DAIRY PROJECTCASE STUDY

VASUDHARA DAIRY

• LOCATION – Chikhli, Alipore, Gujarat

• SITE AREA – 67,623 sq.m

• BUILT UP AREA – 9,946 sq.m

• PRODUCTION – 4 lakh LPD

• DEPARTMENTS-

PROCESSING OF MILK

BY-PRODUCTS (ghee, curd, butter, butter milk)

PACKAGING

site area87%

built up area13%

Area (sq.m)

site area

built up area

INTRODUCTION

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Legend

1.Admin (380sq.m)2.Processing unit (1275sq.m)3.Packaging and Refrigeration unit(1538sq.m)4.Boiler (370sq.m)5.Storage (980sq.m)6.Record Room (570sq.m)7. Crate washer (1070sq.m)8.Security cabin (75sq.m)9.Shops (280sq.m)10.Waste water treatment plant (410sq.m)11.Toilets (220sq.m)12.Technology Transfer Centre(380sq.m)

Key plan

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The site is located near Chikhli andconnects the main National Highway NH8.

SITE - LAYOUT

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Ideal layout

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parking

PROCESSING UNIT

RAW MILK RECEPTION DOCK Bulk milk cooler(BMC)

Reception Dock

Chain Conveyor Belt

Grading

Weight checking

Dump Tank

Chiller

Cilos

Sampling

Crate Washer

• The extra milk from the adjacent villages is collected at the BMC.• The Adulteration is checked during the grading process.• The Raw milk passes to the cilos at 15°C-16°C. There are 4 cilos

(2 cow milk, 1 buffalo milk and 1 mix) with 50,000 lit. capacityeach.

• The milk from the cilos is delivered to the By-products section.• The Dairy collects 4 lakh LPD milk.• IDMC and Alpha leval company products are used in the dairy.

Chain Conveyor belt receiving milk at the BMC

PROCESSING UNIT

MILK PASTEURIZATIONRaw milk Cilo

Balancing Tank

Pasteurization

Flow diversion Valve (FDV)

Homogenization

Separator

Processed milk Cilos

Sampling

Checked by ISO

• The milk is chilled for extended duration in the Balancing Tank.• Pasteurization is done at 85°C. The milk capacity of pasteurizer is

10,000 Lit. per hour and cream capacity is 4000 Lit. per hour.• FDV maintains the temperature at 85°C, where it is held for 15-

16 seconds.• There are 8 Processed Milk Cilos of 40,000 Lit. capacity each.• The milk gets separated in the following types in the separator

section, and then it is stored in the processed milk cilos:1. Slim Fat Milk2. Low Fat Milk3. Medium Fat Milk4. No Fat Milk5. Cream

Pasteurizer FDV

PROCESSING UNIT

MILK BY-PRODUCT: CURDRaw Milk

Dahi Tank

Culturing

Agitation

Curd Setting

Acidity check

Standardization Process

Sampling

Checked by ISO

Packing

• The Fermented Milk by-products are: Plain chaas, Masti Dahi,Jeera Chaas and Pro life Milk.

• Culturing is done in Dahi Tank for 15 min. and then agitation isdone for settling the curd.

• The acidity is checked after 4 hours which should be 1.2ph onthe ph scale.

• Jeera Chaas is made by adding jeera and salt to the aboveprocess.

• There are 2 thermisers of 10,000 Lit. and 20,000 Lit. each and 1pasteurizer of 1000 Lit. capacity.

Dahi Tank Jeera Chaas Tank

PROCESSING UNIT

GHEE AND BUTTER SECTION

Raw Milk

Jacketed type Machine

Clarifier

Packing

• The Butter is passed through steam or hot water in the jacketedtype machine.

• There are 3 Jacketed type machines.• Packing is done in 2 quantities of 500 g and 200 g

Raw Milk

Cream Addition

Churning

Continuous Butter Making

Machine(CBMM)

Storage

Ghee Processing Butter Processing

Ghee Processing

Butter Processing

• The Butter is produced through batch type process.• There are 3 cream tanks of 50,000 Lit. capacity each.• White butter is produced from cow milk and stored at 15°C.

Jacketed type machine

PACKAGING UNIT

MILK PACKING SECTIONProcessed Milk

10 Huge Tanks

8 Small Tanks

Pouch Packing

Affiliated Milk Plant

• The Packaging is done from morning 7 am to evening 8 pm• 10 Huge tanks are of 10,000 Lit. capacity each.• 80 pouch per min. are produced in small tanks.• Pouch packing is done in 500 ml, 300 ml, 200 ml and 5 Lit.

Packing machines

WASTE WATER TREATMENT PLANT

Legend

1.Gas Holder2.Oil Trap3.Old Bio Digester4.New Bio Digester5.Buffer Tank6.Pump Room7.Elare Pipe8.Aerator9.Sludge AreaWaste water

collected in oil trap

Pump room

Buffer Tank

Old Bio Digester

Aerator

Clarifier

Reused

Old Bio Digester

Tank

Membrane Biotechnology Reactor(MBR)

Reused for cleaning boiler

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Plan