MOTHER DAIRY, DELHI

16th Kaizen Conference,

Delhi
(1-2 March,2011)
MOTHER DAIRY ,DELHI
Mother Dairy, Delhi, a strategic unit of Mother Dairy
Fruit & Vegetable (P) Ltd. is catering to the needs of
National Capital Region for Milk and Ice Cream since
last 37 years, established under operation flood for
Ministry of Agriculture, Govt. Of India in 1974 and
managed by NDDB since its inception.

Today, it is the single largest Dairy marketing fluid milk

In metropolis in this part of the world.
MOTHER DAIRY ,DELHI
Mother Dairy, Delhi is an ISO - 9001: 2008, & Food
Safety Management System, ISO-22000: 2005 certified
organization.

It is also certified under ISO-14001:2004 Environment

Management System (EMS).

Quality Assurance laboratory of Mother Dairy is certified

under ISO/ IEC - 17025 :2005 by NABL (National
Accreditation Board for Testing and Calibration
Laboratory), Department of Science and Technology,
Government of India.
HOMOGENIZATION PROCESS
Homogenization is a process of passing the milk
through a small orifice at a velocity to cause breakage &
dispersion of fat globules to < 2 microns for uniform
distribution of fat in milk.

Homogenization is a mechanical process of breaking of

fat under high pressure.

The Homogenizer is a huge Machine used in Dairy

Plant.

At Mother Dairy Delhi, since entire Bulk Vended Milk is

homogenized thus it becomes a very critical machine.
ELIMINATION OF MINOR
STOPPAGE
PROBLEM

FREQUENT MINOR STOPPAGES OF PLANT TO

AVOID MAJOR BREAKAGE IN HOMOGENIZER
COMPONENTS DUE TO VIBRATION IN LINES AND
HUNTING IN HOMOGENIZER (i.e. Avg. 10
Stoppages/Day)
TEAM MEMBER
 TEAM

S/Sh:
P K Bose
Sripal Singh
Sanjay Kausik
Shiv Raj
 BENCHMARK
10 STOPPAGES / DAY

TARGET
ZERO STOPPAGES / DAY

ACTUAL
ZERO STOPPAGES
ANALYSIS
Frequent Stoppages of Plant
Why

High vibration in lines & homogenizer

Why

Air trapping in lines & homogenizers

Why

No separate provision of trapping air in line

Root Cause : No Separate Provision for Air Trapping

COUNTER MEASURE

A separate Vertical Dampener is provided in suction

and discharge lines of homogenizer
 BEFORE

DAMPENER

..
+
DAMPENER HOMOGENIZER
NO. 5
EMULSIFYING
PUMP
 AFTER

NEW DAMPENER

NEW DAMPENER

..

HOMOGENIZER
NO. 5
EMULSIFYING
PUMP

AFTER
RESULTS
Zero Minor Stoppages due to vibration.
No of Minor Stoppages

BETTER
OPERATORS FEEDBACK
• Uninterrupted Processing makes operators
Happy to Work.
• Down Time of 50 Min./ Day has been eliminated
• Productivity increased due to continuous running
of plants by 6% Approx.
• Reduced wear and tear of lines & Homogenizer
parts resulted in inventory reduction of clamps,
supports, spares, vibration pads, pneumatic
valves etc.
• Reduction of Noise level at Plant well below
permissible level.
Achieved Target