The document discusses a report submitted by Manish Kumar on his six-week training project at the Feeder Balancing Dairy in Patna. It includes an introduction to the dairy project, details of the various sections studied including the boiler, refrigeration, and effluent treatment plant sections. It also discusses start-up procedures, common operational problems, and methods to reuse and minimize waste water generated at the dairy.

1. PROJECT ON SEMESTER TRAINING
( SIX WEEKS )
REPORT ON
FEEDER BALANCING DAIRY, PATNA DAIRY PROJECT,
PATNA
SUBMITTED IN PARTIAL FULFILLMENT FOR AWARD OF DEGREE OF
BACHLOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT
P.T.U.G.ZSCET, BATHINDA
SUBMITTED BY:-
MANISH KUMAR
MECHANICAL,2K10
CLG. ROLL NO-510065
UNI ROLL NO-100311129897

2. PATNA DAIRY PROJECT
DT: 30/06/2012
TO WHOM SO EVER IT MAY CONCERN
This is certified that MANISH KUMAR, Student OF 4th
Semester(mechanical
branch), roll no:-100311129897, P.T.U,G.Z.S, CAMPUS, BATHINDA, has done
training at FEEDER BALANCING DAIRY, PATNA DAIRY PROJECT, PATNA from
18th
MAY to 30th
JUNE 2012. He took keen interest in learning all the
activities related to DAIRY ENGINEERING and found to be performed
EXCELLENT .
The organisation wishes all the success in his future career.
Manager(Engg.)
( MAHESWAR PRASAD )
VAISHAL PATLIPUTRA DUGDH UTPADAK SAHKARI SANGH LTD.
Feeder Balancing Dairy complex , phulwari sharif.patna-801505
phone : 2252553, 2252542,2251622 fax: 0612-2250325
E-Mail: vpmunin@satyam.net.in

3. CONTENT
 INTRODUCTION
 SYUDY OF PLANT
 BOILER SECTION
 REFRIGERATION SECTION
 START UP PROCEDURE
 COMMON OPERATIONAL PROBLEM AND TROUBLE SHOOTING
 REUSE,REUTILIZATION & MINIMIZATION OF THE WASTE WATER
 STUDY OF EXISTING EFFLUENT TREATMENT PLANT AT P.D.P PATNA

4. INTRODUCTION
India with a population of more than 100 crores is
potentially one of the largest Consumer market in the
world. With urbanization and development of
economy, tastes and interests of the people changes
according to the advance Nation. Marketing is about
winning this new environment. It is about
Understanding what consumer’s wants a supplying it’s
more efficiently and more conveniently. The consumer
market may be identified as the market for product
and Service that are purchased by individuals as
household for their personal consumptions. Milk is
typical consumer products purchased by Individuals for
many purposes primarily making tea and sweets. The
market of milk is also facing a competition and many
companies are floating in the market with their
products with different brand names. In such a factors
which influence the people choice for milk are taste
and quality. So, marketing is both philosophy and
technology. It is Technology because it suggests ways
and means for effective production and Distribution of
goods and services in the market to give maximum
satisfaction to the consumer the marketing manager is
responsible for both Determining and suitability of

5. goods and services in the market to give maximum
satisfaction to the consumer. The marketing manager
is responsible for both Determiningand suitability of
goods and services presented by the company to the
market and also determining about potential market
and make better relation with retailer.

6. PATNA DAIRY PROJECT, SUDHA PLANT
PHULWARI SHARIF, PATNA

7. TECHNICAL INPUTS
at the door-step has been providing the inputs
required for milk production enhancement
viz.Artificial The union (VPDUSS), in addition to
providing a ready and state market for therurally
produced milk Insemination (AI) with Frozen Semen,
Veterinary First Aid (VFA),
Vaccination,
Supply of Balanced Cattle Feed,
Supply of Folder Seeds,
Treatment of paddy straw/wheat bhusa with Urea,
Supply of Urea Molasses Block (UMB) etc. on
No profit no loss basis
.The response from the milk producers for all these has
been exceedinglyencouraging and the Union is in the
process of extending these facilities to more and
moreDairy Cooperative Societies and farmers.
FEEDER BALANCING DAIRY(FBD):
The Feeder Balancing Dairy(FBD)

8. with a capacity to handle
1.5 lakhs liter perday (LLPD),
has facilities for manufacture of
Milk powder, Butter, Ghee, Ice CreamPeda, Panner,
Plain/Misti Dahi, Lassi Mattha etc.

9. STUDY OF PLANT
1. Raw Milk Receiving Dock
2. Process Section
3. Different section
(dahi,butter,ghee,utility,icecream,peda,packing)
4. Effluent Treatment plant (ETP)
5. Quality Control Section

10. PROCESS SECTION
The Raw milk is being processed with the help of
clarification and homogenization system . In this
section , actually two plants are being operated
continuosly.
The continuous process is followed by HTST (HIGH
TEMP. SHORT TIME) system for pasteurisation.
In each section important parts are sa mentioned
below-
A) Balance Tank
B) Clarifier
C) Pasteurizer
D) Hot water tank
E) Homogenizer

11. Effluent Treatment Plant:
The dairy waste effluent from all above section comes
to this plant.
Huge quantity of milky water mainly from receiving
dock, process and packing section is drained out daily
and flows to ETP. The dairy
Waste water is being added by butter, ghee and Ice-
cream section.
Huge quantity of water is coming from process and
engineering section.
The ETP is situated at one corner in north east of the
dairy campus.
This comprises the airetion type treatment process.
The carrying capacity of ETP is 50,000 litres/day.

12. POWER SECTION
Milk from shallow tank is concentrated in triple effect
evaporaters,
This way condensed milk is formed. Now this
condensed milk is seat to dryer , finally milk powder
collected in bag after being converted into powder in
to spray dryers.
QUALITY CONTROL SECTION
The quality of received raw milk, process milk and
homogenized pasteurized milk is being checked by
vigoriously as per requirement.

13. BOILER SECTION
The boiler used in industry is of fire tube boiler.
The fluid is used in this boiler is C.N.G gas & coal.
The vapour formed by this boiler is being used by
different section
to gain heat from it such as ghee, dahi, peda, making
powder & most importantly in pasteurisation of milk.
There are 3 horizontal type fire tube boiler are used in
this industry.
Capacity is approx 500kg/hr evaporation for
producing 1500 litres/day milk.
The different sections are joined by through pipe line
to the steam generators.

14. Fire tube boiler

15. The source of heat for a boiler is combustion of any of
several fuels, such as wood, coal, oil, or natural gas.
Electric steam boilers use resistance- or immersion-
type heating elements. Nuclear fission is also used as a
heat source for generating steam, either directly (BWR)
or, in most cases, in specialized heat exchangers called
"steam generators" (PWR). Heat recovery steam
generators (HRSGs) use the heat rejected from other
processes such as gas turbines.
In fire tube boiler, hot gases pass through the tubes
and boiler feed water in the shell side is converted into
steam. Fire tube boilers are generally used for
relatively small steam capacities and low to medium
steam pressures. As a guideline, fire tube boilers are
competitive for steam rates up to 12,000 kg/hour and
pressures up to 18 kg/cm2. Fire tube boilers are
available for operation with oil, gas or solid fuels. For
economic reasons, most fire tube boilers are nowadays
of “packaged” construction (i.e. manufacturers shop
erected) for all fuels.

16. REFRIGERATION SYSTEM

17. In the whole process different components are
used they are inlisted below:-
 Kirlosker reciprocating compressor
 Discgarge line
 Oil separator
 Condenser
 Receiver
 Supply line
 Expansion valve
 Evaporating or cooling oil
 Suction line
 Ice bank tank

18. AIR AND SURFACE CONDITIONING PROCESS
IN PLANT

19. DIAGRAM

20. The fuel used in compressor is FREZOL 68 OIL.
The compressor compresses d gas and passes through
oil seperator through which oil seperates from
condensed gas
Now it passes through condensor and get condensed
the receiver collect all the condensed gas and send it
to supply line. There is a expansion valve in pipe line
to control the supply of condensed gas. Now there is a
cooling coil or evaporator. Through suction line it
again comes back to
Compressor.

21. Uses of cooling gas
 PASTURISATION
 IN ICE CREAM SECTION
 DAHI SECTION
 FOR AIR CONDITIONING IN OFFICERS
ROOMS
 IN COLD STORAGE

22. START UP PROCEDURE
 Clean all the units of construction
debis,gunny bags,wooden pieces,metal etc.
 Clear all interconnecting piping of
obstructions.
 Tighten all bolted joints on pipeline especially
suction and discharge end of pumps.
 Check lubrication and free movement of
agitator aerator and pump shafts by hand.
 Take no load trial of equipment.
 Start filling the plant units starting from
screen chamber with raw water.
 Check free flow water of each unit and all the
structures of water tightness.
 Start taking effluent into the ETP.
 Gradually start fat removal,chemical
treatment.

23. COMMON OPERATION AND TROUBLE
SHOOTING
 Sudden variation in quality nor quantity
of the effluent.
 Incorrect procedure followed due to lack
of sufficient operating skill.
 Carelessness during power or equipment.
 Sludge bulking in clariflocculator
 Sludge bulking in secondary clarifier.
 Power failure in the ETP.
 Obnoxious odours from ETP.
 Odour associated with sludge bulking in
secondary clarifier.

24. REUSE, REUTILISATION & MINIMIZATION OF
THE WASTE WATER
 In aggreculture and land scape irrigation
 Ground water recharge with treated waste
water
 Cooling system water reuse
Now, waste water generating in sudha industry is
quite large and thus it should minimized by this-
 Source reduction
 Recycling