Milk Processing Carried Out In Dairy

Industry & Implementation of Industrial

Automation in Milk Processing

Industry : Patna Dairy Project, Feeder Balancing Dairy

Name : Ravi Kashyap

Department : Electronics & Instrumentation Engineering

College : R.V. College of Engineering

 ACKNOWLEDGEMENT
The training opportunity I had with Sudha Milk Dairy was a great
chance for learning and Professional development . The successful
completion of this report would have not been possible without the
help and guidance of number of people and specially my mentor in the
company Mr.Rohit .

I take this opportunity to thank all those who have directly and
indirectly inspired, directed and helped me towards successful
completion of Training Report on :

“Milk Processing Carried Out In Dairy Industry & Implementation of

Industrial Automation in Milk Processing.”
 CONTENTS
 Refrigeration Process

 Boiler Section

 Milk Processing

 Packaging

 Implementation of Industrial Automation

 Conclusion

 References
 Refrigeration Process

In the whole process different components are

used they are inlisted below:-

 Kirlosker reciprocating compressor

 Discgarge line
 Oil separator
 Condenser
 Receiver
 Supply line
 Expansion valve
 Evaporating or cooling oil
 Suction line
 Ice bank tank
Process Overview :

 The Milk Products Stored in the Cold Storage are kept at the desired
temperature with the help of refrigeration section.
 The process of Refrigeration needs to run for 24 hours , all through the 7
week days . To achieve this four different compressors are employed and
are run in turn one after the other.
 The fuel used in compressor is FREZOL 68 OIL.
 The compressor compresses the gas and passes through oil seperator
through which oil seperates from condensed gas Now it passes through
condensor and get condensed
 The receiver collects all the condensed gas and sends it to supply line.
 There is a expansion valve in pipe line to control the supply of condensed
gas.
 Now there is a cooling coil or evaporator. Through suction line it again
comes back to Compressor.
 The refrigerant used in the Industry is ammonia.
 Pressure sensors are employed for the measurement of refrigerant
pressure.
 Temperature sensors are also employed to measure the temperature
achieved through refrifgeration.
 Water is used to transfer the cold temperature achieved to the cold storage
and milk processing unit
 The temperature should not exceed 6-7 oC.
 Boiler Section

 A fire tube boiler is used in the Industry. The fluid is used in this boiler is
C.N.G gas & coal.
 The vapour formed by this boiler is being used by different section to gain
heat for ghee, dahi, peda, powder making & most importantly in
pasteurisation of milk.
 There are 3 horizontal type fire tube boiler are used in this industry.
 Capacity is approx 500kg/hr evaporation for producing 1500 litres/day milk.
 The different sections are joined by through pipe line to the steam
generators.
 In fire tube boiler, hot gases pass through the tubes and boiler feed water
in the shell side is converted into steam.
 Fire tube boilers are generally used for relatively small steam capacities and
low to medium steam pressures.
  As a guideline, fire tube boilers are competitive for steam rates up to
12,000 kg/hour and pressures up to 18 kg/cm2.
 Fire tube boilers are available for operation with oil, gas or solid fuels.
 For economic reasons, most fire tube boilers are nowadays of “packaged”
construction (i.e. manufacturers shop erected) for all fuels.

Milk Processing
PROCESS SECTION : The Raw milk is being processed with the help of clarification
and homogenization system . In this section , actually two plants are being
operated continuosly. The continuous process is followed by HTST (HIGH TEMP.
SHORT TIME) system for pasteurisation. In this section important parts are as
mentioned below:

A) Balance Tank
B) Clarifier
C) Pasteurizer
D) Hot water tank
E) Homogenizer
Effluent Treatment Plant : The dairy waste effluent from all above section comes
to this plant. Huge quantity of milky water mainly from receiving dock, process
and packing section is drained out daily and flows to ETP. The dairy Waste water
is being added by butter, ghee and Icecream section. Huge quantity of water is
coming from process and engineering section. The ETP comprises of the airetion
type treatment process. The carrying capacity of ETP is 50,000 litres/day.

POWDER SECTION : Milk from shallow tank is concentrated in triple effect

evaporaters, This way condensed milk is formed. Now this condensed milk is seat
to dryer , finally milk powder collected in bag after being converted into powder
in to spray dryers.
QUALITY CONTROL : The quality of received raw milk, process milk and
homogenized pasteurized milk is being checked by vigoriously as per requirement.

Pasteurization
Pasteurization is the process of heating a liquid to below the boiling point to
destroy microorganisms. It was developed by Louis Pasteur in 1864.
Types of Pasteurization:

There are basically two methods of pasteurization in use today-

batch and continuous flow.

In the batch process, a large quantity of milk is held in a heated vat at 65°C. for 30
minutes, followed by quick cooling to about 4°C.

In the continuous flow process also known as HTST, for high temperature, short
time, milk is forced between metal plates or through pipes heated on the outside
by hot water.

While flowing under pressure, the milk is held at 72°C. for at least 16 seconds.
Before being chilled back to 4°C. or cooler, it flows through a heat exchanger to
pre-warm cold milk just entering the system.

The Purpose of Pasteurization

1. To increase milk safety for the consumer by destroying disease causing
microorganisms (pathogens) that may be present in milk.

2. To increase keeping the quality of milk products by destroying spoilage

microorganisms and enzymes that contribute to the reduced quality and shelf life
of milk.
 Milk packaging flowchart:
POUCH MAKING BALANCE TANK
↓
POUCH FILLING
↓
CRATING
↓
COLD STORAGE ( <6.C)
↓
DESPACH TO VARIOUS PLACES
Pasteurization conditions used for milk products.

Holding
Pasteurization Type Typical Product Typical Storage Temperature
Time
Batch, vat Milk Refrigerated 145°F (62.8°C) 30 min
Viscous products, or
products with more than
" " 150°F (65.6°C) 30 min
10% fat or added
sweetener
Egg nog, frozen dessert
" " 155°F (68.3°C) 30 min
mixes
Continuous, high
temperature short time Milk " 161°F (71.7°C) 15 sec
(HTST)
Viscous products, or
products with more than
" " 166°F (74.4°C) 15 sec
10% fat or added
sweetener
Egg nog, frozen dessert
" " 175°F (79.4°C) 25 sec
mixes
" " " 180°F (82.2°C) 15 sec
Continuous, higher heat
Milk " 191°F (88.3°C) 1 sec
shorter time (HHST)
" " " 194°F (90°C) 0.5 sec
" " " 201°F (93.8°C) 0.1 sec
" " " 204°F (96.2°C) 0.05 sec
" " " 212°F (100°C) 0.01 sec
Refrigerated,
Continuous,
Milk and cream extended 280°F (137.8°C) 2 sec
Ultrapasteurization
storage
Aseptic, ultra high Room 275-302°F
Milk 4-15 sec
temperature (UHT) temperature (135-150°C)
Sterilization Canned products " 240°F (115.6°C) 20 min
 Implementation of Industrial Automation
Introduction :
Automation is the use of various control system for operating equipment such as
machinery, processes in factories, boilers and heat treating ovens, switching in
telephone networks, steering and stabilization of ships or aircraft and other
applications with minimal or reduced human intervention. Some processes have
been completely automated.
The biggest benefit of automation is that it saves labor; however, it is also used to
save energy and materials and to improve quality, accuracy and precision.

Several aspects must be considered when designing a dairy. Therefore, the final
production solution of a plant is always a compromise between product-related,
process-related and economic aspects, in which external demands on the plant
must be satisfied. These external requirements relate to factors such as legislation,
type and amount of product, product quality, hygiene, production availability,
flexibility, labour and economy.
The product-related aspects include raw materials, product treatment and quality
of the end product, while the process-related aspects include selection of process
equipment to satisfy external demands. Even if the processing units in a plant are
chosen primarily to achieve the stated product quality, various compromises must
be made, particularly if many different products are to be manufactured.

Such considerations apply, for example, to the cleaning requirements of the

equipment and its suitability for connection to the proposed cleaning system.
Compromises must also be made on other matters, such as the consumption of
energy and service media, and the suitability of the equipment to be controlled.
When selecting process equipment, it is important to remember that the process
control solution should also be considered.
Correctly applied process control, in which a thorough knowledge of products,
processes and process equipment guides the design, has many advantages.
 REQUIREMENTS FOR A CONTROL SYSTEM
Reliability, flexibility and economy are the most important requirements for a
modern process control system.

This means that the control system should:

 Be reliable and easy to maintain

 Have a user interface that is logical, self-instructing and efficient
 Be based on off-the-shelf hardware and software
 Include software for diagnostic testing and modification
 Be easy to extend

EXTENDING A CONTROL SYSTEM

One of the most important requirements for a control system is the possibility to
extend the system when required. It should be possible to build a system of any
size, step by step, by adding standard components. A small process controller
installed to control a reception line could be extended later with more controllers
of the same brand that control milk treatment, filling, etc. At the same time,
management routines could be added to existing controllers to feed data into
management computers.
When extending a control system, it is very important that all control system
components, from the remote sensor to the user interface, are easy to connect to
each other in order to create a smooth functioning control system platform. Using
products from a sole supplier will normally guarantee this.

Process Control System :The system executing Process Control.

It normally incorporates:
 User Interfaces, which are used by the process operator to communicate with the
control system and the process.
 Process Control, normally a PLC (Programmable Logic Controller), which executes
actual control of the process.
 I/O-system interfaces with control modules and transmitters in the process.
 Management Execution System (MES) = The system executing
Production Management.
 It can also form a link to other company systems such as Enterprise Resource
Planning (ERP) systems.

Zoom
Fig 6.10.6
Process Control is normally executed by a PLC (Programmable Logic Controller).

LOGIC
Logic is a fundamental concept in Process Control. It denotes the decision-making
mechanism, making it possible to perform a given task according to a given model.
The human mind is programmed by education and experience to perform a task
in a certain way.
Figure 6.10.7 shows in a manual system, how an operator uses logic to solve a
control problem, which involves supplying a process line with milk from a battery
of tanks. He receives information from the process, e.g. that tank T1 will soon be
empty, tank T2 is currently being cleaned, tank T3 is full of product, etc. This
information is processed logically by the operator. The figure illustrates his train
of thought – the questions and decisions he has to formulate. Finally, he
implements his decisions by pushing the correct buttons on his panel to actuate
the right valves, pumps and other control modules.
The operator has no great difficulty in solving this particular control problem.
Even so, the potential for errors is always present. Detergent and milk could be
mixed by mistake. The process line may run out of milk, resulting in burning-on at
the heat transfer surfaces. Milk in the tanks may be wasted when the tank is
cleaned. The risk of such errors increases if the operator is responsible for several
similar sections of the process at the same time. He may be rushed and under
stress, which heightens the risk of him making a mistake.

At first glance it is easy to assume that the operator is constantly faced with
choices between many alternative solutions to control problems. A closer look
reveals that this is not the case. After many hours of operation the dairy has
verified the control sequences, which results in optimum product quality, safety
and economy. In other words, the operator has acquired a more or less
permanent control logic. He selects tanks according to established routines, uses
a stopwatch to time milk drainage from a tank, so that he knows exactly when to
switch to a full tank in order to minimize product losses, and so on. Each process
can be analysed in this way and it is then possible, on the basis of the analysis, to
determine the control logic that produces optimum results.
The control logic is stored in the form of a programme in the specific process
controller, which is normally a PLC.

Zoom
Fig 6.10.7
In a manual process the operator uses his logic to solve the processing demands.
PROGRAMMABLE LOGIC CONTROLLER (PLC)
A Programmable Logic Controller, PLC or Programmable Controller is a digital
computer used for automation of electromechanical processes, such as control of
machinery on factory assembly lines, amusement rides, or light fixtures.
The abbreviation "PLC" and the term "Programmable Logic Controller" are
registered trademarks of the Allen-Bradley Company (Rockwell Automation). PLCs
are used in many industries and machines. Unlike general-purpose computers,
the PLC is designed for multiple inputs and output arrangements, extended
temperature ranges, immunity to electrical noise, and resistance to vibration and
impact.
In essence, a programmable logic controller reads its input signals and responds
to them by turning the output modules on or off. It functions under the classic
"if/then" scenario, only on a much more complicated scale since it controls
multiple input and output devices, all of which must be responded to immediately
and constantly as designated by the user program. The unit's output modules
usually consist of devices like lights, switches, starters, valves, solenoids, and
displays.
Programs to control machine operation are typically stored in battery-backed-up
or non-volatile memory. A PLC is an example of a hard real time system since
output results must be produced in response to input conditions within a limited
time, otherwise unintended operation will result.
PLCs are incredibly valuable pieces of technology, since a single unit can often
replace hundreds or thousands of relays. Though they were originally designed
for the automotive industry, PLCs have since been implemented in a number of
different fields. In large part, the automation processes in most modern factories
are facilitated by PLCs.
These devices are designed to follow their programming instructions precisely,
which is especially vital in a factory assembly line setting where a small mistake or
miscalculation can result in costly errors. Some PLCs function on a very basic level;
others are capable of controlling higher-level, more complicated processes. They
can be used for a wide variety of input/output functions and timing applications.
They also offer motion control and complex networking capabilities.
 CONTROL SYSTEM
All the transmitters and control modules in the process (4) are connected to the
logic by the Input/Output (I/O) system (3). In this way, all the necessary
information regarding temperatures, flows, pressures, etc. is transmitted to the
logic of the control system. After processing of I/O signals and operator
commands, the logic sets the correct output signals to actuate the control
modules involved in the process. This is done in a certain order to comply with the
logical conditions that apply to the process. The control modules send back
feedback signals confirming that the commands have been carried out. These
feedback signals are used by the logic as conditions, permitting the next step in
the sequence to be actuated. The principal layout of a control system is shown in
Figure 6.10.8.
If the output signal and the feedback signal do not match, an alarm signal is
generated, trying to bring the related process to a safe state. This assumes, of
course, that the fault in question can be predicted. As a process becomes more
complicated, and demands on operational security and economy become stricter,
the required control programme (logic) has to be extended accordingly.
All user interfaces (1) are connected to the logic as well as local operator panels.

Zoom
Fig. 6.10.8
Principle of a process control system.

1. Operator interface
2. Printer terminal
3. Input/Output units
4. Process equipment
DISTRIBUTED INTELLIGENCE
Efficient process control requires first-class electronic solutions in the process.
The operation of the entire automatic process control system will be jeopardized
if transmitters and sensors do not work properly.
The valve control system shown in Figure 6.10.9 is an example of distributed
intelligence. Running a dairy of any size involves keeping track of hundreds or
thousands of valves and operating them in different combinations and sequences.
PLCs are dedicated systems to solve these control tasks in the shortest possible
time. To do this, the PLC needs a channel for instant communication with all the
valves. This makes the installation costly, but new valve control systems have
been developed to provide an economical solution.
A modern system consists of a number of valve tops (1), one for each valve. The
valve tops are connected to a common fieldbus cable and a common compressed-
air line. The fieldbus cable is connected to a gateway communicating with the
control system (2) and the power supply serving the valve tops. Several fieldbuses
can be connected to the process controller to control the required number of
valves.
Another important advantage of the system is that the valve top unit reports the
valve status back to the control system. The modem scans the status of all valves
continuously and instantly informs the process controller if a malfunction arises.
This facilitates fault tracing and maintenance, especially since it is possible to
disconnect individual valve units without disrupting the operation of other parts
of the control system.
The fieldbus concept is also starting to be applied for transmitters and
instrumentation as a whole – distributed temperature control and flow-metering
are just two examples.
For the producer, the advantage is not only a significant reduction in installation
and commissioning costs, but also the increased amount of useful information,
which makes the total investment in a control system lower than for a traditional
system.

BATCH CONTROL
Production in liquid food plants is becoming more complex as new and more
complicated recipes are introduced. Strict recipe procedures must be followed to
manage production and guarantee product quality.
The increased number of products demanded by producers means shorter
production runs. In order to stay competitive in this situation, the efficient
planning and running of production is a necessity.
The manufacture of 50 tons of strawberry yoghurt, for example, is called a batch.
Instead of only executing conventional process operations, such as transfers to
and from process units, the batch control system takes total control of production,
from milk reception until the yoghurt cups are stored for distribution. The major
benefit of batch control is that the system helps with all the necessary actions.

RECIPE MANAGEMENT
Using recipe management, a producer will have full control when introducing new
products. If no new process equipment is needed, there is no need to call in
external assistance to reprogramme the control system. All procedures are edited
on site using easy-to-understand tools.
All previous recipes are automatically stored and ready to use whenever needed
in the future. Any existing recipe can be easily modified on line and stored as a
new version or a completely new recipe.
Flexibility is maximized, as all recipes are scalable.

CONTROL OF PRODUCTION

The batch control system gives comprehensive on-line information about what is
happening in production: production figures and totals to date, data on products
scheduled for runs later in the day, and current problems related to production
and lines. All this information can be displayed on any user interface connected to
the network.
 Conclusion
Nowadays, the next step in the evolution of automated processes is taken
towards the totally integrated plant control system.
A plant consists of more than one process area, eg. reception, cheese and liquid
milk production. Each area has a its own configuration of one or more Process
Controllers and they will often have a User Interface for operators, handling
product transfer from one process area to the other.
It is essential to keep track of production and economy in a plant. The Process
Controllers generate a substantial amount of data from the process at all times,
day and night, week and month. Knowing what is happening is a key to be able to
run the plant more efficiently and economically.
The Process Controllers themselves provide all the raw data for the
Manufacturing Execution System (MES), where the data can be further processed
and stored in a database. This is handled by a separate computer.
A modern MES system is dedicated to handle large volumes of data. It computes
and processes the data to transform it to useful information. Visualizing this
information in various types of reports helps the users to analyse production
economy, etc. and to assist in planning and making preventive maintenance
forecasts.
 REFERENCES
 dairyprocessinghandbook.com/chapter/automation
 www.essay.uk.com/free-essays/engineering/milk-process-automation.php