POWDER

SECTION
 Outlines
Introduction
Definition
Standard
Processof powder making
Packaging
CIP
 INTRODUCTION
 Milk powder is the product obtained by the removal
of water from milk by heat or other suitable means , to
produce solid containing 5% or less moisture

 OBJECTIVES OF PRODUCTION
1. To improve storage life of product
2. Reduction in storage space and packaging costs
3. To reduce the transportation cost
 DEFINATION AS PER FSSAI
 Milk powder means the product obtained by
partial removal of water from milk of cow
and/or buffalo. The fat and/or protein content
of the milk may be adjusted by addition and/or
withdrawal of milk constituent in such a way
not to alter whey protein to casein ratio of the
milk being adjusted. It shall be of uniform
colour and shall have pleasant taste and flavor
and rancidity. It shall also be free from
vegetable oil/fat, mineral oil, thickening
agents.
DUDHSAGAR DAIRY POWDER PLANT
 Four types of powder are manufactured ;
1. Infant milk powder (AMUL SPRAY) (IMP)
2. Skim milk powder (SMP)
3. Whole milk powder (WMP)
4. Dairy whitener (AMULYA ) (SWMP)

 CAPACITY -
 NI – 30 TON / DAY
 N2 – 30 TON/ DAY
 FSSAI STANDARD FOR MILK POWDER
PARAMETER IMP SMP WMP SWMP
Moisture NMT 4.5% NMT 5% NMT 5% NMT 4.0%
Milk fat NLT 18% NMT 1.5% NLT 26% & NLT 20%
NMT 42%
Milk protein in NLT 34% NLT 34% NLT 34% NLT 34%
MSNF
Titrable acidity - NMT 1.8 NMT 1.8 NMT1.2%
( ml 0.1N NaOH LA
for 10 g SNF)

Insolubility Index - NMT 2ml NMT 2ml NMT 1.5 ml

Total ash (on NMT 8.5% NMT 9.3% NMT 9.3% NMT 9.3%
moisture and fat
free basis)

Scorched Disc B Disc B Disc B

particles,
maximum
(ADMI chart)
 GCMMF STANDARD FOR MILK
POWDER
PARAMETER SMP IMP SWMP WMP
Moisture % max 4.0 4.5 4.0 4.0
Fat % min 1.5 18.0 20.0 26
Total ash % max 8.2 8.5 5.5 8.5
Solubility index (ml 1.5 2.0 1.5 -
max)

Milk protein % min - 12.0 - -

Milk solid % 96.0 - 77.0 96.0
SPC/g 50,000 50,000 50,000 50,000
Coliform /0.1g Absent Absent Absent Absent
S.Aureus /0.1g Absent Absent Absent Absent
Salmonella &Shigella - Absent Absent -
Titrable acidity % 0.75 - 0.65 1.5
 SPECIFICATION OF POWDER IN DSD
PARAMETER WMP IMP SWMP SMP

Moisture % 3.2 3.2 3.2 3.2

max
Fat % max 26.5 18.5 20.5 1 (max)

Total ash 7.3 6.5 5.5 8.2

Insolubility 0.5 0.5 0.5 0.5

index
Titratable 16 - 16 16
acidity ( 10g
SNF , ml of 0.1
N NaoH MAX )

Bulk density 0.30-0.55 0.30-0.55 0.30-0.55 0.45-0.65

 Basic steps for powder preparation

1. Standardization & Fortification (FEED

PREPARATION)
2. Condensing / Evaporation
3. Drying ( SPRAY DRYING )
4. Powder conveying & Storage
5. Packaging
 STEP1) Feed preparation
A) Standardization
A. For IMP ; Milk having FAT / SNF = 0.312 is used
(Fat 2.70 % , SNF 8.66% )
B. For SMP; Milk having FAT NMT 0.1 % is used

 Standardized and pasteurized milk is received from

process section and stored in silo
 Total 4 silo ; ( CAPACITY : 1 LAKH liter )
 Silo 1&2 for Skim milk
 Silo 3&4 for Infant milk
 B) Fortification
For INFANT MILK POWDER
By adding sugar , whey powder , vitamins and mineral
premix
IMP

KG SUGAR (in 100kg) KG MTS × 0.120

SUGAR % IN FINAL PDT NLT 18%

KG WHEY POWDER (in 100kg) KG MTS × 0.11

For 12000 kg of milk ;
 Approx 165 kg of sugar +

150 kg Demineralized
whey powder
 Vitamin A+D = 100g
 Mineral premix – 775g
 Vitamin premix – 1.661 Kg

Sugar: Condensed water ratio 2:1

Whey powder: Condensed water ratio 1:1
 Two kettle of 12000 lit equipped with agitator is used
to prepare sugar sryup and reconsituted WP
 Sugar syrup passed through Nylon and Magnetic
filter
 Water soluble vitamins dissolved in water approx

5 lits

Oil soluble vitamins dissolved in

homogenized cream (2100 psi )
approx 5-6 lits
 STEP 2 :Evaporation
 EQUIPMENT OF CONDENSING PLANT
1. Balance tank
2. Pre-heater
3. Normal heater
4. High heater
5. Detentioner
6. Falling film evaporator
7. Vapour separator
8 Barometric leg condenser
9 Thermal vapour Recompressor
(TVR)
10 Vaccum pump
N1 condensing plant (Four effect )
N2 CONDENSING PLANT (THREE
EFFECT)
PARAMATER OF N1&N2 CONDENSING
PLANT
PRODUCT IMP SMP

Baume Reading 18 to 19.5 23 to 24.5

Plant Vacuum (mm of 660 to 720 mmHg 660 to 720mmHg

Hg)

Normal Pasteurization 75 to 90 ºc 75 to 90ºc

(°C)

High heater temp. 95 to 102ºc 95 to 102ºc

(°c)
 VAPOUR FROM
LAST VAPOUR
SEPERATOR

CHILLED
WATER
NON
CONDENSABL
E GASES
Barometric leg
condenser

LIQUID RING
VACCUM COOLING
PUMP TOWER
HOT WATER WITH
CONDENSABLE
GASES
 CCP -1 : condensing of milk
Food safety critical limit: high heater temperature: min.
95°C
Quality limit: high heater temperature: min. 95°C-102°C

 OPRP: cleaning of CMST

Hazard:Microbiological (survival)

 OPRP: checking of filter pad of air supply to dryer and

vibro
Hazard: physical

 OPRP: spoon sterilization in IMP

Hazard:Microbiological (contamination)
 3.DRYING (SPRAY DRYING)
LIGHTER CMBT
PARTICLES(<30µm Air heater
+AIR
ATOMIZER
CENTRIFUGAL
MAIN ROTARY DISC
EXHAUST Hot air @160 –
FAN 210 ºc
DRYING
CHAMBER POWDER MC 8-
MAIN CYCLONE 10%
SEPERATOR VIBROFLUDIZED
BED DRYER VIBRO
CYCLONE

POWDER MC % FINES <

2.5 50µm
FINES
BTV Root
blower
 Fines

POWDER
Fines duct × 4
SIEVE

Compressed
air ICP
Return near atomizer
For
POWDER AGGLOMERATION
SILO

PACKAGING
 Components of drying plant
1. Air supply fan
2. Cooling fan
3. Electromagnetic hammer
4. Vibro fluidizer air filter
5. Vibro fluidizer supply air fan
6. Vibro fluidizer air dehumidifier
7. Vibro fluidized bed dryer
8. Powder sieve
9. Main cyclone
10. Vibro cyclone
11. Rotary valve
12. Blow Through Valve
13. Exhaust air fan
DRYING PLANT PROCESS
PARAMETER OF D1 &D2
PARAMETER IMP SMP

Inlet air temp oC 160 - 210 160-210

Outlet air temp Oc

75-100 75-100

Vibro hot 1 air temp 60 - 70 90-100

o
C

Vibro hot 2 air temp 40 - 60 40 - 60

o
C

Vibro cold air temp 20 - 30 20 - 30

o
C
 Components of drying plant
1. Drying chamber : Drying time 6-7 sec
 Height – 11.58 m
 Atomizer type : Centrifugal disc type
 RPM – 15000
 FEED is atomized in small droplets and dried using hot
air to MC 8-10%
 Drying chamber operated under 10 – 20 mm H2O

2. Cooling fan:This fan is used to cool potential hot

spots in the chamber structure or prevent the rise of
temperature in certain dryer components
3.Main cyclone:-
For separation of air and powder particles from the drying
chamber . It is connect to main exhaust fan which maintains
vaccum in drying chamber
4.Vibro cyclone:-
For separation of air and powder particles from the vibro
fluidizer.The product is removed from the bottom
5. Rotary valve:-
For powder discharge from the cyclone
6. Powder sieve:-
For screening the powder and separating out the lumps from
final product. This is a vibrating screen with powder contacts
part made of SS and other parts of painted with MS complete
with top cover and flexible connection inclusive motor
7. Blow Through Valve:-
It is used for feeding powder to the fines return duct
.
8 . Fire extinguishing system:-
 It operates when outlet temperature of the dryer
exceeds the specific if temp increase to 150ºC that
water flow start in line by controller
9. ICP – it has cut off valve and plunger valve to
controll powder conveying to silo using compressed
air

 INTERLOCK
Interlocks in D1:

1. Cooling fan- supply fan

2. Cooling fan- supply fan air heater
3. Chamber vacuum –- exhaust fan
4. Atomizer--feed pump
5. Vibro exhaust fan – -vibro supply fan
 INTERLOCK IN D2
1. Cooling fan- supply fan
2. Frad cooling fan – supply fan
3. Chamber vacuum (-60to -80 mm WC) exhaust
fan
4. Positive pressure (+40 mm WC )  supply fan
5. Atomizer-feed pump
6. Supply fan -- feed pump
7. Supply fan-- root blower
8. Supply fan--air heater
9. BTV--root blower
 CIP OF CONDENSING UNIT
SR. NO PARTICULAR CONCENTRA TEMPERATIO TIME MIN
TION % N ºC

1 Caustic 2-2.5 % Min 70ºC 35

2 HNO3 1-2 % Min 65 ºC 30

3 Sterilizations Min 80ºC 30

with hot water

NOTE: AFTER 12 -14 h CIP OF PLANT DONE.

AFTER 10-12 CAUSTIC CLEANING ACID CLEANING OF
PLANT IS DONE.
 WET CLEANING OF DRYING PLANT

 Wet cleaning done within 2 months.

 First remove all powder manually from drying chamber, vibro

cyclone, cyclone separator, vibro fluidizer by scraping and
sweeping.
 Clean the internal as well as external side of dryer with water.
 Hand scrub the surfaces with brush wherever required.
 Allow to drain the water.
 Refit the plant.
 Sterilization at temp. of min 100°C for 1h.
 POWDER PACKAGING
 There are two packaging section
1. Small packing room – IMP packing
Temperature – 23ºC , RH – 50%
Nitrogen is filling is done in pack to improve shelf life
2. Filling room – Manual bag packing of SMP
Temperature – 24ºC , RH- 58%
Manual bagging :- Powder from powder conveying
system through in bagging line, where it is bagged
manually in 25kg of bag and stored
 Product profile

Product Name Brand Name Types of

Packaging

1 IMP AmulSpray 13.5gm Pouch

100gm Pouch
200gm Pouch/refill
500gm
Pouch/refill/tin

1kg Pouch
1kg Tin
21gm pouch
2 SMP AMUL SMP 25 kg Bag
 Powder Packaging Machine
1. Rovema

 1kg and 500gm IMP are packed in this machine.
 Capacity :- For 1kg pouch :- 32-34 pouch/min.
500gm pouch:-48 – 50 pouch/min.
 Temp. of vertical jaw :- 220°c
Temp. of horizontal jaw :- 215°c
 Weight range :- 1kg pouch:- 997gm – 1010gm
500gm pouch :- 495gm- 507gm
 No. of pouch per CBX :- 1kg pouch – 12 pouch
500gm pouch – 24 pouch
2. Pakona (PK 30-2 & PK 30-3)
 100gm and 200gm IMP pack in this machine
 Capacity :- For 100gm pouch :- 50pouch/min.
200gm pouch :- 45pouch/min.
 Temp. of vertical jaw :- 130°c
Temp. of horizontal jaw :- 120°c
 No. of pouch per CBX :- 100gm pouch – 120 pouch
200gm pouch – 60 pouch

3. Starpack machine

 13.5g and 21 gm IMP are packed in this machine

 Capacity :- 85pouch/min.
 Temp. of vertical jaw :- 160°c

Temp. of horizontal jaw :- 145°c

Two head in this machine
4. Ferrum machine

 1kg Tin of IMP is packed in machine.

 There is 10 holder in this machine.
 Capacity :- 80CBX/hr.
 Pressure of N2 gas flushing is 0.5 kg/cm2

 Fumigation of packaging room

• 200ml formaldehyde(40%)+ 50 gm potassium permagnet
• It takes 12hrs to be completed and doors are opened before
2hrs of packing.