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![Flow chart for boiler
Coal
Hopper
Coal Crusher
Moving Conveyor
Floor Storage ( 50 ton Capacity )
Conveyor Belt
Bucket Elevator
Live Bottom Bunker
Coal Feeder
Furnace 800-900ºc
Memory Panel [ Tubes contains – Water
Shell contains – Flue gases ]
Feed Water Shell [ Tubes contain –
Flue gases
Shell containsWater ]
STEAM
FlueGases
Steam Header
APH
Steam to Different Section
Bag Filter
Cyclone
Chimney](https://image.slidesharecdn.com/haldiramiptppt1-250418162433-df56a5ee/85/Haldiram_IPT_Presentation_On_process-pdf-36-320.jpg)
Haldiram_IPT_Presentation_On_process.pdf
- 1. IN PLANT TRAININGPRESENTATION 2023-24 AT HALDIRAMS FOODS INTERNATIONAL PVT. LTD, NAGPUR SUBMITTED BY JANHVI A. DAHABLE ROSHNI R.GADE PRASHANT S. SAWATKAR AJAHAR T. SHAIKH
- 2. OVERVIEW OF DAIRYPLANT Haldiram’s Foods International Pvt.Ltd. ➢ Establishment - 1970 ➢ Owner and Chairman – Mr Vivek Agrawal. ➢ Plant Location – Gumthala , Bhandara road Nagpur (MH). ➢ Capacity – 5 lakh lit/ day. ➢ Unit Name – vivek Foods Ethnics pvt, ltd. ➢ Vivek unit establishment – 2020. ➢ Plant set up by Gea. ➢ SCADA by Schenell.
- 3. Milk Procurment • Thetotal reception through tankers is 160000 litres • The route of milk collection through tanker includes. • Milk Procured From Ramtek , mauda , Tumsar , Hingna , Railway sindhi , kampte . • Total milk collection – 2 to 2.5 lakh lit. per day. • Total No. of BMCs - 6. • Total No. of chilling centers – 3 • Collection from simple unit – 60000 to 70000 lit/ day
- 4. RAW MILK RECEPTIONDOCK ▪ Haldiram’s Dairy received milk by tankers as well as in milk cans . ▪ Haldiram’s dairy collect daily milk about 2 to 2.5 lakh lit per day( morning and evening.) ▪ Both Cow milk and Buffalo milk is received . ▪ RMRD consist of – 1. Unloading 2. Sampling 3. Testing 4. Weighing
- 5. Milk Reception byCans at RMRD Cans of farmers and milk collection Centre. Milk can conveyor Remove the lids Of Cans Collect milk sample(Lab test) Milk is dump from cans by tipping bar Nylon filter ( 60 Mesh ) Weighing tank Nylon filter Dump tank
- 6. MILK PROCESSING SECTION •Following Processes are Performed in processing section. 1) Pasteurization 2) Homogenization 3) Standardization 4) Separation 5) Bactofugation 6) Chilling
- 7. Milk Reception byTankers at RMRD Tanker weighing bridge Milk sampling & plungering point RMRD lab Unloading of tanker Pump (7.5HP) Filters (stainless steel, nylon, magnetic) Milk chillier Silo
- 8. MILK FLOW CHARTFOR 20 KL PPASTEURIZER
- 9. Equipments in processingsection SR NO EQUIPMENT CAPACITY COMPANY 01 MILK PHE 1 20KL Gea 03 MILK PHE 2 20KL Gea 04 Cream PHE 1 3 KL Gea 05 Homogenizer 1 20 KL Gea 07 Cream Separator 1 20 KL Gea 08 Cream Separator 2 20 KL Gea 09 Bactofuge machine 20KL Gea 10 HMST (5 UNIT) 75 KL Gea 11 Cream Tank ( 2 unit ) 30 KL Gea
- 10. FILL PACK SECTION ➢There are 6 milk Packaging machine and 10 head of Packaging. Machine is operated mechanically. ➢ Every Machine has capacity to pack 500 pouches/Hrs. ➢ There are 2 Packaging line. ➢ 4 machines are of Nichrome Filpack and remaining 2 are of samarpun
- 11. Standards for Packingmilk at Haldiram’s Dairy ➢ Pouch milk have the shelf life of max 3 days from date of packaging . Types of Milk FAT SNF Cow milk 3.6 8.6 Tonned milk 3.1 8.6 DTM 1.6 9.6 FCM 6.6 9.1 Standardized milk 4.6 8.6
- 12. MILK PRODUCTS SECTION •In Haldiram’s foods international Pvt .Ltd ‘following products are manufacture. 1.Dahi 2.Shrikhand 3. Butter milk 4. SMP powder 5.Ghee and Butter 6. UHT
- 13. 1. Dahi • Dahiis made by bacterial fermentation of milk. In this fermentation process lactose in milk converted into lactic acid by using desirable bacterial culture. Parameter Vynjan cup kadhi pouch Taste & Flavour Pleasant & Acidic Pleasant & Acidic Texture Uniform Uniform Milk Fat Min 3.5-4 % for cup Min 0.3-0.4 % for pouch MSNF Min 11.4-11.5 % for cup Min 10.4 % for pouch Milk Protein Min 3.6 % for cup Min 3.3% for pouch Acidity %LA 0.7 – 1.0 % 0.7 – 1.0 % Moisture by wt Max 86.5 % for cup Max 89.5 % for pouch pH 4.2 -5.0 4.2 -5.0
- 14. Flow chart ofDahi manufacturing Receiving milk Filtration Heating of milk (90 ⁰C for 10 min) Storage preheating 43+ 2* Inoculation of starter culture(1-1.5%) Packaging Incubation (at 42+ 2 ⁰ C for 4 Hrs) Blast cold room (-10 ⁰ C for 2 Hrs) cold room (below 5⁰C ) Dahi (0.7-1.0 %LA) Standardization (Fat 3.5 % and SNF 10.5%) Homogenization (I st stage 1400 psi & II nd stage 600 psi) • Dahi is made by bacterial fermentation of milk. In this fermentation process lactose in milk converted into lactic acid by using desirable bacterial culture.
- 15. 2. Shrikhand • Chakkais a fermented, intermediate dairy product obtained during the production of Shrikhand • Chakka is the base material for the production of shrikhand , Amrakhand. • Shrikhand is a semisoft whole milk product prepared from lactic acid fermented dahi .the dahi is partially strained through a cloth to remove the whey and thus produced a solid mass called chakka & It shall not contain any added colouring and artificial flavouring substances . • Its shelf life is 3 months ,when stored below -10⁰C. Product Raw Ingrediants Shrikhand Chakka, Badam , sugar, cardamom, Pista , Jayhal, Salt. Amarkhand Chakka, Sugar , hapus raja amras .
- 16. Flow chart ofshrikhand manufacturing Receiving of milk from RMRD Filtration Pasteurization 900C/15sec) Cooling (@40 to 45⁰C) Inoculation (culture @ 1 to 1.5 % ) Incubation (40 to 45⁰C for8-10 hr) dahi (0.7-1.0% LA) Hanging (10-12 hrs) Chakka Seaving Storage ( At -10⁰C) planetary mixer (Addition of ingredients) Shrikhand Packing Metal Detector Weighing Storage (less than -10 0 c) Standardization (fat 3.5% ,SNF 9.0%)
- 17. Standards of Shrikhand ParameterStandard Moisture max42 % Fat Min 8.5% Ash Max 0.9% Protein Min 9.0% Acidity Max 1.4 % Sugar Max 72 % Standards of Amrakhand Parameter standard Moisture Max 45% Fat Min 7% Ash Max 0.9% Protein Min 9.0% Acidity Max 1.4 % Sugar Max 72 .5%
- 18. Butter • Butter maybe defined as a fat concentrate which is obtained by churning cream, gathering the fat into a compact mass, and then working on it. Butter section is very important as it handles fat, which is the costliest constituent. The cream obtained from process section is fully utilized for butter making. • White butter is used for production of ghee & often supplied for bulk demand. Butter is made by using butter churn (batch method) as well as by Continuous Butter Making machine (CBM). • Types of butter :- 1. White butter
- 19. standards Standard White butterTable butter Colour Whitish tinge Light yellow Taste and flavour Pleasant,free from off odour and rancidity Pleasant,free from off odour and rancidity Acidity Max 0.06 % LA Max 0.06 % LA MSNF Max 1.5% Max 1.5% Milk fat Min 83 % Min 80 % Texture Smooth Smooth Added salt Nil Max 3 %
- 20. Flow diagram ofmanufacturing of Butter Pasteurized cream in storage tank (max 7- 13°c) fat 37-42% fat Transfer of cream to CBMM machine Churning Of Cream Butter from CBMM outlet⟶ Butter milk Sampling & analysis of butter Packaging Weighing Storage in cold storage at -18 °C Dispatch
- 21. Ghee • Process Overview: •Butter received from the butter section is melted at 60 - 70°C. • In White butter, fat is 82%. • Granulation of ghee • The melted ghee on cooling forms a large coarse grain suspended or clustered in a liquid phase. The slow cooling & agitation of ghee to 18-20° C in 2-3 hours gives smaller granules Standards Parameter Colour Golden yellow fat 99.8 – 99.9 % Moisture Max 0.3 % FFA 0.35 – 0.50 % RM Value Min 28 PV Value Max 1-2
- 22. Flow chart ofghee by prestartification Pasteurized cream in storage tank (max 7-13°c) fat 37-42% fat Transfer of cream to CBMM machine Butter milk Churning Of Cream Butter Melting Vat 70℃ Holding Coil Ghee Boiler Settilng for 30 min At 40℃ add cultured ( 0.5- 1 %0 Heating upto 110-112℃ observed berry colour settilng it for 30 mins Filtration- Settling tank Holding for 5 Hrs Ghee Clarifier Storage @ 50-55ºc packaging @ 40ºc Granulation@ 21-24°
- 23. Powder section • Inhaldiram’s skimmed milk powder & whey powder are prepared by spray drying. • The Dryer is planted by Gea . • The Milk Powder Section , dryer has capacity of 8 Tones per day and evaporator has the capacity of 10Tones per day Production . • The Evaporator is falling film type with 3 effect . • The Dryer is of three stages (Drying Chamber, IFBD, EFBD) with Rotary wheel atomizer.
- 24. OPERATING PARAMETERS PARAMATERS SMPWhey TS % OF CONCENTRATE 48 - 50 54 - 58 DENSITY OF CONCENTRATE (kg/m3) 1240 – 1260 1110 -1120 CONC. FEEDING RATE (kg/hr) 5700 4700 CONC. FEEDING TEMP ( 0C) 55-65 65-70 DRYER INLLET TEMP ( 0C) 180-190 180-190 DRYER OUTLET( 0C) 72-75 80-84 NECK COOLING TEMP ( 0C) 40-45 40-45 SHIFTER MESH SIZE(micro meter) 40 40 PACKAGING TEMP ( 0C) BELOW 40 BELOW 40 STEAM PRESSURE (kg/cm2) 18 19 DRYING RATE (kg/hr) 1200-1300 1200-1400
- 25. Flow chart Milk Silo Balancetank (5KL) filter preheater (45°) PCD (70°) Regenerative flash vessel-I (75°) DSI (85-90°) Regenerative flash vessel-II 78° cyclone separator NTP Calandria 1 (65°) vapour separator-I Calandria 2 (55°) vapour separator-II Calandria 3 (52°) vapour separator-II Dryer feed storage tank Dryer
- 26.
- 27. Air filter (HEPA) Dryer feed storage Air delivery fan filter Steam Radiator Hot Air Drying Chamber Cyclone separator IFBD EFBD Exhaust Fan Shifter Packaging Recovery room Metal detector Storage Air supply
- 28. Product Manufactured inPowder plant. Parameter SMP Whey Moisture% max 3.5 max 3.3-4 Total Solid % Min 96 Min 96 Bulk Density g/ml 0.48-0.52 0.50-0.55 Fat by mass Max 1.5 Min 2.0 Protein ( on SNF basis ) Min 34 Min 10 Titratable Acidity ( % LA ) Max 1.5 Max 1.2 Insolubility Index Max 1.5 Max 1.5 Total Ash Max 8.2 Max 9.5 Scorched Particle A A
- 29. UHT • UHT treatmentis used to increase the shelf life of the products. • Plant capacity-1 lakh ltr/ day. • The milk is utilised to improve the shelf life of product and making nutrition reach products. • Uht treatment is given by two types sterilization and retorting. Retorting process for bottle flavored milk. • Capacity- 2000 ltr. • Pressure – 15-20 psi. • Hot water temp – 145-150° • Retort time- 118-120° for 18 min. • Steam temp – 145-180°. • 320 bottle in one tray and six tray in each batch. • After retorting it kept to cool up to 60°c in retort after that it removed and cool at ambient temp for 1 hr
- 30. Process Flow chartfor chocolate milk Receiving milk Heating of milk Addition of pectin and maintain the temp at 80°Holding for 15-20 min at 80°c Addition of sugar and chocolate syrup Cooling upto 40°c Addition of flavour Standardize the batch Cool upto 15°c Transfer to retort ( 118-120° for 18 min) Transfer to packing
- 31. EFFLUENT TREATMENT PLANT( ETP ) SECTION water Inlet effluent Bar screen Decanter Equilization Tank DAF UASB Feed Tank Gas Holder UASB Tank Gas flare Aeration Tank Second Clarifier Sand Filter Activated Carbon filter Treated water Storage tank
- 32. Standard of treatedwater:- Parameters Standard Temperature Below 50 0C pH 5.5-9.0 TDS Max 2100 mg/lit TSS Max 100 mg/lit COD Max 250 mg/lit BOD Max 30 mg/lit Chloride Max 600 mg /lit Sulphate Max 1000 mg/lit
- 33. WATER TREATMENT PLANT( WTP ) SECTION • Water treatment plant is used to optimized most water based industrial processes, such as heating, cooling, processing, cleaning, and rinsing so that the risk of contamination of product should be reduced. • In Haldiram’s Dairy around 25-30 lakh lit water treated through WTP every day. Equipments Capacity Use Raw water Tank 2500000 Ltr Soft water storage tank 100000 Ltr Sand filter - Used to remove the sand, soil, small stones etc. Carbon Filter - Used to remove the smell and fine impurities. Resin filter - Used to remove dissolved minerals i.g. calcium, potassium, magnesium etc .
- 34. WTP Flowchart Water fromDAM/LAKE/CANOL Pump ( 7.5 HP ) Raw water storage tank Sand filter Activated carbon filter Resign filter Soft water storage tank Soft water transfer pump ( 40 HP ) Soft water to different sections REVESE OSMOSIS PROCESS Soft water after resign filter Sand filter Cartage filter Pump ( 4 HP ) RO Membrane Retaindent Raw water tank UV lamp Storage Tank
- 35. Boiler • Boiler isan enclosed vessel in which fluid such as water is heated to produce steam or the vaporized form of liquid. Sr.no. Parameter Standards 1 Boiler type Combipac 2 Manufactured by Thermax 3 Fuel Wood chips/ Biomass 4 Set point pressure 23 kg/cm2 5 Capacity 15 tone 6 Efficiency 70% 7 Temperature of flue gas 160-180 0C 8 Furnance Fluidized bed 9 Coal GCV 3500-3800 Kcal/kg 10 Furnance Temperature 850-900 *C
- 36. Flow chart forboiler Coal Hopper Coal Crusher Moving Conveyor Floor Storage ( 50 ton Capacity ) Conveyor Belt Bucket Elevator Live Bottom Bunker Coal Feeder Furnace 800-900ºc Memory Panel [ Tubes contains – Water Shell contains – Flue gases ] Feed Water Shell [ Tubes contain – Flue gases Shell containsWater ] STEAM FlueGases Steam Header APH Steam to Different Section Bag Filter Cyclone Chimney
- 37.