (pump4,5)(60ºC/600MMHg)

Calendria2(pump6,7,8)(60ºC/

600MMHg)Calendria3(50ºC/660MMHg)

Calendria 4(pump13)

(40ºC/660MMHg)Calendria 5 (pump 15,16)

(40ºC/690MMHg)Condensed,milktank(Be=25,sp.

gravity=1.25)

(Pump 11 used circulate in Calendria

3Pump10foroutwaterinCalendria1,2Pu

mp14 foroutwaterfrom3,4a,4b)
WHENEVAPORATIONANDDRYINGBOTHARERUNNINGTHANOUTPOT=600bags/DAY

weightofbagis25Kg
 SPRAY DRYING
Spray drying is one of the most convenient techniques for producing milk powders
and for stabilizing milk constituents. Before spray drying, the milk under- goes
several processes (such as heat treatment, cream separation, membrane processes,
vacuum evaporation and homogenization).
The Dairy Spray Drying / milk powder production process begins with liquid milk
(skim milk, whole milk, fat filled milk, buttermilk or whey etc)
The milk when it arrives at the factory is rapid tested for temperature, hygiene,
antibiotics, water addition and adulteration.
On acceptance for spray drying the milk is pumped into a silo storage tank at the
spray drying plant and held at temperatures below 7 C and usually below 5 C.
Raw whole milk has varying Fat & Solids Not Fat (SNF) content and typically
between 3.5% and 4.5% Fat and 8% to 9% SNF giving typical Total Solids of
12.5%. Developing countries are milk solids usually lower and care should be taken
in ensuring that costs / yields are calculated accurately for any planned high volume
dairy spray drying plant and we suggest you prepare a very detailed yield
spreadsheet.
Milk is mostly collected in insulated tankers from dairy farms or milk collection
stations. Prior to collection the driver will carry out quality and measurement tests to
ensure the milk is of the required quality.
Adulteration of milk in some countries is prolific and a real barrier to globally
operating companies establishing facilities due to the high brand risk involved.
When the milk arrives at the dairy spray drying plant it is usually separated into
cream and skimmed milk to enable standardization of the fat content prior to spray
drying. High volume manufacturers will automate this cream fat standardization
using an inline “standomat” which doses cream back into the skim to give the
correct fat % in the milk to be processed.
Some high volume spray drying plants particularly in the US also standardise the
SNF content to maximise yields and give a consistent quality.
The microbial quality of spray dryed milk powders is very important and it is
possible at this early stage of spray drying to take out 99.9% of the spore-forming
bacteria by either bacto-fugation or microfiltration prior to heat treatment.
This is a the ideal next stage but many processors primarily due to cost do not
include this stage.

Both processes require that the milk is first separated and then the skimmed milk
portion has the bacteria removed and the cream is them high temperature
pasteurised and returned to the milk (if required)
This is the method used for ESL milk (Extended Shelf Life). Infant Formula
manufactures operating in developing countries should use a bactofuge or
microfiltration plant to ensure finished produt quality.

The milk is high temperature short-time pasteurized (HTST) by heating to at least

72 C, and holding at or above this temperature for at least 15 seconds, (An
equivalent temperature / time combination can be used). Most high volume liquid
milk plants now operate on a higher holding time of 25 to 35 as a precaution over
the possible survival of MAP which can cause Crohn’s disease in humans.
Method of manufacture of spray dried milk powder:-
The milk is separated (in case of skim milk powder) or clarified and standardized (in
case of whole milk powder).
The milk is fore-warmed to 95°C and re-condensed to 40% total solids.
Homogenization of the condensed milk is done in case of manufacture of whole
milk powder.
The spray drier is cleaned, pipelines are connected and general conditions of the
valves and cyclone separators are checked.
The steam is let in to the air heating coils. The exhaust fan is switched on, keeping
the main door partially open.
The blower is started and the main door is closed.
The temperature of the hot air is adjusted to 180°C and this temperature is
maintained for ten minutes to ensure the sterility of the unit.
The atomizer is started and allowed to obtain the required speed.
Initially, 20 litres of water is used for spraying through the feed pump.
When the outlet air temperature reaches 100°C, the feed is changed to concentrate.
The temperature of the inlet air entering the drying chamber usually ranges from
150-260°C and the outlet air exhausted from the drying chamber ranges from 100-
105°C. the relative humidity of the drying chamber is quite low i.e. 3-4%.
The milk powder is collected in the powder silo.
When the flow of milk is over, the balance tank is flushed with about 20 litres of hot
water (90°C) and the flow of milk to the dryer is reduced immediately.
The atomizer and feed pump are stopped when the feed is empty.
The steam supply to the air heating coils is stopped.
The exhaust fan and air blower are stopped.
The dried milk or milk powder is packed in required quantity in suitable containers.
DRYINGOFMILKPOWDER:-
Condensing and Drying Unit of powder plant
 ICE CREAM PLANT
SUDHA ICE-CREAM

Popularity of Sudha milk gave confidence to the Bihar Milk Co-Operative

Federation Ltd, to bring new product in the market. Sudha ice cream was one such
product in the market. Ice cream production began in the year 1995. COMFED
gained knowledge about ice cream production by producing and packaging AMUL
products. After that, they started the production of Sudha ice cream. When
COMFED entered the market, lots of competitors were already there in the market
like AMUL, Vadilal, Golden, Snowballs, Kwality walls etc. competition was tough,
and COMFED had to revise its strategies for this competitive environment. Several
types of ice creams were available in the market; like cup ice creams, cone ice
creams, Cornetto, Brick etc. These different forms of ice creams were available in
different flavors like Vanilla, Strawberry, Chocolate, Mango, Pineapple,
Butterscotch, Kesar Pista etc. Sudha Brand had to compete in very tough
circumstances. Currently, Sudha ice cream has more than 35 flavors, and it is
available in 40% of the Sudha shops/booths in Patna. Sudha ice creams are made
from real milk and not from frozen desserts. Today Sudha ice cream holds the
market share of approximately 25%, and is among the top five ice cream brands in
Patna. Sudha ice cream needs to focus more on advertisement and increasing

The availability in outlets.

Sudha ice cream is available in the following pack sizes:

Cups: 40 ml, 90 ml, 100 ml, 125 ml

Cones: 30ml, 60 ml, 100ml, 125ml

Stick: 30ml, 60ml

Family Packs: 500ml, 1000ml, 4000ml

 PREPARATION OF ICE CREAM MIX –PASTEURIZATION, COOLING,
AGEING AND FLAVOUR ADDITION
Introduction

Once the formulation of ice cream mix is decided and all the necessary ingredients
weighed, the subsequent operations involves blending the ingredients, pasteurizing
the ice cream mix followed by cooling and ageing. Thereafter just prior to taking it
to the freezer appropriate flavor and colour is incorporated.

Pasteurization of Mix

Pasteurization is done to destroy all the pathogenic bacteria in the mix so as to

render the final product safe for human consumption

Advantages of pasteurization are:-

It renders the mix completely free of pathogenic bacteria.

It dissolves and helps to blend the ingredients of the mix.
It improves flavour.
It improves keeping quality.
It produces a more uniform product
Rapid heating and holding of the mix at definite temperature and rapid cooling
below 5°C ensures proper pasteurization.

The temperature time combination for pasteurization of the mix as per BIS is as
follows

For Batch method – 68.5°C for not less than 30 min

HTST method – 80°C for not less than 25seconds
Vacreation – 90°C for not less than 1-3 seconds
UHT pasteurization – 98.8 to 128.3°C for not less than 0-40 seconds
High temperature pasteurization is preferred as there is a greater bacterial kill
resulting in low bacterial count in ice cream
Better body and texture
Better flavour
 Protection against oxidation

Saving of stabilizer
Saving of time, labour and space
Increased capacity

Cooling of Mix

After pasteurization, the mix should be rapidly cooled to a temperature below 4°C
using a plate heat exchanger. Unless the mix is cooled to a temperature of 4°C or
lower, it will become very viscous and the ice cream will not melt down smoothly.
Also, temperatures below 5°C retard the growth of bacteria.

Ageing of Mix

The cooled mix is left to age preferably for a period of 24 h at 4°C.

The changes that occurs during ageing are

Hydration of milk proteins

Crystallization of fats
Absorption of water by any added hydrocolloids
Viscosity is increased largely due to the previously mentioned changes.
Ageing is substantially completed within 24 h and longer period should be avoided
to control spoilage by psychrotrophs.

Flavour Addition

Frozen desserts are valued mainly for pleasing flavour and refreshing effects.
Among the flavouring substances that play an important part in frozen desserts are
vanilla, chocolate, strawberry, pineapple, lemon, banana, mango, orange etc. Type
and intensity of flavours are important characteristics in ice cream where delicate
flavours are preferred to harsh flavours.

Some points to be remembered

Flavours are added by experience to obtain pleasing flavour and colours should
correspond to the flavour.

Fresh or canned fruits should be used as pulp or cut into pieces and added to
partially frozen ice cream or as top dressing

Nuts after cut into pieces, roasted / unroasted, should be added to partially frozen ice
cream while it is in the freezer.

. Ageing Vat

PREPARATION OF MIX
STICK MACHINE
CONE MACHINE