MANUFACTURING OF WHOLE MILK POWDER

CAPACITY: 50 TONNES PER DAY

Project Report submitted in partial fulfillment of the

requirements for the Degree of B.E. (Food Technology)
2020

BY

INAYAT ARORA
CH16511

Dr. S. S. BHATNAGAR UNIVERSITY INSTITUTE OF

CHEMICAL ENGINEERING AND TECHNOLOGY
PANJAB UNIVERSITY CHANDIGARH–160014, INDIA
 CERTIFICATE

This is to certify that Ms. Inayat Arora, CH16511, a fourth

year student of Dr. S.S. Bhatnagar University Institute of
Chemical Engineering and Technology, Panjab University,
Chandigarh has completed her project titled “Manufacturing
of Whole Milk Powder by Spray Drying”. This project
report may be accepted for evaluation as a part of requirement
of B.E. (Food Technology) degree.

Signature

Mrs. Seema Kapoor

DrSSBUICET
PanjabUniversity,
Chandigarh
 ACKNOWLEDGEMENT

I am highly obliged and sincerely thankful for the

encouragement offered by Mrs. Seema Kapoor, Dr S.S.
Bhatnagar University Institute of Chemical Engineering and
Technology, Panjab University, Chandigarh under whose
valuable guidance and support the project work has been
completed. Her rational and unconventional approach
furnished adequate guidelines. She has been the motivating
spirit behind all my efforts in executing the present study. I
express my sincere thanks to her.

Inayat Arora
CH16511
B.E. (Food Technology)
th
4 Year
 INDEX

S. NO. TOPIC PAGE NUMBER

1 INTRODUCTION 5
2 MASS BALANCE 19
3 ENERGY BALANCE 23
4 DESIGNING 29
5 PROCESS 32
INSTRUMENTATION
DIAGRAM
6 PROCESS FLOW DIAGRAM 34

7 COSTING 35
8 PLANT UTILTIES 44
9 PLANT LOCATION AND 46
SITE SELECTION

10 PLANT LAYOUT 49
11 SAFETY, 52
ENVIRONMENTAL
HAZARDS
12 BIBLIOGRAPHY 54
 INTRODUCTION

MILK:

Milk is defined as the normal secretion of mammary gland of mammals. In India, however
milk (in general) refers to cow’s and buffalo’s milk or the combination of two.
Milk may be defined as the whole, fresh, clean, lacteal secretion obtained by the complete
milking of one or more healthy animals, excluding that obtained within 15 days before or 5
days after calving or such periods as may be necessary to render the milk practically
colostrum-free, and containing the minimum prescribed percentages of milk fat and milk-
solids-not-fat.

ANIMAL PROTEIN CASEIN WHEY FAT CHO% ASH

% % PROTEIN % %

HUMAN 1.0 0.5 0.5 4.5 7.0 0.2

HORSE 2.2 1.3 0.9 1.7 6.2 0.5

COW 3.5 2.8 0.7 3.7 4.8 0.7

BUFFALO 4.0 3.5 0.5 7.5 4.8 0.7

GOAT 3.6 2.7 0.9 4.1 4.7 0.8

SHEEP 4.6 3.9 0.7 7.2 4.8 0.8

TYPES OF MILK POWDER

There are basically 2 types of milk powder :

1) WHOLE MILK POWDER (WMP): Made from whole milk .Contains not more than 5%
moisture and not less than 26% fat. Total acidity not more than1.2%.

2) SKIM MILK POWDER (SMP): Made from skim milk and is also known as Non Fat Dry
milk powder. Contains not more than 5% moisture and not more than 1.5% fat. Total acidity
should not exceed1.5%.
WHOLE MILK POWDER (WMP)

Milk powder manufacture is a simple process now carried out on a large scale. It involves the
gentle removal of water at the lowest possible cost under stringent hygiene conditions while
retaining all the desirable natural properties of the milk - color, flavor, solubility, nutritional
value. Whole (full cream) milk contains, typically, about 84% water and skim milk contains
about 91% water. During milk powder manufacture, this water is removed by boiling the milk
under reduced pressure at low temperature in a process known as evaporation. The resulting
concentrated milk is then sprayed in a fine mist into hot air to remove further moisture and so
give apowder.

Dry milk provides a means of handling the excess milk supply in a dairy industry during flush
season, while in the lean season, that meant for production of dry milk can be diverted to
market milk. Thus dry milk can be may be considered as the balance wheel of dairy industry.

SPRAY DRIERS

INTRODUCTION

By far the most important kind of air convention drier is the spray drier. Spray driers turn out
a greater tonnage of dehydrated food products than all other kinds of driers combined. There
are various types of spray driers designed for specific food products. Spray driers are limited
to foods that can be atomized, such as liquids and low viscosity pastes and purees. Atomization
into minute droplets results in drying in a matter of seconds with common inlet air
temperatures of about 200oC. Since evaporation cooling seldom permits particles to get
warmer than about 80oC and properly designed systems quickly remove the dried particles
from heated zones, this method of dehydration can produce exceptionally high quality with
many highly heat sensitive materials, including milk, eggs and coffee.

In typical spray drying, the liquid food is introduced as a fine spray or mist into a tower or
chamber along with heated air. As the small droplets make intimate contact with the heated
air, they flash off their moisture, become small particles, and drop to the bottom of the tower
from where they are removed. The heated air, which has now become moist, is withdrawn
from the tower by a blower or fan. The process is continuous in that liquid food continues to
be pumped into the chamber and atomized, along with dry heated air to replace the moist air
that is withdrawn, and the dried product is removed from the chamber as it descends.

The principal components of the spray drying system differ in construction depending on the
product to be dried. In case of milk, the system includes tanks for holding the liquid, a high
pressure pump for introducing the liquid into the tower, spray nozzles or a similar device for
atomizing the milk, a heated air source with blower, a secondary collection vessel for
accumulation product drawn from the tower, and means for exhausting the moistened air.

The main purpose of the drying tower or chamber is to provide intimate mixing of heated air
with finely dispersed droplets. In the various spray driers, the heated air and the atomized
droplets may enter the tower together at the top or bottom or may enter separately, the particles
may be made to descend straight down or take a spiral path, and the chamber may be vertical
or horizontal.

As in tunnel driers, introduction of droplets and air in the same direction results in quick initial
drying and slower final drying, countercurrent streams may be favoured for highly
hygroscopic materials. Further, if a liquid product is introduced at the top of the tower, it
descends through and out of the tower in one pass, if product is introduced at the bottom, it
first ascends and then descends and its time in the drier can thus be made longer. This also is
true if the droplets are given a spiral motion in the tower. A longer residence time may be
desirable to bring the particles down to a lower moisture content or to permit particles to grow
in size in the drier (longer residence time gives greater opportunity for drying particles to
collide with less dry particles and form clusters). This is one way to carry out the instantizing
process known as agglomeration, which yields clusters that have many voids, sink in water,
and are therefore easier to dissolve than certain spray dried particles which are small in size,
float on water, and are difficult to wet.

PRINCIPLE OF SPRAY DRIER

Spray drying involves evaporation of moisture from an atomised feed by mixing the spray and
the drying medium. The drying medium is typically air. The drying proceeds until the desired
moisture content is reached in the sprayed particles and the product is then separated from the
air. The mixture being sprayed can be a solvent, emulsion, suspension or dispersion.
MIXING OF SPRAY AND DRYING MEDIUM (AIR) WITH HEAT AND MASS
TRANSFER:

The manner in which spray contacts the drying air is an important factor in spray dryer design,
as this has great bearing on dried product properties by influencing droplet behaviour during
drying. This mixing is an important aspect and defines the method of spray drying:

Co-current Flow:

The material is sprayed in the same direction as the flow of hot air through the apparatus. The
droplets come into contact with the hot drying air when they are the most moist. The product
is treated with care due to the suddenvaporization.
Counter Current Flow:

The material is sprayed in the opposite direction of the flow of hot air. The hot air flows
upwards and the product falls through increasingly hot air into the collection tray. The residual
moisture is eliminated, and the product becomes very hot. This method is suitable only for
thermally stabile products.

Combined:

The advantages of both spraying methods are combined. The product is sprayed upwards and
only remains in the hot zone for a short time to eliminate the residual moisture. Gravity then
pulls the product into the cooler zone. Due to the fact that the product is only in the hot zone
for a short time, the product is treated withcare.

Disk atomizer (rotary wheel):

The material to be sprayed flows onto a rapidly rotating atomizing disk and is converted to a
fine mist. The drying air flows in the same direction. The product is treated with care, just as
in the co-current flow method.
OPEN-CYCLE AND CLOSED CYCLE SYSTEM:

Air is mostly used as drying medium. The air stream is heated electrically or in a burner and
after the process exhausted to atmosphere. This is a open-cycle system. If the heating medium
is recycled and reused, typically an inert gas such as nitrogen, this is a closed-cycle system.
These layouts is typically chosen, when flammable solvents, toxic products or oxygen
sensitive products areprocessed.

The most common type of spray dryer is the open-cycle, co-current spray dryer. In such a
design, the atomised feed and the drying air is simultaneously injected into a spray drying
chamber from the same direction.

DRYING OF SPRAY (REMOVAL OF MOISTURE):

As soon as droplets of the spray come into contact with the drying air, evaporation takes place
from the saturated vapour film which is quickly established at the droplet surface. Due to the
high specific surface area and the existing temperature and moisture gradients,

an intense heat and mass transfer results in an efficient drying. The evaporation leads to a
cooling of the droplet and thus to a small thermal load. Drying chamber design and air flow
rate provide a droplet residence time in the chamber, so that the desired droplet

moisture removal is completed and product removed from the dryer before product
temperatures can rise to the outlet drying air temperature. Hence, there is little likelihood of
heat damage to the product.
PROCESS OF WHOLE MILK POWDER MANUFACTURE
RECIEVING MILK

COOLING (4 oC)

PRE-HEATING (40 oC)

STANDARDIZATION (SNF/FAT=2.70)

HOMOGENISATION
(Stage 1-2500 psi)(63 oC -74 oC)
(Stage 2-500 psi)

PRE-HEATING (75 oC -120 oC)

CONDENSING(35%-45% Total Solids)

REHEATING (71 oC)

SPRAY DRYING
(inlet temp: 143-232 oC ; outlet temp: 74-93 oC; m/c: 5%)

COOLING (temp<30 oC)

SIFTING (25 mesh)

PACKAGING and STORAGE

Receiving raw whole milk: The raw whole milk is received at the dock and all the preliminary
tests are performed at the dock to check the quality of the milk. Only high grade milk is
accepted.

Cooling: To preserve the quality of milk, the milk is stored in cold storage at 4° Celsius.

Pre-heating: To increase the efficiency of separation of cream from the milk, the milk is
preheated to a temperature of 40° Celsius. Preheating causes a controlled denaturation of whey
proteins in the milk and it destroys bacteria, inactivates enzymes, generates natural
antioxidants and imparts heat stability to the milk. The exact heating holding regime depends
upon the type of the product and its intended use.

Standardization: To adjust the ratio of fat and solids not fat in raw milk to meet the legal
standards for composition of in dried whole milk powder. Raw milk is standardized by adding
to it a calculated amount of skim milk or cream. In whole milk powder ratio of SNF
/Fat is usually 2.70.

Homogenization: Done to prevent churning of fat during agitation while combining with
water. Another merit is the improvement in the keeping quality of powder. Homogenization
is carried out in a homogenizer in two stages in the temperature range of 63-74 ⁰C. Pressure
of 2500 psi in the first stage and 500 psi on the second stage is sufficient enough to carry out
the process.

Preheating: The next step in the process is "preheating" during which the standardized milk
is heated to temperatures between 75 and 120⁰C and held for a specified time from a few
seconds up to several minutes. Preheating can be done in range of 83⁰C for 15 min to 93 degree
C for 3 minutes. Preheating causes a controlled denaturation of the whey proteins in the milk
and it destroys bacteria, inactivates enzymes, generates natural antioxidants and imparts heat
stability. The exact heating/holding regime depends on the type of product and its intended
end-use. High preheats in WMP are associated with improved keeping quality but reduced
solubility. Preheating may be either indirect (via heat exchangers), or direct (via steam
injection or infusion into the product), or a mixture of the two. Indirect heaters generally use
waste heat from other parts of the process as an energy saving measure.
Condensing: In the evaporator the preheated milk is concentrated in stages or "effects" from
around 13% total solids content for whole milk, up to 35-45% total solids. This is achieved by
boiling the milk under a vacuum at temperatures below 72 degree C in a falling film on the
inside of vertical tubes, and removing the water as vapor .More than 85% of the water in the
milk may be removed in the evaporator. Evaporators are extremely noisy because of the large
quantity of water vapor travelling at very high speeds inside the tubes. The concentrate is
continuously removed from the evaporator with the help of continuous density tester.

Reheating: This is done to increase the efficiency of drying. The temperature of the condensed
milk after leaving the evaporator is boosted to approximately 71° Celsius in a heat exchanger
before beingpumped.

Spray Drying: This is the most important step in the manufacture of whole milk powder.
Spray drying involves atomizing the milk concentrate from the evaporator into fine droplets.
This is done inside a large drying chamber in a flow of hot air using either a spinning disk
atomizer or a series of high pressure nozzles. The concentrated milk is dried with an inlet
temperature of 143 to 232° Celsius and exit air at 74 to 93° Celsius. To reduce the heat damage
during drying and yet obtain the desired moisture, a low exhaust air temperature is preferred.
The milk is usually dried up to 5% moisture content. The aim of spray drying is to dry products
as quickly as possible and at low temperatures. By spraying into stream of hot air, liquid
products can be dried within few seconds. The whole process of spraying and drying is carried
out in a spray drier.

Cooling: Most milk driers have a continuous removal system to immediately separate the dry
product from the hot air stream. The dried product should be cooled at once to a temperature
less than 30° Celsius. If the whole milk powder is too hot when packaged, it may become
lumpy due to heat caking, and development of storage defects in flavor and color may berapid.

Sifting: A 25 mesh screen is used for sifting dried whole milk powder.

Packaging and Storage: The dried milk is finally packaged and stored under appropriate
conditions. Since high storage temperature are detrimental for the keeping quality of the dried
milk and milk products, a temperature lower than 24° Celsius is desirable. Packaging is chosen
to provide a barrier to moisture, oxygen and light. Bags generally consists of several layers to
provide strength and barrierproperties.
OBJECTIVES OF PRODUCTION:

 To reduce moisture content so as to reduce the bulk, thereby effecting a saving in

storage space and packagingcost.
 Reduce the cost oftransportation.
 Provide a product which can be utilized for many food manufacturingoperations.
 To conserve natural properties of original rawmaterial.
 To increase the shelf life than liquidmilk.

APPLICATION AND USES OF MILK POWDER

Milk powders of various types are used in a wide range of products including the following:

 Chocolates and confectionery (e.g. milkchocolate)

 Cheese milk extension (powder is added to local fresh milk to increase the yield of
cheese)
 Manufacture of infantfood.
 Also widely used in various sweets such as the famous Indian milk balls known as
Rasa-Gulla and popular sweet delicacy (sprinkled with desiccated coconut) known as
chum chum.
 Icecream.
 Nutritional products for invalids, athletes, hospital useetc.
 Recombined cheeses, mainly "soft" or"fresh".
 Recombined coffee and whipping creams.
 Recombined yoghurts and other fermentedproducts.
 Baked goods, snacks andsoups
 MILK POWDER TECHNOLOGY

Spray drying has been found the most suitable process for removing the last part of the
water, since spray drying can convert milk concentrate into a powder while still keeping the
valuable properties of the milk.

The principle of all spray dryers is to transform the concentrate into many small droplets
which are then exposed to a fast current of hot air. Because of the very large surface area of
the droplets the water evaporates almost instantaneously and the droplets are transformed
into powder particles.

STAGES OF DRYING:

 One stagedrying
 Two stagedrying
 Agglomeration

One Stage Drying

One stage drying is defined as the spray drying process where the product is dried to the
final moisture content in the spray drying chamber. The initial velocity of the droplets from
the rotary atomizer is about 150 m/sec. The main temperature drop of the drying air, due to
the evaporation of the water from the concentrate, takes place during this period. An
enormous heat and mass transfer therefore takes place in the particles during an extremely
short period of time, and the product quality may be seriously harmed, if the factors
promoting degradation are not known, or are disregarded.

During the removal of water from the droplets considerable reduction in weight, volume, and
diameter of the particle takes place. Under ideal drying conditions the weight will decrease
to about 50%, the volume to about 40%, and the diameter to about 75% of the created
droplet from theatomizer.

Two-Stage Drying

The particle temperature is given by the surrounding air temperature (outlet temperature).As
the last water is the most difficult to remove by the conventional drying, the outlet
temperature has to be high enough to ensure a driving force (∆t or temperature difference
between particle and air) capable of removing the last moisture. That this will very often
have a detrimental effect on the particles.
As the evaporation will go very slowly in this range, due to the diffusion coefficient being
low, the drying equipment or after-dryer should be designed so that the powder will get a
long residence time. It can be done in a pneumatic conveying system using hot air thus
increasing the driving force.
Spray Drying Agglomeration

Agglomeration means getting smaller particles to adhere to each other to form a powder
consisting of bigger conglomerates /agglomerates, which are essential for an easy
reconstitution in water. In spray drying there are two ways of agglomeration: the spontaneous
and the forced, both in a primary and secondary form. During the spray drying process the aim
is to produce particles with a big surface/mass ratio, i.e. small particles. The reconstitution in
water of a powder consisting small particles is however difficult and requires intensive mixing
in order to disperse the powder, before it is totally dissolved. Bigger particles exhibit a better
dispersion, but the solubility is negatively affected during the operation, by agglomeration
both a good dispersion and a complete solution areobtained.

OTHER EQUIPMENTS

HEAT EXCHANGER

A heat exchanger is a device built for efficient heat transfer from one medium to another. The
media may be separated by a solid wall, so that they never mix, or they may be in direct
contact. They are widely used in space heating, refrigeration, air conditioning, power plants,
chemical plants, petrochemical plants, petroleum refineries, and natural gas processing. One
common example of a heat exchanger is the radiator in a car, in which the heat source, being
a hot engine-cooling fluid, water, transfers heat to air flowing through the radiator.

Plate Heat Exchanger:

A gasket PHE consists of a slack of closely spaced thin plates clamped together in a frame. A
thin gasket seals the plates round their edges. The plates are normally between 0.5 and 3 mm
thick and gap between them is 1.5 to 5 mm. Plate surface area ranges from 0.03 to 1.5 m2 with
a plate width: length ratio from 2.0 to3.0.
The size of PHE can vary from very small 0.03 m2 to very large, 1500 m2. The maximum flow
rate of fluid is limited to around 2500 m3/hr. Corner ports in the plates direct the flow from
plate to plate. The plates are embossed with a pattern of ridges, which increases the rigidity of
the plates and improve the heat transfer performance. Plates are available in a wide range of
metals and alloys; including stainless steel, aluminum andtitanium.
ADVANTAGES:
 The maintenance of these heat exchangers is simple, and they can be easily and
quickly dismantled for product surfaceinspection.
 The plate heat exchangers have a sanitary design for foodapplications.
 Their capacity can be easily increased by adding more plates to theframe.
 With plate heat exchangers, we can heat or cool product to within 1 of the adjacent
media temperature, with less capital investment than other non-contact type heat
exchangers.
 Plate heat exchangers offer opportunities for energy conservation byregeneration.

DISADVANTAGES:

 a plate is not a good shape to resist pressure and PHE are not suitable for pressure
greater than 30bar.
 selection of suitable gasket iscritical.
 the maximum operating temperature is limited to about 250 oC , due to the
performance of the available gasketmaterial.

PASTEURIZER

Pasteurization is the process of heating every drop of milk to at least 63⁰Cfor 30 min or 72⁰C
for 15 sec or any other temperature time combination which is equally efficient in approved
and properly operated equipment. After heating, the milk is rapidly cooled to 4- 5⁰C. It is a
process which slows microbial growth in food. The process was named after its creator, French
chemist and microbiologist Louis Pasteur. Pasteurization typically uses temperatures below
boiling since at very high temperatures milk, casein micelles will irreversiblyaggregate.
Objectives:
 To render milk safe for human consumption by destroying 100%pathogenic
microorganisms.
 To improve keeping quality of milk by destruction of almost all (95-99%)
spoilageorganisms.

High –Temperature-Short-Time Pasteurization

It employs a temperature of at least 71.1⁰C for at least 15 sec. In HTST pasteurization, raw
milk held in a cool storage tank is pumped through a plate-type heat exchanger and brought to
temperature. The key to the process rests in ensuring that every particle of the milk remains at
not lower than 71.1⁰C for not less than 15 sec. This is accomplished by pumping the heated
milk through a holding tube of such length and diameter that it takes every milk particle at
least 15 sec to pass through the tube.

EVAPORATORS

Evaporation in the food industry is used principally to concentrate foods by the removal of
water. It is also used to recover desirable food volatiles and to remove undesirable volatiles.

All liquids boil at lower temperature under reduced pressure and this is the key in modern
evaporation. If a heated kettle is enclosed and connected to a vacuum pump, one has a simple
vacuumevaporator.

An evaporator is essentially a heat exchanger in which a liquid is boiled to give a vapour, so

that it is also, simultaneously, a low pressure steam generator. It may be possible to make use
of this, to treat an evaporator as a low pressure boiler, and to make use of the steam thus
produced for further heating in another following evaporator called anothereffect.

OPERATION: The solution containing the desired product is fed into the evaporator and
passes a heat source. The applied heat converts the water in the solution into vapor. The vapor
is removed from the rest of the solution and is condensed while the now concentrated solution
is either fed into a second evaporator or is removed. The evaporator as a machine generally
consists of four sections. The heating section contains the heating medium, which can vary.
Steam is fed into this section. The most common medium consists of parallel tubes but others
have plates or coils. The concentrating and separating section removes the vapor being
produced from the solution. The condenser condenses the separated vapor, then the vacuum
or pump provides pressure to increase circulation.
 MASS BALANCE

Assumptions:
 50,000 kg/hr is being fed for production of whole milkpowder

 50,000 kg milk contains 84% moisture, 6.5% Fat and 9.5%SNF

Material balance on Standardization:

Whole milk Powder contains 26% fat & 70 % SNF

Therefore, In WMP, SNF/FAT= 70/26=2.692

and SNF/FAT in the raw milk is 9.5/6.5=1.46

To maintain this ratio we need to add skim milk and this is known as standardization.

Skim Milk (S)

0.1% MF
9.6% SNF
Whole Milk Standardised Milk
6.5%MF
9.5%SNF Standardize
50,000kg

Let the skim milk be added = S kg

Assumption :

 Skim milk contains 0.1% FAT, 9.6% SNF and 90.3%moisture

50000*(9.5/100) + S* (9.5/100)= 70
50000*(6.5/100) +S*(0.1/100) 26

S= 42869kg

Thus we need to add 42869 kg skim milk to standardize the feed.

Total amount of milk = 50000+ 42869= 92869 kg

Moisture in Standardized Milk= 84% of 50000 + 90.3% of 42869 = 80710.70 kg

%age moisture = (80710.70/92869)*100= 86.90%

Solids in Standardized Milk= 16% of 50000+ 9.7% of 42869 = 12158.29 kg

% solids = (12158.29/92869)*100 = 13.09%

Milk Fat in Standardized Milk= 6.5% of 50000 + 0.1% of 42869= 3292.87 kg

%age fat = (3292.87/92869) *100= 3.54%

Material Balance on Condenser

Moisture (M)

Standa Condensed Milk(X

rdized
Milk(S EVAPORATOR
kg) kg) Solids: 36%
Moisture: 64%
Sol
ids
:
13.
09
%
Mo
ist
ure
:
86.
90
%

Let the moisture removed be M kg

Assumption:
  Condensed Milk obtained from evaporator contains 36% solids & 64%moisture.

Applying overall balance:

S=M+X
Applying balance on Solids:
0.1309*92869 = 0.36* X
X= 33768.2kg
i.e. 33768.2 kg milk is produced after condensing.

Applying balance on Moisture:

0.8690*92869 = M + 0.64*33768.2
M = 59091.51 kg moisture removed
Applying Balance on fat:
0.0354* 92869= 0.0F*33768.2
F = 9.735%

Material balance on Spray Drier

Moisture (M)
Conde WMP (Y kg)
nsed
Milk SPRAY DRIER Solids: 96%
Moisture: 4%
Solids:
36%
Moistu
re:
64%

Air In

Applying balance on Solids:

0.36*33768.2 = 0.96*Y
y = 12663.075 kg WMP produced

Applying balance on moisture:

0.64*33768.2 = M + 0.04*12663.075
M = 21105.127kg moisture removed

Thus from 92869 kg standardized milk we get 12663.075 kg WMP

Required capacity: 50000 kg/day or 2083.3 kg/hr
For 12663.075 kg powder, milk required= 92869 kg
For 2083.3 kg powder, milk required= (92869/ 12663.075)* 2083.3= 15278.8 kg

12663.075 kg WMP produced from 50000 kg raw milk

For 2083.3 kg WMP, raw milk required= (50000/12663.075)*2083.3 = 8226 kg raw milk

Skim Milk Required= 15278.8- 8226= 7052.8 kg

From 92869 kg std. milk condensed milk= 33768.2 kg

From 15278.6 kg std. milk condensed milk= 5555.54 kg

From 33768.2 kg condensed milk, moisture removed= 21105.127 kg

From 5555.54 kg condensed milk, moisture removed= (21105.127*5555.45)/33768.2 kg
= 3472.21 kg
 ENERGY BALANCE

1. On ColdStorage

Cp avg. = 1674.72(FAT) + 837.36(SNF) + 4186.8(Moisture)

For Raw milk, Cp avg. = 1674.72(0.065) + 837.36(0.095) + 4186.8(0.84)

Cp avg. = 3705.3 J/kg K

= 3.705 kJ/kg K

Now the Inlet Temp. = 25oC = 298K

Outlet Temp = 4oC= 277K

Heat Loss (Q) = M Cp (dT)

Q = 8226*3.705*(277-298)

Q = -640023.9300 kJ/kg= -177.7844kJ/sec

Therefore, 177.7844 kJ/sec of the heat is lost to the environment.

1. On pre-heating of Raw Milk( For efficient Filtration/Clarification)

We know that Cp avg. = 3.705 kJ/kg K

Amount of raw milk = 8226 kg

Initial Temp= 277 K

Final Temp= 344 K

Heat Gained = M Cp (dT)

 = 8226*3.705*(344-277)= 2041981.11 kJ/hr

Q = 567.216 kJ/sec

Therefore, 567.216 kJ/sec is the heat supplied by the steam ( at 1 atm, 373K ) ; L s= 540
kCal/kg or 2260.44 kJ/kg.

Applying Heat Balance

M Ls= 2041981.11 kJ/hr

M*(2260.44) =2041981.11

M= 903.355 kg/hr

Therefore, 903.355 kg/hr of the steam is required.

2. ONHOMOGENIZER

Amount of standardized milk = 15278.8 kg

Inlet temp= 344K

Outlet Temp= 347K

Cp avg. = 1674.72(0.0354) + 837.36(0.1309) + 4186.8(0.8690)= 3.807 kJ/kg K

Heat Gained (Q)= M Cp (dT)

= 15278.8*3.807*(347-344)

Q = 174499.1748 kJ/hr

Therefore, 174499.1748 kJ/hr is the heat supplied by the steam ( at 1 atm, 373K ) ; L s= 540
kCal/kg or 2260.44 kJ/kg.

Applying Heat Balance:

M Ls= 174499.1748

M*2260.44= 174499.1748
M= 77.197 kg/hr

Therefore, 77.197 kg/hr of the steam is required.

3. ON HEAT EXCHANGER ( For inactivation ofLipase)

Cp standardized milk = 3.807 kJ/kg K

Inlet Temp= 347K

Outlet temp=356K

Heat Gained (Q)= M Cp (dT)

= 15278.8*3.807*(356-347)

Q = 523497.52 kJ/hr

Therefore, 3181970.547 kJ/hr is the heat supplied by steam.

Applying HeatBalance:

M Ls=523497.52

M*2260.44=523497.52

M= 231.590 kg/hr

Therefore, 231.590 kg/hr is the steam required.

4. ONEVAPORATOR

Applying mass balance

Mf = Mv1 + Mv2+Mp ---------------------------- (1)

Cp(Mf)= 3.807 kJ/ kgK

Cp(Mf1)= 3.374 kJ/kgK

Cp(Mp)= 3.062 kJ/kgK

Assumptions & Equations are referred from Introduction to Food Engineering By Dennis R.
Heldman

Assuming reference temp= 273 K

Hf (mf) = 3.807 (355-273) = 312.174kJ/kg

Hf (mf1) = 3.374 (368-273) = 320.53kJ/kg

Hf (mp) = 3.062 (343-273)= 214.34 kJ/kg

Applying Enthalpy Balance ( On 1 st Evaporator)

mf*(Hf) + ms(Hvs) = mv1(Hv1) + mf1(Hf1) + ms(Hcs)

15278.6*312.174 + ms (2706.31) = mv1 (2668.1) + 7692.18*320.53+ms(503.71) --------- (2)

Using eq. (1)

mf = mv1 + mv2 + mp

mv1 + mv2=9723.15 ---------------------- (i)

Applying Enthalpy Balance ( On 2nd Evaporator)

mf1*(Hf1) + mv1(Hv1) = Mv2(Hv2) + Mp(Hfmp) + Mv1(Hf1)

7692.18*320.53 + mv1(2668.1) = mv2 ( 2626.8) + 5555.54*214.34 +mv1(397.96) ------- (3)

Using (i) in (3)

4896.94 mv1= 24265951.12

mv1= 4955.33kg

mv2= 4767.82kg

Using above values in (2)

2205.59 ms= 15686890.43-4733157.494

ms= 4966.35 kg

Therefore, 4966.35 kg is the steam required per hour.

Steam Economy= (mv1+mv2)/ms

= (4955.33+4767.82)/ 4966.35

Steam Economy = 1.957 kg water vapour/kg steam

5. ON SPRAYDRIER

Specific Heat of water vapour = 1.88 kJ/kg K

Sp heat of water = 4.186 kJ/kg K

Sp heat of air at 200 oC =1.026 kJ/kgK

Sp heat of air at 100oC = 1.009 kJ/kgK

Latent Heat of Vaporisation (at 1 atm) = 540 kcal/kg or 2260.44 kJ/kg

Cp avg. = 1674.72(FAT) + 837.36(SNF) + 4186.8(Moisture)

Cp feed. = 1674.72(0.09757) + 837.36(0.36) + 4186.8(0.64)

Cp feed. = 3.144 kJ/kg

Cp milk powder = 1674.72(0.26) + 837.36(0.7) + 4186.8(0.04)

Cp milk powder. = 1.189 J/kg

Let the reference temp be 273K

Heat with milk = M Cp(dT)

=5555.54*3.144*70

Q = 1222663.243 kJ

Let Ma be the amount of air used for evaporation

Heat inlet with air = Ma Cp (dT)

=Ma*1.026*200

= 205.2 MakJ/hr

Heat output with solids = Ms Cp (dT)

= 2083.3*1.189*80

= 198163.49 kJ/hr
Heat outlet with air = Ma*1.009*100

=100.9Ma kJ/hr

Heat Utilized for evaporation= Mw

=3472.15*2260.44

= 7848586.74 kJ/hr

Applying Heat Balance:

Heat Input = Heat Output + Heat Utilized

1222663.243 + 205.2Ma = 198163.49 + 100.9Ma + 7848586.74

Ma= 65427.48 kg air

Amount of heat required = Ma Cp (dT)

= 65427.48 *1.026*100

Q = 6712860.258 kJ/hr

Heat required per kg water evaporated = 6712860.258 /3472.15 = 1933.34 kJ/kg

ON COOLING

Specific heat of Milk Powder = 1.189 kJ/kg K

Mass fo Milk Powder= 2083.3 kg

Inlet temp= 353K

Outlet temp= 305K

Heat lost = M Cp (dT)

= 2083.3*1.189*(305-353) kJ/hr

Q = -33.027kJ/sec

Heat Lost to the environment= 33.027kJ/sec

 DESIGNING
1. Designing of SprayChamber

Let the Diameter of droplet is assumed to be 100micrometer ( Reference: Sukumar De)

Inlet air temp= 200oC(Tx)

Outlet temp= 100 oC (Tf)

Assuming absolute humidity of inlet air= 0 (Absolute dry)

Therefore from the psychometric charts;

Wet bulb temp= 45 oC (Tw)

Density of air= 1.2676 e -0.0026*0.5*(Tx+Tf)

= 1.2676 * 0.6771 = 0.858 kg /m3

Viscosity of air at 200oC = 2.62* 10-5

Density of water = -0.0028Tw2-0.1213Tw+1000.8 ( Reference: Chapman &hall)

=989.67 kg/m3

Terminal Velocity is given by

Vt= Dp*g*(ρ water- ρ air)/18*µair ( Reference: Coulson & Richardson)

Vt= 0.2056m/s

Assuming Vav= average air velocity indrier=1.5m/s ( Reference:Kessler)

Let the Residence time be = 6sec

Height of Spray Drier Chamber = Residencetime* (Vt+Vav) ( Reference: Kessler)

Height of Spray Chamber= 6* (0.2056+1.5) = 10.234m

Diameter of Spray Chamber is given by:

D=Sqrt(4Ma/π*ρ*Va) (Reference:Kessler)
D = Sqrt( 4*18.26/π* 0.858*0.4)

D=8.233 m

Assuming Height of conical part=

x Cone angle =120o

Tan 60 o = D/2x

Sqrt(3)= 8.233/2x

X= 2.376 m

Therefore, Height of Cylindrical Part = 10.234- 2.376 = 7.858 m

2. DESIGN OF ROTARYATOMIZER
Assuming Revolutions of disc=200rps ( Reference: Coulson & Richardson)

Circumferential velocity =250m/s

Mass flow rate of feed (G)= 5555.54 kg/hr = 1.5432 kg/sec

Density of milk (ρ)= 1023 kg/ cubic m

Volumetric flow rate = 5555.54/1023= 5.4306 m3/hr

= 0.001508 m3/sec

Assuming 1 pore diameter = 1mm

Area of pore= πd2/4 = 7.85 * 10-7m2

Number of pores = Volumetric flow rate(m3/sec)/ velocity(m/sec) * area of pore(m2)

Number of pores = 7.68= 8 pores

Therefore each pore is at an angle of 45O from other.

By Walton& Prewett, disc diameter, D is given by:

D = (0.52/dpN)2* (σ/ρ)
σ = surface tension of milk= 0.0644 N/m

ρ = density of milk=1023kg/m3

N = revolutions per unit time = 200rps

dp = diameter of droplet = 100 micro meter

D = (0.0644/1023)*(0.52/100*10-6*200)2

Disk Diameter = 0.4256m

D=425.6mm

Disk diameter = 425.6mm

SPECIFICATIO
Spra
N SHEET
y
Drier

S. No. Parameter Specification

1. Height 10.234m
2. Diameter 8.233m
3. Cone Angle 1200
4. Height of conical part 2.376m
5. Height of cylindrical part 7.737m

Rotary Atomiser
S.No. Parameter Specification
1. Area of pore 7.85*10-7
2. No. of pores 8
3. Pore Angle 450
4. Disc Diameter 425.6mm
 PROCESS
INSTRUMENTATIONDIAGR
AMS

1. PLATE HEATEXCHANGER
2. SPRAY DRIER

3. DOUBLE EFFECTEVAPORATOR
PROCESS FLOW DIAGRAM
 PLANT UTILITIES
The word Utilities is now generally used for the ancillary services needed in the operation of
any production process. These services will normally be supplied from a central site facility;
and will include:

1. Electricity.
2. Steam, for process heating
3. Cooling water
4. Water for general use
5. Refrigeration
6. Effluent disposal facilities

Electricity

The power required for electrochemical processes; motor drives, lighting, and general use,
may be generated on site, but will more usually be purchased from the local supply company
The voltage at which the supply is taken or generated will depend on the demand. For a large
site the supply will be taken at a very high voltage, typically 11,000 or 33,000 V. Transformers
will be used to step down the supply voltage to the voltages used on the site. If a number of
large motors is used, a supply at an intermediate high voltage will also be provided, typically
6000 or 11,000 V.

Steam

The steam for process heating is usually generated in water tube boilers; using the most
economical fuel available. The process temperatures required can usually be obtained with
low-pressure steam, typically 2.5 bar (25 psig), and steam is distributed at a relatively low
mains pressure, typically around 8 bar (100 psig). Higher steam pressures, or proprietary heat-
transfer fluids, such as Dowtherm), will be needed for high process temperatures.

Combined heat and power (co-generation)

The energy costs on a large site can be reduced if the electrical power required is generated on
site and the exhaust steam from the turbines used for process heating. The overall thermal
efficiency of such systems can be in the range 70 to 80 per cent; compared with the 30 to 40
per cent obtained from a conventional power station, where the heat in the exhaust steam is
wasted in the condenser. Whether a combined heat and power system scheme is worth
considering for a particular site will depend on the size of the site, the cost of fuel, the balance
between the power and heating demands; and particularly on the availability of, and cost of,
standby supplies and the price paid for any surplus power electricity generated. On any site it
is always worth while considering driving large compressors or pumps with steam turbines
and using the exhaust steam for local process heating.

Cooling water

Natural and forced-draft cooling towers are generally used to provide the cooling water
required on a site; unless water can be drawn from a convenient river or lake in sufficient
quantity. Sea water, or brackish water, can be used at coastal sites, but if used directly will
necessitate the use of more expensive materials of construction for heat exchangers

Water for general use

The water required for general purposes on a site will usually be taken from the local mains
supply, unless a cheaper source of suitable quality water is available from a river, lake or well.

Refrigeration

Refrigeration will be needed for processes that require temperatures below those that can be
economically obtained with cooling water. For temperatures down to around 10°C chilled
water can be used. For lower temperatures, down to 30°C, salt brines (NaCl and CaCl2) are
used to distribute the “refrigeration” round the site from a central refrigeration machine.
Vapour compression machines are normally used.

Effluent disposal

Facilities will be required at all sites for the disposal of waste materials without creating a
public nuisance.
PLANT LOCATION AND SITE SELECTION
The geographical location of the final plant can have strong influence on the success
of the industrial venture. Considerable care must be exercised in selecting the plant site, and
many different factors must be considered. Primarily the plant must be located where the
minimum cost of production and distribution can be obtained but other factors such as room
for expansion and safe living conditions for plant operation as well as the surrounding
community are also important. The location of the plant can also have a crucial effect on the
profitability of a project.

The choice of the final site should first be based on a complete survey of the
advantages and disadvantages of various geographical areas and ultimately, on the
advantages and disadvantages of the available real estate. The various principal factors that
must be considered while selecting a suitable plant site are briefly discussed in this section.
The factors to be considered are:

1. Raw material availability

2. Location (with respect to the marketing area)

3. Availability of suitable land

4. Transport facilities

5. Availability of labors

6. Availability of utilities (Water, Electricity)

7. Environmental impact and effluent disposal

8. Local community considerations

9. Climate

10. Political strategic considerations

11. Taxations and legal restrictions

Raw Materials Availability:

The source of raw materials is one of the most important factors influencing the selection of a
plant site. Attention should be given to the purchased price of the raw materials, distance from
the source of supply, freight and transportation expenses, availability and reliability of supply,
purity of raw materials and storage requirements.

Location:

The location of markets or intermediate distribution centers affects the cost of

product distribution and time required for shipping. Proximity to the major markets is an
important consideration in the selection of the plant site, because the buyer usually finds
advantageous to purchase from near-by sources.

Availability of Suitable Land:

The characteristics of the land at the proposed plant site should be examined carefully.
The topography of the tract of land structure must be considered, since either or both may
have a pronounced effect on the construction costs. The cost of the land is important, as well
as local building costs and living conditions. Future changes may make it desirable or
necessary to expand the plant facilities. The land should be ideally flat, well drained and have
load-bearing characteristics. A full site evaluation should be made to determine the need for
piling or other special foundations

Transport:

The transport of materials and products to and from plant will be an overriding
consideration in site selection. If practicable, a site should be selected so that it is close to at
least two major forms of transport: road, rail, waterway or a seaport. Road transport is being
increasingly used, and is suitable for local distribution from a central warehouse. Rail
transport will be cheaper for the long-distance transport. If possible the plant site should have
access to all three types of transportation. There is usually need for convenient rail and air
transportation facilities between the plant and the main company headquarters, and the
effective transportation facilities for the plant personnel arenecessary.
Availability of Labors:

Labors will be needed for construction of the plant and its operation. Skilled
construction workers will usually be brought in from outside the site, but there should be an
adequate pool of unskilled labors available locally; and labors suitable for training to operate
the plant. Skilled tradesmen will be needed for plant maintenance. Local trade union customs
and restrictive practices will have to be considered when assessing the availability and
suitability of the labors for recruitment andtraining.

Availability Of Utilities:

The word “utilities” is generally used for the ancillary services needed in the operation
of any production process. These services will normally be supplied from a central facility
and includes Water, Fuel andElectricity.

Environmental Impact And Effluent Disposal:

Facilities must be provided for the effective disposal of the effluent without any public
nuisance. In choosing a plant site, the permissible tolerance levels for various effluents should
be considered and attention should be given to potential requirements for additional waste
treatment facilities. As all industrial processes produce waste products, full consideration
must be given to the difficulties and coat of their disposal. The disposal of toxic and harmful
effluents will be covered by local regulations, and the appropriate authorities must be
consulted during the initial site survey to determine the standards that must bemet.

Political And Strategic Considerations:

Capital grants, tax concessions, and other inducements are often given by
governments to direct new investment to preferred locations; such as areas of high
unemployment. The availability of such grants can be the overriding consideration in site
selection.

Taxation And Legal Restrictions:

State and local tax rates on property income, unemployment insurance, and similar
items vary from one location to another. Similarly, local regulations on zoning, building codes,
nuisance aspects and others facilities can have a major influence on the final choice of the
plantsite
 PLANT LAYOUT

After the flow process diagrams are completed and before detailed piping, structural and
electrical design can begin, the layout of process units in a plant and the equipment within these
process unit must be planned. This layout can play an important part in determining construction
and manufacturing costs, and thus must be planned carefully with attention being given to future
problems that mayarise.

Thus the economic construction and efficient operation of a process unitwill depend on how well
the plant and equipment specified on the process flow sheet is laid out. The principal factors that
are considered are listed below:

1. Economic considerations: construction and operatingcosts

2. Processrequirements

3. Convenience ofoperation

4. Convenience ofmaintenance

5. Health and Safetyconsiderations

6. Future plantexpansion

7. Modularconstruction

8. Waste disposalrequirements

Costs:

Adopting a layout that gives the shortest run of connecting pipe between equipment, and
leastamountof structural steel work can minimize thecoat of
construction.However,thiswillnotnecessarilybethebestarrangementforoperationand
maintenance.
Process Requirements:

An example of the need to take into account process consideration is the need to elevate the base
of columns to provide the necessary net positive suction head to a pump.

Convenience Of Operation:

Equipment that needs to have frequent attention should be located convenient to the control
room. Valves, sample points, and instruments should be located at convenient positions and
heights. Sufficient working space and headroom must be provided to allow easy access to
equipment.

Convenience Of Maintenance:

Heat exchangers need to be sited so that the tube bundles can be easily withdrawn for cleaning
and tube replacement. Vessels that require frequent replacement of catalyst or packing should be
located on the outside of buildings. Equipment that requires dismantling for maintenance, such as
compressors and large pumps, should be placedundercover.

Health And Safety Considerations:

Blast walls may be needed to isolate potentially hazardous equipment, and confine the effects of
an explosion. At least two escape routes for operators must be provided from each level in process
buildings.

Future Plant Expansion:

Equipment should be located so that it can be conveniently tied in with any future expansion of the
process. Space should be left on pipe alleys for future needs, and service pipes over-sized to allow
for future requirements.

Modular Construction:

In recent years there has been a move to assemble sections of plant at the plant manufacturer’s
site. These modules will include the equipment, structural steel, piping and instrumentation. The
modules are then transported to the plant site, by road or sea.
THE PLANT LAYOUT KEY WORDS

1. Raw materialStorage

2. Raw materialhandling

3. Container Wash

4. Showers &Toilets

5. Ingredients

6. HygieneFacilities

7. TippingSection

8. General Store

9. Office AdministrationBuilding

10. Quality Control &R&D

11. Effluent treatmentplant

12. Pasteurization &Condensation

13. Emergency waterstorage

14. Plantutilities

15. PackagingArea

16. Library andLaboratories

17. Secondary ProcessingArea

18. ChemicalStore

19. Loading

20. Final productstorage

PLANT LAYOUT

This plant layout is just a reference plant layout. There may be a lot of changes in actual plant
layout
SAFETY, ENVIRONMENTAL AND
ETHICALISSUE
All manufacturing processes are to some extent hazardous but in chemical processes, there are
additional special hazards associated with it like toxicity, flammability, explosions, pressure
variations, temperature variations and noise.

Toxic and corrosive chemicals, fire explosions and mechanical equipment are the major health
and safety hazards encountered in the operations of the plant in the process industries,
Maximum protection must be provided to the plant personal and there must be a minimum
chance of occurrence of accidents.

CHEMICAL HAZARDS:

Many chemicals cause dangerous burns if they come in contact with the tissues. Eyes and
membranes of nose and throat are particularly susceptible to the effects of corrosive dusts, mist
and gases. Tolerance levels of toxic chemicals and explosive limits for various flammable
materials must be known.

FIRE AND EXPLOSIONHAZARDS:

Careful plant layout and judicious choice of constructional material reduces the chance of this
hazard. Eliminating all the unnecessary ignition sources such as flames reduces possiblesources
of fire. Other sources include sparks of heated materials, matches, smoking, welding, non-
explosion proof electrical equipmentetc.

Fire alarms, temperature alarms, firefighting equipment, and sprinkler system must be available
readily in the plant. First aid stations, protected walkways and work areas should be providedin
the finalplant.

AIR & LAND POLLUTION:

Electrostatic scrubbers, venturi scrubbers, cyclones, washers and many other equipment and
treating methods should be used to remove atmospheric contaminants from waste gases.
Incineration and burying in concrete encased blocks are possible solutions of dangerous solid
waste.

WATER POLLUTION:

Dissolved inorganic solids, acids, alkalis, suspended solids and floating matter, oxygen
consuming materials, other toxic materials, taste and colour producing materials etc. must also
be taken care of.
SAFETY IN PLANT:

There are primarily two types of major hazards in a chemical industry

• The first is due to flammability, low flash point and wide explosive limits of thechemicals
handled. • Toxic hazards due to toxicity and carcinogenic nature of variouschemicals.

Complete understanding of the chemicals, their physical and chemical properties, especially
with respect to reactivity, is very important for their safe handling.

ROUTINE CHECKS:

The various routine checks that have to be kept in mind are:

• The safety valves are regularly checked for setting, • The water deluge system is checked
every week. • The reactor start up and operation checklist includes the testing of safetysystems
connected with thereactor.

• The pipelines are checked regularly for leakages. • The valves and other instrumentsare
regularly checked and replaced in case there is anyfailure.

.
 BIBLIOGRAPHY

LIST OF BOOKS REFFERED:

1. Sukumar De, Outlines of Dairy Technology, 38th Edition, OxfordUniversityPress,

2013.

2. R Paul Singh & Dennis R Heldman, Introduction to Food Engineering, 3 rd

Edition, Academic Press,2004.

3. RK Sinnot, Coulson & Richardson's Chemical Engineering Series Chemical

Engineering Design, 4th Edition(Volume 6), Elsevier Butterworth Butterworth,2005.

4. Max S. Peters & Klaus D. Timmerhaus, Plant Design and Economics for
Chemical Engineers, 4th Edition, McGraw-Hill,1991.

LIST OF WEBSITES EXPLORED:

1. www.amul.com

2. www.dairyconsultanat.co.uk

3. www.pipingdesigns.net