Milk processing

Presented by: Chandni jadav Geeta ram

Milk Processing

section in Mother Dairy

INTRODUCTION Of PLANT

INTRODUCTION Of PLANT

Full capacity:- Full capacity:- 10LLPD10LLPD Now a days dairy Now a days dairy receives 6-7 LLPD receives 6-7 LLPD of milkof milk Dairy processes appDairy processes app. 3 LLPD of market . 3 LLPD of market milkmilk Capacity of plantCapacity of plant:-6-7LLPD:-6-7LLPD** Reception :by cans (300)*per dayReception :by cans (300)*per day by tanker (16-17)*per dayby tanker (16-17)*per day Reception time:- morning at 10:00 to 11:00 am Reception time:- morning at 10:00 to 11:00 am evening at 06:00 to 07:00pmevening at 06:00 to 07:00pm

(approx *)(approx *)

MOTHER DAIRY- JUNAGADH

Certification

mandatorymandatory FSSAIFSSAI Weight and Weight and

measure(legal measure(legal metrology)metrology)

Boiler actBoiler act Labour actLabour act

Non mandatoryNon mandatory ISO-9001:2008 (QMS)ISO-9001:2008 (QMS) ISO-22000 (FSMS)ISO-22000 (FSMS) ISO-14001:2004 (EMS)ISO-14001:2004 (EMS) OHSAS 18001:2007OHSAS 18001:2007 HALAL (for export)HALAL (for export) AGMARKAGMARK BIS BIS ISO-50001ISO-50001

Vision statement of dairy

We are dedicated to receive, manufacture and We are dedicated to receive, manufacture and supply consistent quality product by supply consistent quality product by innovative, effective, compliant, safe, innovative, effective, compliant, safe, sustainable with latest emerging technologies sustainable with latest emerging technologies through energetic motivated people for through energetic motivated people for customer satisfaction.customer satisfaction.

PolicyPolicy:-:-environment policy energy policy quality and food safety policy occupation health and safety

policy..

value1.1. Performance with intrigrityPerformance with intrigrity2.2. Customer firstCustomer first3.3. DisciplineDiscipline4.4. InnovationInnovation5.5. ManagementManagement6.6. TransparencyTransparency7.7. Trust and respect.Trust and respect.

Department of mother Department of mother dairydairy

Processing Processing Quality AssuranceQuality Assurance Engineering Engineering MIS(management information system)MIS(management information system) Purchase /StorePurchase /Store HR/ACCHR/ACC

Cont….

11 silo 11 silo in our plant in which the capacity of all silo is 100kl except 1 which have in our plant in which the capacity of all silo is 100kl except 1 which have capacity of 40klcapacity of 40kl

10 HMST 10 HMST (horizontal milk storage tank) with the capacity of 10 to 15kl.(horizontal milk storage tank) with the capacity of 10 to 15kl. 5 milk pasteurizer 5 milk pasteurizer :2 pasteurizer have 20kl capacity :2 pasteurizer have 20kl capacity 1 pasteurizer have 10kl capacity1 pasteurizer have 10kl capacity 2 cream pasteurizer have 5kl capacity.2 cream pasteurizer have 5kl capacity. 3 Cream separator3 Cream separator:2 separator have 20kl capacity:2 separator have 20kl capacity 1 separator have 10kl capacity.1 separator have 10kl capacity. 2 Homogenizer2 Homogenizer:: with the capacity of 10kl.with the capacity of 10kl.

..

MILK SILO

HMST

RMRD(Raw Milk Reception

Dock)

Equipment of RMRD

1.1. Lid openerLid opener2.2. Weighing bowlWeighing bowl3.3. Dumped tankDumped tank4.4. Milk pumpMilk pump5.5. Can washerCan washer6.6. Chain conveyorChain conveyor

Raw Milk reception by can

Adulteration

Drain

Sour/curd

Hand over to pro.dept. Can

washing

Conti.....

Description of can capacity:- 40lit.capacity:- 40lit. Neck dia.:-200mmNeck dia.:-200mm Height of can:- 515mmHeight of can:- 515mm Weight of empty can:- 7kgWeight of empty can:- 7kg Made of :-aluminium and S.S.Made of :-aluminium and S.S.

Can washing

Can used for farm milk collection are required to be Can used for farm milk collection are required to be effectively cleansed in accordance with the milk & dairy effectively cleansed in accordance with the milk & dairy regulation 1959.regulation 1959.

To satisfy physical requirement can should not have rust To satisfy physical requirement can should not have rust patches or open seams.patches or open seams.

They should be free from fat and milk solid.They should be free from fat and milk solid. Can washing is carried out in 3 section.Can washing is carried out in 3 section. First section temp.:-35-40First section temp.:-35-40ċċ Second section temp.:-50-60ċSecond section temp.:-50-60ċ Third section temp.:70-80ċThird section temp.:70-80ċ Steam pressure:-3-5kg/cm2Steam pressure:-3-5kg/cm2 Caustic strength :-0.35% Caustic strength :-0.35%

Can washing

Raw milk reception by Tanker

Milk reception by tanker

Weight of empty tanker

Cleaning

Tanker reception

Operational principle of weigh bridge

The principle of Weigh Bridge is to The principle of Weigh Bridge is to weigh the incoming and outgoing weigh the incoming and outgoing tankers. First of all, the loaded tankers. First of all, the loaded tankers come on the weigh bridge tankers come on the weigh bridge and checked for their gross weight and checked for their gross weight and then after unloading, the tare and then after unloading, the tare weight is taken so that final net weight is taken so that final net weight of the product would be weight of the product would be determineddetermined

Raw milk tanker cleaning

Automation of milk tank cleaning can enable the tank Automation of milk tank cleaning can enable the tank to be cleaned immediately after emptying, reducing the to be cleaned immediately after emptying, reducing the risk of milk residues setting on the tank surfaces, and risk of milk residues setting on the tank surfaces, and therefore limiting the opportunity for bacterial growth.therefore limiting the opportunity for bacterial growth.

Sr Step Description

1 Pre- rinse With water at 40 cel temp

2 Scrubbing Hand scrubbing3 Detergent Cleaning With Odour less detergent at 45 cel

4 Hot Water rinsing Hot water

5 Sterilization By live steam

Quality checking test of Milk

Milk testing after receiving

Organolaptic testOrganolaptic test:- :- visual observation like visual observation like colour and appreance of milk, smell, taste etc.colour and appreance of milk, smell, taste etc.

Other test is being carried out for different Other test is being carried out for different milk adulteration like salt adulteration, urea milk adulteration like salt adulteration, urea adulteration, vegetable oil addition, adulteration, vegetable oil addition, neutralizer adulteration, water addition, sugar neutralizer adulteration, water addition, sugar addition, powder & flour adulteration etc.addition, powder & flour adulteration etc.

Lactometer reading, BR reading, fat, SNF, Lactometer reading, BR reading, fat, SNF, content etc.content etc.

Detection of major Detection of major adulterants in milkadulterants in milk

To overcome the To overcome the increasing need of milk increasing need of milk and milk products and to and milk products and to make maximum profit make maximum profit there is increase in there is increase in adulteration casesadulteration cases

In adullteration test we In adullteration test we used raw milk in 2 test used raw milk in 2 test tubes for each test, one of tubes for each test, one of them containing only raw them containing only raw milk and the other one milk and the other one was added with the was added with the tested material.tested material.

Adulteration testAdulteration test

Sugar TestSugar Test Take 15 ml milk in test tube.Take 15 ml milk in test tube. Add 1 ml concentrated HCL and shake Add 1 ml concentrated HCL and shake well.well. Add 0.1 gm resorcinol.Add 0.1 gm resorcinol. Put the test tube in boiling water bath for 5 Put the test tube in boiling water bath for 5 min.min.

Conclusion : Left Test tube contains raw Conclusion : Left Test tube contains raw milk and right contains pasteurized milk. milk and right contains pasteurized milk. Reddish colour would indicates presence of Reddish colour would indicates presence of sugar. So here in both samples sugar is sugar. So here in both samples sugar is absent.absent.

Adulteration testAdulteration testSalt TestSalt Test

Take 5 ml silver nitrate in a test tube.Take 5 ml silver nitrate in a test tube. Add 2-3 drops of potassium dichromate Add 2-3 drops of potassium dichromate solution which will give brick red colour.solution which will give brick red colour. Add 1 ml of milk.Add 1 ml of milk.

Conclusion : In the test tube on left side Conclusion : In the test tube on left side containing only raw milk, the brown colour containing only raw milk, the brown colour shows absence of salt but in test tube on shows absence of salt but in test tube on right side in which raw milk and salt were right side in which raw milk and salt were added, the yellow colour confirms the added, the yellow colour confirms the presence of salt.presence of salt.

Adulteration testAdulteration testUrea testUrea test

ProcedureProcedureTake 2 ml milk in a test tube. Take 2 ml milk in a test tube. Add 2 ml DMAB solution and mix the contents.Add 2 ml DMAB solution and mix the contents.

ObservationsObservationsYellow Colour is observed.Yellow Colour is observed.

ResultResultAppearance of yellow colour indicates the presence of urea.Appearance of yellow colour indicates the presence of urea.

Adulteration testAdulteration test

Ammonium Compound Ammonium Compound TestTestTake 1 ml milk in test tube.Take 1 ml milk in test tube.

Add 2 ml Nesslar’s reagentAdd 2 ml Nesslar’s reagent

Result and conclusion:Result and conclusion: Test tube on Test tube on the left side contains only raw milk but the left side contains only raw milk but right test tube contains both raw milk right test tube contains both raw milk and ammonia. So in the right side test and ammonia. So in the right side test tube brown colour confirms the presence tube brown colour confirms the presence of ammonia.of ammonia.

Acidity Test Bacteria that normally develop in raw milk produce more or less of lactic acid. In the acidity test the acid is neutralised with Sodium hydroxide and the amount of alkaline is measured. From this, the percentage of lactic acid can be calculated. Procedure• Take 10 ml milk in 10 ml conical flask. • Hold the flask against white surface.• Add 5 drops of phenolphthalein to the milk sample and stir gently • Titrate against N/9 NaOH using phenolphthalein indicator to check acidity.• Continue until the appearance of a light pink colouring which persists for 10-20 seconds.

Adulteration testAdulteration test

ResultResult

The milk with acidity 0.15 is the The milk with acidity 0.15 is the best milk.best milk.

Sample No.Sample No. AcidityAcidity1.1. 0.190.192.2. 0.150.153.3. 0.170.17

Adulteration testAdulteration test

Fat and SNF TestFat and SNF TestFat & SNF can be determined using Gerber’s method or using a Fat & SNF can be determined using Gerber’s method or using a milcoscan.milcoscan.

Gerber’s MethodGerber’s Method Procedure ProcedureTake about 10 ml of HTake about 10 ml of H22SOSO44 in Butyrometer. in Butyrometer.Add slowly 10.75 ml milk in it.Add slowly 10.75 ml milk in it.Add 1 ml isoamyl alcohol and adjust level with distilled water.Add 1 ml isoamyl alcohol and adjust level with distilled water.Cap butyrometer with lock stopper.Cap butyrometer with lock stopper.Centrifuge for about 5 minutes.Centrifuge for about 5 minutes.Take reading of the % fat in butyrometer.Take reading of the % fat in butyrometer.Warm milk in lactometer jar at about 40˚C then cool at 15.5˚C.Warm milk in lactometer jar at about 40˚C then cool at 15.5˚C.Immerse lactometer in jar and take C.L.R.Immerse lactometer in jar and take C.L.R.

Calculations/Formula UsedCalculations/Formula Used SNF is determined using lactometer SNF is determined using lactometer

reading and Fat value and putting the reading and Fat value and putting the formulaformula

% SNF = CLR/4+0.2×fat+0.29% SNF = CLR/4+0.2×fat+0.29

ObservationsObservations

Sample 1 and 2 are of Packaged milk and Sample 3 is Raw milkSample 1 and 2 are of Packaged milk and Sample 3 is Raw milk

Sample Sample No.No.

FatFat CLRCLR SNF(%)SNF(%)

1.1. 4.254.25 29.429.4 8.498.492.2. 3.53.5 26.426.4 7.597.593.3. 6.76.7 3131 9.389.38

Milkoscan

Milkoscan is the latest technology machine for scanning of milk and uses infra red rays to analyze the milk for Fat, SNF.

CHILLING SECTION

Chilling of milk after receiving

Chilling of milk means rapid cooling of raw milk to Chilling of milk means rapid cooling of raw milk to sufficiently low temperature so that the growth of sufficiently low temperature so that the growth of micro-organisms present in milk is checked. In micro-organisms present in milk is checked. In chilling process the temperature of milk should be chilling process the temperature of milk should be reduced to less than 10 0Cpreferably reduced to less than 10 0Cpreferably 3 - 43 - 4˚C˚C

The most effective means of controlling the growth The most effective means of controlling the growth of microorganisms without affecting the physico-of microorganisms without affecting the physico-chemical properties and nutritive value of milk is to chemical properties and nutritive value of milk is to chill it. Lower temperatures inhibit the growth of chill it. Lower temperatures inhibit the growth of most of the microorganisms. It should be clearly most of the microorganisms. It should be clearly understood that chilling process does neither kills understood that chilling process does neither kills microorganisms nor it renders milk safe for human microorganisms nor it renders milk safe for human consumption. It is only a means of checking the consumption. It is only a means of checking the growth of microorganisms for sometime.growth of microorganisms for sometime.

Chilling sectionTypes of chiller make capacity

Raw milk chiller(3) IDMC 30KLPH20KLPH

Glycol chiller(1) IDMC 20KLPH

Pouch milk chiller(2) IDMC 20KLPH

Chhas chiller (1) IDMC 10KLPH

PASTEURIZATION

What is pasteurization? PasteurizationPasteurization:-:-Pasteurization refers to the Pasteurization refers to the

process of heating each and every particle of milk to process of heating each and every particle of milk to at least at least 6363ċċ for 30min. for 30min., or , or 7272ċċ for 15 sec for 15 sec.(or to any .(or to any time-temp. Combination which is equally efficient), time-temp. Combination which is equally efficient), in approved and properly operated equipment. after in approved and properly operated equipment. after pasteurization, the milk is immediately cooled to pasteurization, the milk is immediately cooled to 55ċċ or below.or below.

Object(purposeObject(purpose)):- :- to render milk safe for human to render milk safe for human consumption by destruction of pathogenic micro- consumption by destruction of pathogenic micro- organisms. To improve the keeping quality of milk by organisms. To improve the keeping quality of milk by destruction of almost all spoilage organisms. And to destruction of almost all spoilage organisms. And to destroy the target micro-organism coxilla burette.destroy the target micro-organism coxilla burette.

Milk pasteurizationtemp.<

5ċ

Temp.<35ċ

Temp.65ċ

creamSkim milk

Conti.....

okNot ok

Balance tank

Milk pasteurization

Balance tank

Holding tube

Cooling, reg.1, reg.2, heating<5c 40c 65c 80c

Milk flow in pasteurizer

Pasteurization line1.Balance tank1.Balance tank2.Fed pump2.Fed pump3.Flow controller3.Flow controller4.Regenerative pre heating 4.Regenerative pre heating

sectionsection5.Clarifier5.Clarifier6.Heating section6.Heating section7.Holding tube7.Holding tube8.Booster pump8.Booster pump9.Hot water heating system9.Hot water heating system10.Regenerative cooling 10.Regenerative cooling

sectionsection11.Cooling section11.Cooling section12.FDV12.FDV13.Control panel13.Control panel

Function of important parts

Float control balance tankFloat control balance tank:-:-maintain a maintain a constant head of milk for feeding the raw milk pump; constant head of milk for feeding the raw milk pump; also receive any sub-temp. Milk diverted by FDV. also receive any sub-temp. Milk diverted by FDV.

PumpPump:-:-generally in dairy industry centrifugal pump generally in dairy industry centrifugal pump is used for the milk flow.is used for the milk flow.

PlatePlate:-:-plates are supported in a press between a plates are supported in a press between a terminal block in each heating and cooling section. terminal block in each heating and cooling section. The heat moves from a warm to a cold medium The heat moves from a warm to a cold medium through S.S. Plates. PHE Plate through S.S. Plates. PHE Plate thicknessthickness vary from vary from 1.25mm to 3.00mm1.25mm to 3.00mm.And space between two plate is .And space between two plate is 1.25mm to 1.75mm 1.25mm to 1.75mm is maintained between the plates is maintained between the plates by a non-absorbent rubber gasket. greater capacity is by a non-absorbent rubber gasket. greater capacity is secured by adding more plates in regeneration section. secured by adding more plates in regeneration section.

Function of important parts

Regeneration(heating)Regeneration(heating):-:-the (raw) cold incoming the (raw) cold incoming milk is partially and indirectly heated by the hot outgoing milk is partially and indirectly heated by the hot outgoing milk (milk-to-milk regeneration ). This adds to the economy milk (milk-to-milk regeneration ). This adds to the economy of the HTST process ,as the incoming milk requires less of the HTST process ,as the incoming milk requires less heating by hot water to raise its temp. For holding.heating by hot water to raise its temp. For holding.

FilterFilter:-filter unit to connect directly to the HTST system :-filter unit to connect directly to the HTST system are placed after pre-heater or regenerative section. these are placed after pre-heater or regenerative section. these unit, using 40-90 mesh cloths, are usually cylindrical in unit, using 40-90 mesh cloths, are usually cylindrical in shape.shape.

HoldingHolding:-:-the holding tube ensures that the milk is held the holding tube ensures that the milk is held for a specified time, not less than 15 sec., at the for a specified time, not less than 15 sec., at the pasteurization temp. of 76pasteurization temp. of 76ċċ or more. or more.

Function of important parts

FDV(flow diversion valve):-FDV(flow diversion valve):-this routs the milk this routs the milk after heat treatment. If the milk has been properly after heat treatment. If the milk has been properly pasteurized , it flows forward through the unit; that pasteurized , it flows forward through the unit; that which is unpasteurized (i.e., in which the temp. Does which is unpasteurized (i.e., in which the temp. Does not reach the legal limit) is automatically diverted back not reach the legal limit) is automatically diverted back to the FCBT for reprocessing. it is usually operated by to the FCBT for reprocessing. it is usually operated by air pressure working against a strong spring. Should the air pressure working against a strong spring. Should the temp. Fall, air pressure is released and the valve snaps temp. Fall, air pressure is released and the valve snaps shut immediately. when the temp. Is regained, air shut immediately. when the temp. Is regained, air pressure builds up and the valve opens to forward flow. pressure builds up and the valve opens to forward flow. The system is so arranged that any failure of air or The system is so arranged that any failure of air or electricity moves the valve in the diverted position.electricity moves the valve in the diverted position.

Test used to detect Test used to detect pasteurization of milkpasteurization of milk

Phosphatase TestPhosphatase Test

Take 1 ml of milk.Take 1 ml of milk.Put 5 ml of nitrate Phosphate buffer solution.Put 5 ml of nitrate Phosphate buffer solution.Incubate it in water bath at temperature of about Incubate it in water bath at temperature of about 37˚C.37˚C.Check for colour change after 15 minutes.Check for colour change after 15 minutes.If colour changes then the milk is not If colour changes then the milk is not pasteurized.pasteurized.Conclusion : In the image Test tube on left side Conclusion : In the image Test tube on left side with pale yellow colour is showing test of Raw with pale yellow colour is showing test of Raw milk confirms alkaline phosphate activity and test milk confirms alkaline phosphate activity and test tube on right side is showing no colour change in tube on right side is showing no colour change in case of packed milk confirming Pasteurization.case of packed milk confirming Pasteurization.

MBRT Test It is indirect method of estimation of total bacterial content of milk. Instead of

counting bacteria directly, a correlation is made between the time required to reduce dye to colourless in milk.

Procedure To 10 ml of milk in a sterilized MBR tube add 1 ml of MBR dye Plug with a

sterilized cork, invert the tube to mix the contents. Incubate at 37°C in a water bath. Check the tube for decolorization just after 10 minutes Next time after 30 minutes

and subsequently every hour.

Time Required for Reduction(in Time Required for Reduction(in

hrs)hrs)

Quality of MilkQuality of Milk

5 and above5 and above Very GoodVery Good

3 and 43 and 4 GoodGood

1 and 21 and 2 FairFair

0.5 and below0.5 and below PoorPoor

Cream separation

Equipment for cream processing

equipment

make capacity No. material

Cream pasteurizer

IDMC 10 KLPH 1 S.S.316

Cream pasteurizer

IDMC 5KLPH 1 S.S.316

Cream separator

Frautech 20KLPH 2 S.S.316

Cream separator

Frautech 10KLPH 1 S.S.316

Parameter of cream separator

Bowl max. RPM – 5000 Bowl max. RPM – 5000 Product feed min. pressure – 1 barProduct feed min. pressure – 1 bar Skim milk outlet max. Pressure – 5 barSkim milk outlet max. Pressure – 5 bar Cream outlet max. Pressure – 3 barCream outlet max. Pressure – 3 bar Feeding temp. - 35-55Feeding temp. - 35-55ċċ Operating liquid max. Density – 1 Operating liquid max. Density – 1

kg/cm3 kg/cm3 Motor power – 22kwMotor power – 22kw No. Of disc – 214 in 20 KL, 213 in 10 KLNo. Of disc – 214 in 20 KL, 213 in 10 KL

Cream separator A separator is a centrifugal device that separate a milk A separator is a centrifugal device that separate a milk

into into creamcream and and skimmedskimmed milkmilk.. C. G. de Laval C. G. de Laval of Sweden devised the first mechanical of Sweden devised the first mechanical

cream separator c.1880, based on the principle of cream separator c.1880, based on the principle of centrifugal forcecentrifugal force. Whole milk is conducted into a bowl, . Whole milk is conducted into a bowl, commonly through a central tubular shaft. A spindle commonly through a central tubular shaft. A spindle rotates the bowl at a rate of from rotates the bowl at a rate of from 6,000 to 9,000 rpm6,000 to 9,000 rpm, , and a series of identical conical disks separates the and a series of identical conical disks separates the milk into vertical layers. The heavier skim milk collects milk into vertical layers. The heavier skim milk collects on the outer circumference of the rapidly whirling bowl, on the outer circumference of the rapidly whirling bowl, and the lighter cream tends to remain in the center. The and the lighter cream tends to remain in the center. The pressure of the whole-milk supply above the bowl then pressure of the whole-milk supply above the bowl then forces the cream and skim milk out of the machine and forces the cream and skim milk out of the machine and into separate collecting vessels. into separate collecting vessels. 

Cream separatordisc

Cream pasteurization

CCP:min.86ċ

Cream pasteurization

Cream which is come from cream separator is Cream which is come from cream separator is pasteurized same as milk but there is difference in pasteurized same as milk but there is difference in time & temp. Combination.time & temp. Combination.

After separation of cream, it will be pasteurized at After separation of cream, it will be pasteurized at 90c temp. For 15-16 second to retard growth of 90c temp. For 15-16 second to retard growth of pathogenic micro-organism. And also the resultant pathogenic micro-organism. And also the resultant butter.butter.

To destroy desirable micro-organism and inactivate To destroy desirable micro-organism and inactivate the enzymes present, so as to prolong the keeping the enzymes present, so as to prolong the keeping quality of cream and butter.quality of cream and butter.

Homogenization of milk

Homogenization of millk Homogenization is a mechanical treatment of the fat Homogenization is a mechanical treatment of the fat

globules achieved by passing milk under globules achieved by passing milk under high pressure high pressure through a thin slit, which result in stability of milk due through a thin slit, which result in stability of milk due to a decrease in the to a decrease in the average diameter average diameter and an increase and an increase in number and surface area of the fat globules.in number and surface area of the fat globules.

Why Milk Is Homogenized?Why Milk Is Homogenized? Milk is a combination of fats, proteins, and water. When Milk is a combination of fats, proteins, and water. When

raw milk is left to stand for any length of time, the fat raw milk is left to stand for any length of time, the fat molecules typically float to the top.molecules typically float to the top.

Homogenized milk also has a longer shelf life because Homogenized milk also has a longer shelf life because the cream cannot rise to the top and clump together; the cream cannot rise to the top and clump together; this allows it to be transported over greater distances.this allows it to be transported over greater distances.

Homogenization also enhance the colour, flavour, Homogenization also enhance the colour, flavour, appearance of the milk.appearance of the milk.

Mechanism of homogenizer

Homogenizer consist of a high pressure piston Homogenizer consist of a high pressure piston pump which forces the milk at high pressure(and pump which forces the milk at high pressure(and velocity) through a narrow opening between the velocity) through a narrow opening between the homogenizing valve its seat; the fat globules in homogenizing valve its seat; the fat globules in the milk are thereby sub-divided into smaller the milk are thereby sub-divided into smaller particles of more uniform size. the homogenizing particles of more uniform size. the homogenizing valve is held down by a heavy pressure spring valve is held down by a heavy pressure spring against the seat of valve .the valve and seat are against the seat of valve .the valve and seat are made of extremely hard material. Homogenizer made of extremely hard material. Homogenizer are either single stage or double stageare either single stage or double stage

High pressure homogenizer are generally needed High pressure homogenizer are generally needed when high efficiency homogenization is required.when high efficiency homogenization is required.

homogenizer As it first enter the valve, liquid As it first enter the valve, liquid

velocity is about velocity is about 4 to 6m/s4 to 6m/s.. If then moves into the gap If then moves into the gap

between the valve and the valve between the valve and the valve seat and its velocity is increased seat and its velocity is increased to to 120m/s.120m/s.

The homogenization phenomena The homogenization phenomena is complete before the fluid is complete before the fluid leaves the area between the leaves the area between the valve and seat, and therefore valve and seat, and therefore emulsification is initiated and emulsification is initiated and completed in less than completed in less than 50 50 μμs.s.

homogenizer

The product may then pass The product may then pass through a second stage valve through a second stage valve similar to the first stage.similar to the first stage.

While most of the fat While most of the fat globules reduction takes globules reduction takes place in the first stage, there place in the first stage, there is a tendency for clumping or is a tendency for clumping or clustering of the reduced fat clustering of the reduced fat globules.globules.

The second stage valve The second stage valve permits the separation of permits the separation of those clusters into individual those clusters into individual fat globules.fat globules.

homogenizer The product enters the pump blockened is pressurized The product enters the pump blockened is pressurized

by the piston pump. The pressure that is achieved is by the piston pump. The pressure that is achieved is determined by the back-pressure given by the distance determined by the back-pressure given by the distance between the forcer and seat in the homogenization between the forcer and seat in the homogenization device.device.

The piston pump is driven by a powerful electric motorThe piston pump is driven by a powerful electric motor.. Water is supplied to the space between the seal to cool Water is supplied to the space between the seal to cool

the piston.the piston. The homogenizer is equipped with one common oil The homogenizer is equipped with one common oil

tank.tank. Higher pressure may increase the tendency for the milk Higher pressure may increase the tendency for the milk

to curdle when cooked , due to the increased to curdle when cooked , due to the increased destabilizing effect on milk-proteins.destabilizing effect on milk-proteins.

Parameter of homogenizer No of homogenizer - 2No of homogenizer - 2 Capacity - 10 KLPHCapacity - 10 KLPH Make – FBF (Italia)Make – FBF (Italia) Working pressure of 1Working pressure of 1stst stage – 2000psi stage – 2000psi Working pressure of 2Working pressure of 2ndnd stage – 500psi stage – 500psi Installed power – 76.5kwInstalled power – 76.5kw Reduction size of fat globule - <2 micronReduction size of fat globule - <2 micron temp. Of homogenization – 60-65temp. Of homogenization – 60-65ċċ Oil pressure – 7 barOil pressure – 7 bar

CIP of pasteurizer CleaningCleaning:-:- Removal of the soil (primarily Removal of the soil (primarily

milk or milk product residue) from the surface milk or milk product residue) from the surface of the equipments.of the equipments.

SanitationSanitation:-:- Destruction of all pathogenic Destruction of all pathogenic and almost all non pathogenic organisms.and almost all non pathogenic organisms.

Water QualityWater Quality:-:- Low hardness preferably Low hardness preferably <100 ppm. <100 ppm.

CIP procedureSr Step Description1 Pre Rinse With With fresh water at 45- 50 cel for 3 Minutes

recupe water at 45- 50 cel for 5 Minutes2 Hot Caustic Min 1-1.2 % caustic at 75-80 cel for 30 minutes

3 Fresh Water Rinse

With fresh water at 45-50 cel till removal of caustic + 2 minute extra time

4 Acid Nitric Acid 0.8- 1 % at 70-75 cel for 20 minute

5 Fresh Water Rinse

With fresh water at 45-50 cel till removal of caustic + 2 minute extra time

6 Hot Caustic Min 1-1.2 % caustic at 75-80 cel for 30 minutes7 Fresh Water

RinseWith fresh water at 45-50 cel till removal of acid + 2 minute extra time

8 Hot water Sanitation

With fresh water at 85 cel for 15 Minutes or 80 cel for 10 minutes

9 Fresh Water Rinse

Till the equipment is cooled at < 35 cel

Types of milk variantvariant fatfat SNFSNF

skim milkskim milk 0.05-0.1 %0.05-0.1 % 8.8-8.9%8.8-8.9%

double toned double toned milkmilk

1.5-1.6 %1.5-1.6 % 9.o-9.1%9.o-9.1%

Toned milkToned milk 3.0-3.1%3.0-3.1% 8.5-8.6%8.5-8.6%

standardizedstandardized milkmilk

4.7-4.8 %4.7-4.8 % 8.8-8.9%8.8-8.9%

full cream milkfull cream milk 6.0-6.1%6.0-6.1% 9.0-9.1 %9.0-9.1 %

super full cream super full cream milkmilk

7.0-7.1%7.0-7.1% 9.0-9.1%9.0-9.1%

Standardized milkStandardized milk This is milk whose fat and This is milk whose fat and

SNF content have been SNF content have been adjusted to a certain pre adjusted to a certain pre determined level. the determined level. the standardization can be standardization can be done by partially done by partially skimming the fat in the skimming the fat in the milk with a cream milk with a cream separator.separator.

Toned milkToned milk Toned milk refers to Toned milk refers to

milk obtained by the milk obtained by the addition of water and addition of water and SMP to whole milk.SMP to whole milk.

Double toned milkDouble toned milk Same as the toned milk, Same as the toned milk,

except that under the except that under the PFA rules DTM contain PFA rules DTM contain 1.5%fat and 9.0%SNF.1.5%fat and 9.0%SNF.

Full cream milkFull cream milk Whole milk + creamWhole milk + cream