DDC

1

Kathmandu University

School of Engineering

Department of Mechanical Engineering

A report on industrial training at

Dairy Development Corporation (DDC)

Under Supervision of

Er. Subash Bhattarai

Interns

Nikhel Gurung (32062)

Atma Ram Kayasta (32067)

Amod Panthi (32071)

Biraj Dhungana (06056)

August 6, 2010

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Chapter 1

Introduction

1.1 History

Dairy Development Corporation (DDC) was established in 2026 B.S by the cooperation between

the government of Nepal and the government of New Zealand, under the corporation act of 2021

B.S as a fully state owned corporation for the economic growth of poor farming communities. In

the year 2010/11 B.S, the Central Dairy Plant, Lainchor was established at the initiative of Diary

Development Board and started milk collection, processing and marketing activities from the

year 2014 B.S. The head office of this organization is located at Lainchor, Kathmandu.

Kathmandu Milk Supply Scheme (KMSS) was established in 2037 B.S. at Balaju Industrial

District, Balaju, Kathmandu under the joint corporation of Government of Nepal and New

Zealand. The Dairy Rehabilitation and Extension Project was undertaken by DANIDA. The plant

was expanded in1992 A.D. There are six Dairy Development Projects working under it

KMSS is the biggest project of the DDC situated inside the complex of Balaju Industrial District

and it deals with the supply of standard milk, butter, ghee, and fresh milk. The demand of the

milk and milk products for Kathmandu valley and its surrounding areas is fulfilled by this

scheme. There are 14 chilling centers in different places and 447 milk processing cooperatives

working under it.

Products of the KMSS

Products at Balaju

o Packaged milk: whole and standard milk

o Ghee

o Butter

o Fresh milk

o Cream

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1.2 Vision of the Organization

The main vision of the organization is to provide a source of income for the farmers and supply

quality milk products to the consumers. Milk is collected from the farmers in the different parts

of Nepal and processed before being dispatched for sale. The DDC is the only such industry in

Nepal which directly deals with the farmers and provides them a large source of income. The

DDC collects milk from the chilling centers at different locations and it pays the farmers through

cooperatives. Therefore the farmers directly receive cash for their milk from DDC.

1.3 Objectives

1. Provide a guaranteed market for milk to the rural farmers with fair price.

2. Supply pasteurized milk and milk products to urban consumers.

3. Develop organized milk collection system to meet increasing demand for pasteurized

milk and milk products.

4. Develop and organized marketing system for milk and milk products.

1.4 Organization

The corporation is governed by the Board of Directors formed by Nepal Government of Nepal.

Under the board of directors the corporation has been revising its organizational structure

according to the changing need, at the central level as well as at the regional level. Following

this, the recent Management Structure of DDC at the central level is as follows:

Present Schemes :

Milk Supply Scheme District Production Cap. (Per Shift)

Kathmandu Kathmandu 75,000 Lts.

Biratnagar Morang 25,000 Lts. and 3 M. T. Powder Milk from

40,000 Lts. of Milk (per day)

Hetauda Makawanpur 15,000 Lts

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Milk Supply Scheme District Production Cap. (Per Shift)

Pokhara Kaski 10,000 Lts.

Lumbini Rupandehi 2,500

Total

127500

Table 1: Dairy Development Projects

There is a mini processing plant recently established under the Lumbini Milk Supply Scheme.

Thus the scheme has just started selling pasteurize milk in the local market. Since the sales

volume is small, the scheme is transshipping the raw milk to KMSS and PMSS to cater the

demand of those areas.

1.5 Observation about KMSS

Project Name: Kathmandu Milk Supply Scheme

Address: Balaju Industrial District, Balaju, Kathmandu

Phone No: 01-4350181, 4350092, 4355024 Sales: 01-4355024 Project Manager(Quater): 01-

4355025 Fax No: 977-1-4350039

Established Date: 2037 B.S

Major Production: pasteurized Milk, Butter, Ghee, Flavored

Milk Plant Capacity: 15,000 Lts per hour (75,000 Lts Per shift)

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Project Chilling

centre

name

District C.C

Qty

Cooling

capacity

Average daily

milk collection

K.M.S.S Banepa Kavre 1 10000 7000

Panauti Kavre 1 10000 6000

Panchkhal Kavre 1 11000 6000

Sipaghat Kavre 1 10000 7000

Charaudi Dhading 1 3000 1000

Mahadev Besi Dhading 1 3000 3000

Balephi Sindhupalchowk 1 7000 6000

Tikabhairav Lalitpur 1 5000 6000

Bhaktapur Bhaktapur 1 6000 7000

Sankhu Kathmandu 1 6000 4000

Ranitar Kavre 1 5000 6000

Chanauli Chitwan 1 6000 6000

Sangha Kavre 1 2000 2500

Bharatpur Chitwan 1 6000 6000

Jyamire Chitwan 1 12000 16000

Melamchi Sindhupalchowk 1 5000 3000

Tin Peeple Kathmandu 1 1000 1000

Dhungkharka Kavre 1 1200 1500

Meghauli Chitwan 1 1000 1000

Saradanagar Chitwan 1 2000 1000

Bahunepati Sindupalchowk 1 2000 2500

Total 21

Table 2: Name, Capacity, Location, District and details of chilling centres under KMSS

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Description of Human Resource according to KMSS

Scheme Technical Administration

Kathmandu Milk Supply Scheme Officer Assistant Others Officer Assistant

31 210 44 13 108

Table 3: Description of Human Resource according to KMSS

1.5.1 Collection Programme

DDC has been collecting cow, buffalo and chauri milk from 33 districts. Milk is collected

through the farmers owned,Milk producers Cooperative Societies (MPCS). Its present milk

collection network has spread from Panchthar in the East to Surkhet in the West.

Hetauda Milk Supply Scheme also supports KMSS & BMSS by supplying excess milk above

their local requirement. Biratnagar Milk Supply Scheme manufactures skimmed milk powder

from its excess milk and milk excess from other supply schemes.

DDC has been playing a special role in contributing to uplift the economic status of rural

farmers. Thus dairy has been recognized as an effective tool for poverty alleviation. In the Fiscal

Year 2062/2063 DDC purchased about (approx.) 1,50,000 liters of milk per day from the

farmers.

1.5.2 Collection Network

The collection network under different Milk Supply Schemes is presented below. Chilling

Centers (CC) established under the Milk Supply Schemes are in operation across the country for

chilling the milk collected from the MPCCs:

Schemes MPCCs Chilling Center District Covered

KMSS 484 17 7

BMSS 140 11 7

HMSS 127 8 5

7

LMSS 63 6 4

MWMSS 32 3 4

MPPSS 52 - 8

TOTAL 888 45 33

Table 4: Collection Network (Source: //htp.www.dairydev.com.np)

1.5.3 Quality

Quality of the milk is obtained by testing acidity, adulteration and fat contained in milk.

Following procedure is carried out for fat contained in milk:

Milk sample is taken from the tank of 10.75 ml in the test-tube.

10 ml of sulphuric acid is added by measuring through bitometer.

1ml of amyl alcohol is added.

Closing its head with cork and kept in centrifuge machine.

By the application of centrifugal force in centrifuge we are able to take the reading of fat

contained in milk.

Normally, Cow milk Posses 3.5% - 5% of fat and Buffalo milk posses 4.5% - 6.5% of fat.

Acidity and adulteration test is done at boiling temperature .Generally milk shows 0.14 – 1.7 %

of acidic nature.

1.6 Similar other Industries

Dairy industry is a profitable business venture. DDC is a government organization which

provides quality milk products to the customers. It is a service oriented organization.

There are few private industries emerging in the dairy business which are as follows:

o Gokul Dairy

o Nepal Dairy

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o Himalaya Dairy

o Kathmandu Dairy

o Anmol Dairy

o Janta Dairy etc

1.7 Organizational Structure and Hierarchy

The corporation is governed by the Board of Directors formed by Nepal Government. The Board

of Directors comprises of a Chairman, two members from Agriculture & co-operative Ministry,

one from Finance Ministry & GM of DDC as a member secretary.

Figure 1: Organizational Structure

General Manager

Deputy General Manager

Administration

Technical Management

Financial Administration

Training and operation

Planning, Monitoring and Evaluation

Internal Audit

Quality Control and Technology Development

Marketing Management

Project Manager

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1.8 Organizational Chart for the Milk Supply Scheme

Figure 2: Organizational Chart for the Milk Supply Scheme

1.9 Human Resource Management

The people in this industry work at different levels according to their qualifications. Majority of

the staffs are the labors, which work at the factory, in the manufacturing section. The schedules

of the labors are organized according to different shift hours. Milk is collected from different

chilling centers and distributed by the people working in Transportation section. The

maintenance and engineering section are mobilized for the effective running of the factory. The

staffs which comprise of the administration section work during the regular working hours

specified by the Government.

The company facilitates all the staffs in every level by providing them two packs of milk per day

and 1kg of ghee per month.

Project Manager

Assistant Project Manager

Collection Production Engineering

and

Maintenance

Administration Financial

Administration

Quality

General Auto

Chilling

Centre Filling Chilling vat

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Chapter 2

Technical Specification about the Company

2.1Equipments, Types and Applications

2.1.1Milk processing equipments

1. Chilling Vat

Chilling vat is used to store the milk immediately after collection of milk or during

transportation. It is also called as Milk Cooling Tank or Bulb Milk Cooler. It is available in

vertical or horizontal shape and its capacity ranges from 3000 liters to 15000 liters. The milk

to be stored is first chilled at 4 degree Celsius in batch and then stored in a chilling vat. The

tank has two layers of stainless steel SS304 between which an insulation with PUF(Poly

Urethane Foam) is provided. The vat is designed such that there is no more than 1 degree

Celsius rise during a period of 24 hrs. PUF provides cold insulation, (Glass wool is used for

hot insulation in other applications). Thermo cool can be other cold insulator but it has

higher thermal conductivity when compared to PUF. So, use of PUF is advantageous over

thermo cool.

Type RK-C chilling vat are closed tanks of horizontal cylinders, made up of rustproof

stainless steel. The inner container is made of 2mm and outer shell of 1mm thick plates.

Various components of chilling vat are:

1. Agitating Motor

2. Agitator

3. Manhole

4. Temperature Sensor

5. Two layers of stainless steel with heat insulator in between.

2. Milk and Cream Filters

In-line filter used in milk and cream lines, are cylinders of large diameter made up of sanitary

SS pipe line in which the filter bags are installed over perforated metal frames. For proper

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filtration, the ratio of cloth area to milk flow should be large. If milk is having more than 4%

milk fat, temperature of 305 to 315 K is used for rapid flow. A good guide to proper filtration

is to keep pressure difference between the inlet and outlet on the filter unit, below 71 KPa

.For continuity of operation, two filters in parallel with bypass valve are used so that one of

the two filters will be in operation when the other is being cleaned of the sedimentation and

change of filter bag.

Filters are generally located in receiving line between receiving station and storage tanks

or pasteurizer.

3. Centrifugal Pump

A Centrifugal Pump consists of:

a. Impeller

The rotating part of the centrifugal pump is called impeller. It consists of series of

backward curve vanes. The impeller is mounted on a shaft which is connected to the

shaft of the electric motor.

b. Casing

The casing of centrifugal pump is similar to the casing of reaction turbine. It is an

air tight passage surrounding the impeller and is design in such a way that kinetic

energy of the water discharge at the outlet of the impeller is converted into pressure

energy before the water leaves the casing and enters the delivery pipe.

There are three types of casing:

i. Volute Casing

ii. Vertex Casing

iii. Casing with guide vanes

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c. Suction pipe with float valve and strainer

A pipe which one end is connected to the inlet of the pump and other end into in a

sump is known as suction pipe. The float valve which is a non return valve or one

way type of valve is fitted in the lower end of the suction pipe. The Strainer is also

fitted at the lower end of the pipe. The float valves open only in upwards direction.

d. Delivery pipe

A pipe which one end is connected to the outlet of the pump and other end delivers

the water at the required height is known as delivery pipe.

4. Air Separator

This equipment separates air from milk while pumping from the road milk transfer unit

because the air trapped in the pipe gives error in the measurement and there is risk of milk

contamination.

5. Flow Meter

The measuring principle is based on the continuous filling and emptying of the measuring

spaces formed by the walls of the measuring chamber and the rotary piston as well as of the

radially installed separating wall situated between inlet and outlet ports.

The oscillating movement of the piston is transferred to the indication device. The

transmission device consists of the magnets, one of which situated in the measuring chamber

and the other outside. Thus there is no need to use packing, which is not recommended for

sanitary reasons.

2.1.2 Chilling and storage of milk

For the storage of milk chilling process is very necessary because in normal temperature the

growth rates of pathogens are very fast. Hence to prevent the breading of pathogens, low

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temperature must be maintained which is done with Plate chiller in the line and stored in

insulated tank. Storage tank is chilled by passing chilled water through the jacket.

a.) Plate Heat Exchanger(PHE)

Almost all heat treatment of dairy products is done in PHE. The PHE consists of a pack

of Stainless Steel Plates clamed in a frame. The frame may contain several separate packs

known sections, in which different stages of treatment such as pre-heating, final heating,

holding and cooling takes place. The plates in the pack are corrugated in a pattern

designed for optimum heat transfer efficiency. The plate pack is compressed with great

force in the frame. The liquid enters and leaves the channels by the holes in the corner of

the plate, varying patterns open and through blind holes route the liquids passes from one

channel to the next. Gaskets are used round the edges of the plates and the holes from the

boundaries of the channels to prevent leakage. The heating or cooling medium is

introduced at the other end of the section and passed in the same way through alternate

inter plate channel.

2.1.3 Milk pasteurization Plant

Pasteurization

Heating the milk at a particular temperature and then cooling it, in order to kill harmful

bacteria is called Pasteurization.

Can be done in three processes

i. Low temperature long time method

Heated up to 62ºC for about 30 minutes.

Rapid cool to 4ºC.

ii. High temperature shorter time method.

Heated up to 72ºC for about 15 seconds.

Rapid cool to 4ºC.

iii. Ultra high temperature method

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Heated up to 125ºC for very few seconds.

Rapid cool to 4ºC.

Rapid cooling is done is case of pasteurization because at high temperature pathogens

dies, but the bacteria which are not killed grows rapidly in case of heat, so during pasteurization

rapid cooling is needed.

Complete pasteurization plant consists of

a) Float hopper

The float control inlet valve regulates the inflow of milk to maintain a constant level in

the float hopper. If the supply of milk is interrupted, the level will begin to fall. The

pasteurizer must be filled with liquid at all times during operation to prevent the product

from burning on the plates. The float hopper is therefore often equipped with a low level

electrode which transmits the signal as soon as the level reaches the minimum point. The

signal actuates the flow diversion valve so that product from the pasteurizer is re-

circulated to the float hopper.

b) Feed pump

From the float hopper, which provides constant suction head, the milk is pumped at

virtually constant capacity to the pasteurizer inlet.

c) Flow regulator

The flow regulator keeps the float to the pasteurizer exactly the correct volume to

guarantee stable temperature control and constant length of the hold.

d) Regenerative preheating

The untreated milk proceeds from the flow regulator to the first section of the pasteurizer,

the preheating section. Here it is regenerated and heated with already pasteurized milk

which is cooled at the same temperature.

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e) Heating section

The preheated milk either can be send to the cream separator or directly to the heating

section according to the need. In this section heating is done by the hot water.

f) Holding section

Holding section is the arrangement of the pipes in which the milk after heating is kept for

certain period of time.

g) Diversion valve

Flow diversion valve operates automatically and is located between the holding section

and the regenerative section. The valve allows the milk to move forward to the

regenerative section. Certain preset temperature is assigned. If milk reaches to flow

diversion valve below this preset valve, the automatic control closes the valve port for

forward flow and opens the port connected to float balance tank. The flow diversion

valve is safety device to ensure diversion of improperly heated milk.

h) Cooling section

After leaving the holding section, the milk is returned to the regenerative section for

cooling, here the pasteurized milk gives up its heat to the cold incoming untreated milk.

The outgoing pasteurized milk is then chilled first with cold water then with ice water.

2.1.4 Homogenizing Unit

Homogenization means that the fat globules are subjected to mechanical treatment which breaks

them down into smaller globules uniformly dispersed in the milk. As the milk is forced through a

narrow orifice at high pressure and velocity, broken fat globules distribute uniformly throughout

the fluid by means of the process of explosion on release of pressure and cavitations.

The principle components are the high pressure pump (usually a three cylinder pressure pump)

and a back pressure device, the homogenizer head. The pump is driven by a power electrical

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motor through a crank shaft and a connection rod transmission which converts the rotary motion

of the motor into the reciprocating motion of the pump piston. The piston run in a cylinder bored

in a high pressure block. They are made of highly resistant material, piston rings are provided to

prevent oil from leaking into the product. Water can be supplied to the space between them to

cool the piston.

2.1.5 Cream Separator

The machine works on the principle of centrifugal force; a physical mixer of substances of

different densities will stratify or separate from each other subjected to an action like force of

gravity. The force applied in the separator is multiplied enormously compared to the valve of g,

separation of fat and serum takes place almost instantaneously and more completely. Milk is feed

into rapidly rotating ball above the stationary axial inlet tube. The milk is accelerated to the

rotational velocity of the ball in the distributor, and then ascends through the aligned distribution

holes in the discs stack to reach the separation channel between the discs. The heavier solid

particles settle outwards and are deposited in the sediment space, while cream settles inward

towards the axis of rotation and passes through the channels to the cream paring chamber. The

skim milk leaves the disc stack at the outer edge and passed between the top and the bowl hood

to its own paring chamber. By regulating the cream discharge opening the percentage

(concentration) of cream can be regulated. The machine is periodically shutdown for cleaning.

2.1.6 Refrigeration Unit.

Refrigeration is essential for preserving the dairy products such as butter, cheese, and milk. The

above products are stored in cooled stores. Additionally chilled water is required to chilled the

pasteurized milk and too store it in the milk tanks. There are two types: Natural and Artificial.

Natural refrigeration utilizes ice water or ice salt mixtures. Artificial refrigerators makes use

refrigeration machinery. Artificial refrigeration employs different systems, but mechanical

vapour compression system is the most widely used of its dependability, of control and

simplicity.

Vapour compression refrigeration is used for chilling purposes. This refrigeration effect is based

on the fact that it absorbs heat when liquid is converted into vapour. Starting from compressor it

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helps to maintain the flow of refrigerant in the system. Compressor sucks the refrigerant which is

at low pressure and temperature to compress it by raising its pressure and temperature. In the

condenser latent heat of vaporization is removed from high temperature and high pressure

vapour. The vapour is then condensed to a high temperature liquid. Although the vapour is

condensed to liquid they are still at high temperature form. From the condenser high temperature

liquid flows to the receiver where it is stored. From the receiver the high temperature liquid

flows to the thermostatic expansion valve. Thermostatic expansion valve automatically controls

the flow of liquid refrigerant to the evaporator. It is the dividing point between the high pressure

and low pressure side of the system. As the high pressure liquid refrigerant passed though the

expansion device some of its changes into vapour and cools the remaining liquid. High

temperature liquid now changes to a low temperature liquid. In the evaporator this liquid absorbs

heat from the surroundings and changes to vapour form.

The process and parts related to refrigeration unit are given below:

1. Compressor

A gas compressor is a mechanical device that increases the pressure thereby reducing the volume

of the gas. Different types of compressors may be centrifugal, mixed flow, axial, reciprocating,

rotary, or a diaphragm compressor.

The basic function of a compressor is to increase the pressure. In function it is similar to the

pump as pump is used to increase the pressure thereby creating head and helping the fluid to

transport.

Reciprocating compressors: These compressors use pistons driven by a crankshaft. They can be

either stationary or portable, can be single or multi-staged, and can be driven by electric motors

or internal combustion engines. In certain applications, such as air compression, multi-stage

double-acting compressors are said to be the most efficient compressors available, and are

typically larger, and more costly than comparable rotary units.

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Figure 4: Compressor classification

A reciprocating type compressor may be of three different types:

1. Hermetic - compressor-motor assembly contained in a welded steel case, typically used

in household refrigerators, residential air conditioners, smaller commercial air

conditioning and refrigeration units.

2. Semi-hermetic - compressor-motor assembly contained in a casting with no penetration

by a rotating shaft and with gasketed cover plates for access to key parts such as valves

and connecting rods.

3. Open - compressor - only with shaft seal and external shaft for coupling connection to

belt - or direct-drive using as electric motor or natural gas engine. These are largely used

for ammonia refrigeration applications as hermetic designs cannot be used with ammonia

refrigerant, and for engine-driven units

Reciprocating compressor (six cylinder piston type) has been used. It sucks the refrigerant at low pressure

and temperature and compresses it to raise the temperature and pressure. When the pressure in the

compressor exceeds the specified range then high pressure cut-off occurs, falls below the limit then low

pressure cut-off takes place. To control oil pressure oil pressure cut-off is used.

Specification

Make : Sabroe, 1988

Compressor

Positive Displacement Dynamic

Reciprocating Centrifugal

Diaphgram

Double Acting

Single Acting

Rotary Axial

Vane

Screw

Lobe

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Model : SMC 112L

Refrigerant : R717 Ammonia

Motor : 960 RPM, 110 KW

Capacity : 296000 Kcal/ hr

Working pressure : 18 bar

Condensing temperature: 450C

Evaporating temperature:-250C

2. Oil Separator

Lubricating oils are used in the compressor. To prevent this oil from entering the gas line oil

separator is used in the discharge side.

3. Non return valve

In cases when the compressor is shut down the pressure in the compressor falls below the pipeline

pressure. To prevent the gas from returning into the compressor due to pressure difference a non

return valve is used at the discharge side.

4. Condenser

It consists of a tank in which hot vapour is circulated and is cooled by spraying cold water over

the pipes carrying ammonia vapour. In addition to the cold water the ammonia vapour in the

pipes is cooled by cooling fans. The vapour is condensed into high pressure liquid and is

collected in the receiver tank.

5. Ammonia receiver

It provides storage for the condensed ammonia so that the constant supply is available to the

evaporator. When gas demand is less than the compressor capacity the excess liquid is stored in

this receiver and is used when the demand increases. From this tank it passes through the solenoid

valve (it controls the flow of liquid) to the evaporator.

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6. Solenoid Valve

When maintenance and cleaning of the ice bank has to be done the solenoid valve is closed and

the gas is collected in the ammonia receiver. This is done to prevent gas leakage during cleaning

and repair.

7. Evaporator

The gas flowing through the solenoid valve is distributed into different pipe line for effective heat

transfer between the water and the gas.

Ammonia extracts heat from the water in the ice bank and vaporizes to low pressure vapour hence

cooling the water in the ice bank. The water in the ice bank is continuously stirred for uniform

temperature distribution throughout the ice bank.

8. Surge drum

It provides storage for the low pressure ammonia vapor from the chiller tank. The liquid ammonia

remains into surge tank while the gaseous ammonia is passed into the compressor. The level of

gas in the surge drum is controlled by means of a float valve.

Equipments used for control purposes are

i. Capillary tube

ii. Hand operated expansion valve

iii. Low presser float valve

iv. Automatic expansion valve

v. High pressure float valve

vi. Thermostatic expansion valve

vii. Solenoid valve

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Refrigeration system

Figure 5: Refrigeration Cycle

Non Return Valve

Condenser Receiver

Evaporator

Compress

or

Oil

Separator

Expansion

(Float) Valve

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2.1.7 Boiler

Boiler is used for steam generation. It is a closed pressure vessel into which water can be fed and

evaporated into steam continuously. This steam produced is used in pasteurizer, heating tanks, vats.

Thermal energy released by burning fuel is utilized in converting water into steam, which is used for

different purposes. In both MPPSS and KMSS, fire tube boilers are used.

Specification

Make : Forbes Marshall

Type : Horizontal Fire Tube

Capacity : 2000kg/hr

Steam temperature : 1500C

Working pressure : 9kg/cm2

Safety valve pressure : 10.5kg/cm2

Heat generation : 1130 kcal/hr

Fuel : Diesel

Consumption : 60lt/hr

The different parts connected to the boiler drum are as follows:

1. Fuel pre-heater:

Fuel is preheated using immersion heater.

2. Water softening unit:

Water softening is obtained by ion exchange method by the use of salt solution unit.

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3. Filtration unit:

This is done to filter the water to prevent the corrosion of boiler surface from foreign

impurities.

4. Feed water pump:

There are two centrifugal pumps working in parallel to pump the water into the boiler

drum. One or both of the feed water pumps is used depending upon the steam

consumption rate.

5. Level indicator :

The level of the water in the drum may fall significantly and may result in the

overheating of the pipes. If the water level falls below the limit, the control system

triggers the alarm.

6. Float switch :

There are two switches which control the feed water pump. One turns the pump on when

the water level in the boiler decreases below the minimum level. The other turns the

pump off when the water level rises above the maximum level.

7. Distribution pipeline :

The steam generated is distributed throughout the plant in a pipeline. The pipe is

insulated and gate valves are fitted at different places to control the flow of steam as

required.

2.1.8. Steam production and distribution system

a.) Steam Production

Fuel such as diesel and furnace fuel are used for the generation of steam. When this fuel

burns in presence of air heat energy is liberated and is utilized for heating purposes. The

efficiency of the boiler is 80-90% and heat losses in the piping system are about

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15%.Therefore only 65-77% of the total thermal energy of fuel is utilized for the

production.

Figure 6: Steam production and distribution system

Boiler

Pressure reducing

valve Steam

distribution

vessel

Distribution vessel for

low pressure steam

Pasteurizer Heating

tanks

Steam

traps

Condensate

tank

Condensate

pump

Feed

water tank

Softening unit Chemical

dosing

Feed water

pump

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b.) Steam piping system

When the steam is produced it passes through the main valve on the steam dome of the

boiler to the distribution vessel via a pressure reduction valve. After that steam is utilized

in different heating units such as pasteurization, heating tanks etc.

The steam pressure in the boiler is about 9-11 bar so that the piping system utilized must

be strong enough to resist the pressure and a proper insulation must be done so that the

heat loss to the surrounding gets minimized and increases the efficiency. The steam

piping is exposed to extensive variations in temperature which results in considerable

thermal expansion of the pipes. Therefore the pipes must be installed to permit axial

movement of the steam.

c.) Pre-treatment of boiler feed water

If hard water is feed to the boiler then problem of scaling on the pipes may arise, which

acts as a resistant medium for the heat transfer between the water and steam. Therefore

proper heat transfer doesn’t occur. In order to reduce such problem water softening plant

is mandatory. The softening of boiler feed water is done by using ion exchange resin,

periodically charged by salt solution. For scale prevention chemical dosing unit

containing sulphite and phosphate is used.

d.) Auxiliary devices in the boiler

i. Water gauge

It is device which is used to indicate the height of the water in the boiler.

ii. Safety valves

A safety valve is a circular valve connected with the steam space of a boiler and

underweight to such an extent that when the pressure of the steam exceeds the sudden

point the valve is lifted and allows the steam to be released. The loading of the valve may

be by a weight or spring.

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iii. Pressure gauge

It measures the pressure of steam inside the boiler.

iv. Stop valve

It is a non return valve placed directly on a boiler and connected to the steam pipe which

leaves to the engine. It has a hand wheel and screw only to close the valves. It is used to

regulate or completely shut off the steam.

v. Automatic return valve

It is usually placed on the main vapour outlet of the boiler. When the steam pressure rises

above the pressure in the main line, it reaches the non return valve and pushes the boiler

on the line. In case the boiler pressure falls below the main line pressure, the non return

valve closes and boiler is cut out.

vi. Check Valve

This valve regulates supply of water to the boiler and maintains the water level. It is

known to be non return valve because when the steam is under pressure, the check valve

can be examined by closing the upper valve.

vii. Blow off valve

This valve is provided on the boiler for discharging mud, scales or other impurities. Blow

off valve is a cork and is fitted to the lowest part of the boiler.

viii. Fusible plug

It fuses when the temperature is in excess of its capacity and lets the steam out.

27

2.1.9 Air Compressor

Objective: to supply air to refrigeration unit, packing unit and for pneumatic pressure.

Process: With the aid of two air compressors, air is sucked in and passed through water-cooling

where the moisture of the air settles as water. This air now is accumulated in air receiver tank

where the excess moisture settles as water droplet that is vented out from the gate valve

provided. From receiver, air is filtered. When the air passes through drier, the air is ready to be

distributed to the various plants.

Compressor 1

Compressor 2

Air

Rec

eiver

Wat

er

cooli

ng

Wat

er

Cooli

ng

Fil

ter

Dri

er

Supply

Fig7: Schematic diagram of air compressor

28

2.1.10 Cleaning Internal Parts (CIP) unit

Figure 8: CIP unit

Description

Manual scrubbing of tank and vats is not effective. This method of cleaning is time consuming,

expensive and often unsatisfactory in terms of bacteriological cleanness, therefore manual

cleaning has been replaced by mechanized system and in many cases by automatic cleaning. This

technique is known as CIP which means that rinsing water and detergent solution are circulated

through tank piping and process lines with no need to dismantle the equipment as in manual

cleaning.

Raw

Water

Hot water

(About 80ºC)

Caustic water

(0.5 kg for 500

lt water)

Pump

Pump

One way valve

29

CIP can best be defined as circulation of cleaning fluids through machines and other items of

equipment interconnected to form a cleaning circuit. The passage of high velocity of liquids over

the surface of the equipment generates a mechanical scouring effect which dislodges deposits of

dirt. This however applies only to the flow of pipe, heat exchanger pumps, valves separator etc.

2.1.11 Generator

There is one generator in MPPSS and two stands by generators in KMSS factory. The generator

is operated by diesel in both cases. It is used to provide power supply during power cut. The fuel

pump pumps fuel from the fuel tank, fuel is sprayed under pressure by the nozzle. The amount of

fuel is controlled by solenoid valve. There are two solenoid valves for each nozzle. Excess fuel is

returned back to the fuel tank. Air is sucked and blown by blower fan and the mixing of the fuel

and air takes place and power is generated when combustion takes place.

2.1.12 Fill packing Unit

The Fill packing unit is used for filling the milk in pouches. A milk pouch contains 200ml milk.

The unit consists of a vertical sealing component, horizontal sealing component, filling tube,

which are driven by a single motor and controlled by cams, gears and chain drives.

2.1.13 Water Treatment Plant

The water used in cooling is contaminated due to mixing of oil and refrigerants during the

refrigeration cycle. It must be purified before reusing it. Water treatment plant is installed in

DDC for the purification of water. The water is first passed through trays for aeration. This

removes the gases present in the water. The aerated water is collected in a tank. It is then pumped

to filter and chemical dosing is done. The filter consists of layers of different material like coal,

sand, and gravel. When the water passes through the filter, the solid particles are trapped in the

filter and the water gets clean. The filter is cleaned at regular interval to ensure proper operation

of the plant. The filter is cleaned by passing the water in the opposite direction, which flushes the

solid particles trapped in the filter. The flow of water is controlled by a three way valve.

30

2.2 Plant Layout

Figure 9: Plant layout (K.M.S.S. Balaju)

31

2.3 Production Process

2.3.1 Chilling and Storage of milk

Milk needs to be chilled while it is stored. Bacteria grow rapidly at normal temperature hence,

low temperature must be maintained. Plate chillers are used in the line and the milk is stored in

insulated tank. Passing chilled water through the jacket chills storage tank.

2.3.2 Milk Processing

The milk collected from various chilling centres is transported to KMSS in milk tankers. The

milk is then pumped through the in-line filter and passes through the air separator, where air is

separated from the milk. The milk passes through the flow meter which shows the volume of milk

collected. It then enters the plate chillers where it is cooled to 40C and the milk is stored in SILO

tank. The stored milk is collected in a balance tank when required. From there, it goes to plate

heat exchanger where it is heated and kept in holding for a certain time. It is then cooled by

passing through the plate heat exchanger to pasteurize it. After the milk is pasteurized, it is stored

in standard milk storage tank. From the storage tank, milk is packed in plastic pouch. This pouch

is then stored in cold store before being distributed for sale.

2.3.3 Milk Processing Equipment

In-line filter used in milk and cream lines are cylinders of large diameter made up of sanitary SS

pipeline in which the filter bags are installed over perforated metal frames. For proper filtration,

the ratio of cloth area to milk flow should be large. If milk is having more than 4% milk fat,

temperature of 205 to 315 K is used for rapid flow. A good guide to proper filtration is to keep

pressure difference between in inlet and outlet on the filter unit below 71 kPa. For continuity of

operation, two filters in parallel with bypass valve are used so that one of the two filters will be in

operation when the other is being cleaned of the sedimentation and change of filter bag.

Filters are generally located in receiving line between receiving station and storage tanks of

pasteurizer.

32

2.3.4 Homogenization

Homogenization means breaking down of fat globules by subjecting to mechanical treatment. As

the milk is forced through a narrow orifice at high pressure and velocity, the broken fat globules

uniformly distributed throughout the fluid by means of explosion on release of pressure.

Homogenization is done only at the time of shortage that is when the raw milk availability is low.

In such case, milk powder is added to raw milk to increase milk production capacity and

undergoes homogenization.

2.3.5 Pasteurization

Heating the milk to a particular temperature and then cooling it to kill harmful bacteria is called

pasteurization.

Pasteurization can be done in three ways

1 Low temperature long time method: Milk is heated up to 620C for about 30 minutes and

rapidly cooled to 40C.

2 High temperature shorter time method: Milk is heated up to 710C for about 15 seconds

and rapidly cooled to 40C.

3 Ultra high temperature method: Milk is heated up to 1250C for very few second and

rapidly cooled to 40C

33

Receiving and chilling at chilling centre (1)

Receiving at Factory (2)

Filtration and Cooling (3)

Cream Separation (4)

Homogenization and standardization (5)

Pasteurization (6)

Cooling (7)

Intermediate holding in tank (8)

Filling (9)

Cooling /refrigeration (10)

Loading (11)

Transportation (1)

Cream

Addition

of Butter

(16)

Packaging material

purchase and receipt

(17)

Packaging Material

Storage (18)

Packaging material

(19)

Packed milk

for

reprocessing

(13)

Distribution (12)

Skim

milk

powder

storage

(15)

Addition

of skim

milk (16)

Figure 9: Process Flow Chart of Milk

Skim Milk

powder

purchase and

receipt (14)

34

Fig 11: Flow Chart of Milk Processing

Flow

meter

Plate

chiller

Milk

Storage

Homogenizer

Milk

Storage

Dispatch Package

storage

Fill

Packing

Milk tanker

In-line

Filter

Pump Air

Separator

Cream

Separator

Heating Reg2 Reg1 Cooling

In-line

Filter

Pasteurization Plant

35

2.3.6 Fresh Milk Production

Fresh milk is produced using the pasteurized milk. The pasteurized milk is kept in a

chilling vat and colour and flavour are added to the milk. It is then stirred for minutes. After the

milk is mixed well with the flavour, it is pumped into the filling machine. The milk is filled in

the bottle and the bottle is sealed. The milk is then heated at 1250C for 25 minutes.

Fig12: Fresh Milk Production Flow Chart

Receiving milk at fresh milk plant and storage

Addition of sugar, colour and

flavour

Filing of 200ml bottle

Crowning

Sterilizing at 1200C for 20 to 25 min

Cooling to room temperature

Storage at room temperature

Receiving used bottle

Dipping in 1% NaOH

solution at 700C for half an

hour

Rinsing of bottle

with clean water

Outside brushing

Inspection of washed

bottle

36

2.3.7 Ghee Processing

The bi-product cream, which is obtained from cream separator, is further processed to get

ghee. The process begins with pasteurization at 40-45 degrees for 30 minutes. This is actually

Low Temperature Long Time pasteurization and batch processing. Then the butter is send to the

balance tank. From cream balance tank, we pump the cream for the pasteurization, through the

deodorization where pleasant flavour is shocked out. Then cream is pasteurized at 80-85 degree

centigrade, and chilled it to 25-30 degrees and send to the cream storage tank. The chilled cream

is pumped to the butter churning machine and churned it here until the cream will convert into

butter. To preserve the butter for longer time some amount of salt and yellow colour is added to

it. So formed butter contains 80% milk fat and 1-1.5% of salt.

The following steps are basis to prepare the final product (ghee) from the butter:

1. Melting in a melting vat: Butter is melt to about 40 degrees at a time in this vat.

2. Pumping process: An electric motor is used with stainless steel pipes to pump up the

melted ghee.

3. Settling tank: the butter is passed to settling tank, where its temperature rises to about 60

degrees. The outlet is controlled through a valve.

4. Filtering process: Filtering process filters the impurities and moistures that are present in

the ghee. Nylon cloth is used as filter. The final filtering is performed in ghee clarifier.

5. Packaging system: This is a mechanical system. It consists of a cylinder associated with

rotating shaft. One complete rotation of shaft pulls and pushes the piston inside the

cylinder required volume of ghee. This pull of piston fill the required volume of ghee to

the cylinder and it is filled in to the PVC bag and the horizontal sealer acts as a sealer and

cutter also.

37

Figure 13: Ghee Production Flow Chart

Cream, bi-product from

Cream separator

Pasteurization

Chilling at 4 degrees

Churning

Butter

Melting at melting vat

Settling

Boiling to 120 deg. till about 5

min and then cooling to

normal temperature

Filtration in a clarifier

Stores in a tank

Filling

Packing in corrugated Box

38

Figure 14: Ghee Packing Mechanism

This is fully mechanical system. The timer section consists of a piston of cylinder attached to

rotating shaft. The distance of joint of piston from the centre of rotating shaft determines the

pull/ push length of the piston inside the cylinder. Thus, we can increase/decrease the volume of

cylinder. This liquid ghee transferred to the plastic bag through the vertical pipe and the

horizontal sealer seals and cut the filled

2.4 Maintenance management

The company has its own engineering and maintenance department which handles all the

machinery and equipments for their optimum performance under normal conditions. The

department has its own workshop for maintenance and repair work for any problem encountered

during operation.

Timer set (length of the piston

pull/push inside the cylinder)

Ghee filling in the bag and

sealed with horizontal sealer

and cut.

Final product manually put into

paper box

Liquid

ghee input

Liquid ghee flows through pipe Plane packing plastic

Converted into bag

with v shaped folder

and vertical sealer

39

2.4.1 Preventive Maintenance

Preventive maintenance means all actions intended to keep durable equipment in good operating

condition and to avoid failures. A good preventive maintenance (PM) program is the heart of

effective maintenance. Success is often a matter of degree. The proper balance that achieves

minimal downtime and costs can be tenuous between preventive maintenance and corrective

maintenance. Everything is going to fail at sometime. PM can prevent those failures from

happening at a bad time, can sense when a failure is about to occur and fix it before causes

damage, and can often preserve capital investments by keeping equipment operating as well as it

did on the day it was installed.

However, PM can also cause problems. Whenever any equipment is touched, it is

exposed to potential damage. It is excessively costly to replace components prematurely. A PM

program requires an initial investment of time, parts, people, and money. Payoff comes months

later. While there is little question that a good preventive maintenance program will have a high

return on investment, many people are reluctant to pay now if the return is not immediate. PM

supports a commitment to long term life cycle cost/total cost of ownership.

2.4.2 Advantages

i. Management control

ii. Reduce overtime

iii. Balance workload

iv. Increases equipment uptime

v. Increases production

vi. Standardization

vii. Parts inventories

viii. Standby equipment

ix. Safety and checks pollution

x. Assure quality output

xi. Access to equipment

40

2.4.3 Maintenance Job Card and Machine Card

The method of overhauling of the specific machine as per the manufacturer is given in

maintenance job card below as a sample. After performing the scheduled maintenance job, then

the report of job description is written in the machine card .Sample of machine card is shown fig

10.

The machine card is supposed to be an inventory file where all important information regarding

the machine is listed. This information will not be changed in the lifetime of the machine unless

it is completely rebuild. Each machine is identified by its flow code. Machine card shows clearly

the job code, work order number, description of job, maintenance information and routine

maintenance operations. The matching of the machine card with scheduled time, indicated by

different colour is summarized in a table called maintenance board. The meaning of the colours

for maintenance operation can be stated as:

Colours indicated Operation to perform

White Overhaul

Red Oil change

Green Cleaning

Yellow Periodic check

Blue Wear and tear

Orange Lubrication

Table 6: Colours for maintenance operation

A chart is present which consist of machine codes on rows and weeks on columns. There are

fifty two weeks in the chart that enables to plan work and maintenance for whole year. Each

work is carried out in span of weeks. This results to the effective management of work and

maintenance.

41

Maintenance Job Card

MAINTENANCE JOB CARD

WEEK NO: WORK ORDER NO:

NAME:

FLOW CODE: JOB CODE: MAN NO:

JOB DESCRIPTION:

SPARE PARTS TO BE AVAILABLE:

LUBRICANTS:

CONSUMABLES:

ESTIMATED MAN HOURS:

SPECIAL TOOLS:

PRECUATIONS:

Figure 15: Maintenance Job Card

42

Machine Card

FLOW CODE

NAME

MACHINE CARD The Dairy Development PAGE NO:

Corporation of Nepal

MODEL

TYPE DTD DRG NO MAN. NO.

MANUFACTURE

SERIAL NO

CAPACITY

MOTOR TYPE

SIZE RPM VOLTAGE

YEAROF MANUFACTURE

DATE OF INSTALLATION

MAINTENANCE JOB NO:

DATE JOB

CODE

WORK

ORDER

NO

DESCRIPTION MAINTENANCE COST

MATERIALS MANHOUR

/CONTRACTOR

REF

NO

Figure 16: Machine Card

43

2.5 Inventory management

The materials are well managed by storing in different warehouse according to their type, usage

and function. To facilitate quick finding the materials stored are given numbers. These numbers are

recorded in ledger. Ledger keeps the record of machine codes to get the information about the parts

present in the store and also its condition.

The responsibility is given to the store keeper who keeps the ledger and the records. Spare parts

are bought usually from the same shop from which machine is purchased. The store keeper also checks

the damage, life span of the parts for backup. Finally all these information are recorded in computer for

future references.

2.6 Quality Management

There is a well equipped laboratory for testing the quality at DDC. The collected milk is tested

before it is pumped to the storage. The collected milk is tested for bacteria, and adulteration. If the milk is

found to be adulterated, the company gives a warning by sending letter to the related place.

The tests that are performed are:

1. COB test: It stands for Clout on Boiling Test. It is done to test the freshness of delivered

milk.

2. Acidity test: It is done to check the acid percentage in milk. Too much acidity results in

milk being sour.

3. Fat test: It is done to test the fat content of the produced milk. It is done at regular

intervals. The fat standard must be maintained.

The packet milk ready for delivery should have 3% fat and 8% SNF (solid non fat). Similarly

butter should have 80% fat, 16% moisture and ghee should have 0.5% moisture and 3% fat acid.

44

Chapter 3

Training Details

Proposed Time Plan for internship

Day Description

July 1-2 Introduction and History

July 4-5 Chilling Centre

July 6-7 Milk Processing Unit

July 8-9 Identification of pipeline distribution

July 11-12 Printing and Packing unit

July 13-15 Boiler section

July 16- 18 Cream and Butter unit

July 19 Ghee dispatch Unit

July 20 Spares parts and maintenance

July 21 Problem finding and solving

July 22-27 Refrigeration and Electric control section

July 28 Fresh milk section

July 29-30 Report writing and viva

3.1 Methodology

The total time period of industrial training at DDC Balaju was one month including one day

observation at DDC Lainchour. During this period we worked under the supervision of engineer

from engineering section. We also worked under the personnel from maintenance section.

First we were given handouts of the machines to self study then we visited the machine sites and

the details were explained. We learned about preventive maintenance of machine. We learned

record keeping of preventive maintenance and its working procedure. Besides these we also had

a chance to visit DDC Lainchour. We prepared layout of process after study of various processes

like refrigeration, heating, cleaning, boiler and various milk processing units etc.

45

3.2 Works Assigned

Study of the milk chilling system

Study of the milk process plant

Study of the CIP

Study of the butter and ghee plant

Study of the boiler system

Study of the refrigeration plant

Identification of different pipeline systems

1.

Fig: Distribution of pipeline from tanker to storage tank

2.

Fig: Distribution of channel from compressor to ice bank

Inline filter

Inline FIlter

Pump Chiller Analog/Digital

Meter

Air

Filter

Storage

Tank

Oil Filter

Oil Filter

Open type Compressor

Open type Compressor

Evaporative

Condensor Receiver

Expansion

Valve

Expansion

Valve

Cold Store

Ice Bank Suction

Accumulator

46

3.

Fig: Distribution of pipeline from storage tank to pasteurizing units

Pasteurizing

unit

Cold Region

Hot Region

Raw Milk from

Storage Tank Balance Tank Pump Flow

Controller Hydro cyclone

Cream

Sepera

tion

Homo

geniz

er

Holding Shell FDV

Storage Tank

From/to Steam

Generator

From/to Ice Bank

47

4.

Fig: Distribution of cold vapors from ice bank to various units

Ice bank

Plate chiller

Plate chiller

Pasteurizing Pasteurizing

Fat collection

tank

Fat collection

tank

Cream tank

Cream tank

Cold storage room

48

3.3 Works Accomplished

Studied the milk chilling system

Studied the milk process plant

Studied the CIP

Studied the butter and ghee plant

Studied the boiler system

Studied the refrigeration system

Identified the different pipeline system

49

3.4 Limitations

The guidance of our supervisor helped us to in understanding of overall plant and refrigeration

system. DDC did not have separate R&D department and all machines were imported. So, we

were limited in detail knowledge about design of machine.

3.5 Problems Encountered

We found difficulty to understand user manual of machines that were provided to us during our

training due to lack of detail knowledge about technical specification about machines. Also, the

sequence of guidelines related to operation of heating and cooling systems were complex to

follow. The root cause of the problem encountered was the lack of technical knowledge of

heating, cooling and preservation systems.

50

Chapter 4

Conclusion and Recommendation

4.1 Conclusion

In industrial training at DDC we have learned about the practical application of refrigeration

system, boilers and different accessories related to the proper functioning of dairy plant. We

gained knowledge on operation and maintenance of various machineries used in production line.

We gained valuable knowledge related to operations done to heat, cool and preserve dairy

products. The knowledge gained during about industrial safety is vital. Also, working in a team

of expert to achieve a production target is the most valuable industrial exposure we received.

4.2 Recommendation

During our visit to plant we identified defect on insulating system in the pipeline. We

recommend that PUF(Poly Urethane Foam) in cold insulation to be maintained

periodically so that loss due to insulation damages could be reduced in the plant.

We have also recommended a modification in the original design for uniform heating to

maintain the quality of fresh milk and to reduce time for sterilization.

To compete with the rising competitors in dairy business we also recommended

establishing R&D division for rise in production, sales and customer satisfaction.

The cleaning system of bottles in Fresh Milk Section is not mechanized well. It would be

advantageous for both the interns and the organization if the project was assigned to the

interns to design a cleaning system.

51

Bibliography

Arrora, C.P. Refrigeration and air conditioning, Delhi, 2003.

Kumar, D.S. Refrigeration and air conditioning, Patna, 2004.

Manual, CR and CRN Installation and Operating conditions, Grundfos

Manual, Marshall Boilers, Oil Fired Packaged Boilers

Manual, Instruction Manual and Part List- separator with self cleaning tool, Westfalia AG

52

Appendix 1: List of Equipments

Item

No

Flow

Code

Description Type Capacity Manufacturer Motor

KW RPM Impeller

D101 0101 Air Separator A 40 L 15000 L/Hr Diessel

D102 0102 Centrifugal Pump ZMK-1 15000 L/Hr APV Rosista 4.0 2860 150

A103 0103 Inline Filter FSH 76 15000 L/Hr APV Rosista

D104 0104 Flow Meter RZ2N50R 15000 L/Hr Diessel

Electronic Flow

Meter

REIL

Jumbo Digital

Display

REIL

A105 0105 Plate Heat Exchanger N 35 -RK 15000 L/Hr Pacilac Therm

A106 0106 &

107

Milk Tank- 2 Nos 7331 15000 L APV Pasilac 2.2 940

201 0108, 0109

0401,0402, 0403

Milk Tank - 5 Nos 15000 L Alfa Laval 0.75 1385

E101 0110 Ticket Printing

Device

Diessel

108 0118 Plate Cooler P13-RB 5000 L/Hr Alfa Laval

Milk Tank 5000 L Kadam 1.1 900

001 0120 Milk Tank MAH 32000 L APV Pasilac 2.2 900

0121/1 Milk Tank 32000 L Kadam 0.75 31

2121/2 Tank 10000 L -

012 0121 Centrifugal Pump W 20/20 15000 L/Hr APV Rosista 1.5 2900 115

001 0122 Panel APV Rosista

A201 0201 Centrifugal Pump ZMK-2 15000 L/Hr APV Rosista 2.2 900 180

Hydro Cyclone 15000 L/Hr Westfalia

Water Treatment C-4-S

(Aqua

Nomics)

11400 L/Hr J Mortensen &

Co.

A306 0202 In-line double filter FHS 51 15000 L/Hr APV Rosista

A202 0203 Balance tank 7147 300 L APV Pasilac


A204 0205 Plate Heat Exchanger N35-RKS 15000 L/Hr APV Baker

A204 0206 Heat equipment incd. Pump

ZMK-2 25000 L/Hr APV Rosista 5.5 2880 140

A206 0207 Self Cleaning

Separator

MSD 90-01-

076

15000 L/Hr Westfalia 18.5 1465

B207 0208 Plate Heat Exchanger P13-RB 5000 L/Hr Alfa Laval

B208 0209 Water Pump ZMK-1 15000 L/Hr APV Rosista 4.0 2860

B210 0211 Centrifugal Pump FM-A 5000 L/Hr Alfa Laval 3.0 2880

B 213 0214 Homogenizer SS 3000 SGR 5000 L/Hr Cherry Burrell 37.0

B215 0217 Cream PHE P5-RB 1000 L/Hr Alfa Laval

B216 0218 Water Pump FM-0 - Alfa Laval 1.1 2850

B217 0219 Cream Pump FM-0 1000 L/Hr Alfa Laval 1.1 2850

B218 0220/1 Cream Tank 603 1000 L Alfa Laval 1.1 1350

B218 0220/2 Cream Tank 603 1000 L Alfa Laval 1.1 1350

0221/1 Processing Tank SBQ-R 2500 L APV Pasilac 0.75 920

53

0221/2 Centrifugal Pump ZMA-1 - APV Rosista 1.5 1420 190

0221/3 Processing Tank SBQ-R 2500 L APV Pasilac 0.75 900

013 0221/4 Centrifugal Pump ZMA-1 5000 L/Hr APV Rosista 1.5 1500 190

002 0221/5 Panel - - APV Pasilac

B219 0222 Balance Tank EAC 500 L APV Pasilac

002 0222/6 Panel - - APV Pasilac

D207 0223 Control Panel CH+Flow

Div

- Faxholm

D208 0224 Tubular Holder - 15000 L/30s

D210 0225 Sterilizing Tank for

cream sep.

- 200 L VM Tram

D205 0226 Homogenizer 75.8 15000 L/Hr Rannie 132 980

D220 0227 Deodorizer VFN-3 1000 L/Hr APV Pasilac

D220 0228 Centrifugal Pump ZMK-2 1000 L/Hr APV Rosista 2.2 1430

D220 0229 Vacuum Pump VOHS-

032.030

- VLC/Lowener 2900

D221 0230 Control Panel CH+Flow

Div

- Faxholm

B217 0231 Centrifugal Pump FM-0 - Alfa Laval 1.1 2850

E209 0233 Crane Hoist for bowl WJ-10 1000 Kg A.C. Crane

A303 0301 Centrifugal Pump ZMK-1 20000 L/Hr APV Rosista 4.0 1435

A304 0302 Powder Mixer TPM-1-170 20000 L/Hr APV Rosista 5.5 2880

A305 0303 Centrifugal Pump ZMK-1 5000 L/Hr APV Rosista 1.1

A310 0307 Belt Conveyor 3.35m 11 TL 6m/min Q Transport 0.37

A310 0308 Belt Conveyor 9.35m 11 TL 12m/min Q Transport 0.25

D301 0309 Magenetic ind.

Flowmeter

PD-340 20000 L/Hr Process Data


A403 0405 Crate Washer CV-A1000 1000 Cr/Hr H&F Machinery 3x2.2 2870

0405/1 Crate Washer 1000 Cr/Hr Goma 15 2880

0405/2 Crate Washer 1000 Cr/Hr Goma 15 2880

Crate Conveyor

(Filling Side)

24m/min Q Transport 0.37

Crate Connection

Conveyor

180 deg 24m/min Q Transport 0.37

A404B 0414 to

0419

Belt Conveyor 15m/min SKF 0.24 x

6

A405 0426 SS Vat 250 L VM Tram

A406 0427 Centrifugal Pump ZMB-1 15000 L/Hr APV Rosista 1.1 2850

D408 0428 Filling Machine - 1 IS-6 5000

Bags/Hr

Prepac 6.0

0429 Filling Machine - 2 CMD 5000

Bags/Hr

Nichrome

0430 Filling Machine - 3 CMD 5000

Bags/Hr

Nichrome

0431 Filling Machine - 4

CMD 5000

Bags/Hr

Nichrome

IS-6 5000

Bags/Hr

Prepac


54

CMD 5000

Bags/Hr

Nichrome

CMD 6000

Bags/Hr

Nichrome


CMD 5000

Bags/Hr

Nichrome

CMD 6000

Bags/Hr

Nichrome

A501 0501 Butter Churn 60 3000 L S Orum Hansen 6.0 1400/700

A502 0503 Transport pump with

tray strainer

SI-ZMK 15000 L/Hr APV Rosista 2.2 2870 170

A502 0504 Butter Trolley 700 Kg S Orum Hansen

A503 0506 Butter Packing

Machine

Nova pac 505

EXP

20 Pkt/min Simon Freres 1.5 640

D506 0508 Butter Freezing Store (Inside)

47 m2 DC-System

D506 0509 Compressor CMO 24 7600

Kcal/Hr

Sabroe 18.5 1425

D506 0510 Condenser LST-A-14-H Søby 0.8 700

D506 0511 Receiver RHNH 2707 60 L Søby

D506 0512 Air Cooler FKP-9-12-

3V88E

17700

Kcal/Hr

Søby 2x0.55 1380

D506 0513 Electrical Defrosting Søby 1.7

D506 0514 Electrical Defrosting Søby 5.0

0520 Butter Milk Tank 5000 L APV Pasilac 0.37 930

Butter Freezing Store

No. 1

004A 0521/1 Compressor TCMO 28 Sabroe 18.5

004A 0521/2 Condenser LMR Sabroe

004A 0521/3 Receiver Sabroe

004A 0521/4 to

521/5

Air Cooler FKP-9-12 Sabroe 4x0.55 1400

0522/1 Butter Freezing Store No. 2

20 MT Freeze King

Compressor Kriloskar 5.5 1440

Condenser Fan Kriloskar 0.75 x

2

1410

Evaporator Fan Crompton Greaves

0.37 x 2

1400

0522/2 Butter Freezing Store

No. 3

20 MT Freeze King

Compressor Kriloskar 5.5 1440

Condenser Fan Kriloskar 0.75 x

2

1410

Evaporator Fan Crompton Greaves

0.37 x 2

1400

D901 0901 CIP- Unit for

Tankers

VM-1 s 15000 L/Hr VM-Tram 3.0 2890

D902 0902 CIP- Unit for

Equipment

VM-1 h 15000 L/Hr VM-Tram 4.0

D903 0903 to Self-Priming Pump SRG-103N 20000 L/Hr APV Rosista 2.2 x 3 2870

55

0905

0906 CIP Return Pump FM -0 Alfa Laval 1.1 2850

0907 CIP Unit Filling

Machine

A1001 1001 &

1002

Single Stage

Compressor

SMC 112L 296000

Kcal/Hr

Sabroe 110 x

2

985

A1002 1003 Evaporative

Condenser

FKS-595 770000

Kcal/Hr

Søby 2x4.0

A1002 1004 Water Circulation

pump

AKV-80 Flygt 1.5

A1003 1005 Receiver Drum R-3120 3127 L Søby

A1004 1006 Ice Water Bank 2000 m 1200000

Kcal/Hr

Søby

A1005 1007 to

1010

Agitator for Ice

Water Bank

RV-30 3x4 1400

A1005 1011 to

1014

Centrifugal Pump CR 30-

30AAA

300000 L/Hr Grundfos 4x4 2860

A1101 1101/1 Steam Boiler TDA 2000 2000 Kg/Hr Tøma 40

1102 &

1103

Boiler Feed Water

Pump

CR-4-

120AAA

4000 L/Hr Grundfos 2.2 x 2 2860

1101/2 Steam Boiler Wee

Marshall IV

2000 Kg/Hr JN Marshall

Boiler Feed Water

Pump

4000 L/Hr Salmoson

A1102 1104 Condensate Tank 1000 L Tøma

A1103 1105 Water Softening

Plant

SM 22 CSC 2 Tanks Silhorko

A1104 1106 Insulated Chimmeny 20 M High Tøma

A1105 1105 Oil Tank 5000 L Erik Roug

1105/1 Oil Tank 11000 L Local

1105/2 Oil Tank - 2 Nos 16000 x 2 Local

A1103 1109 Dosing Unit MK 4-6A Silhorko

A1201 1201 Bag Pressure Filter

(Double)

2 EF-3F 10 m3/h Silhorko

1201/1 Water Treatment

Plant includes bore

hole, areation, rapid

sand filter, sotrage

tank-60000 L and

pump

12 m3/h Local

1201/2 Water Treatment

Plant including

areation, pumps &

multimedia filters

30 m3/h

A1203 1203 Vertical Water Tank 60000 L Tune

1203/1 RCC Water tank 60000 L

A1205 1205 &

1206

Centrifugal Pump CR-30 20000 L/Hr Grundfos 4.0 x 2 2860

A1206 1207 Water Pressure Tank 3000 L Grundfos

1208 1209 Air Compressor KA FF Luft 0.32 1360

1210 Centrifugal Pump CR 8-

30NAA

8000 L/Hr Grundfos 1.1 2820

56

1212 Air Compressor KA13B Stenhoj 1.0 2860

1212/1 Air Compressor Elgi

D1301 1301 Single Stage

Compressor

CMO 24 28300

Kcal/Hr

Sabroe 18.5 1425

D1301 1302 to

1305

Air Cooler FL 12-5-175 13900

Kcal/Hr

Søby 8x0.18 920

D1301 1306 &

1307

Liquid Separator S-80 84 L Søby

1308 &

1309

Climaster ZL-10 DL Novenvo 2.2 1430

1310 to

1312

Roof Extractor HJB-400 Novenvo

A1602 1602 Transformer TKO 750 KVA EB Nati. Tran

A1603 1603 Diesel Generator NTTA-855-

G2

450 KVA Cummins 1500

1605 Ghee Unit

1605/1 Butter Melting Tank RS/BMV

1000

1000 L aar ess exim

1605/2 Startification Tank RS/TST 2000 2000 L aar ess exim

1605/3 Ghee Boiler RS/TK 1000 1000 L aar ess exim

1605/4 Balance Tank - 3 Nos 200 L aar ess exim

1605/5 Centrifugal Pump - 3

Nos

Zuetech

1605/6 High Pressure Filter aar ess exim

1605/7 Clarifier VLB 038-24 1000 L/Hr Alfa Laval

1605/8 Ghee Storage Tank RS/GST

2000

2000 L aar ess exim

1605/9 Filling Machine aar ess exim

1605/10 Control Panel aar ess exim

1606 Flavor Milk Plant

1606/1 Bottle Washing

Motor

0.37 x

3

1606/2 Bulk Milk Cooling

Tank

1000 L

1606/3 Bottle Filling & Crowning

3000 Bottles/Hr

1606/4 Bottle Inspection

Unit

1606/5 Rotary Collection

Table

1606/6 Retort 2900

Bottles/Batch

1606/7 Air Compressor

1606/8 Steam Boiler RF 0.25/2-7A 300 Kg/Hr Antriebstechnik 0.55 2800

57

List of Tools and Equipments in MPPSS Layout

S.N FLOW CODE MACHINE NAME ACTIVITY FREQUENTLY

1 103 Centrifugal Pump Overhaul of motor 24 M

2 104 Insulated Tank Cleaning of spray turbine 2 M

3 105 Insulated Tank Agitator Overhaul of agitator motor 24 M


5 501 Ghee Boiler Overhaul of motor for agitator 24 M

6 601 Batch Pasteurizer Oil change 6 M

7 602 Batch Pasteurizer Overhaul of agitator motor 24 M


9 607 Air Heater Change of ball bearing in motor 24 M

607 Air Heater Cleaning 3 M

10 608 Air Heater Change of ball bearing in motor 24 M

608 Air Heater Cleaning 3 M


701 Batch Pasteurizer Overhaul of agitator motor 24 M


702 Batch Pasteurizer Overhaul of agitator motor 24 M


14 704 Homogenizer Check of homogenizing valve 3 M

704 Homogenizer Oil change 12 M

704 Homogenizer Change of 4 rings 12 M

15 705 Plate Cooler Cleaning 1 M

16 706 Ice Cream Freezer Cleaning of air filter 6 M

706 Ice Cream Freezer Oil change in air compressor 6 M

706 Ice Cream Freezer Check of V belts 6 M


18 711 Freezing Cabinet Periodic check 6 M




22 715 Batch Pasteurizer Oil change in gear box 6 M

23 801 Cheese Vat Lubrication 3 M

24 803 Transport Pump Overhaul of motor 24 M

25 806 Vacuum Packer Oil change and change of oil filter 6 M

806 Vacuum Packer Change of exhaust filter 12 M

26 808 Vacuum Packer Lubrication 5 W

27 809 Cheese Grinder Lubrication 2 M

28 810 Cheese Crusher Lubrication 2 M

29 811 Cheese Mixture Lubrication 2 M

30 901 CIP-Unit Overhaul of motor 24 M

31 1001 Ice-water Plant Leak testing 4 W

1001 Ice-water Plant Cleaning 4 W

32 1002 Circulation Pump Overhaul of motor 24 M

33 1101 Steam Boiler Cleaning of smoke side and burner 2 M

1101 Steam Boiler Function of safety valves 6 M

1101 Steam Boiler Overhaul of boiler 12 M

58

34 1102 Feed Water Pump Overhaul of motor 36 M

35 1103 Feed Water Pump Overhaul of motor 36 M

36 1104 Condensate Tank Cleaning 6 M

37 1105 Water Softening Plant Cleaning of brine tank 3 M

38 1107 Oil Tank Cleaning 12 M

39 1109 Dosing Unit Cleaning 3 M

40 1201 Bag Pressure Filter Cleaning 8 W

41 1202 Flow Meter Cleaning 8 W

42 1203 Vertical Water Tank Cleaning 6 W


44 1206 Water Pressure Tank Cleaning of sight glass 8 W

45 1207 Air Compressor Oil Change 3M

1207 Air Compressor Cleaning of air filter 3 M

46 1208 Air Compressor Oil change 3 M

1208 Air Compressor Checking of valves 12 M

47 1210 Water Tank Cleaning 5 W

48 1211 Water Pump Overhaul of motor 24 M

49 1301 Refrigeration Compressor Oil drain 4 M

1301 Refrigeration Compressor Oil change 12 M

50 1302 Condenser Cleaning 2 M

51 1302/1 Circulation Pump Overhaul of motor 24 M

52 1304 Freon Condensing Unit Leak testing and cleaning 4 W




56 1601 Main Switch Board Cleaning of switch board 6 M

1601 Main Switch Board Retightening(Periodic check) 12 M

1601/1 Cheese Store Switch Board Cleaning of switch board 6 M

1601/1 Cheese Store Switch Board Retightening(Periodic check) 12 M

57 1602 Diesel Generator Oil change 6 W(250 hr)

1602 Diesel Generator Periodic check 6 W(250 hr)

58 Trepko Filling Machine Lubrication 5 W

59 Ghee Pump Oil change 10 W

Ghee Pump Periodic check 12 M

Ghee Pump Overhaul 12 M

60 Ultraviolet Sterilizer Cleaning of quartz sleeve 3 M

Ultraviolet Sterilizer Overhaul 13 W

61 Buffer Tank Cleaning 13 W

62 Factory Drain Cleaning Cleaning 6 M

63 Cascade Aerator Cleaning 5 W

64 1701 Batch Freezer Cleaning and Periodic Check 3M

65 1702 Brine Tank Maintain the level of brine time to time

66 1703 Condenser Unit Cleaning and Periodic Check 1M

67 1704 Thawning Tank Periodic check 1M

68 1705 Dipping Tank Periodic check 1M

59

Appendix 2: Plant layout

Fig: Plant layout

60

Appendix 3: List of Figures

Figure a: Boiler Figure b: Ammonia Tank

Figure c: Ammonia Receiver Figure d: Compressor

Figure e: Compressor piston cylinder with connecting rod Figure f: Multistage Pump used in Boiler

61

Figure g: Electrodes used in Boiler Figure h: Fuel Injector

Figure i: Filter in Fuel Injector Figure j: Homogenizing valve

Figure k: Printing Machine Figure l: Pneumatic sensor in Printing machine

62

Figure m: Expansion valve Figure n: Pasteurizing Section

Figure o: Refrigerant Figure p: Cream Separator

Figure q: Milk Packaging Machine

DDC

Documents

pasteurized milk

raw milk

powder milk

supply of standard milk

lumbini milk supply

milk processing cooperatives

supply quality milk

flavored milk plant