2. 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 area
87%
built up area
13%
Area (sq.m)
site area
built up area
INTRODUCTION
3. Entry
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12
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9
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
N
The site is located near Chikhli and
connects the main National Highway NH8.
SITE - LAYOUT
Entry
Entry
8
Ideal layout
2
3
4
parking
4. 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. capacity
each.
• 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
5. PROCESSING UNIT
MILK PASTEURIZATION
Raw 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 Milk
2. Low Fat Milk
3. Medium Fat Milk
4. No Fat Milk
5. Cream
Pasteurizer FDV
6. PROCESSING UNIT
MILK BY-PRODUCT: CURD
Raw 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 is
done for settling the curd.
• The acidity is checked after 4 hours which should be 1.2ph on
the ph scale.
• Jeera Chaas is made by adding jeera and salt to the above
process.
• There are 2 thermisers of 10,000 Lit. and 20,000 Lit. each and 1
pasteurizer of 1000 Lit. capacity.
Dahi Tank Jeera Chaas Tank
7. PROCESSING UNIT
GHEE AND BUTTER SECTION
Raw Milk
Jacketed type Machine
Clarifier
Packing
• The Butter is passed through steam or hot water in the jacketed
type 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
8. PACKAGING UNIT
MILK PACKING SECTION
Processed 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
9. WASTE WATER TREATMENT PLANT
Legend
1.Gas Holder
2.Oil Trap
3.Old Bio Digester
4.New Bio Digester
5.Buffer Tank
6.Pump Room
7.Elare Pipe
8.Aerator
9.Sludge Area
Waste 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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9
Plan
