Tuesday 13 December 2011

MILMA-WAYANAD DAIRY-REPORT


  
IN-PLANTTRAINING REPORT   

MILMA WAYANAD DAIRY (MRCMPU LTD.)

Chuzhali, Kalpetta, Wayand




ACKNOWLEDGEMENT
We take this humble opportunity to those who have inspired and motivated us to undergo industrial training during the summer vacation of 2011.We are grateful to the Principal Dr.Benny Joseph.He is the leading light of the institution.We would like to thank Mr.Rahul Antony(HOD,Dept of AEI) for allowing us to undergo the training and Mrs.Reema Mathew(Lr,Dept of AEI) who coordinate the industrial training in the best possible way.
We would like to express our deep sense of gratitude to Mr.K T Thomas (Managing Director,MCMPU), Mr.D.S.Konda (Manager,Wayanad Milma) and our guide Mr.Roopesh(Trainingcoordinator,Wayanad Milma)for constant and appropriate guidance throughout the period always.I am also thankful to all the engineers,technical staffs,officers and workers in Wayanad Milma Dairy for their support and guidance during the course of the training.




CONTENTS

1.      About MILMA…………………………………………………3
2.      About Wayanad dairy……………………………………….….4
·         MILMA for farmers……………………………….….….....3
·         MILMA for consumers……………………………..……....5
·         Awards & recognitions…………………………………..…5
·         Energy conservation policies in the dairy………….….……6
3.      Products…………………………………………….…..…….....6
4.      Milk Processing…………………………………………...……7
·         Pasteurization…………………………………………….…9
5.      Cleaning in position…………………………………..………..13
6.      Steam boilers…………………………………………..……....16
7.      Quality control lab……………………………………..………20
8.      Effluent treatment plant…………………....................................22
9.      Conclusion………………………………………………..……23









1.    ABOUT MILMA
Milma was established in April 1980 by Kerala Co-operative Milk Marketing Federation (KCMMF). The mission of Milma is ‘Farmer’s Prosperity through consumer satisfaction’. The objective of Milma is to build up a viable dairy industry in the State and to provide constant market and stable price to the dairy farmers for their produce. The Malabar Cooperative Milk Producers’ Union(MCMPU), head quartered at Kozhikode (Calicut) in Kerala, was started in 1991. It has the 6 Northern Districts of Kerala as its area of operation and an average milk procurement of 4 lakh litres per day. The Union operates 5 Dairy plants and 2 Milk Chilling Centers. It has a Milk Products Dairy too. The network of Bulk Milk Coolers is in fast expansion. Currently a BMC capacity of 2 lakh litres is in place with 75 BMCs installed in the villages. The products comprise Market milk (4 lakh litres per day), curd (40, 000 Kg /Day), Ghee (150 MT per month), Ice-cream (1500 Litres per day), Peda (10 MT per month), Butter milk, Milk Lollies, Sterilized flavored milk etc.
            Malabar Regional Co-operative Milk Producers’ Union (MRCMPU) Limited is a Union of more than 1000 village level dairy co-operative societies located in the six northern districts of Kerala State in South India and it is owned by the dairy farmers who are members of each affiliated society and who live in the area of operation of these societies. The societies function on the pattern of the societies affiliated to the world famous Anand Milk Union Ltd. (AMUL) at Anand (Gujarat), India and hence are also known as Anand Pattern Co-op Societies or “APCOS”. The area of operation of MRCMPU Ltd. comprises of the six revenue districts of North Kerala, viz Kasaragod, Kannur, Wayanad, Kozhikode, Malappuram and Palakkad. The Union sells its products under the Milma brand, a common brand for the Kerala Cooperative Milk Marketing Federation, which has two more Milk Unions under it at Ernakulam (Kochi) and Thiruvananthapuram (Trivandrum).




2.    ABOUT THE WAYANAD DAIRY
The Wayanad dairy ,coming under MCMPU located at Kalpetta, Wayanad was established on 9/10/2008. The entire process is controlled The processing unit of theDairy is very well organized with each department taking care of specific tasks. There is good networking between each department which adds to the smooth working of this plant. Effective time management is displayed since the processing in itself takes about 20 hours and the rest 4 hours is dedicated to cleaning the equipment. Per day it processes about 2 lakh liters of milk. According to D.S. Konda, Manager, Wayanad dairy,The Wayanad Dairy is the only unit of Milma that has got license to export dairy products to foreign countries. During the last onam festival period, 1,12,000 liters of milk and 63,000 litres of curd were sold. This firm also has an effluent treatment plant and the recycled water is reused for primary purposes (watering and manure).  This firm comprises of about 150 workers working via 2 shifts per day.The operations of this dairy are thus very eco-friendly.
Fig.(1).wayanad Dairy kalpeta




MILMA  FOR  FARMERS
The following programmes are carried out at the farmer level to enhance quantity and quality of milk production
1)Artificial insemination
2)Feed and fodder program
3) Total mixed ration programme
4)Heifer development programme
5)  Malabar rural development foundation
6)Decentralized veterinary units
7)Procurement of milk by societies or union
8)Insurance schemes
9)Women cattle care program
10)Co-operative development program
11) Awards and scholarships
MILMA FOR CONSUMERS
a)    Marketing department
1)Marketing of fresh products
2)Marketing of long life products
          b) Implementation of quality management system
                1)ISO 9001:2008
                 2)HACCP( hazard analysis and critical control point)
3)ISO 22000:2005
AWARDS AND RECOGNITIONS
1)Won the Kerala state award for safety in 2010
2)Got the certificate of approval from the export inspection counsel of India
3)Won the pollution control award of the pollution control board of Kerala in 2009-2010
4)Won the Kerala state award for best marketing management
ENERGY CONSERVATION  POLICIES IN THE DAIRY
Some of the widely used technologies for possible energy savings in the dairy plant are as follows:
·         Solar Water Heating System: For process heating & wash water
·          Tri-generation system / VAM: For generation of electricity, steam and refrigeration
·          Waste heat Recovery: By installation of De-super heater for Refrigeration Plant
·          Installing hot water fan coil unit in incubation rooms in place of electrical heaters
·         Installing Variable Frequency Drives (VFD) for on ID & FD fans of Spray dryers & Boilers
·         DG Set performance optimization
·          Optimization of compressed air generation and utilization
·         Use of energy efficient pumps
·         Improvement in Regeneration efficiency of Pasteurizers
·         Introduction of  two temperature levels for different usage etc


3.PRODUCTS
Milma–SmartMilk
Contains 1.5 percent fat and 9.0 percent non-fat solids. Ideal for elderly people since fat content is low. Can also be used for whitening tea/coffee and for the preparation of milk based drinks like fruit shakes. Fat will not settle at the top since the milk is homogenized. Available in 500 ml sachets.

MilmaTonedMilk
Contains 3.0 percent fat and 8.5 percent non-fat solids. Ideal for consumption by children in the form of milk or in the form of brown beverages like Bournvita. Fat will settle at the top if Milk is kept still for some time. Available in 500 ml sachets.

HomogenisedTonedMilk
Contains 3.0 percent fat and 8.5 percent non-fat solids. Ideal for whitening tea/coffee and for the preparation of solid curd. Since the milk is homogenised, whitening capacity is more and less amount of milk will be sufficient for whitening tea/coffee. The milk will not stick to vessels on heating and hence washing of used vessels is easier. Fat will not settle at the top since the milk is homogenised. Available in 500 ml sachets.

Milma-RichMilk
Contains 4.5 percent fat and 8.5 percent non-fat solids. Ideal for the preparation of payasam and sweets. Fat will settle at the top if Milk is kept still for some time since the milk is not homogenised. Available in 500 ml sachets.


SkimmedMilkCurd
Contains 10 percent non-fat solids. Ideal for making curries. Prepared under hygienic conditions by fully mechanized processes. Cannot be used as starter-curd for converting milk into curd. Available in 500 ml sachets.

Milma-Sambharam(ButterMilk)
Contains 4.5 percent total solids and natural flavour extracts. Ideal as thirst quencher during hot season. Prepared under hygienic conditions using fully mechanized processes. Available in 200 ml sachets.

MilmaGhee
Contains 99.7 percent milk fat. Manufactured by melting fresh cream under hygienic conditions. Milma ghee has the ideal golden yellow colour due to presence of natural carotene in cow milk. (In contrast, ghee manufactured from buffalo milk is white in color). No artificial colours or flavours are added in Milma ghee. Natural aroma and flavour of ghee is retained since ghee is produced directly from fresh cream instead of going in for melting stored butter

Milma-sipup
 Contains the mixture of flavours, color powders, sugar and this mixture is added to the milk. Flavours used arechocolate, orange, pineapple, pista etc.








4.MILK PROCESSING
In Milma, following prioritation is done in the order given here:
·         Refrigeration System: Ice Bank Tank (IBT) & Cold store
·          Pasteurizers: Milk& Cream
·         Packing: Milk & Products
·         Boilers, DG Sets, Incubator Room having electrical heaters, Spray Dryers, Blowers, Air Compressors, Pumps, AC & Lightings Systems
·         Effluent Treatment Plants and Other motive loads.
SCHEMATIC DIAGRAM OF MILK PROCESSING

Unloading & Platform Test


     Queuing


   Quality check




   Pasteurization

    Quality check after pasteurization



      Packaging


Operations (Processing of milk)
1.      Unloading & Platform test
2.      Queuing
3.      Quality check
4.      Pasteurization
5.      Quality check after pasteurization
6.      Packaging

Unloading & platform test:
Milma buys raw milk from various societies (including Karnataka and Andhra Pradesh), which is then unloaded at the plant. This raw milk is subjected to a manual platform test. Here, the milk is checked for any foul smell or visible impurities. If there is any such mentioned, then the milk is discarded.
Queuing:
Only one society’s milk is queued at a time. All the cans from that particular society are transferred into a huge container which has a capacity of 3000 liters. This point is called the Raw Milk Reception Dock (RMRD).
Quality Check:
At the RMRD, a sample of the raw milk is taken and a quality check is done. The fat and SNF (solid non fat) content are checked. Once the milk undergoes the quality check, it is then chilled (to 5 degrees) and transferred into a tank (SILO tank) which has a capacity of 60,000 liters.
 In SILO tank the raw milk undergoes a cleaning process for which a CIP (cleaning in position) unit is set up. Here the raw milk is treated with containers washed with 0.1% nitric acid then with alkali (sodium hydroxide) and finally with hot water. A recuperation tank is attached to it which recycles water. 
Pasteurization:
From the SILO tank, the milk is then pumped to a flow control value. It controls the flow of the raw milk to be pasteurized. Simultaneous process of heating (79 degrees) and cooling (4 degrees) is done. In an hour, 1000 liters of milk can be pasteurized.  Once this process is complete, the milk is transferred to another SILO tank.
Quality check after pasteurization:
The quality of the milk is checked to find if it has 3 % fat and 8.5 % SNF (solid non fat). If the fat and SNF contents are not met, then skimmed milk is added to it to attain the required standards. The milk is stored in cylose tankers with 60,000 L capacity and normally stored to a maximum of 12 hrs.

Packaging:
After checking the quality standards, the milk is then pumped into overhead tank. From these tanks the milk is then transferred to a sophisticated packaging machine. This packaging equipment filters the milk and fills them into sachets of different volumes. The weight of the milk sachets is checked randomly at regular intervals .These sachets are put into a tray, where each tray contains 20 milk sachets. In 15 minutes, a packaging equipment can fill 25 such, which is then taken to the dispatching unit
Fig. (2). Package Report



PASTEURIZATION
The heating of every particle of milk or milk product to a specific temperature for a specified period of time without allowing recontamination of that milk or milk product during the heat treatment process.
Pasteurized plant is intended  for the production of pasteurized milk.Raw milk  stored in silos is passed through pasteurizer .There it is heated to 72 degree Celsius for 15sec .The time 15sec is adjusted by making the tube longer.Most of the pathogenic organisms are eliminated during this time.The next step is to cool this milk suddenly to about 4 degree.Milk having 60 degree Celsius goes to homogeniser and 40 goes to cream seperator.Due to the high pressure applied the milk goes through very narrow nozzle and the fat globules are broken down into smaller particles and  equally mixes with the milk,resulting in the production of homogenised milk.The basic principal of cream separator is centrifugal action by which the low density fat is accumulated at the top and the high density milk is obtained as skimmed milk.
BASIC DESIGN OF A PASTEURIZER
Fig. (3). Pasteurizer
It mainly consist of a Product supply,Product Balance Tank, Product Pump, Flow controller, Regenerative section, Bypass for equipment  like filters, separators, homogenizers.
Product Balance tank
It consist of a float as a Level controller
·         To keep the count level above the  product pump inlet
·         To damp fluctuations in the flow after the pump
·         To get rid of incoming air bubbles in the incoming product
·         Flow controller maintains constant flow through the plate heat exchanger.
Adjustable flow Controller
 Is designed to control and maintaina constant flow rate.It is equipped with an adjustable setting cone to control any flow within its capacity range.Main parts of this flow controller are
·         Nut/clamp
·         Outlet pipe
·         Setting cone
Actuator
 The Pneumatic actuator is designed so that an axial movement of a piston is transformed into 90 degree rotation of the shaft.The torque of the actuator increases at the end of the movement to improve the closing security.
Milk strainer
Particles in the milk flowing through the strainer are caught by the perforated strainer bag or by the filter.The filter consist of two halve body and cover with filter bag or PVC and hold together by clamp.The filter bag is of size 120 mesh.
  Fig.(4). Milk Strainer
      The milk or bottom outlet .Product enters the ECD filter from the top jet, filtered through the mesh and comes out from the  bottom outlet.The temperature sensor PT-100 is a resistant  temperature detector RTD.The temperature of the platinum changes as the temperature changes.
ElectroPneumatic positioner
The Electro Pneumatic positioner produces the preselected relationship between  valve stem position(controlled variable) and controller output signal(signal output).The Positioner  consist  of  an  electropneumatic   converter unit  and  the  Pneumatic   part  with  lever shaft measuring spring, the control system with nozzle,flapper and amplifier.The dc control signal is supplied by the controller fed to the coil in the field of permanent magnet.At the beam the force of the coil which is proportional to the current is balanced to the force of the air pressure produced at the flapper.The air pressure supplied to the control system varies proportionally with the current signal.The air pressure inturn produces a positionary force at the measuring diadhragm which is compared to the force of the measuring spring.The motion of the measuring diaphragm is transmitted to the flapper by a pin and the nozzle is activated.Changes in the control signal or in the valve stem position produce a pressure change in the amplifier downstream of the nozzle and the signal pressure supplied by the amplifier causes the plug stem to assume a position corresponding to the input signal.

Regulatory valve
 The valve is operated by means of a handwheel which makes it possible to open it gradually.The plug can be fixed in adjusted position with lockscrew.
fig.(5). Regulatory Valve
5. CLEANING IN POSITION (CIP)
All food products demand a very high standard of hygiene in the manufacturing  process. The raw materials are in contact with a number of surfaces which are potential sources of infection.Sterilisation can reduce but not entirely eliminate the consequences of such infection. Hence  the cleaning and disinfectant equipment is the most important factor  in a food processing plant.Control of the CIP is controlled by a processcontrol system, the once the program has been started the cleaning sequence  os fully automatic regarding timer ,temperature.Operating station is in front of control station.
Fig.(6). CIP



Buffer tank
It Is used for
·         Preparing cleansing solution
·         Contain cleansing solution to minimise cleansing solution losses
These tanks are equipped with low level switches indicating when the tanks are empty

Digital dinrail timer
                  T25 is a microcontroller based two digit user programmable timer.Operator can view and set the parameter through LED display and the 2 keys on the pannel.The set time is set using the keys and display in program mode.The instrument has reset key and one relay output.














6. STEAM BOILERS

Boiler is a product at many years of Engineering effort and expertise.This effort has produced a rugged ,compact and one of the safest units equipped with modern control for safe and efficient operation.
CONSTRUCTIONAL FEATURES
This is a smoke tube,single pass boiler which can be fired on a no of fuels.
eg:coal,baggase,husk and wood.Depending on the type fuel ,it has either balanced draught or an induced draught system.The boiler consists of 3 parts.
1:Refractory lined external furnace.
2:Shell and tube exchanger preesure part.
3: Atmospheric water preheater.


OPERATIONAL FEATURES
Fuel is burnt on the grate in the furnace and flue gases released during burning of the fuel enter the stroke tube and then the flue gas chamber to pass off to the chimney directly or via the water preheater.


SAFETIES AND CONTROL
1:Water level control.
 2:Steam injector.
 3:Steam pressure switch.
 4:Flue gas temperature control.

 MAINTENANCE

 The performance of a boiler depends very greatly on the maintenance carried out.The boiler,its surroundings,water pipelines,filters,strainer etc should be kept clean to maintain proper fluid flow to boiler so that it works efficiently.The maintenance checks be carried out and preferably should be recorded on a log book daily by the boiler operator.




BOILER FEED WATER

                                         Fig.(7).Boiler

Boiler is used for converting water into steam by evaporation in the boiler.Only the water gets evaporated and solids dissolved in the water remain in the residual water.Apart from getting converted into steam,water has many important function in the boiler which is to keep the heat exchanger portions cooled and heatly.To ensure that the water behaves as a proper cooling medium.It is essential to see the
1:The water continuosly wets the heating surfaces.
 2:The water does not corrode the heating surfaces.
 3:The water has necessary chemicals with in it such that a protective oxide layer is found on the surfaces.

DIGITAL TEMPERATURE CONTROLLER

This instrument is designed to suit applications requiring a highly accurate indication and control of temperature.The instrument provide a digital indication of temperature on a 3 and half digit seven segment LED display with a revolution of 1 degree celcius or 0.1 degree celcius.Sensor brake protection and ambient temperature compensation are added features of this instrument.

 PRINCIPLE OF OPERATION
      The millivolt output of the thermocouple is added to the output of the cold junction compensation circuit.The resultant of which is amplified and fed to the digital voltmeter which gives a readout of the same in terms of temperature in degree centigrade.The same output is also compared to a highly stable reference fixed by the position of the set potentiometer.The comparator through a buffer drives the relay which remains enegised as long as the measured temperature is below the set point.

BOILER
      The force fan is used to suck in the air into the furnace at a high pressure.Firewood is burned inside the furnace and this heat is used to boil the water and the steam for cleaning purpose is made from the boiler.The shell tube type boiler is usually used.The feedback water used for the purpose is at 80 degree celcius.The preheating of water is done at economiser.The heat from the feedwater passed to the economiser.The feed water is filtered using softwater instrument.The dust from the economiser is collected in the dust collector and the water gas is send out through the chimney.Inorder to reduce pollution,the chimney is created at a very big height.

ECODRAFT CONTROL SYSEM IN BOILER
Most solid fuel boiler are designed to operate under a negative furnace draft to the extend of -2 to -5 mm wc.Thin draft is critical both from the maintenance of proper combustion and ensuring safe and efficient operation of the boiler.In a typical solid fuel boiler 1D fan consumes the maximum portion of the allocated energy.In case we are all to control the 1D fan power consumption at part loads,while maintaining the necessary draft in the furnace.We can easily  cut on our total power costs. The furnace draft is dependent 1 degree on the following
1:The amount of combustion air admitted into the furnace.
2:The amount of flue gases scavengered by the level switches indicating when the tasks are empty.



TECHNICAL SPECIFICATIONS

SL.NO
PARAMETERS
UNITS
RANGE
A
DRAFT CONTROLLER
MAIN INCOMING POWER SUPPLY (AC)
V
3PHASE
ANALOG OUTPUT
mA
4-20
ANALOG INPUT
mA
4-20
OUTPUT ACCURACY

+/-0.3%
B)
ADJUSTABLE FREQUENCY DRIVE
INCOMING POWER FREQUENCY
Hz
50 +/- 3%
AMBIENT TEMPERATURE FOR INVERTER
DEGREE CELCIUS
40
POWER FACTOR MAINTAINED BY VFD

>0.95(LEADING)
RANGE OF MOTOR RPM OFFERED BY SYSTEM
RPM
500 – 1440(TYPICAL)






























CONTROL PANEL
Contains all equipment necessary for
  1:Indication of process status.
  2:Supervision of process performance.
  3:Control of automatic function.
  4:Process sequence control.
  5:Timer.
  6:Control loop.
  7:Text display.
  8:Pneumatic and functional keyboard.

PLATE HEAT EXCHANGER
      Plate heater exchanger is used to heat cleaning solution with use use of steam.The plater are assembled in packs and clamped in frame,each adjuscent pair of plates forming a flow channel,with the 2 media flowing in alternate channels.
      Two or more sections can be housed in the same frame CIP supports 5 types of programs and total 16 cleaning objects for each circulation.Cleaning program are
  1:Lye
  2:Acid
  3:Lye and Acid
  4:Sanitation
  5:Flush
COMPRESSOR
The blank tank or IBT is used to form ice.The ammonia sucked through the compressor is used to produce ice.The water in IBT which is at 1 degree celcius returns back at 7 degree celcius.This cannot be wasted hence it is recycled.




7.    QUALITY CONTROL LAB
Ø  Testing of milk to calculate MSNF & FAT
Ø  Latest technique using ekomilk digital meter.
Ø  Garber method for FAT determination
       10ml Gerber sulphuric acid+1ml amyl alcohol+10.75ml milk
        in beuterometer.
        After shaking place it in a centrifugal machine for 3 minutes
        %MSNF=CLR/4+0.2*F+0.5      at 29 degree celcius
Ø   For finding CLR
         heated to 29 degree, poured to lactometer cylinder then  lactometer is dipped in the cylinder











8.    EFFLUENT TREATMENT PLANT
Fig.(8). Effluent Treatment Plant
 The dairy industry involves processing raw milk into products including milk, butter, cheese, yogurt, using processes such as chilling, pasteurization, and homogenization. Typical by-products include buttermilk, whey, and their derivatives.
       Huge amounts of water are used during the process producing effluents containing dissolved sugars and proteins, fats, and possibly residues of additives. These effluents have the following characteristics
·      Biochemical oxygen demand (BOD), with an average ranging from 0.8 to 2.5 kilograms per metric ton (kg/t) of milk in the untreated effluent
·      Chemical oxygen demand (COD), which is normally about 1.5 times the BOD level
·      Total suspended solids (TSS), at 100–1,000 milligrams per liter (mg/l)
·      Total dissolved solids (TDS): phosphorus (10–100 mg/l), and nitrogen (about 6% of the BOD level).
         Cream, butter, cheese, and whey production are major sources of BOD in wastewater. The waste load equivalents of specific milk constituents are: 1 kg of milk fat = 3 kg COD; 1 kg of lactose = 1.13 kg COD; and 1 kg protein = 1.36 kg COD. The wastewater may contain pathogens from contaminated materials or production processes. A dairy often generates odors and, in some cases, dust, which also need to be controlled.
The effluent treatment plant in MILMA is as shown in the block diagram given above.The reuse of wastewater from the dairy industry can also be provided for by usage of adsorption and membrane separation among other processes. The color and the odor may be removed completely after activated carbon treatment. The pretreated water can be passed through a cross flow reverse osmosis membrane system and the permeate water can then be reused.













9.    CONCLUSION
The processing unit of Milma Dairy is very well organized with each department taking care of specific tasks. There is good networking between each department which adds to the smooth working of Milma. Effective time management is displayed since the processing in itself takes about 20 hours and the rest 4 hours is dedicated to cleaning the equipment. Per day it processes about 2 lakh liters of milk. Milma also has an effluent treatment plant and the recycled water is reused for primary purposes (watering and manure). The operations of Milma are thus very eco friendly.
Achieving energy efficiency in cooperative set up has important implications. The trade off between energy concerns and livelihood concerns are at the core of these implications. Milma has taken this perspective very seriously. The achievements Milma gained were possible through a strict monitoring system.. Through the ENCON measures, MILMA hope to mix the welfare concerns of human population as well as environmental concerns of mother earth in the future too.The training session was very motivating for instrumentation engineering students and gives and overview about  how instrumentation career is implemented in the dairies and how an engineer can work for common man.







BY,
   FENIL P CYRIAC