Module contents theory

1.

Introduction

2.

Dairy processing

3.

Dairy products manufacturing

4.

Dairy factory & the environment

5.

Quality assurance of dairy products

6.

Marketing of fresh milk and milk products

4. Dairy factory & the

environment

1.

Establishment of a dairy factory

2.

Understanding the utilities &

services

3.

Maintenance of a safe environment

4.

Disposal of liquid and solid waste

Dairy factory & the environment

Why study on Dairy factory & the
environment?
Quality assurance of products

1.
1.

Customer satisfaction

2.

Sustainable business

Health & hygiene

2.
1.

3.

Staff & consumers

Environmental protection

1. Establishment of a dairy factory

Site selection criteria

Following aspects should be considered when selecting a site

Water supply and quality

Milk catchments supply area

Land availability, drainage and quality

Proximity of other buildings and activities

Proximity to a road

Effluent disposal

Good drainage

Avoiding environmental pollutants & contaminants

Cont; Establishment of a dairy

factory

Design & constructions- type of building

Structural soundness

Building for raw materials

Building for processing

Building for product store

Building for office

Building for other

Cont; Establishment of a dairy

factory

Construction materials
Foundation, floor, walls, roofing etc

Avoid deterioration, cleaning problem, infection, safety hazards etc

Floor non slip, resistant to materials, easy clean, free draining etc

Water supply & accessories

Effluent piping & drainage

Light and power supply

Ceiling

Doors & windows

Ventilation and air circulation systems

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Follow the dairy processing standards

Maximum for 0.5 m partcals/m3 respective areas such as aseptic filling, culture rooms, processing
area, stores

Floors & Ceiling

Cont; Principles for the

establishment

Arrangements & installations of equipment

Arrangement of equipment

Need to consider segregation of process

Prevent cross-contamination

Consider hygiene and safety of operation

Flow of raw material through to product

Process sequence

Access to each item & equipment

Operation, cleaning, storage etc

Storage & dispatch of products

Disposal of by-products

Cont; Principles for the

establishment

Installation

Some equipment must be securely fixed

Some should be at a convenient height for working

Portables can be located as desired

Water supply should be installed on opposite walls

Electric wiring and installation

Should be carried out by qualified personnel

Should be installed appropriately

Layout of a small dairy plant

Establishment of collection & reception

unit

4 C

4 C

39 C

Milk run in a closed system from cow to cooling tank

Cont; Establishment of collection & reception

unit

Small scale collection unit

An insulating cover protects the milk from heat and cold

Cont; Establishment of collection & reception

unit

Large scale collection unit

Measuring milk intake in a tanker reception

hall

Cont; Collection & reception of

milk
Large scale collection unit

Establishment of a cooling & chilling

unit

Bulk cooling tank with agitator & chilling unit

Establishment of a process control

system

Video Display Unit

Establishment of a quality control

unit

Testing for raw materials

Testing for products

Processing & manufacturing

equipments

Suitable processing
equipments

Hygienic
handling

2. Utilities & services

Supply of water

1.
1.

Potable water

2.

Hot water

3.

Cool water

4.

Steam

Refrigeration

2.
1.

Chilling - variable

2.

Deep freezing

3.

Compressed air

4.

Electricity

Dairy water supply

Specifications for water

Water is used for all cleaning purposes in a milk processing

plant
So, satisfactory bacteriological & chemical quality is required

Water supply
Water should be processed

Natural water body

Pipe well with submersible

pump

Water pressure tank

1 Tank
2 Drain valve
3 Safety valve. Opens at 600 kPa
4 Pressure switch
5 Check valve
6 Liquid-ring pump
7 Vent valve
8 Pressure gauge
9 Level glass

Heat production

Water

Heating

Enthalpy ?

Steam/hot
water

Enthalpy

Phase change of water

What is enthalpy

Energy or heat content of water

Reference point for enthalpy of water and steam is 0 C

Enthalpy increases by 4.18 kJ/kg until boiling point

At the boiling point;

Large input of enthalpy causes

No temperature change but a phase change

Latent heat is added and steam is produced

Once all the water has vaporized;

Temperature again increases with the addition of heat

Sensible heat of the vapor

Thermodynamics of steam

Steam & Hot water production

Dairy requires large quantities of thermal energy

Heat various products

Heat detergent solutions

Steam at 140 150C used as a heating medium

Steam production

Produce in large tube

Tubes surrounded by the flame

Chest heat exchangers

Direct hit flame

Steam production & distribution

Pressure inside boiler is high, 300-800 kPa

Pressure create high steam temperature

Saturated steam distributed to heat exchanger

It provides heat by condensing back to water

Giving up its latent heat

Desired temperature gain by pressure reducing valve

Condensate hot water return to the boiler & reuse

Steam production & distribution

system
1. Boiler
2. Distribution vessel for high-pressure steam
3. Pressure reducing valve
4. Distribution vessel for low-pressure steam
5. Points of consumption
6. Steam traps
7. Condensate tank
8. Condensate pump
9. Feed-water tank
10. Water softening filter
11. Feed-water degassing
12. Feed-water pump

Steam Production & utilization

Steam Production

Steam boilers

System for steam distribution and condensate

collection

Refrigeration
Refrigerators have four basic elements
1.

Evaporator

2.

A compressor

3.

A condenser

4.

A refrigerant flow controller

Refrigerant circulates through above elements

CFC, NH3

Change from liquid to gas back to liquid

Refrigeration cycle
Evaporator

Liquid refrigerant evaporates in low pressure

Absorbs latent heat of vaporization

Cools the surroundings

Evaporator is at the lowest temperature in the system

So, heat flows to it

Compressor

Refrigerant vapor is sucked into a compressor

Compressor pump increases the pressure

Then exhausts it at a higher pressure to the condenser

Cont; Refrigeration
cycle
Condenser

Condense refrigerant back to liquid

Release latent heat to cooling medium

Water

Air

Refrigerant flow controller

Refrigerant passes to flow controller

It expanse the refrigerant

Then release to lower pressure evaporator

Refrigeration cyclerefrigerator

Schematic representation of a refrigeration system

Compressed-air
installation

3. Maintenance of a safe environment

1.

Plant/buildings hygiene

2.

Machinery hygiene

3.

Raw materials hygiene

4.

Workers hygiene

5.

Storage hygiene

Cont; Maintenance of a safe

environment

Plant hygiene
People -Do & dont

1.

People do

Protective clean clothing

Cleaning system hands

Before & after processing activities

Clean hands thoroughly immediately after lavatory

Report any diseases

Cover any cuts or wounds

People dont

2.

Smoking

Eating

Others

Aspects cleaning

Cont; Maintenance of a safe

environment

Aspects cleaning means;

Cleaning, sanitising & sterilising of dairy & its equipment
Milk manufacturers obliged to maintain high hygienic
standards

This applies to equipments & the staff

Obligation can be considered under three headings

1.

Trade obligation

2.

Moral obligation

3.

Good for trade

Customers trust

Legal obligation

Law attempts to protect the customer

Cont; Maintenance of a safe

environment

Cleanliness of equipment can be classified at four

levels
1.

Physical cleanliness (pre-rinse)

2.

Chemical cleanliness

3.

4.

Remove all visible dirt from the surfaces

Remove all microscopic residues

Sanitation

Attained by disinfection

Inactivate or remove micro-organisms on surfaces

Sterilization

Destroy all micro-organisms on the equipment

Deposits on a heated surface

Chemical effects and soil characteristics

Cont; Maintenance of a safe

environment

Cleaning & sanitizing should prevent;

Accumulation of undesirable micro-organisms

In the equipment & surroundings

Development of bad smells in the equipment

Which pass on to the product

Loss of efficiency in a dirty separator

Possible corrosion of metal parts due to lactic acid

Mould growth on surfaces

On equipments & surroundings

Contamination of the product with pathogens

Cleaning procedure
Pre wash the equipment with clean cold water

1.

Remove as much of the dairy products

Do immediately after the product removed

Wash the equipment with warm water (50C)

Wash the equipment with a detergent solution

2.

Following the manufacturers instructions

Drain the detergent solution

3.

Rinse at least three times with clean cold water

Ensure removal of all traces of the detergent

Sanitize the equipment

4.

Choose suitable sanitizer with manufacturers instructions

Rinse the equipment with clean water

Remove all residues of the sanitizing agent

Sterilize the equipment

5.

6.

Remove fatty material

Use suitable chemical sterilizer

Scald with 80C water when no sterilize

Lastly, store equipments in a clean, dry, dust-free area

Cleaning and biological

agents

Water

1.

Solvent transport medium and biocide (when heated)

Soft water for cleaning

Total hardness: < 50ppm (as CaCO3)

Chloride: <50ppm (as NaCl)

Chlorine: 1ppm

pH: 6.5 to 7.5

Iron: <1ppm

Manganese: <0.5ppm

Suspended solids: Substantially free

Cont; Cleaning and biological

agents
2. Detergents

Has combine the actions

Such as wetting, dissolving, dispersing, buffering,

rinsing etc

Properties of detergents

Wetting and penetrating power

Emulsifying power
Saponifying power
Defloculating power
Completely and quickly soluble in water
Non corrosive

Cont; Cleaning and biological

agents

Dairy detergents are broadly classified into four groups

Multipurpose Alkali detergents

1.

NaOH
Sodium metasilicate
Trisodium phosphate
Sodium polyphosphates
Sodium carbonate

Acid detergents

2.

Nitric acid
Phosphoric acid
Sulphamic acid
Tartaric
Citric acids

Enzymes

3.

Proteases

Biocides/sanitizers

4.

Heat, chlorine, hypochorites, iodophors, H2O2, formaldehyde

Ultra-violet, radiation, electron beam

4. Disposal of liquid and solid

waste

Various stages of a sewage treatment

plant

Cont; Disposal of liquid and solid

waste

Cont; Disposal of liquid and solid waste