8/21/2017 B-TECH PROJECTS & GUIDE: MILMA-WAYANAD DAIRY-REPORT

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B-TECH PROJECTS & GUIDE

ENGINEERING ,{BE, B-TECH ,DIPLOMA} TECHNICAL MAIN PROJECTS MINI PROJECTS REPORTS
SEMINAR REPORTS ARE AVAILABLE HERE

TUESDAY, 13 DECEMBER 2011

MILMA-WAYANAD DAIRY-REPORT

IN-PLANTTRAINING REPORT

MILMA WAYANAD DAIRY (MRCMPU LTD.)

Chuzhali, Kalpetta, Wayand

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ACKNOWLEDGEMENT
We take this humble opportunity to those who have inspired and
motivated us to undergo industrial training during the summer vacation of
2011.We are grateful to the Principal Dr.Benny Joseph.He is the leading light of
the institution.We would like to thank Mr.Rahul Antony(HOD,Dept of AEI) for
allowing us to undergo the training and Mrs.Reema Mathew(Lr,Dept of AEI)
who coordinate the industrial training in the best possible way.
We would like to express our deep sense of gratitude to Mr.K T Thomas
(Managing Director,MCMPU), Mr.D.S.Konda (Manager,Wayanad Milma) and
our guide Mr.Roopesh(Trainingcoordinator,Wayanad Milma)for constant and
appropriate guidance throughout the period always.I am also thankful to all the
engineers,technical staffs,officers and workers in Wayanad Milma Dairy for
their support and guidance during the course of the training.

CONTENTS

1. About MILMA3

2. About Wayanad dairy..4

MILMA for farmers.......3

RECENT POSTS
MILMA for consumers......5
SPONSOR
Awards & recognitions..5
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LABELS
Energy conservation policies in the dairy..6
AUTOMATIC ROOFING
3. Products........6 FARM AUTOMATION
KALPETA
4. Milk Processing...7 LABVIEW
MILMA
Pasteurization.9 simple railway signalization and interlocking
system using the Petri Net logic
5. Cleaning in position....13 SMART ROOF
WAYANAD DAIRY
6. Steam boilers......16
PAGES
7. Quality control lab..20
Home

8. Effluent treatment plant....................................22 milma

south india tourism
9. Conclusion..23
TOTAL PAGEVIEWS

1 5 3 5 5

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FOLLOWERS
Followers (2)

1. ABOUT MILMA
Milma was established in April 1980 by Kerala Co-operative Milk Follow
Marketing Federation (KCMMF). The mission of Milma is Farmers
Prosperity through consumer satisfaction. The objective of Milma is to
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build up a viable dairy industry in the State and to provide constant

market and stable price to the dairy farmers for their produce. The
Malabar Cooperative Milk Producers Union(MCMPU), head quartered BLOG ARCHIVE
at Kozhikode (Calicut) in Kerala, was started in 1991. It has the 6
2011 (4)
Northern Districts of Kerala as its area of operation and an average milk
December (4)
procurement of 4 lakh litres per day. The Union operates 5 Dairy plants
simple railway signalization and
and 2 Milk Chilling Centers. It has a Milk Products Dairy too. The interlocking syst...
network of Bulk Milk Coolers is in fast expansion. Currently a BMC SMART ROOFING SYSTEM
capacity of 2 lakh litres is in place with 75 BMCs installed in the villages. FARM AUTOMATION-USING
The products comprise Market milk (4 lakh litres per day), curd (40, 000 LABVIEW
Kg /Day), Ghee (150 MT per month), Ice-cream (1500 Litres per day), MILMA-WAYANAD DAIRY-REPORT
Peda (10 MT per month), Butter milk, Milk Lollies, Sterilized flavored
milk etc.
Malabar Regional Co-operative Milk Producers Union SPONSOR
(MRCMPU) Limited is a Union of more than 1000 village level dairy co-
operative societies located in the six northern districts of Kerala State in FIND US ON FACEBOOK
South India and it is owned by the dairy farmers who are members of
each affiliated society and who live in the area of operation of these POPULAR POSTS

societies. The societies function on the pattern of the societies affiliated MILMA-WAYANAD DAIRY-REPORT
to the world famous Anand Milk Union Ltd. (AMUL) at Anand (Gujarat), IN-PLANTTRAINING REPORT MILMA
WAYANAD DAIRY (MRCMPU LTD.)
India and hence are also known as Anand Pattern Co-op Societies or Chuzhali, Kalpetta, Wayand
APCOS. The area of operation of MRCMPU Ltd. comprises of the six ACKNOWLEDGEMENT We take this hu...
revenue districts of North Kerala, viz Kasaragod, Kannur, Wayanad,
FARM AUTOMATION-USING LABVIEW
Kozhikode, Malappuram and Palakkad. The Union sells its products
ABSTRACT With the rapid race of
under the Milma brand, a common brand for the Kerala Cooperative Milk globalisation and an ever increasing global
Marketing Federation, which has two more Milk Unions under it at population, the agricultural field has great
importance and ...
Ernakulam (Kochi) and Thiruvananthapuram (Trivandrum).
SMART ROOFING SYSTEM
CHAPTER 1 INTRODUCTION Weather, is
a state of the atmosphere at a particular
time and place. Raining conditions also will
be changing wit...
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2. ABOUT THE WAYANAD DAIRY simple railway signalization and interlocking

The Wayanad dairy ,coming under MCMPU located at Kalpetta, system using the Petri Net logic
Wayanad was established on 9/10/2008. The entire process is CHAPTER I INTRODUCTION Petri nets as
graphical and mathematical tools provide a
controlled The processing unit of theDairy is very well organized with uniform environment for modelling, formal
each department taking care of specific tasks. There is good networking analysis, ...
between each department which adds to the smooth working of this
plant. Effective time management is displayed since the processing in LABELS
itself takes about 20 hours and the rest 4 hours is dedicated to cleaning AUTOMATIC ROOFING
the equipment. Per day it processes about 2 lakh liters of milk.
FARM AUTOMATION
According to D.S. Konda, Manager, Wayanad dairy,The Wayanad Dairy KALPETA
is the only unit of Milma that has got license to export dairy products
LABVIEW
to foreign countries. During the last onam festival period, 1,12,000 liters
MILMA
of milk and 63,000 litres of curd were sold. This firm also has an effluent
simple railway signalization and interlocking
treatment plant and the recycled water is reused for primary purposes system using the Petri Net logic
(watering and manure). This firm comprises of about 150 workers SMART ROOF
working via 2 shifts per day.The operations of this dairy are thus very WAYANAD DAIRY
eco-friendly.
Fig.(1).wayanad Dairy kalpeta
VIDEO OF THE DAY

MILMA FOR FARMERS FLICKR IMAGES

The following programmes are carried out at the farmer level to
enhance quantity and quality of milk production POPULAR POSTS VIDEO OF DAY

1)Artificial insemination MILMA-WAYANAD

DAIRY-REPORT
2)Feed and fodder program
IN-
3) Total mixed ration programme PLANTTRAINING
REPORT MILMA
4)Heifer development programme WAYANAD DAIRY
5) Malabar rural development foundation (MRCMPU LTD.)
Chuzhali, Kalpetta,
6)Decentralized veterinary units Wayand
ACKNOWLEDGEM
7)Procurement of milk by societies or union
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ENT We take this

8)Insurance schemes hu...
9)Women cattle care program
FARM
10)Co-operative development program AUTOMATION-
11) Awards and scholarships USING LABVIEW
ABSTRACT With
MILMA FOR CONSUMERS the rapid race of
globalisation and
a) Marketing department an ever increasing
1)Marketing of fresh products global population,
the agricultural field
2)Marketing of long life products has great
importance and ...
b) Implementation of quality management system
1)ISO 9001:2008 SMART ROOFING
SYSTEM
2)HACCP( hazard analysis and critical control point) CHAPTER 1
3)ISO 22000:2005 INTRODUCTION
Weather, is a state
AWARDS AND RECOGNITIONS of the atmosphere
1)Won the Kerala state award for safety in 2010 at a particular time
and place. Raining
2)Got the certificate of approval from the export inspection counsel of conditions also will
India be changing wit...
3)Won the pollution control award of the pollution control board of Kerala
simple railway
in 2009-2010 signalization and
4)Won the Kerala state award for best marketing management interlocking system
using the Petri Net
ENERGY CONSERVATION POLICIES IN THE DAIRY logic
Some of the widely used technologies for possible energy savings in the CHAPTER I
INTRODUCTION
dairy plant are as follows: Petri nets as
graphical and
Solar Water Heating System: For process heating & wash water mathematical tools
Tri-generation system / VAM: For generation of electricity, steam provide a uniform
environment for
and refrigeration modelling, formal
analysis, ...
Waste heat Recovery: By installation of De-super heater for
Refrigeration Plant
LABELS
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Installing hot water fan coil unit in incubation rooms in place of AUTOMATIC ROOFING
FARM AUTOMATION
electrical heaters
KALPETA
Installing Variable Frequency Drives (VFD) for on ID & FD fans of
LABVIEW
Spray dryers & Boilers MILMA
DG Set performance optimization simple railway signalization and interlocking
system using the Petri Net logic
Optimization of compressed air generation and utilization
SMART ROOF
Use of energy efficient pumps
WAYANAD DAIRY
Improvement in Regeneration efficiency of Pasteurizers
Introduction of two temperature levels for different usage etc

3.PRODUCTS
MilmaSmartMilk
Contains 1.5 percent fat and 9.0 percent non-fat solids. Ideal for elderly
people since fat content is low. Can also be used for whitening tea/coffee and
for the preparation of milk based drinks like fruit shakes. Fat will not settle at
the top since the milk is homogenized. Available in 500 ml sachets.

MilmaTonedMilk
Contains 3.0 percent fat and 8.5 percent non-fat solids. Ideal for consumption
by children in the form of milk or in the form of brown beverages like
Bournvita. Fat will settle at the top if Milk is kept still for some time. Available
in 500 ml sachets.

HomogenisedTonedMilk
Contains 3.0 percent fat and 8.5 percent non-fat solids. Ideal for whitening

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tea/coffee and for the preparation of solid curd. Since the milk is homogenised,
whitening capacity is more and less amount of milk will be sufficient for
whitening tea/coffee. The milk will not stick to vessels on heating and hence
washing of used vessels is easier. Fat will not settle at the top since the milk is
homogenised. Available in 500 ml sachets.

Milma-RichMilk
Contains 4.5 percent fat and 8.5 percent non-fat solids. Ideal for the preparation
of payasam and sweets. Fat will settle at the top if Milk is kept still for some
time since the milk is not homogenised. Available in 500 ml sachets.

SkimmedMilkCurd
Contains 10 percent non-fat solids. Ideal for making curries. Prepared under
hygienic conditions by fully mechanized processes. Cannot be used as starter-
curd for converting milk into curd. Available in 500 ml sachets.

Milma-Sambharam(ButterMilk)
Contains 4.5 percent total solids and natural flavour extracts. Ideal as thirst
quencher during hot season. Prepared under hygienic conditions using fully
mechanized processes. Available in 200 ml sachets.

MilmaGhee
Contains 99.7 percent milk fat. Manufactured by melting fresh cream under
hygienic conditions. Milma ghee has the ideal golden yellow colour due to
presence of natural carotene in cow milk. (In contrast, ghee manufactured from
buffalo milk is white in color). No artificial colours or flavours are added in
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Milma ghee. Natural aroma and flavour of ghee is retained since ghee is
produced directly from fresh cream instead of going in for melting stored butter

Milma-sipup
Contains the mixture of flavours, color powders, sugar and this mixture
is added to the milk. Flavours used arechocolate, orange, pineapple, pista etc.

4.MILK PROCESSING
In Milma, following prioritation is done in the order given here:
Refrigeration System: Ice Bank Tank (IBT) & Cold store
Pasteurizers: Milk& Cream
Packing: Milk & Products
Boilers, DG Sets, Incubator Room having electrical heaters,
Spray Dryers, Blowers, Air Compressors, Pumps, AC &
Lightings Systems
Effluent Treatment Plants and Other motive loads.
SCHEMATIC DIAGRAM OF MILK PROCESSING

Unloading & Platform Test

Queuing

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Quality check

Pasteurization

Quality check after pasteurization

Packaging

Operations (Processing of milk)

1. Unloading & Platform test
2. Queuing
3. Quality check
4. Pasteurization
5. Quality check after pasteurization
6. Packaging

Unloading & platform test:

Milma buys raw milk from various societies (including Karnataka and
Andhra Pradesh), which is then unloaded at the plant. This raw milk is
subjected to a manual platform test. Here, the milk is checked for any foul smell
or visible impurities. If there is any such mentioned, then the milk is discarded.
Queuing:
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Only one societys milk is queued at a time. All the cans from that particular
society are transferred into a huge container which has a capacity of 3000 liters.
This point is called the Raw Milk Reception Dock (RMRD).
Quality Check:
At the RMRD, a sample of the raw milk is taken and a quality check is
done. The fat and SNF (solid non fat) content are checked. Once the milk
undergoes the quality check, it is then chilled (to 5 degrees) and transferred into
a tank (SILO tank) which has a capacity of 60,000 liters.
In SILO tank the raw milk undergoes a cleaning process for which a CIP
(cleaning in position) unit is set up. Here the raw milk is treated with containers
washed with 0.1% nitric acid then with alkali (sodium hydroxide) and finally
with hot water. A recuperation tank is attached to it which recycles water.
Pasteurization:
From the SILO tank, the milk is then pumped to a flow control value. It
controls the flow of the raw milk to be pasteurized. Simultaneous process of
heating (79 degrees) and cooling (4 degrees) is done. In an hour, 1000 liters of
milk can be pasteurized. Once this process is complete, the milk is transferred
to another SILO tank.
Quality check after pasteurization:
The quality of the milk is checked to find if it has 3 % fat and 8.5 % SNF
(solid non fat). If the fat and SNF contents are not met, then skimmed milk is
added to it to attain the required standards. The milk is stored in cylose tankers
with 60,000 L capacity and normally stored to a maximum of 12 hrs.

Packaging:

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After checking the quality standards, the milk is then pumped into overhead
tank. From these tanks the milk is then transferred to a sophisticated packaging
machine. This packaging equipment filters the milk and fills them into sachets
of different volumes. The weight of the milk sachets is checked randomly at
regular intervals .These sachets are put into a tray, where each tray contains 20
milk sachets. In 15 minutes, a packaging equipment can fill 25 such, which is
then taken to the dispatching unit
Fig. (2). Package Report

PASTEURIZATION
The heating of every particle of milk or milk product to a specific
temperature for a specified period of time without allowing recontamination of
that milk or milk product during the heat treatment process.
Pasteurized plant is intended for the production of pasteurized milk.Raw
milk stored in silos is passed through pasteurizer .There it is heated to 72
degree Celsius for 15sec .The time 15sec is adjusted by making the tube
longer.Most of the pathogenic organisms are eliminated during this time.The
next step is to cool this milk suddenly to about 4 degree.Milk having 60 degree
Celsius goes to homogeniser and 40 goes to cream seperator.Due to the high
pressure applied the milk goes through very narrow nozzle and the fat globules
are broken down into smaller particles and equally mixes with the
milk,resulting in the production of homogenised milk.The basic principal of
cream separator is centrifugal action by which the low density fat is
accumulated at the top and the high density milk is obtained as skimmed milk.
BASIC DESIGN OF A PASTEURIZER
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Fig. (3). Pasteurizer

It mainly consist of a Product supply,Product Balance Tank, Product
Pump, Flow controller, Regenerative section, Bypass for equipment like filters,
separators, homogenizers.
Product Balance tank
It consist of a float as a Level controller
To keep the count level above the product pump inlet
To damp fluctuations in the flow after the pump
To get rid of incoming air bubbles in the incoming product
Flow controller maintains constant flow through the plate heat
exchanger.
Adjustable flow Controller
Is designed to control and maintaina constant flow rate.It is equipped with an
adjustable setting cone to control any flow within its capacity range.Main parts
of this flow controller are
Nut/clamp
Outlet pipe
Setting cone
Actuator
The Pneumatic actuator is designed so that an axial movement of a
piston is transformed into 90 degree rotation of the shaft.The torque of the
actuator increases at the end of the movement to improve the closing security.
Milk strainer
Particles in the milk flowing through the strainer are caught by the
perforated strainer bag or by the filter.The filter consist of two halve body and

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cover with filter bag or PVC and hold together by clamp.The filter bag is of size
120 mesh.
Fig.(4). Milk Strainer
The milk or bottom outlet .Product enters the ECD filter from the top jet,
filtered through the mesh and comes out from the bottom outlet.The
temperature sensor PT-100 is a resistant temperature detector RTD.The
temperature of the platinum changes as the temperature changes.
ElectroPneumatic positioner
The Electro Pneumatic positioner produces the preselected relationship
between valve stem position(controlled variable) and controller output
signal(signal output).The Positioner consist of an electropneumatic
converter unit and the Pneumatic part with lever shaft measuring spring,
the control system with nozzle,flapper and amplifier.The dc control signal is
supplied by the controller fed to the coil in the field of permanent magnet.At the
beam the force of the coil which is proportional to the current is balanced to the
force of the air pressure produced at the flapper.The air pressure supplied to the
control system varies proportionally with the current signal.The air pressure
inturn produces a positionary force at the measuring diadhragm which is
compared to the force of the measuring spring.The motion of the measuring
diaphragm is transmitted to the flapper by a pin and the nozzle is
activated.Changes in the control signal or in the valve stem position produce a
pressure change in the amplifier downstream of the nozzle and the signal
pressure supplied by the amplifier causes the plug stem to assume a position
corresponding to the input signal.

Regulatory valve

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The valve is operated by means of a handwheel which makes it possible to

open it gradually.The plug can be fixed in adjusted position with lockscrew.
fig.(5). Regulatory Valve
5. CLEANING IN POSITION (CIP)
All food products demand a very high standard of hygiene in the
manufacturing process. The raw materials are in contact with a number of
surfaces which are potential sources of infection.Sterilisation can reduce but not
entirely eliminate the consequences of such infection. Hence the cleaning and
disinfectant equipment is the most important factor in a food processing
plant.Control of the CIP is controlled by a processcontrol system, the once the
program has been started the cleaning sequence os fully automatic regarding
timer ,temperature.Operating station is in front of control station.
Fig.(6). CIP

Buffer tank
It Is used for
Preparing cleansing solution
Contain cleansing solution to minimise cleansing solution losses
These tanks are equipped with low level switches indicating when the tanks
are empty

Digital dinrail timer

T25 is a microcontroller based two digit user programmable
timer.Operator can view and set the parameter through LED display and the 2

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keys on the pannel.The set time is set using the keys and display in program
mode.The instrument has reset key and one relay output.

6. STEAM BOILERS

Boiler is a product at many years of Engineering effort and expertise.This effort

has produced a rugged ,compact and one of the safest units equipped with
modern control for safe and efficient operation.
CONSTRUCTIONAL FEATURES
This is a smoke tube,single pass boiler which can be fired on a no of
fuels.
eg:coal,baggase,husk and wood.Depending on the type fuel ,it has either
balanced draught or an induced draught system.The boiler consists of 3 parts.
1:Refractory lined external furnace.
2:Shell and tube exchanger preesure part.
3: Atmospheric water preheater.
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OPERATIONAL FEATURES
Fuel is burnt on the grate in the furnace and flue gases released during burning
of the fuel enter the stroke tube and then the flue gas chamber to pass off to the
chimney directly or via the water preheater.

SAFETIES AND CONTROL

1:Water level control.
2:Steam injector.
3:Steam pressure switch.
4:Flue gas temperature control.

MAINTENANCE

The performance of a boiler depends very greatly on the maintenance carried

out.The boiler,its surroundings,water pipelines,filters,strainer etc should be kept
clean to maintain proper fluid flow to boiler so that it works efficiently.The
maintenance checks be carried out and preferably should be recorded on a log
book daily by the boiler operator.

BOILER FEED WATER

Fig.(7).Boiler

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Boiler is used for converting water into steam by evaporation in the

boiler.Only the water gets evaporated and solids dissolved in the water remain
in the residual water.Apart from getting converted into steam,water has many
important function in the boiler which is to keep the heat exchanger portions
cooled and heatly.To ensure that the water behaves as a proper cooling
medium.It is essential to see the
1:The water continuosly wets the heating surfaces.
2:The water does not corrode the heating surfaces.
3:The water has necessary chemicals with in it such that a protective oxide
layer is found on the surfaces.

DIGITAL TEMPERATURE CONTROLLER

This instrument is designed to suit applications requiring a highly accurate

indication and control of temperature.The instrument provide a digital
indication of temperature on a 3 and half digit seven segment LED display with
a revolution of 1 degree celcius or 0.1 degree celcius.Sensor brake protection
and ambient temperature compensation are added features of this instrument.

PRINCIPLE OF OPERATION
The millivolt output of the thermocouple is added to the output of the cold
junction compensation circuit.The resultant of which is amplified and fed to the
digital voltmeter which gives a readout of the same in terms of temperature in
degree centigrade.The same output is also compared to a highly stable reference
fixed by the position of the set potentiometer.The comparator through a buffer

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drives the relay which remains enegised as long as the measured temperature is
below the set point.

BOILER
The force fan is used to suck in the air into the furnace at a high
pressure.Firewood is burned inside the furnace and this heat is used to boil the
water and the steam for cleaning purpose is made from the boiler.The shell tube
type boiler is usually used.The feedback water used for the purpose is at 80
degree celcius.The preheating of water is done at economiser.The heat from the
feedwater passed to the economiser.The feed water is filtered using softwater
instrument.The dust from the economiser is collected in the dust collector and
the water gas is send out through the chimney.Inorder to reduce pollution,the
chimney is created at a very big height.

ECODRAFT CONTROL SYSEM IN BOILER

Most solid fuel boiler are designed to operate under a negative furnace
draft to the extend of -2 to -5 mm wc.Thin draft is critical both from the
maintenance of proper combustion and ensuring safe and efficient operation of
the boiler.In a typical solid fuel boiler 1D fan consumes the maximum portion
of the allocated energy.In case we are all to control the 1D fan power
consumption at part loads,while maintaining the necessary draft in the
furnace.We can easily cut on our total power costs. The furnace draft is
dependent 1 degree on the following
1:The amount of combustion air admitted into the furnace.
2:The amount of flue gases scavengered by the level switches indicating when
the tasks are empty.

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TECHNICAL SPECIFICATIONS

SL.NO PARAMETERS UNITS RANGE

A DRAFT CONTROLLER
MAIN INCOMING POWER SUPPLY (AC) V 3PHASE
ANALOG OUTPUT mA 4-20
ANALOG INPUT mA 4-20
OUTPUT ACCURACY +/-0.3%
B) ADJUSTABLE FREQUENCY DRIVE
INCOMING POWER FREQUENCY Hz 50 +/- 3%
AMBIENT TEMPERATURE FOR DEGREE 40
INVERTER CELCIUS
POWER FACTOR MAINTAINED BY VFD >0.95(LEADING)

RANGE OF MOTOR RPM OFFERED BY RPM 500

SYSTEM 1440(TYPICAL)

CONTROL PANEL
Contains all equipment necessary for
1:Indication of process status.
2:Supervision of process performance.
3:Control of automatic function.
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4:Process sequence control.

5:Timer.
6:Control loop.
7:Text display.
8:Pneumatic and functional keyboard.

PLATE HEAT EXCHANGER

Plate heater exchanger is used to heat cleaning solution with use use of
steam.The plater are assembled in packs and clamped in frame,each adjuscent
pair of plates forming a flow channel,with the 2 media flowing in alternate
channels.
Two or more sections can be housed in the same frame CIP supports 5 types
of programs and total 16 cleaning objects for each circulation.Cleaning program
are
1:Lye
2:Acid
3:Lye and Acid
4:Sanitation
5:Flush
COMPRESSOR
The blank tank or IBT is used to form ice.The ammonia sucked through the
compressor is used to produce ice.The water in IBT which is at 1 degree celcius
returns back at 7 degree celcius.This cannot be wasted hence it is recycled.

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7. QUALITY CONTROL LAB

Testing of milk to calculate MSNF & FAT
Latest technique using ekomilk digital meter.
Garber method for FAT determination
10ml Gerber sulphuric acid+1ml amyl alcohol+10.75ml milk
in beuterometer.
After shaking place it in a centrifugal machine for 3 minutes
%MSNF=CLR/4+0.2*F+0.5 at 29 degree celcius
For finding CLR
heated to 29 degree, poured to lactometer cylinder then lactometer is
dipped in the cylinder

8.
EFFLUENT TREATMENT PLANT
Fig.(8). Effluent Treatment Plant
The dairy industry involves processing raw milk into products including milk,
butter, cheese, yogurt, using processes such as chilling, pasteurization, and
homogenization. Typical by-products include buttermilk, whey, and their
derivatives.

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Huge amounts of water are used during the process producing effluents
containing dissolved sugars and proteins, fats, and possibly residues of
additives. These effluents have the following characteristics
Biochemical oxygen demand (BOD), with an average ranging from
0.8 to 2.5 kilograms per metric ton (kg/t) of milk in the untreated
effluent
Chemical oxygen demand (COD), which is normally about 1.5 times
the BOD level
Total suspended solids (TSS), at 1001,000 milligrams per liter (mg/l)
Total dissolved solids (TDS): phosphorus (10100 mg/l), and nitrogen
(about 6% of the BOD level).
Cream, butter, cheese, and whey production are major sources of BOD in
wastewater. The waste load equivalents of specific milk constituents are: 1 kg
of milk fat = 3 kg COD; 1 kg of lactose = 1.13 kg COD; and 1 kg protein = 1.36
kg COD. The wastewater may contain pathogens from contaminated materials
or production processes. A dairy often generates odors and, in some cases, dust,
which also need to be controlled.
The effluent treatment plant in MILMA is as shown in the block diagram
given above.The reuse of wastewater from the dairy industry can also be
provided for by usage of adsorption and membrane separation among other
processes. The color and the odor may be removed completely after activated
carbon treatment. The pretreated water can be passed through a cross flow
reverse osmosis membrane system and the permeate water can then be reused.

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9. CONCLUSION
The processing unit of Milma Dairy is very well organized with
each department taking care of specific tasks. There is good networking
between each department which adds to the smooth working of Milma.
Effective time management is displayed since the processing in itself
takes about 20 hours and the rest 4 hours is dedicated to cleaning the
equipment. Per day it processes about 2 lakh liters of milk. Milma also
has an effluent treatment plant and the recycled water is reused for
primary purposes (watering and manure). The operations of Milma are
thus very eco friendly.
Achieving energy efficiency in cooperative set up has important
implications. The trade off between energy concerns and livelihood concerns
are at the core of these implications. Milma has taken this perspective very
seriously. The achievements Milma gained were possible through a strict
monitoring system.. Through the ENCON measures, MILMA hope to mix the
welfare concerns of human population as well as environmental concerns of
mother earth in the future too.The training session was very motivating for
instrumentation engineering students and gives and overview about how
instrumentation career is implemented in the dairies and how an engineer can
work for common man.
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BY,
FENIL P CYRIAC

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