TRIBHUVAN UNIVERSITY

INSTITUTE OF ENGINEERING
NATIONAL COLLEGE OF ENGINEERING

A
Case Study
On
“NEPAL DAIRY PVT. LTD.”

Submitted by:
Ashok Tamang (077BCT007)
Bibek Aryal (077BCT008)
Kapil KC (077BCT014)
Prerana Subedi (077BCT022)
Sarina Tamang (077BCT031)

Submitted To:
DEPARTMENT OF COMPUTER AND ELECTRONICS ENGINEERING

AUGUST, 2023
LALITPUR, NEPAL

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 ABSTRACT

Instrumentation II is a more specialized level of instrumentation engineering that builds on the

ideas covered in Instrumentation I. In order to monitor, measure and regulate physical quantities
like temperature, pressure, flow and level, it entails the study and use of various instruments used
in industrial processes.

The presented report provides an overview of the practical application of microprocessor and
automation system in Nepal Dairy Pvt. Ltd. to enhance production so as to help convert this private
industry into public enterprise within a few years. Hence, we are proposing some modification with
the hope to achieve improved production capacity.

Having said that, we do not claim to develop a perfect and faultless system as opposed to the
existing one. We do have in mind that no system can be a 100 percent accurate. But we do hope to
provide a fresh perspective for the modification of the existing system

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 Table of Contents
ABSTRACT..................................................................................................................................... 2
INTRODUCTION ........................................................................................................................... 4
OBJECTIVES .................................................................................................................................. 4
General Objectives ....................................................................................................................... 4
Specific Objective ........................................................................................................................ 4
PRODUCTION ................................................................................................................................ 4
1. Importing milk ..................................................................................................................... 5
2. Purification........................................................................................................................... 5
3. Homogenization ................................................................................................................... 5
4. Storage ................................................................................................................................. 5
5. Milk distribution .................................................................................................................. 5
CURRENT INSTRUMENTATION SYSTEM ............................................................................... 5
SYSTEM BLOCK DIAGRAM ................................................................................................... 5
SYSTEM DESCRIPTION ........................................................................................................... 7
Preliminary Lab Test.................................................................................................................... 7
1. Sampling .............................................................................................................................. 7
2. Acidity test ........................................................................................................................... 7
3. Fat test .................................................................................................................................. 7
MILK PROCESSING .................................................................................................................. 7
Pasteurization ............................................................................................................................... 8
Homogenization ........................................................................................................................... 8
LIMITATION .................................................................................................................................. 8
RECOMMENDED SYSTEM ....................................................................................................... 10
DESCRIPTION: ........................................................................................................................ 11
Use of Electric Heater: ............................................................................................................... 11
Use of IoT (Raspberry pi): ......................................................................................................... 11
Use of updated near real time production monitoring system: .................................................. 11
DISCUSSION AND CONCLUSION ............................................................................................ 12

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INTRODUCTION
Nepal Dairy Pvt. Ltd. was established in 1980 by a group of entrepreneurs. It started as a cottage
dairy in the busy Mahaboudha Street. It operated its business in a modest way with yogurt in a clay
pot. Since its inception, Nepal Dairy has been growing steadily and broadening the customer base.
Today, Nepal Dairy is growing faster than ever anticipated with its acronym ND’s.

Nepal Dairy today has been making the finest quality Dairy Products. It has been enjoying a well-
established reputation of “The Cream of Dairy”. What appreciates Nepal Dairy is her skill in
diversification to various dairy based products according to the consumers’ taste like Pizzas, cakes,
pastries, sweets and fast foods. Nepal Dairy has dedicated its business to the rural milk producers
and urban milk consumers of Kathmandu. Nepal Dairy safeguards the interest of the rural milk
producers by providing highly competitive price. Nepal Dairy is committed to providing the highest
quality product to you at the most reasonable cost.

OBJECTIVES
General Objectives
Traveling to the target industry and working alongside experienced technicians to examine the
instrumentation system's detailed functioning offers practical insights that classroom learning
cannot replicate. Direct interaction allows for immediate clarification of doubts and fosters in-depth
discussions, leading to a contextual understanding of how the system operates within the real
production environment. This approach enables the identification of real-time problems and the
development of tailored solutions for improved operational efficiency and quality control.

Specific Objective
• analyze the company's current technology and dairy production system.

• to observe the issues caused by manual operation in the various industries and to provide a
design to fully automate the system.

• to research how various controls and instruments are applied in business.

PRODUCTION
The production of dairy product in Nepal Dairy broadly involves four steps:
1. Importing milk

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 2. Purification
3. Homogenization
4. Storage
5. Milk Distribution

1. Importing milk
• The Nepal Dairy Pvt Ltd. imports 15000 liters milk from 18 different cooperatives a day.

2. Purification
• Purification of milk is important to obtain quality end product. This process includes
pasteurization process in which milk is heated up to 72 degrees Celsius for about 15
seconds so as to eliminate all the bacteria from the milk. This process of pasteurization is
called High-Temperature Short-Time (HTST).

3. Homogenization
• Milk and other dairy products' fat molecules are broken down and dispersed mechanically
during homogenization, a procedure employed in the dairy business. Homogenization is
done by using high-pressure homogenizer. Homogenizer has the homogenization and
hydraulic system.

4. Storage
• The produced dairy is then stored in storage tanks of capacity 700 to 1200 liters.

5. Milk distribution
• The distribution is done to 11 distributers within Kathmandu and 9 outside of it.

CURRENT INSTRUMENTATION SYSTEM

SYSTEM BLOCK DIAGRAM

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 Raw milk

Lab test

Weighing balance

Filtration

Steam boiler
Pasteurization

Milk
Holding tank

Ice-cream
Milk

Yoghurt

Packing Storage

homogenization

Cheese

Ghee
Cream

Butter

Paneer

Figure 1: Existing System Block Diagram

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SYSTEM DESCRIPTION

Milk collection is done from 18 different co-operatives in the amount of 15000 liters per day. This
milk is subjected to preliminary lab test which is done as follows:

Preliminary Lab Test

1. Sampling
For a fair and just quality control system, accurate sampling is the first requirement. Before
a milk sample is taken for any chemical control tests, liquid milk in cans and bulk tanks
are carefully mixed to distribute the milk fat. Milk samples are selected with great care for
bacteriological tests. In order to prevent contamination of the sample, the dippers were
sanitized in an autoclave or pressure cooker for at least 15mm at 120° C prior to use. A
70% alcohol swab is used for on-the-spot sterilization, followed by a minute of flame,
scaling, or boiling water. Then, representative samples of packaged goods are obtained for
quality analysis.

2. Acidity test
Bacteria that normally develop in raw milk produce more or less of lactic acid. In the
acidity test the acid is neutralized with 0.1 N Sodium hydroxide and the amount of alkaline
is measured. From this, the percentage of lactic acid can be calculated. Fresh milk contains
in this test also "natural acidity" which is due to the natural ability to resist pH changes.
The natural acidity of milk is 0.16 - 0.18%. Figures higher than this signifies developed
acidity due to the action of bacteria on milk sugar.

3. Fat test
By adding sulfuric acid (H2SO4), milk fat is separated from proteins. Amyl alcohol and
centrifugation are used to speed up the separation, which is carried out inside a centrifuge.
Typically, raw milk provides 4-5% of the body's total fat requirements. The extra fat was
manually added if the amount of fat did not equal the minimum requirement. Using a
specialized, calibrated butyrometer, the fat content is directly read. The aforementioned
tests are completed by hand. The milk that passes the test is collected for further processing,
and then the milk and cream are separated.

MILK PROCESSING

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1. Pasteurization
In the pasteurization process, a meal, typically a liquid, is heated to a specified temperature for a
predetermined amount of time, after which it is promptly cooled. Food microbiological
development is slowed by this technique. The only method that effectively eliminates 90% or more
of dangerous germs in milk is pasteurization. Modern equipment is easily able to test for and
identify bacteria in milk that is being processed, despite the fact that only a small number of
pathogens are heat resistant.

The High Temperature/Short Time (HTST) method is employed in nd’s. An HTST pasteurization
system is a modular device that consists of a stainless-steel balancing tank, plate-and-frame heat
exchanger, pumps, holding tubes, valves, and controls. Milk is driven through pipes heated on the
exterior by hot water or between metal plates as part of the HTST process.

2. Homogenization
Homogenization is a mechanical process that reduces the average diameter of milk's fat globules
while increasing their quantity and surface area. Homogenization is accomplished by passing milk
through a small opening while being subjected to high pressure. Utilizing a high-pressure
homogenizer, ND homogenizes materials. an intense pressure. Both a hydraulic system and a
homogenizer are present. The piston pump presses the substance when it enters the pump block.
The piston pump increases the milk's pressure from its inflow pressure of roughly 300 kPa (3 bars)
to its homogenization pressure of 10 to 25 MPa (100 to 250 bars), depending on the product. It
automatically maintains a consistent homogenization pressure at the first step before to the device.

LIMITATION
Following our field visit to nd’s, it is evident that the factory is being run efficiently, maintaining
a high level of hygiene and upkeep. Our observations have led us to the conclusion that the factory
is in compliance with legal production standards. However, in relation to the instrumentation and
machinery equipment, it is noteworthy that the controls are not completely automated. It has come
to our attention that a single control room oversees all control systems, with manual operation by
human personnel.
1. Temperature and pressure in machines and equipment are not automated.
2. The use of hot water or low-pressure steam results in an excessive use of water resources,
which raises water-related issues.

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3. The excessive response time to a malfunction or breakdown results in lost time and product
waste.
4. A new version of the real-time production monitoring system is required.
5. Lack The absence of automated testing equipment in the laboratory hampers the ability to
analyze milk samples efficiently and accurately. of automatic testing machine in lab to test
milk sample.

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RECOMMENDED SYSTEM

Raw milk

Automated
analyzer

Weighing
balance

Filtration

Electric
heater

Milk
Pasteurization

IOT
(Raspberry pi)

Holding tank Ice-cream

Real time
production
Milk monitoring
system

Yoghurt

Packing Storage

homogenization Cheese

Ghee

Cream

Butter

Paneer

Figure 2: Recommended System Block Diagram

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DESCRIPTION:
1. Use of Electric Heater:
We discovered on our field visit to the ND that milk is heated using hot water or low-pressure steam
as a heating medium. Water is wasted in significant quantities because a lot of milk needs to be
heated, which uses a lot of water. Therefore, we employ electric heaters or boilers to reduce the
vast amount of water that is wasted.

2. Use of IoT (Raspberry pi):

IoT - Raspberry Pi can be used to identify a system failure or breakdown and notify the responsible
party or engineers. A display that includes LEDs and a breakdown status is connected to nodes that
have various sensors, including temperature sensors, and different control buttons on the control
unit. Each node is now continuously providing data to the Raspberry Pi via a wifi server that has
been established. Additionally, a GSM SIM900A module attached to a Raspberry Pi sends an SMS
to the responsible party in the event of a failure.

3. Use of updated near real time production monitoring system:

A technique called a "production monitoring system" is intended to capture the total efficiency of
the production line in real time. Production monitoring is possible with the Techna Check PM-1
device. The Techna-Check PM-1 is immediately mounted onto the production line's electrical
cabinet. The data collection method is carried out via Ethernet and specialized production
monitoring software. The system is typically connected to the different operations along the line,
including robotics and automated equipment. The system gets data signals indicating the processes'
status, including whether they are having any issues or are working properly. Employees and
management can alter the production line appropriately once the data has been gathered and studied
by them.

4. Use of Automated Analyzer

Automated analyzers, originally designed for clinical laboratories to analyze bodily fluids like
blood and urine, can also be adapted for milk sample testing in dairy labs. These analyzers are
equipped with modules that can be programmed to perform specific chemical tests on milk samples,
similar to how they process clinical samples. By configuring the analyzer's software and adapting
the necessary reagents, the system can perform tests relevant to milk quality, such as fat content,
protein content, lactose levels, and somatic cell counts. The analyzer's automation capabilities,
including sample handling, reagent addition, and data analysis, streamline the milk testing process,
enhance accuracy, and provide quicker results compared to traditional manual methods. This

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adaptation allows dairy labs to benefit from the efficiency and precision of automated technology
in ensuring milk quality and safety.

DISCUSSION AND CONCLUSION

The field trip to Nepal Dairy PVT LTD gave us a thorough understanding of the many facets of
milk production and the opportunity to evaluate the company's milk production process's strengths
and opportunities for improvement. The use of a variety of tools and equipment demonstrated the
company's dedication to updating and streamlining its processes. However, despite the obvious
attempts, some flaws were found, underlining the urgent need for improvement. The explosion of
milk-producing businesses has spurred fierce competition in today's dairy industry, which is
continually expanding. As a result, the bar for success has been raised, forcing businesses to pursue
excellence in every aspect of their operations. The quality of the products is the main factor in this
case.

As part of our field trip to Nepal Dairy PVT LTD, we saw several different aspects of milk
production. We assessed the state and functionality of the milk production equipment and
machinery. Although the use of various tools and machinery was excellent, there were still several
areas that needed improvement, and those are listed above in our report. The emergence of
numerous milk-producing enterprises has caused the competition to quickly ratchet up and become
fierce. Therefore, the industry's standard must be raised in order to develop products that are of
high quality, purity, hygienic, consumable, and reliable. The degree of the industry is determined
by the product's quality. Therefore, in order to produce products of high quality, the machinery
must be in top functioning order.

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