CONTENTS

SL NO PARTICULARS PAGE NO.

1 INDUSTRY PROFILE 01

2 INTRODUCTION 2-9

3 FUNCTIONS OF DEPARTMENT 10-17

4 ENGINEERING SECTION 17

5 REFRIGERATION SECTION 17-25

6 ELECTRICAL SECTION 26

7 BOILER SECTION 27-28

8 EFFLUENT PLANT TREATMENT 29-34

9 COLD STORAGE ROOM 35-37

10 GENERATOR 38-39

11 MARKETING DEPARTMENT 40-43

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1. INDUSTRY PROFILE

1. General

Milk is an opaque white liquid produced by the mammary glands of mammals. It provides the
primary source of nutrition for young mammals before they are able to digest other types of food.
The early lactation milk is known as colostrum’s, and carries the mother’s antibodies to the baby.
It can reduce the risk of many diseases in the baby. The exact component of milk vary by species,
it contains significant amount of saturated fat, protein and calcium as well as Vitamin C.

2. Dairying and its Necessity

Dairying is branch of agriculture. It encompasses the breeding, raising and utilization of animals.
Dairy is water based industry that requires large quantity of water for various operations like
washings. Hence waste water generation is also large. Generally dairy can be classified into two
categories viz.

1. Milk dairies
2. Milk product oriented dairies

The main objectives of dairy industries are collection, transportation, processing, pasteurizing,
bottling and sacheting of milk. The milk will then be sold to consumers through distribution
network. The dairy may or may not produce milk byproducts. In product oriented dairy, bottling
or sacheting of milk will be carried out along with the number of milk products like butter, ghee,
skimmed milk powder, condensed milk, flavored milk, casein, cheese, milk based sweets, curd,
butter milk etc.

Being a good source of nutrients and having an ideal pH, milk is most readily contaminated by
microbes that may be spoilage microbes or pathogens. The source of pathogenic organisms
occurring in the milk may be either the cow or method of milking. The following are the modes
of transmission of various diseases through milk.

* Pathogens from infected cow to milk and then to man (TB, brucellosis mastisis).
* Pathogens from man, (infected or carriers) to milk and then to man (typhoid, fever,
diphtheria, dysentery and scarlet fever).

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3. ABOUT THE ORGANIZATION
1. INTRODUCTION:

Dairy is a place for handling milk and milk products. Technology refers to the application of
scientific knowledge for practical purposes. Bidar Dairy Plant is a unit of Karnataka Co-
Operative Milk Producers Federation Limited, situated at ,Janwada road-Bidar KARNATAKA. It
was designed, installed and commissioned by Hon’ble Ministry of veterinary AH and Dairy
Development in 1978. It was inaugurated on 24th of January 1971 by Shri. VeerendraPatil. The
unit has equipped with state of art technology utility sections.

CERTIFICATION
ISO-9000-2001 certificate from the Bureau of Indian standard (BIS) Government of India.

1.3.2 Salient features of the Dairy Plant:

Infrastructure:

 The project is setup in a 12.2 Acres of land, beside Janwada road-Bidar

 Refrigeration plant using environment friendly ammonia liquid over feed system with
ICE BANK TANK.
 Milk storage facility :30 KL
 Curd storage: 5 KL
 Butter milk storage : 5KL
 Effluent treatment plant using environmental friendly, aerobic technology.

The Bidar dairy is show in fig.1.1

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 Fig 1.1 Bidar Dairy

1.3.3 Objectives of GUMUL Dairy

The main functions of the union are;

1.To provide remunerative market for the milk produced by the rural farmers throughout the year
irrespective of the quality supplied by them.
2. First aid facility at the society level.

3.Emergency visit to the animals on the nominal fee to be collected from the producers.
4.Cross breeding facility thorough artificial insemination services.
5. Supply of balanced cattle feed to the farmers of the cooperative societies at subsidized
rates.
6.Technical guidance and supply of the root slip/seeds for fodder cultivation by the members of
cooperative societies.
7. Effective supervision/ extension services through field executives of the union.

8.Intensive cooperative education program to the women member of the dairy cooperative
societies through cooperative development program.

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 1.3.4 Vision of GUMUL Dairy

 To march forward with a missionary zeal, this will make KMF a trailblazer of exemplary
performance and achievements beckoning other Milk Federations in the country in pursuit of
total emulation of its good deeds.
 To ensure prosperity of the rural Milk producers who are ultimate owners of the
Federation.
 To promote producer oriented viable cooperative society to impart an impetus to the rural
income, dairy productivity and rural employment.
 To bridge the gap between price of milk procurement and sale price.
 To develop business acumen in marketing and trading disciplines so as to serve consumers
with quality milk, give a fillip to the income of milk producers.
 To compete with MNCs and Private Dairies with better quality of milk and milk
products
and in the process sustain invincibility of cooperatives.

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1.4 ORGANIZATIONAL SET UP (MEDUIM SIZED DAIRY)

Fig 1.2 indicates the organizational setup of Bidar dairy .

Union Board

Managing Director

General Manager

Asst.Manager Asst. Manager Asst.Manager Asst.Manager

(Production) (Engineering) (Accounts & Finance) (Marketing)

T.O Technical officer Accounts officer Marketing

Supervisors supervisor Attendees Attendees

Helper se workers Helper

Fig 1.2 The Organizational Setup of Bidar Dairy

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5. PRODUCTS
Product may any thing that can offered to the market to satisfy wants and needs.The various
products produced at Bidar cooperative milk producers society union limited and their description
are described below.

1. Nandini Homogenized Milk

Nandini homogenized milk is pure milk which is homogenized and pasteurized. Consistent right
through, it gives more cups of tea or coffee and is easily digestible. Available in 250ml and 500ml
packs.

2. Nandini Special Milk

This pure milk contains 4.0% fat and 9.0% SNF. It is available in 250ml and 500 ml packs. This
milk is rich creamier and testier. It is ideal for preparing home mode sweets and savories.

3. Butter milk

Butter milk is are freshing health drink. It is made from quality curds and is blended with fresh
green chilies, green coriander leaves, as a fetida and fresh ginger. Buttermilk is packaged in 200
ml packet.

4. Curd

It is thick and delicious. It is available in 200 grams, 500 grams and 1000 grams sachet etc.

5. Peda

Peda is very delicious made from pure milk. It can be stored for 7 days and available in 250
grams containing 10 pieces each.

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 The Product list of Gulbarga-Bidar-Yadgir milk union producers is summarized in Table 1.1
Table.1.1Product list of Gulbarga-Bidar-Yadgir milk union producers

Nandini 3.0% fat and 8.5% SNF

Homogenized Easily digestible
Toned Milk

Nandini 3.5%fat and 8.5%SNF

Homogenized Available in 250ml and 500ml packs
Cow Milk

Nandini Curd Available in 200 grams and 500 grams pack

Nandini It is available in 200 ml packs and is priced at most

spiced Buttermilk competitive rates

Nandini Samrudhi
Milk 6.0% Fat & 9.0% SNF. Available in 515 ml packs.
This is more fatty milk.

Available in 100 gms& 250 gms packs.

Nandini Peda

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1.6 Employees Details of Organization
The total number of people working in Gulbarga-Bidar-Yadgir milk union limited is 96
members.Permanent working employer is 40 and daily wages workers are 56 members.

1.7 The Different Departments and its Functions.

Efficient operation of a dairy plant and for the production of good quality milk and milk products
depends on how the dairy plant personnel is conversant with the best practices of milk plant. They
should have a thorough understanding of the milk processing and quality control aspects of milk
and milk products.

The keeping quality of the milk depends largely on its immediate processing and adherence to
chemical, microbiological and technological parameters of milk production processing
manufacture. Skilled manpower development is an important task in this direction.

The underlying principle of developing a trainee is primarily through on-the job training and
wherever applicable, the trainee should be given opportunities to analyze the milk quality in
actual situation encountered during plant operations.

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 2.FUNCTIONS OF DEPARTMENT
1. PROCESSING AND RECEIVING DEPARTMENT
After weighing and decanting milk in the Reception section it is carried into the Processing
section.Processing means production and distribution of milk and milk products economically.
Within processing section the raw milk collected from reception dock is processed and supplied to
different section such as butter and ghee section, Peda milk, curd milk.

1. Reception Section

In the Reception Section Bidar Dairy procures from can milk routes .RMRD (Raw Milk
Reception Dock) software is used for weight recording.

 Reception is done by both cans and tankers

 Type of conveyor – roller type conveyor (6-8 cans capacity)
 Weighing bowl -300 liters
 Dump tank – 1000 liters
 Type of pump – centrifugal pump
 Milk chiller capacity – 10KLPH

Fig2.1
Reception Dock

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Flowchart of Can Reception

Fig 2.2 represents the flow chart of can reception

Arrival of raw milk in cans

Unloading of cans over chain conveyer

Lid removal

Organoleptic evaluation (COB Screening, Adulteration Screening)

Dumping of milk to weigh bowl (capacity-13cans)

Automatic weight recording

Sample collection from each society

Dump tank

Filter

Pumping to chiller less than 40 C

Pump to raw milk silos

Fig.2.2 Flowchart of Can Reception

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Flowchart of Can Washing

Fig 2.3 shows the flow chart of can washing .

Empty cans for washing

Cold water rinse

Detergent rinse [0.6% @ 650 C]

Hot water rinse [75-800 C]

Hot air blower

Can tilting

Can unloading

The Bidar dairy in plant standards of raw milk is shown in below table 2.1

Table 2.1 Bidar Dairy Implant Standards of Raw Milk

Sl. No. Particulars Raw Milk

1. Temp. 25-28C
2. COB -Ve
3. Acidity 0.134-0.153
4 CLR Min28
5 Fat 4.6
6 SNF <8.5 = low SNF
7 Sugar -ve
8 Neutralizer -ve

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2.1.2 Processing Section

After weighing and decanting milk in the Reception section it is carried into the Processing
section.Processing means production and distribution of milk and milk products economically.
Within processing section the raw milk collected from reception dock is processed and supplied to
different section such as butter and ghee section, Peda milk, curd milk.The processing section is
shown in below Fig.2.2

Fig 2.4 Processing Section

Chilling and storage of milk

After satisfying the above, the milk is unloaded from weighing tank and the milk received in
tankers at 6°C to 8°C is transferred to the raw milk silos by pumping and the milk received in
cans is pumped through the chiller, chilling the milk to 4°C to 6°C and then stored in raw milk
silos. From the raw milk silos the milk is drawn for processing like pasteurization, cream
separation, homogenization and standardization. This chilling is necessary to avoid the growth of
bacteria that find their maximum growth at temperatures of about 20°C to 40°C. The capacity of
chilling plant is 20,000L/hr. The chilled milk then pumped and stored in milk silos. All the
storage tanks are insulated and provided with manholes for cleaning and maintenance.

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Pasteurization of milk

Pasteurization is the heat treatment process that destroys pathogenic microorganisms gets killed
except spores. For killing of these spores sterilization can be included. The efficiency of
pasteurization can be known by alkaline phosphatase test. This is an enzyme test; if that enzyme is
killed the pasteurization process gets completed. Pasteurization of milk requires temperatures of
about 63° for 30 minutes to kill the Mycobacterium tuberculosis and other more heat resistant
bacteria in the milk. This is the batch process. Alternatively heating to a temperature of 72°C-
75°C for 15 seconds and then cooling to 4°C and below is practiced in the dairy, which is known
as the HTST (High Temperature Short Time) method. This is continuous process generally
adopted. Pasteurization includes following steps,

Cream separation

First the milk is heated to 45°C and sent to cream separator. Its operation is based on the fact that
skim milk is heavier than cream. The separator consists of centrifuge in the form of a rapidly
revolving bowl containing a set of 100 discs. As the milk enters the bowl at the top, it is
distributed to the discs through a series of openings, the distributor. Thin films of milk is
generated as a whole milk is forced out between the discs, the milk assumes the speed of the
bowl, approximately 6000-8000rpm and the heavier milk is thrown to the edge of the bowl and let
off through an opening. The cream concentrates in the interior and moves up to cream outlet near
the center of the bowl i.e., during that time fat will be concentrated to the edges. Milk is then
passed to storage tanks. The cream obtained from the cream separator is pasteurized (heating to
80°-90°C for 15 seconds and then chilling to 13°C). This cream is stored for aging for in cream
ripening tanks for 24-48 hours that converts the fat liquid condition to semisolid condition, which
in turn is used foe butter making.

After separation, the cream is stored in cream storage tanks a 8°C. Thereafter, butter is obtained
by churning in butter churn. The butter is stored in 25Kg boxes freezer maintained at -10°C.

For the ghee preparation, the 25kg weight butter boxes are manually unloaded into the ghee
boiler and temperature maintained at 100-105°C. the ghee is packed in sachets or tins and
dispatched.

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Standardization

The fat content of the procured milk varies. Hence, it needs standardization. The standardization
means that the milk is processed to be marketed with a specified and constant fat. The stream of
milk and cream after separation must be recombined to a specified fat content by adjusting the
throttling values of the cream outlet. As the value is progressively opened, larger amount of cream
with diminishing fat content is discharged from the cream outlet. The milk is processed into
varieties of pasteurized milk like the following mentioned:

 Toned milk-3.1% fat and 8.5%SNF

 Double toned milk-1.6% fat and 9%SNF
 Standardization milk-4.5%fat and 8.5%SNF
 Full cream milk-8%fat and 9% SNF

After the processing, the milk is stored in PM at 4°C to 6°C. Thereafter, it is drawn for sachets of
different quantity or bulk. This is kept at the milk cold strees maintained at 4°C before dispatch.

Homogenization

Homogenization is a mechanical treatment of the fat globules in milk, brought about by passing
milk under high pressure through a tiny orifice, which results in a decrease in the diameter and
increase in number and surface area, of the fat globules. The principle involved in the process is
that milk is forced through small nozzle, so that the bigger particles of fat will split into smaller
ones(<2 microns). Milk is homogenized to prevent fat globules from floating to the top and
forming a cream layer. Homogenizers are simply heavy duty, pressure pumps equipped with a
specialvalve at the discharge end. Hot milk is pumped through the valve at the discharge end. In
addition to avoid a cream layer, other benefits of homogenized milk include a white appearance,
richer flavor, more uniform viscosity, better whitening in coffee and other softer curd tension.
After homogenization, milk is stored in PM tanks and softer obtaining positive results from lab on
quality of milk, sent for packing or to other dairies according to the need. Soon after packing
milk, the sachets are stored in cold storage at 4°C before dispatch. The self-life of pasteurized
milk is 24-48 hours without refrigeration.

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2. Cleaning of milk silos and tank

 Rinse the milk tanks with water after removing entire quantity of milk.
 Flush with hot water.
 Circulate alkali solution for 30 min.
 Maintain the temperature of alkali solution at 70-75C.
 Maintain the alkali solution strength to 0.5-0.6%.
 Flush the alkali solution after 30 min. by hot water.
 Circulate hot water about 80C for 5 min.
 Flush with cold water to reduce the temperature of milk tanks to ambient temperature.
 Rinse the tanks with sanitizers for pasteurized milk silos and cream tanks.
 Allow the milk after confirming the milk temperature.
 Cleaning should be carried out as per the cleaning schedules.
The quantity of Wastewater generated in Processing section is 80,000 l/d.

The hierarchy of production department is shown below and Schematic Diagram of production
process is shown in Fig 2.8

Hierarchy of Production Department

Deputy Manager

Technical Officers (To)

Technicians

Helpers

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 Milk Chilling & Separation Pasteurization & Storing in
reception storage Standardization tanks

Store cream in Products Packing in

CT tank sachet or
bulk

Butter Churn Peda Curd

production

250ml
Continuou 500ml

DEPARTMENT OF MECHANICAL ENGINEERING

Butter 1000ml
s curds
To FGS milk

Store in deep
Add culture
freeze
Dispatch Store in
milk cold
Ghee boiler Pack in sachet storage

Ghee
Curds Dispatch

Pack in
sachets or Lassi Masala butter

Fig 2.8 Schematic representation of production process

milk

Page 17
Dispatch
Dispatch
 3 ENGINEERING SECTION
The engineering section includes the following sections :

3.1.Refrigeration section.

3.2.Electrical section.
3.3.Boiler section.

4. ETP (effluent
treatment plant)
section

5. Storage room

6. Generator

3
.
1

R
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F
R
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G
E
R
A
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S
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Refrigeration is ‘Heart’ of the dairy industry because milk is safe by cooling for long time.
Refrigeration system is based on Heat transfer method.“Refrigeration may be defined as an art
of producing & maintaining the temperature in a space below atmospheric temperature.”
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The capacity of a refrigeration unit is 75 tons of refrigeration.

Principle of Vapour Compression Refrigeration (VCR) System:

low-temperature vapors, which are again sucked by compressor. In this way all these processes go
on continuously and as long as the compressor runs, the system produces cooling around the
evaporator. A block diagram of a vapour compression refrigeration system is shown in Fig. 2.9

Fig 2.9 Vapour Compression Refrigeration Cycle

3.1.1 COMPRESSOR

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 (RECIPROCATING AIR COMPRESSOR)

A reciprocating compressor is a positive-displacement machine that uses a piston to compress a

gas and deliver it at high pressure.They are often some of the most critical and expensive
systems at a production facility, and deserve special attention. Gas transmission pipelines,
petrochemical plants, refineries and many other industries all depend on this type of equipment.

Compressor Details :
1. Company : Kirloskar Company

2. Bore : 160 mm

3. Maximum Pressure : 21kg/cm^2

4. Spec No : 336.9

5. Stoke :110mm’

6. Maximum RPM : 1000

7.Number of cylinders : 2

8.Refrigerant used : Ammonia

Working of a Reciprocating Compressor:

As the name signifies, a reciprocating compressor works by the to and fro motion of the piston
inside a cylinder.

When the piston moves downward, it creates a vacuum between the piston top and cylinder head.
This causes the inlet valve to open and low-pressure gas fills in. During this time, inlet valves
remain open and discharge valves remain closed.

Next, the piston moves upward forcing the inlet valve to close and the gas is trapped in the
cylinder. As the piston moves further the area between the piston head and cylinder reduces
which results in gas compression. When the gas pressure exceeds the discharge valve spring
resistance, it opens and the gas is transferred to the receiver. The same process is repeated.

Parts of a Reciprocating Compressor :

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The main gas end Parts of the reciprocating compressor (Fig. 4)

Fig 4 . Parts of compressor

1. Cylinder

2. Head

3.Piston & piston rod.

4.Suction valves.
5. Discharge valves.

6. Piston rod Packing

7. Suction and
discharge gas jacket

1.Cylinder & Liner

The piston reciprocates inside a cylinder of the reciprocating compressor. To provide for reduced
reconditioning cost, the cylinder may be fitted with a liner or sleeve. A cylinder or liner usually
wears at the points where the piston rings rub against it. Because of the weight of the piston,
wear is usually greater at the bottom of a horizontal cylinder.

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2. Head

The ends of the cylinder are equipped with removable heads, these heads may contain
water/liquid jacket for cooling. One end is called head-end head and other crank-end head. The
crank-end contains packing (a set of metallic packing rings) to prevent gas leakage around the
piston rod.

3. Piston

The piston moves forward and backward to suck and compress the gas. It pushes the gas in the
discharge pipe during the compression stroke.For low-speed (up to 330 rpm) and medium speed
reciprocating compressors (330-600 rpm), pistons are usually made of cast iron.Up to 7”
diameter cast iron pistons are made of solid bars. Those of more than 7” diameters are usually
hollow (to reduce cost).Carbon pistons are sometimes used for compressing oxygen and other
gases that must be kept free of lubricant.

*Clearance in Piston and Cylinder As the reciprocating compressor reaches operating

temperature, the piston and rod expand more than the liner/cylinder does. In order to prevent
seizure adequate clearance should be provided. Similarly, end clearance is also important.A cold
piston is usually installed with one-third of its end clearance on the crank end and two-third of its
end clearance on the head end.

4. Piston Rings

Piston rings provide a seal that prevents or minimizes leakage through piston and cylinder liner.
Metal piston rings are made either in one piece, with a gap or in several segments. Gaps in the
rings allow them to move out or expand as the compressor reaches operating temperature. Rings
of the heavy piston are sometimes given bronze, Babbitt or Teflon expanders or rider Lubrication
is a must for metallic rings. Teflon rings with Teflon rider bands are sometimes used to support
the piston when the gas does not permit the use of a lubricant.

5. Oil Seal

An arrangement of scraper rings serves to keep the oil, entrained by piston rod, from leaking out
of the crankcase. The oil scraped is returned to the crankcase reservoir.

6. Valves

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Valves (Suction and Discharge valves): allow gas to enter into the piston during suction stroke
and allow gas to go out into the discharge line during the compression stroke.

Fig 3.1.1;Compressor section

3.1.2.Condenser Section
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 (SHELL AND COIL TYPE CONDENSER)

Here we are using Shell and coil type condenser to convert high temperature and high pressure
ammonia into low temperature and low pressure. From compressor high temperature and
pressure ammonia will move to condenser where is ammonia is in gaseous state then ammonia is
converted into liquid state by using water as a coolant. where ammonia flows through coils while
water flows through the shell. The water from shell will going fall into coils where there is a heat
exchange take place. Then high temperature and pressure ammonia will change into low
temperature and low pressure and gaseous form transfer into liquid form . The heat is rejected in
the water which in tern cooled in the cooling tower and the same water is circulated in the Shell
and Coil type condenser. Then ammonia is transfer into evaporator.

Fig 3,1,2 shell and coil type condenser

3.1.3 EVAPORATOR

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 (shell and tube type evaporator)
The shell-and-tube type evaporators are very efficient and require minimum floor space and
headspace. These are easy to maintain, hence they are very widely used in medium to large
capacity refrigeration systems. The shell-and-tube evaporators can be either dry type or flooded
type. As the name implies, a shell-and-tube evaporator consists of a shell and a large number of
straight tubes arranged parallel to each other. In dry expansion type, the refrigerant flows through
the tubes while in flooded type the refrigerant is in the shell. A pump circulates the chilled water
or brine. The shell diameters range from 150 mm to 1.5 m. The number of tubes may be less than
50 to several thousands and length may be between 1.5 m to 6 m. Steel tubes are used with
ammonia while copper tubes are used with freons. Ammonia has a very high heat transfer
coefficient while freons have rather poor heat transfer coefficient hence fins are used on the
refrigerant side. Dry expansion type uses fins inside the tubes while flooded type uses fins
outside the tube. Dry-expansion type require less charge of refrigerant and have positive
lubricating oil return. These are used for small and medium capacity refrigeration plants with
capacity ranging from 2 TR to 350 TR. The flooded type evaporators are available in larger
capacities ranging from 10 TR to thousands of TR.

Fig3.1.3.shell and tube type evaporator

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 3.2 ELECTRICAL SECTION

1.The electrical section is necessary to run an any industry or food companies like dairy industry.
The power supply is very necessary for any industry to operate or to run any machines operation
or processes.

2.The electrical section provides power supply to dairy plant; it also provides pressurized air for
some operations. The electrical section consists separate DG (diesel generator) rooms for DG sets.
DG sets are should be there to provide power during the power cut off from KPTCL.

3.The electrical consists of DG sets and transformers for power supply. There are four numbers of
transformers present in the electrical section. They are 500kva which are three in numbers and
other one is of 100kva.

4.There are one diesel generators which are used during the power cut-off. In that one generator is
of 500kva.

5.The 500kva diesel generator is having the frequency of 50 Hz, runs on 415volts; the rated
current is 557amps, 400kw and 0.8pf.

2.3 BOILER SECTION

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The boiler section is to supply the required quantity of steam for the other sections like processing
section for pasteurization of milk and cream, for drying of cans and for CIP cleaning etc.The
boilers are two in numbers. They are stand by where one is used and other one is kept for cleaning
or repair it. The boiler is of fire tube type. The capacity of the boiler is one ton capacity. The
working pressure of this boiler 10.54 pressure. The fuel used for ignition or to produce steam is
diesel.
The boiler contains a pressure gauge to measure the pressure, feed water pump to water into the
boiler, feed check valve, main valve, burner, PRV valve, bourdon valve. The boiler is of three pass
fire tube type. The fuel tank is of 1000 liters capacity of 1in numbers. A water softener is there
which softens water to 2ppm-10ppm. Water is softened by salt.

Boiler Details:

1.Vertical Shell And Fire Tube 3 Pass Boiler

2.Shanti Boilers And Pressure Vessels Ltd

3.Nos.-1

4.Steam generation-7 kg/hr

5.Fuel used - DIESEL

6.Operating pressure-
10.54kg/cm2

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 FIG 2.3 STEAM BOILER

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 WASTE MANAGEMENT SYSTEM

The waste management system at Gulbarga-bidar-yadgir milk union limited is as

follws.

Water Consumption And Waste Water Generation

About 200000 litres of water per day is required. Domestic purposes requires 30,000 litres and
industrial purpose makes use of 1,70.000litres of water per day. Industrial purpose includes

 Process
 Washings
 Boiler feed
 Cooling

Effluent generated from domestic use is treated by providing scale tanks and also septic tank is
provided. ETP is provided in order to treat the industrial water where treated water is pumped to
fodder plant from ETP.

Water pays a supreme importance in the dairy industry. Approximately 3-4 liters of water
required for processing of 1 liters of milk. Water is used in the dairy in various ways.

*As an integral part of the product.

*As a heating and cooling medium.
*For cleaning of dairy equipment’s and utensils.

The water consumption and waste water generation is shown in below Table 2.2

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 Table 2.2 Details of water consumption and wastewater generation

Sl.no. Purpose Water consumption Wastewater

generation

1. Domestic (canteen, toilets, 25 KLD 20 KLD

etc.,)

Industrial 125 KLD 120KLD

2. 1. Process 25 KLD 10KLD
2. Boiler 25 KLD NIL
3. Cooling

3. Gardening Treated water NIL

Total 200 KLD 150 KLD

DEPARTMENT OF MECHANICAL ENGINEERING Page 30

 2.4.Effluent Treatment Plant

Description of Existing Effluent Treatment Plant

On the basis of the effluent characteristics, typical location of the processing plant, and past
experience of treatment and performance of similar treatment scheme is provided. The raw
effluent generated at the plant, from the last man hole, is taken into the existence raw effluent
collection sump, from where the effluent will be pumped into the oil and grease removal unit for
removal of floatable fatty material by means of mechanized fat scrapper mechanism.

 It treats the raw water and waste water for re-use. The ETP should be there in every food
industries so that they can minimize the water usage and wastage. Also they can reduce
the cost spent for water.
 ETP is the place where waste water is treated; this waste water contains organic matters
like total solids, total suspended solids, and high BOD and COD values.
The ETP water test report is shown in below Table 2.3

Table 2.3 ETP Water Test Report

Parameters Inlet Treated effluent char.

Flow 450 m3/d 450 m3/d

Ph 6.5-7.5 5.5-9

BOD at 20C 1200 mg/ l <30 mg/ l

COD 2200 mg/ l <250 mg/ l

TDS (Total dissolved solids) 2100 mg/ l <2100 mg/ l

Oil & Grease 150 mg/ l <10 mg/ l

Suspended Solids 650 mg/ l <100 mg/ l

DEPARTMENT OF MECHANICAL ENGINEERING Page 31

The various units used for waste water treatment in GUMUL are as follows:

Screen Chamber

Screening is process of removal of coarse and settable solids by surface straining. It is the first
operation in any treatment plant. Screens are the devices with openings generally of uniform size
placed across the floor to retain coarse solids. Screening elements consists of parallel bars or rods
or wires or mesh. Screens with parallel bars or rods are referred to as ‘Bar racks’. The bars used
for the screens will be usually rectangle or trapezoidal section. These are placed vertically or
inclined at a slope of 100-300 with horizontal. Generally the spacing between the bars is about
50mm. They will collect about 6 liters of solids/ million liters of sewage. The materials separated
by screening usually include plastics, leaves, wood etc. These are placed before the collection
tank.

Collection tank

The purpose of the collection tank is to collect the waste water which is generated from various
sections of the GUMUL plant.

Fat and Grease removal unit

It is provided with baffles at the inlet and outlet ends, a through for carrying the skimmed
floatable solids into collection chamber. A mechanized fat removal/scrapper unit with aluminium
scrapper and driving mechanism is provided. Platform is provided hand rails on both sides for
easy operation and safety during skimming.
Aeration tank
Aeration tanks are usually constructed of reinforced concrete and are left open to the atmosphere.
Aerator tanks have impellers such as centrifugal, Radial-axis, or axial. In surface aerators, oxygen
is entrained from the atmosphere and for some types; air or pure oxygen is introduced from the
bottom of the tank. In either case, the pumping or agitating action of the aerators help to keep the
contents of the aeration tank or basin mixed.
Clarifier
After biologically treating the waste water in the aeration tank, it’s led to the clarifier for the
separation of solid-liquid materials.A scraper mechanism is provided in the clarifier tank to scrap

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and collect the sludge at the central chamber of the clarifier. The sludge collected in the central
chamber of the clarifier tank to maintain the required MLSS concentration.

Sludge Drying Beds

Sludge drying beds provide the simplest method of dewatering. Digested sludge slurry is spread
on an open bed filled completely with sand and then allowed to remain until the slurry completely
dries. The excess sludge from the clarifier is pumped to the series of drying beds for dewatering
and drying. Two numbers of sludge pumps are provided for the purpose of pumping with one
pump as standby. The sludge pump is operated alternatively for uniform wear and tear and for
long life. The appearance of cracks on the sludge indicates that it has dried. The sludge cakes thus
formed should be removed and disposed off as manure or as landfill in low lying areas.

V-notch Chamber

The chamber is provided of 100mm thick and PCC 1:4:8 shall be provided below base raft
extending 100mm on all sides, with internal baffles/partition as required. V-notch plate should be
properly grouted I the side walls of the unit, pipes etc. The flow chart of ETP is shown in below

Flow Chart of ETP

Raw influent

Bar Screen

Aerobic/ aeration tank

Clarifier Sludge beds

Treated effluent plant Sludge press

Water used for garden Discharge

DEPARTMENT OF MECHANICAL ENGINEERING Page 33

 Fig 2.4 Effluent Treatment Plant

DEPARTMENT OF MECHANICAL ENGINEERING Page 34

 2.5.COLD STORAGE ROOM
Introduction

The basic purpose of cold storage is to store the perishable food products at optimum
temperature to enhance the self life of the products. In dairy plants, cold storage are required for
storage of milk, butter, cheese etc.Cold storage is a basic requirement for the storage of
perishable dairy and food products. For example milk is stored at around 4 °C . The design of
cold storage requires information on the following aspects.

(i) Size of the cold storage

(ii) Products to be stored

(iii) Incoming temperature of the product

(iv) Storage temperature

(v) Ambient temperature

(vi) Air change load

(vii) Numbers of persons working in the cold storage.

Location of Cold Storage

The location of cold storage is important in terms of ease of product movement as well as
operating and construction cost of the cold storage. The cold storage room preferably is located
on the cold side of the plant. In case of more cold storages, all the cold storages should be
located side by side to reduce the cost of insulation in common wall of adjacent cold stores. It
should be located in such a way that finished product can be transferred to the cold stores easily
and finished products can be dispatched conveniently. In cash of milk cold storage, conveyers
are used to transfer the milk crates directly from packaging machine.

Size of the Cold Store

The size of the cold storage is estimated based on the capacity requirement for the storage of
product. The method of storage, working space, air circulations etc. are considered to decide the
dimensions of the cold storage. Considering number of milk pouch crates which can be stacked,
working space etc; the capacity of storage per m2 area of the cold room is worked out. Similarly
for potato, apples, butter etc., the dimensions of the cold storage can be calculated e.g. 600 kg

DEPARTMENT OF MECHANICAL ENGINEERING Page 35

butter/m2 area, 500 lit ice-cream/m2 etc. Storage period is one of the basic requirements to
decide the size of cold storage to store the product. The capacity and number of of cold storages
required for storage of cheddar cheese will be more as the cheese is stored in the cold storage for
4-5 months for ripening. This may not be the requirement for milk cold storage as it is dispatched
twice a day. In addition to exact space required for storage of product, 30 to40 % space is kept for
moment.

Construction of Cold Storages

The basic construction of cold storage is just similar to other rooms except the requirement of
insulation for the cold storages. The room is constructed by using masonry work and it is
plastered with at least 25 mm thick plaster material (mortar). After curing of the plaster
insulation of wall, ceilings & floor is carried out to make it cold storage. Thermocol or expanded
polystyrene, cork etc. were widely used for insulation. Presently PUF panels are available to
insulate the cold storage. The material of application of insulation varies depending on the type
of insulating material and the thickness of insulation required. It is recommended to use PUF
panels having stainless steel as the panel material to get long life of the insulation. Holes
prepared in PUF panels for inserting support for evaporator, cables, pipes etc. should be sealed
perfectly to prevent water vapour inside the insulation.

Insulating materials

The materials having extremely low thermal conductivities are called insulating materials. It is
necessary to insulate the cold storages to prevent the entry of heat through the walls, ceilings and
floor of the cold storage when ambient air temperature is higher than the cold storage
temperature. Insulation of cold storages is important to reduce the operating cost of the
refrigeration plant by reducing heat gain through structure of the cold storage. Insulation is also
necessary on suction pipe line of the refrigeration plant in order to reduce the super-heating of
suction gas. Chilled water pipelines are also insulated to prevent surface condensation on the
pipeline.

DEPARTMENT OF MECHANICAL ENGINEERING Page 36

Describe properties of insulating materials

The desirable properties of insulating materials are listed below.

(i) Low thermal conductivity

(ii) Higher structural strength

(iii) Light in weight

(iv) High water repellent property

(v) Odorless

(vi) Non-inflammable

(vii) Low cost

Vapour barriers

The vapour barriers are the materials which are placed on the hot side of the cold storage to
prevent moisture migration and to protect the insulation from moisture condensation. Various
types of vapour barriers such as structural sheet of Aluminum and S.S., thin aluminum foils,
plastic film hot melt type bitumen, special type of paints etc. are used to prevent moisture transfer
through the insulating material. Bitumen and aluminum foil are widely used in insulation as
permeance is very low. Vapour penetration into the insulation will occur as vapour pressures are
lower at lower temperature and warm air will condense which in term will form ice which may
damage the panels. Panel and electrical services are carefully designed to ensure long term
vapour sealing. Penetrations are required for evaporator supports, electrical wiring and
refrigeration pipes. In such cases, make a hole in the panel and use PVC sleeve for the required
penetration and sealing materials such as silicon may be used to make it air tight.

DEPARTMENT OF MECHANICAL ENGINEERING Page 37

 2.6.GENERATOR SECTION

(DESIEL GENERATOR)
A diesel generator (DG) (also known as diesel genset) is the combination of a diesel engine with
an electric generator (often an alternator) to generate electrical energy. This is a specific case of
engine-generator. A diesel compression-ignition engine is usually designed to run on diesel fuel,
but some types are adapted for other liquid fuels or natural gas.

A diesel generator is actually a machine that converts mechanical energy (produced by an in-
built combustion engine) into electrical energy. There are different components of the diesel
generator that work in synergy to produce electricity. Some of these essential components of a
power diesel generator include:

Engine – Being the primary component of the diesel generator set, the engine supplies the
mechanical energy which is later transformed into electrical power. As a matter of fact, the
power output of these diesel generators is directly proportional to its engine’s size.

Alternator – This is another key component of a diesel generator that uses the mechanical input
supplied by the engine and converts it into electrical output. An alternator includes a rotor that
produces a magnetic field to eventually generate some alternating current. This is why the rotor
is referred to as the main part of the alternator.

Fuel System – This component stores and supplies the fuel to the generator. In general, a fuel
system can easily keep a 62.5KVA silent generator running for about 6 to 8 hours.

Lubricating System – This unit ensures the smooth functioning of different parts of a diesel
generator. This is why it is recommended to keep a proper check on the lubricating system of the
generator to avoid any malfunctioning.

Control Panel – This unit not only includes the Start/Stop button but also contains indicators for
various parameters like current, voltage, and frequency. You can easily operate your 2.5KVA
portable generator through its control panel.

DEPARTMENT OF MECHANICAL ENGINEERING Page 38

Working Principle of a Diesel Generator
Well, it is important for you to know that a diesel generator works in 4 cycles:

Suction Intake

Compression

Power

Exhaust

The functioning principle of a diesel generator is actually based on the law of energy conversion.
This law states that the energy can neither be created nor be destroyed but can only be
transformed from one form to other.A diesel generator contains an engine that uses diesel for its
functioning. Now, it is the chemical energy of the diesel that is converted into mechanical energy
during the combustion process. The mechanical energy which is generated is further converted
into electrical energy in order to be used during power outages.Modern diesel generators that are
provided by Genset Manufacturers are usually well set-up with high specs, and they are readily
available in different models. So, you can consider investing in a highly efficient diesel generator
to ensure continuous power supply in your home and office.

For more information about the working principle and the incredible benefits of diesel generators,
please get in touch with the experts at Skyline Power Solutions.

DEPARTMENT OF MECHANICAL ENGINEERING Page 39

 2.7 Marketing Department
Marketing is the business function that identifies customer needs and wants,determines
which targets markets the organization can serve the best designs appropriate products,services
and programs to serve these markets.However,marketing is much more than just an isolated
business functioning.It is a philosophy that guides the entire organization.

Duties of Marketing Officers

To fix necessary targets to the retailers,wholesalers,depots,day counter and milk

parlors. To take necessary actions to appoint retailers in the new extension

To adopt necessary extension programmes for consumer programmes.

To arrange for consumers meets/fairs/exhibition and to take participation in such

programmes to improve nandini milk sales. The hierarchy of marketing department is shown
below.

Heirarchy of Marketing Department

Deputy Manager(Marketing)

Assistant Manager(Marketing)

Marketing Assistant

DEPARTMENT OF MECHANICAL ENGINEERING Page 40

2.7.1Finance Department
Every organization requires an accounts or finance department where circulation of all essential
issues like salary billing,sales ,purchase etc.,are carried out .It acts as a heart of the organization
without whatever may be result of functioning of a unit ,The accounting at the same time , it
ensures the results experienced and qualified person identified as purchase officer.

Objectives

 To ensure that accounting records of various divisions are properly maintained.

 To ensure that sales realization are properly accounted and reminded the marketing section
from time to time over the debtors portion in order to enable them to collect the dues.
 The account section objective is also to see that regular payment of milk bill due are made to
milk producer on priority.
 To see that the payment to the creditors is made within stipulated time.
 Account section has to provide management timely information about the financial position of
the union and guide them as to viability of the proposals that come in the course of business
activity.
 To include timely submission of financial statement to auditors and ensure smooth audit is
conducted and give audit reports to management. The hierarchy of finance department is
below.

Hierarchy of Finance Department

Manager(Finance)

Assistant Manager (Finance)

Account Super indent

Accounts assistant

DEPARTMENT OF MECHANICAL ENGINEERING Page 41

2. Roles And Responsibilities of Individuals In The Department

Technical Officers
 To take overall in charge of quality management
 To co-ordinate with the production department to make correction if any complaints from
market.
 To propose to the general manager to purchase the equipment,which are required for the
laboratory.
 To maintain all records of Laboratory equipment’s and quality control and send all the
records to the general manager.

Production Manager

 He shall be overall in charge of production/plant section

 He shall ensure and implement and cost service majors to production section.
 To plan and implement the disposal of excess milk in bulk sales and if shortage,
arrangement to get milk from inter dairy as per requirements.
 He shall plan well in advance requirements of chemicals/detergents on any other material
of the production section.
 He shall take care of entire plant and machinery.

Marketing Officer

 To inspect the milk parlors regularly and to keep watch on sale of other product.
 If the parlor contractor are found to sell products other than nandini products,action
should be taken.
 To keep close watch on the milk distribution vehicles movement of routes and to check
that the milk and milk products reach the retailers within in the described time.
 To conduct distance survey of milk distribution route and to certify them regularly.
 To take necessary action to make recoveries if any due from the retailers.

DEPARTMENT OF MECHANICAL ENGINEERING Page 42

Chemist

 To completely take care of the quality control section based on their respective section.
 To register the complaints of the milk quality from the societies ,and should be brought to
the observation of technical officer.
 Quality checking of the adulterated milk,daily testing should be carried out on milk from
societies, tankers such as MBRT etc.,
 Quality testing of the milk sample from the storage tank and then providing milk to the
packing section for packing.

 To demand the lab requirements.

REFERENCES
 Information Collected Through Industry ( Gulbarga-Bidar-Yadgir Milk Union Ltd.)Visit
Available With The Management.

 Rao M.N And Datta A.K (2012), “Waste Water Treatment’’, Third Edition, Page No.262-
266.

 www.Kmfnandini.Coop.

DEPARTMENT OF MECHANICAL ENGINEERING Page 43