Process in Milk Industry

The milk dairy process plant familiar instruments are explained here. Majorly describes the report Evaporation plant, refrigeration plant, reception of milk, pasteurization, homogenizing and finally packaging and storage.

RECEPTION OF MILK:

            The basic or raw milk is get from formers and after reaching company milk cans are travelled by a conveyor and weight calculated using weighing scale in litter format. Kilogram is converted litter using below formulae.

EX:      10/1.027=9.737lt

Here, 10 represent – Kg of weight

1.0  represent – universal standard value (it is a constant not a variable)

27 represent – CLR value (it differ from every state depending on whether)

Then the milk is filtered the purpose of removing a physical dust. Then it is stored to Silo at 5°C

Milk is standard for following standards,

TM – Toned milk

DTM – Double toned milk

SM – Skimmed milk

FCM – Full cream milk

PASTUERIZING:

 Milk is piped into a pasteurizer to kill any bacteria. Here we are using high-temperature, short-time (HTST) process in which the milk is heated as it flows through the pasteurizer continuously. Whole milk and must be heated to 165° F (80° C) for 15 seconds. Other milk products have different time and temperature requirements. The hot milk passes through a long pipe whose length and diameters are sized [Heat exchanger] so that it takes the liquid exactly 15 seconds to pass from one end to the other. A temperature sensor  is placed to back of the outlet type indicates temperature of outlet.

RTD- Resistance temperature detector is using in our plant

HOMOGENIZING:

 Homogenizing process is to reduce the size of the remaining milk fat particles. This prevents the milk fat from separating and floating to the surface as cream. It also ensures that the milk fat will be evenly distributed through the milk. The hot milk from the pasteurizer is pressurized to 2,500-3,000 psi (17,200-20,700 kPa) [Always pressure 20Kg/cm^2 ] by a multiple-cylinder piston pump and is forced through very small passages in an adjustable valve. We are using 5000LPH (Litter per hour) capacity homogenizer. The shearing effect of being forced through the tiny openings breaks down the fat particles into the proper size. The milk is then quickly cooled to 40° F (4.4° C) to avoid harming its taste.

REFRIGERATION PLANT:

            We have two types of Refrigeration system. There are,

1.    chilling using ammonia compressor(NH3)

2.    chilling using Vapor Absorption Machine(VAM)

AMMONIA COMPRESSOR:

            We hold three NH3 Compressor. Here NH3 act as refrigerant.  Liquid ammonia is spearing in milk tubes, then the milk is cooled certain temperature depending on the length of the tube. The basic characteristic of NH3 is vapory in atmosphere. It can changed liquid state to gaseous state.

VAPOR ABSORPTION MACHINE (VAM):

            Vapors absorption machine is called as VAM. It is a advanced chilling unit, it can give a chilled output on 4° C to standard continues output which is 7° C. here Li-Br is acting as a Refrigerant  It mainly depends on Li-Br (Lithium bromide) chemical characteristics, it acting like a heat exchanger process. Stream or super heated stream is going to inside of the unit from boiler, raw milk and glycol is also together inside VAM unit. The Li-Br is chilled a milk between 4° C to 6° C. the main thing is Glycol chemical is using for avoid  freezing in VAM unit.

COOLING TOWERS:

            It is also support a cooling process. It could release a amount of heat from substance or container. It may cool a negligible to compare VAM or NH3 compressor cooling units.

EVAPORATION PLANT:

Evaporation main part is Boiler. Here our plant boiler capacity is 10kg/cm^2. But we are generating 9kg/cm^2 pressure. Our plant evaporated milk water is a also one of the feed water of boiler. It having emergency exhaust for critical high pressure.

CURD PREPARING MACHINE:

            Actually curd preparing machine is operated by PLC (Programmable Logic Controller) operation. It is doing an already programmed process of our needs. Controlled by SCADA.

PACKAGING:

            Packaging process of plant is automated one. Nicrome  brand name machine is perfectly suit for our process. Simple pneumatic actuators, pressure valves and hot electrode are the parts of the packaging machine.

CONTROLLED BY SCADA:
            Temperature indication, control switchs are done with the help of the  SCADA. Here majorly all instruments are controlled manually. But similar cases SCADA here using for indication purpose (visuvalize)

SMALL INSTRUMENTS:

Induced draft fan (ID): using in boiler . Capacity- 12HP motors

Forced draft fan (FD): using boiler. Capacity- 2HP motors

MEMO – using boiler. It controls the automatic on – off controls of boiler feed water motors

Actuators: Pneumatic control actuator is using in milk traveling pipes near to heat exchangers

EFFLIUNT TREATEMENT PLANT (ETP):

            The ETP plant is almost having all types of industries. Especially for food product industries. The main target of this plant is to collect industrial processed water and other waste water, to equalize the pH value to similar related to pure water pH (app 7.0). This is a basic environmental pollution control for industries. 

Proximity sensor

Proximity sensor

What is the meaning proximity means?

Proximity is nearness in space means things are near to the object known as proximity.

What is proximity sensor?

Sensor which sense the very near object is known as proximity sensor.

What are types of proximity sensor?

Capacitive

Inductive

Optical

Capacitive Proximity sensor

It is working on the basic principle of the capacitance coupling.  The senor detect anything is conductive or has a dielectric different from that of air the best example of the capacitive proximity sensor is the “Touch Screen”

Inductive proximity sensor

It is working on the basic principle of the Inductive. The sensor consists of an induction loop. Electric current generates a magnetic field. The best example for the inductive proximity sensor is the “Metal detector”

Optical proximity sensor

 It is working on the basic principle of the Infrared and photoelectric.  In one end infrared and other end is the photoelectric sensor means Photo transistor. If the light beams gets disturbed means it gives signal as 1 or else 0 (or) it depends on the applications we use. Best example is the “smoke detector”  

Sensors

Sensors

Sensors detect the presence of energy, changes in or the transfer of energy. Sensors detect by receiving a signal from a device such as a transducer, then responding to that signal by converting it into an output that can easily be read and understood. Typically sensors convert a recognized signal into an electrical – analog or digital – output that is readable. In other words, a transducer converts one form of energy into another while the sensor that the transducer is part of converts the output of the transducer to a readable format. Consider the previous examples of transducers. They convert one form of energy to another, but they do not quantify the conversions. The light bulb converts electrical energy into light and heat; however, it does not quantify how much light or heat. A battery converts chemical energy into electrical energy but it does not quantify exactly how much electrical energy is being converted. If the purpose of a device is to quantify an energy level, it is a sensor.

Thermal Sensors

· Thermometer – measures absolute temperature (discussed in the previous section)

· Thermocouple gauge– measures temperature by its effect on two dissimilar metals

· Calorimeter – measures the heat of chemical reactions or physical changes and heat capacity

 A thermocouple is a device that directly converts thermal energy into electrical energy. When two dissimilar metal wires are connected at one end forming a junction, and that junction is heated, a voltage is generated across the junction (see the figure below). If the opposite ends of the wires are connected to a meter, the amount of generated voltage can be measured. This effect was discovered by Thomas Seebeck, and thus named the Seebeck Effect or Seebeck coefficient. The voltage created in this situation is proportional to the temperature of the junction

See beck effect

Chemical sensor ( O2 analyser)

Oxygen analysers determine oxygen concentration using the conductivity of a ceramic cell.  Ceramic cells only allow oxygen ions to pass through at high temperatures. With reference gas on one side and sample gas on the other, oxygen ions move from the side with the highest concentration of oxygen to that with the lowest concentration. The movement of ions generates an EMF (Electro Motive Force) which can be measured to determine the oxygen content.

O2 analysers