HATSUN AGRO PRODUCTS LTD

DESIGN OF NOZZLE FOR MINIMIZING WATER IN CLEANING SILO

TANK

By,
Vignesh. S
AravindhKumar. K
Saravanan. K

Guided by
Mr.S. Thangakasi Rajan M.E(P
Abstract
• The main objective of water auditing in Hatsun agro product plant is
to quantify the water flows and with a view of reducing water usage
while cleaning the “Silo tank” present in the plant.
• Here hoses are maintained for cleaning the tank, because of this
more amount of water has been wasted.
• Here we have analyzed the water losses while cleaning silo tank, so
we designed a nozzle for reducing water losses through power
washing.
• This nozzle design is frequently used to control the rate of flow,
pressure and velocity of water coming out from the outlet of the
nozzle.
Literature Review
• Jagatheesan, V., Lee, S. H., Visvanathan, C., Tariman, C. A., Shu, L.,
and Maria Marzella, “A case study on waste auditing in an ice
cream factory”,Environmental Engineering Research, vol.4, no. 2,
pp. 103-111, 1999.

• Lipp, Charles W., Practical Spray Technology: Fundamentals and

Practice, 2012.
• Hatsun often called Hatsun Agro Products is the largest private sector
dairy Company in India based in Chennai. It was founded
by R.G.Chandramogan in 1986.

• Totally it has 14 plants across Tamil Nadu and Karnataka for processing
and packaging.

• The company today collects milk from 3,00,000 farmers every day and
has a network of 6000 collection centers and 62 chilling centers in
various parts of Tamilnadu and Karnataka.
There are more than 1250 Hatsun Distribution Centres selling the complete range
of Hatsun products such as Milk, Ice Cream. Curd, Panner, Buttermilk, Ghee, Butter
and Milk powder.
Hatsun Dairy Ingredients are supplied to various prestigious large, medium and
small customers across India and also to 38 countries around the world including
Canada. The company has three major divisions, Ice Cream, Milk and Milk
Products & Ingredients. The Hatsun brand includes Arun Ice Creams, which is the
leading ice cream brand in South India, Arokya milk – largest private sector liquid
milk brand in India, selling 1 million litres per day, Hatsun – the fast moving
consumer goods brand in Ghee, Butter and Milk powder.
The Chennai based Hatsun Agro Product Ltd, which is the largest
private sector dairy in India, has set up the biggest state of the art
plant in South India near Palacode, in Dharmapuri District, Tamilnadu.

This plant, has the most modern systems and technology and a
processing capacity of 9,00,000 liters of milk per day.

Milk powder producing capacity of the plant 63Tonnes/per day.

INTRODUCTION
• Industrial water use includes water used for such purposes as
fabricating, processing, washing, diluting, cooling, or transporting a
product; incorporating water into a product; or for sanitation needs
within the manufacturing facility.
• A reliable, high quality water supply is essential to dairy farms. Water
is used for animal consumption, milk cooling, cleaning and sanitizing
equipment, cow cooling, irrigating crops, producing value added
products, moving manure and cleaning the barns via flush systems.
WATER RESOURCES

1.Bore well
2.Municipal water
3.Rivers
4.Dug well
5.Contractors
WATER USAGE AREAS
1.Process Water
2.Cooling Water
3.Boiler feed water
4.Miscellaneous water

• Process water: Water used for direct preparation of products,

cleaning purposes and various technical purposes. Examples are:
washing / cleaning of equipment, transport of product, dissolution of
ingredients, water remaining in the final product etc. A characteristic
of process water is that it comes into contact with product directly or
indirectly.
Cooling water:
Cooling water is the water used for removal of heat from process
streams and products.

Boiler feed water:

Boiler fed water is required for steam production. The main
quality requirements are low hardness and low air and carbon dioxide
content.

Miscellaneous:
Other uses of water in a dairy plant are for ancillary purposes
such as amenities and gardens, and extraordinary incidents (e.g. fire
protection).
FLOW DIAGRAM

RAW WATER RAW WATER

MGF ACF
TANL

RO STORAGE RO WATER SOFTWATER SOFTWATER FILTER WATER

TANK PLANT STORAGE TANK TREATMENT TANK

PROCESS SECTION
PROCESS

The water Consumption of the plant is about 7,00,000 ltrs to
9,00,000 ltrs per day

Here raw water is obtained as a contract basis. The company has
totally 13 contractors to supply raw water

The contractors averagely supply 6,00,000 ltrs per day.

The raw water undergoes some lab test, they are mentioned below;
1.Hardness Test
2. pH Test

Raw water storage tank is about 4,00,000 ltrs capacity.
The raw water can’t be directly used for the food process,hence raw
water is processed to following catagories;

TDS pH HARDNESS

Raw Water 0 – 1000ppm 6.5 – 8.5 0 – 400ppm

Filter Water 0 – 1000ppm 6.5 - 8.5 0 – 400ppm

Soft Water 50 – 150ppm 0 – 30ppm

RO Water 0 – 50ppm 6 – 6.5 2ppm (or)Nil

Condensed Water 0 – 150ppm 0 – 4ppm

FILTER WATER

During the water intake from contractors Hypo chloride is added to the
raw water to avoid formation of scale and smell in the water itself.
 Anything that removes any amount of particles, sediment, bacteria and
removes the chlorine taste, can be called water filtration and that water is
called Filter Water.
 After that water is passed into two types of filters mentioned below,
1.MGF(Multi Grade Filter)
2.ACF(Active Carbon Filter)
MGF consist of four layers of stones and sand, which filters the minute
solid particles.
 ACF is similar to MGF and the only difference is the upper layer is
filled with salt shaped carbon
 Then the water is passed through the UV(Ultra violet) Treatment;
here the UV Lamp treats the bacteria and eliminates them from
water.
 Then water will be send to the “Filter water storage tank” which has
the capacity of 2,00,000 ltrs.
 The Hardness level for the “Filter water” is about 0 – 400ppm and
TDS value is about 0 – 1000ppm.
 Filter water is used in Hygiene section,Tanker cleaning and soft water
processing.
SOFT WATER
 water that has been produced by a water softening process although
such water is more correctly termed softened water. In these cases
the water may also contain elevated levels
of sodium and bicarbonate ions .
 Soft water is produced by processing the “Filter water”.
 The soft water is produced with the help of “Softening filter”.
 Softening filter is similar to MGF and the only difference is the upper
layer is filled with Resins.
Then it will send to the “Soft water storage tank” which has the
capacity of 2,00,000 ltrs.
The Hardness level for the “Soft water” is about 0 – 30ppm and TDS
value is about 50 – 150ppm.
Soft water is used in cream separator, boiler section and RO water
processing.
RO WATER
 Reverse osmosis (RO) is a water purification technology that uses a
semipermeable membrane to remove ions, molecules and larger
particles from water.
 RO water is produced with the help of “Soft Water”.
 Here separate RO plant is used to produce the RO Water required.
 Then it will be send to the “RO Water storage tank” which has the
capacity of 2,00,000 ltrs.
 The Hardness level for the “RO water” is about 2ppm or Nil and TDS
value is about 0 – 50ppm.
 RO Water is used in flavored milk section and silo cleaning.
CONDENSED WATER
 The vapors that “boil out” from the powder section aren’t allowed
to escape. Instead, the vapors are condensed (cooled, so they turn
back into a liquid) into water and comes back to the WTP(Water
Treatment Plant) for further purpose.
 The cow water is processed similar to the raw water processing into
“Condensed filter water”.
 Then it will send to the “Condensed filter water storage tank” which
has the capacity of 2,00,000 ltrs.
 This water is only used for CIP(Cleaning in plant) purpose.
WATER WASTAGES
PROCESS SECTION:
• Operating pasteurizers for short durations
• Condensate from pasteurizers allowed to drain
• Water being allowed to overflow the balance tank when
pasteurizers and other equipment are on rinse
• Manual cleaning of separator with running water hoses
• Cleaning of milk tanks by high pressure discharge points
MILK FILLING SECTION:
• Manual cleaning of crates with running water hoses
• Machine cooling water drained

BUTTER AND GHEE SECTION:

• Draining of cooling water sprayed over butter churns
• Draining of condensate from ghee boilers
• Draining of cooling water from settling tanks
CIP SYSTEMS:
• CIP done without recirculation, or used CIP solutions being
drained frequently
• CIP systems not recovering final rinse water for reuse as pre-rinse
water

REFRIGERATION SECTIONS:
• Draining of chilled water or leakages in chilled water system
• Evaporation losses in atmospheric condensers
Problems while water auditing :

• During cleaning process, large amount of water is getting wasted and

because of this more amount of water is needed for several purposes.
And the flow of water level is taking more time.

• Sewage water is excluded because of more dirty liquid substances in

it .

• Recycled used plant water is not again recycled for another usage of
water .
Remedies :

• Using nozzles for obtaining time consumption and flow of water level
is reduced which will be helpful to clean at precise time and less water
usage .

• Effluent treatment plant can be used for essential purification of

waste or sewage water which comes from industry.

• RO plant is suggested for the water purification, contains partially

permeable membrane to remove ions molecules and large particals
from the recycled water .
Design Water Nozzle :
Design and Analysis of Water Nozzle
Study Result of Stress Analysis of Nozzle
Calculation
Conclusion
• By this project, I have concluded that our suggestions and ideas are used to
enhance the development of the industry as well as it increases the economical
state .
• Through effluent treatment plant and RO plant, the waste water level will be
reduced , due to the recycling process. This processes lead to save the raw pure
water from the river basins. Also the cleaning process requires lot of water when
using normal hoses without nozzles.
• Due to this process, a lot of water is wasted in terms of cleaning purpose. So we
have designed a nozzle for reducing the amount of water used in the washing
process of silo tanks.
The nozzle reduces the water level by increased velocity of water and
decreases the flow rate of water.
Initially they purchase the raw water at the cost of Rs.375 in winter
season and Rs.450 in summer season and sometimes the amount of
raw water is vary between above mentioned values.
Foresaid amount is only for one load; one load is equal to around
6,000 Liters.
They bought nearly 121 loads from suppliers which is equal to
6,00,000Ltrs.
The total amount of raw water they purchase is between
Rs.45,375 to Rs.54,450 per day.
The price of their purchase is between Rs.0.0625 to Rs.0.075 per liter.
Approximately they use 3,00,000Ltrs of water for cleaning
purpose.
Water use has been reduced by 25% after nozzle is applied.
Amount of water used for cleaning purpose = 3,00,000Ltrs.
Amount of water reduced for cleaning purpose(In percent) = 25%.
25% of 3,00,000Ltr = 0.25 * 3,00,000
= 75,000Ltr
Totally 75,000Ltrs of water usage is reduced per day, which cost is
between Rs.4,876.50 to Rs.5,625
 Total load purchased per day 121 Loads

Amount of water per load 6,000Ltrs

Price of water per load (In Winter) Rs.375
Price of water per load (In Summer) Rs.450
Price of water per liter(In Winter) Rs.0.0625
Price of water per liter(In Summer) Rs.0.075
Price of water purchased per day(In Winter) Rs.45,375

Price of water purchased per day(In Summer) Rs.54,450

Water Usage per day Price of water used per day

(In Ltrs) (In Rs.)
Before nozzle fixed 3,00,000 18750 to 22500
After nozzle fixed 2,25,000 14062 to 16875
Result :
• In first step 100 liters of water is used before nozzle fixed

• And in second step 75 liters of water is only used continuously after

the nozzle is fixed.