CIP IN DAIRY PLANT,

COMPOSTING OF
BIOLOGICAL WASTE
& EFFLIUENT
1.ALVIN THOMAS
2.ALAN PAUL
PARAKKAL
3.AMEERA C B
4.AMRITA T
 TABLE OF CONTENTS

01 02 03 04
CIP in Dairy Composting of Composting of Reference
plant Biological Sewage effluent
waste
 CIP
● Cleaning-in-Place (CIP) involves circulation or recirculation of appropriate
water rinses and chemical cleaning and sanitizing solutions through plants and
equipment which is maintained in the assembled state.
● It involves use of hotter, stronger and more soil aggressive chemical solution
than manual cleaning.
 Consider....
● Minimum temperature should be about 3 – 5°C higher than the melting point of
fat.
● Maximum temperature will depend upon the temperature at which the protein in
the system is denatured.
● The turbulence due to velocity of detergent has also a bearing on the cleaning
efficiency. A velocity of 1.5 m/s is satisfactory.
● The hardness of water must be below 50 – 60 ppm.
● Presence of > 3 ppm of Iron and > 0.2 ppm of Manganese.
Important aspects for effective cleaning are
● Design of plant, material used and ancillary equipment should be suitable for CIP
cleaning.
● ii. Cleaning procedure to be adopted depending on soil type, detergent type,
concentration, temperature, contact time, type of surface.
● iii. CIP cycle must effectively and automatically controlled with minimum of
intervention or unauthorized alteration.
● iv. Supervision is important although high degree of automation is available
TYPES OF CIP CLEANING
There are two types of CIP cleaning-
1.Single use system
2.Reuse system
1. SINGLE USE SYSTEM
Cleaning one process circuit at a time with all liquids drained after use. This is also
called De-centralized system of CIP cleaning. A Typical cycle has-
i) 3 Pre- rinses of 20 sec. With gap of 40 sec to remove gross soil contamination.
ii) Cleaning detergent of certain temperature for 10 to 12 min.
iii) Rinse with warm water for 5 min.
iv) Rinse with acid solution, pH about 4.5 to 5.0, for 3 min.
v)Two rinses with cold water.
2. REUSE SYSTEM

● It is mostly Centralized Cleaning system, the cleaning solutions like acid, alkali are
reused by circulation from tanks storing these solutions.
● In order to make complete use of chemicals it is used as many times possible. Due to
prerinses detergents are not much polluted.
 CIP PROGRAMS:
Dairy CIP programs differ according
to whether the circuit to be cleaned
contains heated surfaces or not
CIP PROGRAMS:
 DESIGN OF CIP SYSTEMS
● CIP station in dairy consists of all necessary equipments for storage,
monitoring and distribution of cleaning fluids to the various CIP
CIRCUITS.
● CIP system may be centralized or decentralized
CENTRALIZED CIP
● Rinsing water , heated detergent solutions and hot water are supplied from a
central CIP station by a network of pipes to all the CIP circuits in the dairy.
● Centralized systems are used manly in small dairy plants with relatively short
communication lines.
● Water and detergent solutions are pumped from the storage tanks in the central
station to the various CIP circuits
 DECENTRALIZED CIP
● Also called satellite CIP system
● It is an attractive alternative for large dairies where the distance between a
centrally located CIP station and peripheral CIP circuits would be extremely
long.
● The large CIP station is replaced by a number of smaller units located close to the
various groups of process equipment in the dairy
 CENTRALIZED OR DECENTRALIZED
CENTRALIZED
●Central handling of detergents
simplified utility distribution.
●Central recovery of milk rinses
possible( flushed out every time )
●Collection and neutralisation of
alkaline and acid solutions some
what simplified
●Long supply piping
DECENTRALIZE
D
●Optimum location of CIP units.
●Modular constrution, adaptable if plant
is rebuilt or expanded.
●Simple collection of milk rinses.
●Reduced space requirements in some
cases.
●Short supply piping low installation
costs,minimized rinsing loses, shorter
flushing times, easier adjustments.
 COMPOSTING
 Composting is a controlled, aerobic (oxygen-required)
process that converts organic materials into a nutrient-
rich, biologically-stable soil amendment .The end
product is compost.

 Microorganisms feed on the materials added to the

compost pile during the composting process.

 They use carbon and nitrogen to grow and reproduce,

water to digest materials, and oxygen to breathe.
 Benefits of compost
 Add nutrients to the soil.

 Introduces valuable organisms to the soil.

 Good for environment

 . Enhances soil fertility.

 Benefits soil structure.

 Replenishes the soil.

 Compost is renewable .
 TYPES OF COMPOSTING

AEROBIC COMPOSTING ANAEROBIC COMPOSTING

Ex:
Ex: • Bangalore Method
• Indore Method • Coimbatore Method
• Pit Method
 AEROBIC COMPOSTING
 Aerobic composting: This means to compost with air. High nitrogen wastes (like grass clippings or other
material ) will grow bacteria that will create high temperatures. organic waste will break down quickly and
is not prone to smell.

 Aerobic microorganisms breaks down organic matter and produce – carbon dioxide ,ammonia, heat ,
humus etc.

 Although aerobic composting produce intermediate compounds such as organic acids ,aerobic
microorganism decompose them further.

 This type of composting is high maintenance ,since it will need to be turned every couple days to keep air
in the system.

 Processing time is shorter .

 It is considered more efficient and useful than anaerobic composting for agricultural production.
 INDORE METHOD
 This method was developed by A .Howard and Y.D.WAD at institute of plant industry, Indore India.

 Urine soaked earth, scraped from cattle sheds is mixed with water and sprinkled over the layer of
wastes twice or thrice a day .

 Layering process continued for about a fortnight .A thin layer of well decomposed compost is
sprinkled over top and the heap given a turning and reformed .

 Old compost acts as inoculum for decomposing the material.

 The heap is left undisturbed for about a month .Then it is thoroughly moistened and given a
turning .The compost is ready for application in another month .
 Size of pit:

Breadth - 6-8feet
Depth - 2-3 feet
length - 10 feet or more as per
Requirement

 Raw material:

Mix plant residues, weeds, sugarcane

leaves, grass , Animal dung, wood
ashes ,water, urine soaked mud etc.
 FILLING THE PIT
 1st layer: farm waste to a height of 3“

 2nd layer: cattle dung 2"and soil.

 The layers are repeated 1' above the ground level.

 1/4th of the pit is kept empty to facilitate turning.

 Turnings

 1st turning:10-15days
 2nd turning:15days after 1st
 Subsequent turning: after 60 days
 PIT METHOD
 Site and pit dimension:-The site selected for the compost pit should be at high level so that no
rainwater gets in during the monsoon season;

 it should be near to the cattle shed and a water source .

 Access raw material.

 By making the pit close to the crop waste,you can reduce the transport cost.

 Not to do:- In region of low temperature .

 In high rainfall, water is collected in the pit .Hence the soil microorganisms don’t get sufficient
oxygen amount for activity as well as nutrients can be washed out from rain
● Dig the hole for your compost pit. Your
compost hole should be about 0.5m deep.
The area of the hole will be determined by
the amount of organic matter you want to
add. Sizes can be vary according to the
requirement.
 FILLING THE PIT
 The material brought from cattle shed is spread evenly in the pit in layers 10-15 cm .
 on each layer is spread a slurry made with 4.5 kg dung ,3.5kg urine earth and 4.5 kg of
inoculum taken from a 15 day –old composting pit .

 Sufficient quantity of water is sprinkled over the material in the pit to wet it.

 The pit is filled in this way ,layer by layer ,and it should not take longer than one week to
fill.

 A temporary shed may be constructed over it to protect the compost from heavy rainfall .
 The material is turned three times during the whole period of composting .
 first time 15 days after filling the pit
 second after another 15 days and the third after another month
 factors affecting Aerobic composting
 Oxygen and aeration:-In aerobic composting oxygen is major limiting factor. The growth of
aerobic microbes is directly affected by the oxygen supply.

 Temperature :- temperature is a major factor and it can be regulated by turnings and aeration
of compost.

 Moisture :- the major role of moisture content in aerobic composting is to maintain the
metabolic activity of the microorganisms. proper Aerobic composting process the moisture
content should be 40-65 percent.

 pH value:- optimum pH for proper microbial growth in composting pile is recommended

between 6.0 and 7.5 for most microbes.

 Nutrients :- carbon ,nitrogen , phosphorus, potassium major nutrients in compost

 ANAEROBIC COMPOSTING
• Decomposition occurs in the absence of oxygen or
under limited supply of oxygen
• Intermediate compounds like methane,organic
acids ,hydrogen sulphide
• In anaerobic composting four major stages takes
place such as:
● Hydrolysis, Acidogensis, Acetogensis,
Methanogenesis.
● These substances have strong odour and some are
phytotoxic.
● Anaerobic composting technique:- Bangalore
method, Coimbatore method
BANGALORE METHOD
● Developed by Dr.C.N. Acharya in 1939

● Compost is done in the trenches of 9.1m*1.8m*0.9m or in the pits 6.1 m*1.8m*0.9m.

● Method is suitable for areas with scanty rainfall

● Steps:- trenches or pit about 1m deep are dug 1m in breadth,and length of trenches can vary
according to the availability of land and the type of material to be composted.

● Organic residues and night soil are put in alternate layers.The trench or pit is filled like wise till
the raw material reaches about 50 cm above the surface.
● Here 100% space of pit is used.

● The pit is covered with 15-20cm thick layer of refuse and plastered with a 2-5 cm layer of
mixture of mud and cowdung.

● C:N ratio of finished product drops to a value below 20:1 with no odour, indicating that
compost is ready to use.

● Decomposition rate is slow it takes 6-8 months.

● Well decomposed compost contain 0.8-1.0%N.

COIMBATORE METHOD
● Developed by Manickam in 1967

● Steps: First layer:- 15 cm – farm waste materials for eg :- maize stalks ,straw, cattle shed
wastes,wood powder.

● Second layer:-It is moistened with a suspension of 5-10kg cowdung in 20 to 25 litre of water

and 0.5 to 1.0 kg fine bone meal sprinkled over it uniformly. Similar layers are laid one over
the other till the material rises 0.75 m above the ground level

● Top plastering:-Top layer is plastered with wet mud and left undisturbed for 8 to 10 weeks
● After 65-70 days plastering is then removed ,material moistened
with water , give a turning and made into a rectangular heap under
shade .It is left undisturbed for 3 months

● Compost will be ready in 5-6months

 Factors affecting Anaerobic
Composting

TEMPERATUR pH SUBSTRATE PATHOGENS

E
Optimum temperature Major threats to
Ranges from 6.5 Initial substrate
for mesophilic composting material
to 8.0 concentration directly
digesters is 35C
influence the anaerobic
digestion
Differences between Anaerobic and
Aerobic compost
AEROBIC ANAEROBIC
COMPOST COMPOST
●Decomposition is faster(3-6 months) ●Decomposition takes 6-a year

●Pathogen suppression is high ●Pathogen suppression is low

●Reduce the chances of formation ●Formation and emissions of odour is

and emissions of unpleasant gases more
VERMICOMPOSTING
● Vermicomposting is the scientific method of making compost,
by using earthworms. They are commonly found living in soil,
feeding on biomass and excreting it in a digested form.

● Earthworms feed on the organic waste materials and give out

excreta in the form of “vermicasts” that are rich in nitrates and
minerals such as phosphorus, magnesium, calcium and
potassium. These are used as fertilizers and enhance soil quality.
 STEPS
1) To prepare compost, either a plastic or a concrete tank can be used. The size of the tank
depends upon the availability of raw materials.

2) Collect the biomass and place it under the sun for about 8-12 days. Now chop it to the required
size using the cutter.

3) Prepare a cow dung slurry and sprinkle it on the heap for quick decomposition.

4) Add a layer (2 – 3 inch) of soil or sand at the bottom of the tank.

5) Now prepare fine bedding by adding partially decomposed cow dung, dried leaves and other
biodegradable wastes collected from fields and kitchen. Distribute them evenly on the sand
layer.
6) Continue adding both the chopped bio-waste and partially decomposed cow dung layer-wise in
the tank up to a depth of 0.5-1.0 ft.

7) After adding all the bio-wastes, release the earthworm species over the mixture and cover the
compost mixture with dry straw or gunny bags.

8) Sprinkle water on a regular basis to maintain the moisture content of the compost.

9)Cover the tank with a thatch roof to prevent the entry of ants, lizards, mouse, snakes, etc. and protec
the compost from rainwater and direct sunshine.

10)Have a frequent check to avoid the compost from overheating. Maintain proper moisture and
temperature.

11) After the 24th day, around 4000 to 5000 new worms are introduced and the entire raw material is
turned into the vermicompost.
 Composting of sewage
Composting sewage is an eco-friendly method of waste
management that transforms sewage sludge into nutrient-rich
compost. Composting sewage involves using organic materials
and microorganisms to break down sewage sludge into a
nutrient-rich compost that can be used as fertilizer. This process
helps to recycle nutrients and organic matter while reducing the
volume of sewage sludge that needs to be disposed of in
landfills or incinerated. However, it requires careful
management to ensure pathogens are destroyed and that the
resulting compost is safe for use.
 What is sewage?
Sewage refers to wastewater containing human waste, household waste, and often
industrial and stormwater runoff. It’s typically transported through pipes to
treatment plants where it’s treated to remove contaminants before being
released back into the environment or reused.
 STEPS
Composting sewage is an eco-friendly method of waste
management that transforms sewage sludge into nutrient-
rich compost. The process involves several steps:
Collection and Separation: Sewage is collected from
households and industries and undergoes preliminary
treatment to remove large solids.
● Sludge Treatment: The sludge is separated from the
wastewater and treated to remove pathogens and
harmful chemicals.
 Composting: The treated sludge is mixed with bulking agents such as wood chips or
sawdust to improve aeration and moisture control. It is then placed in composting piles
or bins.

Aeration and Moisture Control: Regular turning of the compost pile provides oxygen for
aerobic decomposition. Monitoring and adjusting moisture levels ensure optimal
composting conditions
Microbial Action: Microorganisms break down organic matter in the sludge, converting
it into stable compost over time.

Maturation: The compost undergoes a curing period to allow for further decomposition
and stabilization of organic materials.
Quality Control: The final compost is tested for pathogens, heavy metals, and
other contaminants to ensure it meets regulatory standards for land
application.

Land Application: The mature compost can be used as a soil amendment in

agriculture, landscaping, and restoration projects, improving soil fertility and
structure while reducing the need for chemical fertilizers.
 WHAT ARE IT’S BENEFITS
Pathogen Reduction:
Waste Reduction: Decreases the volume Destroys
of sewage sludge needing disposal. pathogens,lowering
Nutrient Recycling: Converts sewage
disease risk.
into nutrient-rich compost for
fertilization. GreenhouseGas Reduction
Renewable Energy: Produces biogas
through anaerobic digestion for energy. Cost saving
REFERENCE
● https://agrimoon.com/dairy-technology-icar-ecourse-pdf-books/
● www.agrifarming.in
● www.Fao.org