This document discusses dairy plant maintenance. It describes the different types of maintenance including preventive, predictive, corrective, and breakdown maintenance. Preventive maintenance aims to retain equipment health and prevent failures. It includes periodic and predictive maintenance. The objectives, elements, and advantages of preventive maintenance are outlined. A preventive maintenance program involves collecting equipment data, inspection schedules, and cost estimates. Corrective maintenance improves equipment reliability while breakdown maintenance repairs failures that don't significantly impact operations. Proper lubrication is important to prevent equipment breakdowns.

1. Seminar on
Dairy Plant Maintenance
Name:- Shamim Hossain
Roll:- DT-18/12
Course:- DT-4712
Submitted to:- PROF. S.K.GANGOPADHYAY
West Bengal University of Animal and Fishery Sciences
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2. Introduction:
The determination of plant efficiency at all
essential points of the process is the first step in
creating a maintenance system which is fundamental
to achieving optimal performance in any milk plant.
Maintenance section is a very important
section in any dairy plant mainly high capacity plant.
Maintenance schedule should be designed and
maintained to optimize the overall plant performance.
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3. Types of Maintenance:Maintenance
Preventive
Maintenance
Periodic
Maintenance
Predictive
MaintenanceCorrective
Maintenance
Breakdown
Maintenance
Maintenance
Prevention
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4. Preventive maintenance:
It is a daily maintenance (cleaning, inspection,
oiling and retightening), design to retain the healthy
condition of equipment and prevent failure through
the prevention of deterioration, periodic inspection or
equipment condition diagnosis, to measure
deterioration.
It is further divided into --
1. Periodic maintenance
2. Predictive maintenance
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5. 1. Periodic maintenance (Time based maintenance-
TBM) which consists of periodically inspecting,
servicing and cleaning equipment and replacing
parts to prevent sudden failure and process
problems.
2. Predictive maintenance is a method in which the
service life of important part is predicted based on
inspection or diagnosis, in order to use the parts
to the limit of their service life. It manages trend
values, by measuring and analyzing data about
deterioration and employs a surveillance
system, designed to monitor conditions
through an online system.
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6. Objectives of Preventive Maintenance
1. Increase the efficiency and improve the performance of all
processing and auxiliary equipment.
2. Increase the overall productivity of the entire plant by
achieving coordinated and continuous operation of all plant
equipment.
3. Increase the certainty of meeting daily production schedule.
4. Reduce unscheduled downtime.
5. Reduce costs of maintenance and repair.
6. Reduce overall processing costs.
7. Reduce utility usage.
8. Reduce Bio-chemical Oxygen Demand (BOD) of sewage.
9. Minimize property and personal hazards.
10. Conserve raw materials.
11. Conserve fuel.
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7. Element of Preventive maintenance
1. Planning and scheduling
2. Proper installation
3. Periodic inspection
4. Planned lubrication
5. Adjustment of machines and instruments
6. Replacement of worn and damaged parts
7. Recording and reporting observations, adjustments, repairs, and
replacements
8. Periodically reviewing records on inspection, lubrication, repairs
and performance of equipment
9. Keeping an adequate supply of spare parts
10. Determining maintenance costs
11. Cleaning and painting equipment and buildings
12. Inspection and maintenance of all emergency, personnel and plant
protective equipment
13. Maintaining full serviceability of all utilities
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8. Advantages of Preventive Maintenance
1. Less production interruptions
2. Fewer large-scale repairs
3. Less raw material and product spoilage
4. Increased life expectancy of equipment
5. Less standby equipment needed
6. Identification of items with high maintenance costs
leading to investigation and correction of causes, such
as misapplications, operator abuse or obsolescence
7. Better spare parts control, greater work safety and
lower manufacturing cost.
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9. Preventivemaintenanceprogramme(PMP)
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• The first comprises collecting and recording all basic
information on machines and installations: the equipment
records of the plant.
2
• The second comprises identification of inspection objectives,
frequency and location, and is known as the Inspection
Schedule.
3
• The third part of the PMP procedure is the action which starts
with the analysis of the records and is followed by decisions on
what must be done, by whom, when and by what means.
4
• The last component of the action part of the PMP is the
maintenance cost estimate.
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10. Corrective maintenance
It improves equipment and its components so that
preventive maintenance can be carried out reliably. Equipment
with design weakness must be redesigned to improve reliability
or improving maintainability.
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11. Breakdown maintenance
It means that people wait until equipment fails and repair
it. Such a thing could be used when the equipment failure does
not significantly affect the operation or production or generate
any significant loss other than repair cost.
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12. Maintenance prevention
It indicates the design of new equipment. Weakness of
current machines is sufficiently studied and is incorporated
before commissioning new equipment.
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13. Lubrication System
Lack of lubrication is one of the principal causes of
equipment breakdown. The best solution is to have a regular
lubrication schedule, and perhaps a lubrication chart for each
machine, setting the frequency of lubrication, type of lubrication
needed, and places to be lubricated.
Modern equipment calls for certain types of lubricants for
certain types of bearings e.g. light, high speed bearing will
require a light oil, whereas a heavy duty, low speed bearing will
require heavier oil
.
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14. Benefits of Lubrication
1. Less production downtime (because fewer breakdowns)
with all its related in-plant savings and customers' benefits.
2. Fewer major overhauls, hence less costly repair bills.
3. Fewer repetitive repairs.
4. Less spoilage and product waste, hence a factor in better
quality control.
5. Postponement or elimination of cash outlays for premature
replacement of physical plant and/or equipment/ because
of better conservation of assets and increased life
expectancy.
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15. 6. Requirement of less standby equipment thus reducing
capital investment.
7. Shift from inefficient “breakdown” maintenance to less
costly scheduled maintenance/ hence better work control
and saving due to
8. Less plant outage and reduced maintenance costs.
9. Better spare parts control, leading to minimum inventory
yet having appropriate spares at hand when needed.
10. Greater safety for workers and improved protection for
plant.
11. Reduced utility and fuel costs.
12. Lower unit costs of manufacture.
13. Greater certainty in meeting production schedules.
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