Dahi Plant & Machinery

Dahi Plant & Machinery

Basis of design

Dahi shall packed in cups, Matka and pouches as per the requirement

Reconstituted milk shall be prepared separately through a turbo blender of 1 TPH capacity, chilled and stored in a separate 2 KL tank.

Raw chilled milk (5% Fat and 8% SNF) shall be unloaded in 2 x 25 KL vertical outdoor type tanks. These tanks shall be kept outside the building.

Skimmed milk shall also be unloaded in the above mentioned 2 x25 KL vertical outdoor tanks so that the mix of RCM and skim milk has fat ….% and SNF8%

Reconstituted milk (for SNF Make up) shall also be pumped from 2 KL tank to 2 x 25 KL vertical tank which already has milk of 3%fat and 8% SNF so as to increase the SNF to 11%

The standardised milk in the 1 x 25 KL tank after proper mixing and laboratory confirmation for standardisation shall then be kept undisturbed for at least 1-2 hours for hydration purpose. Therefore 1 x 25 Kl tanks shall act as storage cum standardisation cum hydration tank.

After the hydration process is complete the Dahi milk shall be pasteurised, homogenised through a 5 KLPH pasteuriser which shall have temperature profile of 10-55-95-4. Holding time shall be 6 minutes at 95 deg C)

The pasteurised milk shall be stored in 2 x 15 KL vertical tanks

From 15 KL storage tank milk shall be heated through a  5 KLPH PHE/THE up to 42 deg C and stored in inoculation tank. The number in inoculation/culture addition tank shall be as per the packing machine requirements

Culture shall be added in inoculation tank

Dahi shall packed in cups, Matka and pouches as per requirement

Cups shall be put on trays which shall be kept on the moving trolleys . Trolleys shall be kept in incubation room. Pouches shall be kept in a perforated crates

Incubation room shall have capacity to hold minimum 4 hours of cup/pouch production

After incubation Dahi cups/ Matka / pouches shall be transferred to blast room.

Blast room shall have capacity to hold minimum 4 hours production. Blast room shall be designed to bring down the temperature of Dahi from 42 deg  C to less than 20 deg C to restrict the acidity development.

From blast room cups will be packed in the cartons, transferred to the cold room. The cold room temperature shall be 4 Deg C. The pouches shall also be transferred from perforated crates to regular crates and transferred to cold room. The cold room shall have capacity to store at least 50 MT dahi.

Incubation room, blast room and cold room shall be constructed from PUF insulated sandwich panels

The refrigeration system for Blast and cold room shall be of self contained type Freon based refrigeration system.

Steam, compressed air, raw water, chilled water, Electrical power is required in processing.

There shall be a dedicated CIP system consisting of rinse water, hot water, acid and caustic tanks.

Packing material like cups, cartons and pouch film shall be stored in plant area.

Sr.No.	Equipment	Qty	UOM
	Milk reception & milk Storage
1	Milk Piping & fittings	2	Lot
4	Flow plate for CIP of unloading hose, pump and line up to tank inlet	1	No
5	25 KL Vertical insulated milk storage tank with alcove. The tank shall be is SS 304 construction with side mounted/vertical agitator, manhole, sight glass, light glass, breather, railing with toe guard, RTD,High level and low level switches. Insulation thickness 100 mm (50mmx 2 layers of EPS of 18 Kg/Cum density)	3	No
6	Self priming type CIP return pump Capacity 15 KLPH, 25 MWC	1	No
	Reconstitution Section
1	Turbo blender 1 TPH	1	No
2	Reconstituted Milk storage tank insulated with agitator capacity 5 KL with Manhole, railing, sight glass, light glass, CIP spray balls, inlet and outlet connections	1	No
3	Reconstituted milk chiller, Capacity 5 KLPH, TS 25%, Temperature profile inlet: 35 Deg C , outlet:4 Deg C, Chilled water temperature 2 Deg C.	1	No
4	Reconstituted milk transfer cum recirculation pump capacity 10 KLPH,25 MWC	1	No
5	Mass flow meter with remote display unit 10 KLPH to measure quantity  of reconstituted milk transferred in 25 KL tank	1	No
6	Self priming type CIP return pump Capacity 15 KLPH, 25 MWC	1	No.
	Milk Processing section
1	Sanitary Design Milk transfer pump from 25 KL storage tank to balance tank of milk pasteuriser 5 KLPH, 25 MWC	1	No
2	Skid Mounted Milk Pasteuriser 5 KLPH, Temperature profile 8-55-90-4. The milk pasteuriser shall be complete with milk balance tank of 200 L capacity with ball float, PHE, Homogeniser, holding tube for 10 minutes(selectable in multiple of 2 minutes), hot water generator with control valve and ball float type trap, flow diversion valve on heating section, control panel, frequency drive for homogeniser, inter connecting piping, hot water pump, required instruments like temperature indicators, controllers etc. Regeneration efficiency 93%,	2	No
3	Pasteurised milk storage tank 15 KL vertical with agitator, manhole, Sight glass, light glass, inlet, oultet connections, CIP spray balls-01 Nos, 100 MM EPS insulated cladded in 2 mm thick SS 304 Coil, Temerature indicator	4	No
4	Self priming type CIP return pump Capacity 15 KLPH, 25 MWC	1	No
	Milk Heating section / innoculation tank
1	Sanitary design Milk  pump from 15 KL milk tank to balance tank of milk heater 5 KLPH, 25 MWC	1	No
2	Skid mounted milk heating module, capacity 5 KLPH to heat the milk from 4 deg C to 42 deg C through a PHE. The skid shall be complete with 150 L balance tank with float, Milk pump, Milk heater PHE, hot water generating unit with PHE, inlet steam control valve, ball float type steam trap , hot water pump, flow diversion valve at the outlet of PHE (increase the temperature is not attained the milk shall be diverted to balance tank). The heater module shall be completely with inter connecting pipes, required instruments, thermograph etc)	2	No
3	Insulated culture addition / inoculation tank common for cup filling machine. Fabricated from SS 304 with agitator and insulated with 50 MM glass wool of 120 Kg per cum density and cladded with 2 mm thick SS304. Capacity 2 KL	3	No
4	Insulated culture addition / inoculation tank common for pouch filling machine. Fabricated from SS 304 with agitator and insulated with 50 MM glass wool of 120 Kg per cum density and cladded with 2 mm thick SS304. The tank shall have a manhole for culture addition, CIP spray ball and RTD for temperature indication along with inlet and outlet connection. Capacity 2 KL	4	No
5	Insulated culture addition / inoculation tank common for Matka filling machine. Fabricated from SS 304 with agitator and insulated with 50 MM glass wool of 120 Kg per cum density and cladded with 2 mm thick SS304. The tank shall have a manhole for culture addition, CIP spray ball and RTD for temperature indication along with inlet and outlet connection. Capacity 1 KL	3	No
	Cup/ Pouch Packing Section
1	Rotary PLC Operated Dahi cup packing machine for 90 ml. cup capacity- 4000 Cups/hr	1	No
2	Rotary PLC Operated Dahi cup packing machine for 200 ml cup capacity- 5000 Cups/hr.	1	No
3	Rotary PLC Operated Dahi cup packing machine for 400 ml cup  capacity- 2500 Cups/hr.	1	No
4	FFS Servo/PLC based pouch packing machine suitable for 200ml. and 500ml., Capacity 5000 pouches/hr	2	No
5	SS trolleys of 720 x 470 mm. Height 1800 mm with 20 selves	50	No
7	SS perforated tray 710 mm x 405 mm 25 mm high fabricated from 2.0 thick SS 304 sheet	1000	Nos.
	Incubation room (Considering 4 hours incubation time)
1	Incubation room made from 60 mm thick PUF insulated Sandwich panel. The panel shall be cladded with 0.5 mm thick PCGI sheet on both the sides. Room size 4x5 Meters. Two sliding type doors for each room.	2	No
2	Incubation room Electrical heater with blower. Ceiling mounted type suitable for 4 x 5 meter. Room temperature to be maintained : 42 Deg C. Input.	2	No
	Blast room (considering 2 hrs time)
1	Blast room made from 100 mm thick PUF insulated Sandwitch panel. The panel shall be cladded with 0.5 mm thick PCGI sheet on both the sides Room size 6x4 Meters.	2	No
2	Air handling unit for blast room 25 TR each. Inlet temperature of refrigerant: -15 Deg C. Room temperature to be maintained  : -10 Deg C	2	No
3	Refrigeration system 50 TR for the blast room complete with compressors, condensers etc, receiver, control system ,operating panel, temperature indicators etc.	2	No.
	Cold room (Suitable for 50 MT of Dahi)
1	Cold room made from 80 mm thick PUF insulated Sandwich panel. The panel shall be cladded with 0.5 mm thick PCGI sheet on both the sides. Room size 10 x 6 Meters. (with cooling unit)	2	No
2	Air handling unit for blast room 8 TR each. Inlet temperature of refrigerant: -5 Deg C. Room temperature to be maintained  : 4 Deg C	2	No
3	Refrigeration system 20 TR for the cold room complete with compressors, Condensers etc, receiver, control system, operating panel, temperature indicators etc.	2	No
	FAV System
1	FAV System complete with air filter, washer, demister, fan, ducting, louvers. Suitable for room size of 12x6x8 m. No of air changes 15-20/hr	1	No
	CIP System
1	Lye dissolving tank 200 L with agitator	1	No
2	Acid storage tank 200 L	1	No
3	Lye dosing pump 500 LPH	1	No
4	Acid dosing pump 500 LPH	1	No
5	Acid solution tank 3000L	1	No
6	Lye solution tank 3000L	1	No
7	Hot water tank 3000L	1	No
8	Rinse water tank 3000L	1	No
9	CIP solution supply pump 15 KLPH 30 MWC	1	No
10	CIP heater 15 KLPH, Delta T : 20 Deg C	1	No
11	Duplex filters	1	No
12	Interconnecting piping and fittings	1	No
13	Control panel	1	No
	MISCLLENEOUS
1	MCC	1	No
2	Cables	1	Lot
3	Cable trays	1	Lot
4	Earthing material	1	Lot
5	Chilled water piping	1	Lot
6	Steam piping	1	Lot
7	Compressed air piping	1	Lot
8	raw water piping	1	Lot
9	SS product and CIP piping	1	Lot
10	Hot and cold insulation	1	Lot
11	Laboratory equipment’s	1	Lot

Mass Balance

	Qty in Ltrs/Day	fat%	SNF%	Fat Kgs	SNF Kgs
Dahi (cups , Matka and pouch)
Cups	15000	3.1	10.5	465	1575
Matka	35000	3.1	10.5	1085	3675
Dahi in pouch (Light)	40000	1	11	400	4400
Dahi in pouch (fresh)	10000	3.1	10.5	310	1050
Total Dahi	100000			2260	10700

Refrigeration plant
	Rate/Hr	Inlet	Outlet temp	Delta T	Refrigeration required K Cal/hr	TR	Chilled water flow rates L/Hr	Total hour per day requirement	Total TR requirement per day
Dahi milk pasteuriser	5000	9	4	5	24720	8.17	10000	18	147
Blast room for Dahi						50		16	800
Cold room for Dahi						20		20	400
					Total TR/Hr	78.2	10000		1347

Steam requirement
	Rate/Hr	Inlet	Outlet temp	Delta T	K Cal/hr	Steam Requirment kg/ Hr
Dahi milk pasteuriser	5000	75	90	15	75000	139
Milk heating for Dahi	5000	4	42	38	190000	352
CIP	5000	60	70	10	50000	93
Total						583

Dahi Packing details
	Production in Kgs		Machine capacity cups / pouch /hr	No of m/c.	Ltr./hr	Production hours	Total Machine requirement
Dahi in Cups	15000	Kgs/Day
90 g (20%)	3000	Kgs/Day	2400	1	216	14	2
200 g (60%)	9000	Kgs/Day	2400	1	480	19
400 g (20%)	3000	Kgs/Day	2400	1	960	3	1
Dahi in Matka	35000	Kgs/Day			1656
Matka in 1 Kgs	2000	Kgs/Day			2000	1	Manual
Matka in 2 kgs	3000	Kgs/Day			2000	2	Manual
Matka in 5 Kgs	12000	Kgs/Day			2000	6	Manual
Matka in 15 kgs	18000	Kgs/Day			2000	9	Manual
Total Dahi in pouches	50000	Kgs/Day
Total Light Dahi in pouch	40000	Kgs/Day
Light Dahi 200g pouch	30000	Kgs/Day	5000	3	3000	10	3
Light Dahi 400g pouch	10000	Kgs/Day	5000	1	2000	5	1
Total Fresh Dahi in pouch	10000	Kgs/Day					1
Fresh Dahi 200g pouch	7500	Kgs/Day	5000	1	1000	7.5
Fresh  Dahi 400g pouch	2500	Kgs/Day	5000	1	2000	1.3
Total Dahi Production	100000	Kgs/Day			19312
Incubation room capacity should be minimum for 5 hours					96560	Kgs
No. of Incubation rooms					2
One Incubation room capacity					48280	Kgs