Presentation of Layout and dezign of dairy industry

Layout and dezign of dairy industry

1. Layout and Design of the dairy industry Subtitle: From construction to Processing and packaging Presented by: Seerat Zahra Ena Fatima Aqeela bibi Iman shakoor Sabiqa Zahra Noor Fatima Sajjal batool

2. Introduction A dairy industry collects, processes, and sells milk and milk products. Proper layout helps in smooth working and hygiene. In this project, we design a small dairy plant that can be built by ourselves.

3. Objective To Design a clean and Safe dairy layout. To plan all areas and equipment properly. To produce different milk products efficiently To ensure hygiene through cleaning and SWAP method.

4. Location and Area Location : Near rural semi-urban area where milk supply is easy. Area : About 6000- 7000 sq.ft.for small plant. Requirements : Clean water and electricity supply. Away from pollution, dust, and traffic. Easy road access for milk transport. Close to milk – producing farms. Proper waste disposal and drainage .

5. Building Design Prefer single – storey for easy product flow. Walls : smooth, light- colored, washable . Floor : non slip, sloped to drain . Ceiling : moisture – proof , easy to clean ,Smooth ceiling.

6. Bulbs windows and door Bulbs : 25 total( 2-3 per room, bright white LED) Window :8 ( for light and air) Doors : 10( washable, insect – proof). Proper lighting keeps the area bright and safe.

7. Products prepared Pasteurized Milk Yogurt (Dahi) Butter Ghee Ice cream Cheese Flavored milk

8. Ice cream Collect fresh milk and cream. Add sugar and flavor (like vanilla or chocolate). Mix all ingredients well. Pasteurize the mixture (heat and cool). Freeze while stirring to make it creamy. Pack and store at –18°C.

9. Layout and flow line Simple product Flow : Gate → Milk Reception → Processing Room → Packaging → Cold Storage → Dispatch Support Areas : Office – Lab – Washing Room – Worker Rest Area – Sales Dept.

10. Milk collection Area Raw milk received from farms in refrigerated tankers. Sampling for quality and contamination check. Milk stored in chilled tanks before processing.

11. Processing section Includes pasteurization, homogenization , and separation Controlled temperature and pressure Stainless steel equipment used

12. Packaging section Fully automated to reduce human contact Uses sterilized bottles, tetra packs or pouches. Labeling with date , batch number, and expiry

13. Cold storage and dispatch Products stored at 2–5°C before distribution.
Cold chain maintained during transportation.
Refrigerated vehicles used for delivery.
Vehicles and storage areas cleaned and sanitized regularly.
Ensures freshness and product quality till reaching market.

14. Flow Diagram ( Milk ) Flow diagram Milk Collection ↓ Filtration ↓ Cooling (4°C) ↓ Pasteurization (72°C for 15 sec) ↓ Homogenization ↓ Product Preparation (Yogurt, Butter, Ice Cream) ↓ Packaging ↓ Cold Storage ↓ Distribution / Sales

15. Structure of Administration Managing Director – Head of plant. Production Manager – Controls daily production. Quality Control Officer – Ensures product safety. Lab Technician – Conducts product tests. Workers & Helpers – Do milk processing Cleaning Staff – Maintain hygiene. Sales Manager – Handles sales & marketing. HR Officer – Handles staff & records. Flow diagram : Managing Director ↓ Production Manager → Quality Control Officer → Lab Technician ↓ HR Office → Cleaning Staff → Sales Department

16. Proper set up plant design Separate areas for milk, packaging, storage, and cleaning. Smooth, washable floors and tiled walls. Ventilation windows and bright lighting. Drainage slope for easy washing water flow. Entry and exit for raw and finished products should be separate. FIFO (First In, First Out): In the dairy industry, the oldest products are used or sold first to keep everything fresh and safe.

17. Industry Rooms Room Functions . Milk Reception Collect milk from farmers Processing Room Pasteurization and mixing Packaging Room Packing and labeling Cold Cold Storage Store products Laboratory Product testing Administration office Manager work Sales Department Customer and product sales Wash Area Cleaning of tools Worker room Staff rest area Prayer room. Place for staff to pray

18. Equipment list Equipment Uses Storage Heating milk Milk fat evenly Cooling milk Make butter Pack milk Cold storage Several hygiene Product testing Milk tanks. (2) Pasteurizer (1) Homogenizer. (1) Chiller (1) Butter churner (1) Packing machine (1) Refrigerator (2) Cleaning tools Lab Equipment set. (1)

19. Workers and Staff Total workers: Around about 18-20 5 for production
2 for lab
2 for packaging
3 for cleaning
3 for sales
2 for office
Trained in hygiene and safety rules.

20. Laboratory (Quality Control Room) Tests milk for fat %, SNF, and acidity.
Microbiological testing for bacteria and spoilage.
Records every batch result.
Ensures safe, high-quality products

21. Work Station (Main Production Area) Machines are placed in order of process.
Stainless steel tables for easy cleaning.
Workers wear gloves, caps, and aprons.
Temperature and hygiene are checked regularly.

22. Personal Hygiene Rules Wash hands before and after work.
Always wear uniform, mask, gloves, and hair cap.
No jewelry or open shoes.
Eat or drink only in rest area.
Health checkups every 6 months .

23. Cleaning & washing time table Area Cleaning Frequency Material used Processing Room. Daily Hot water & detergent
Equipment After each use Detergent & sanitizer
Floor Twice daily Water & disinfectant
Walls Weekly. Sanitizer
Storage Area Daily Mop & sanitizer

24. Methods of cleaning CIP ( Clean-In-Place ): Cleaning done inside the equipment ( like pipes , tanks ) without taking them apart . COP (Clean-Out-of-Place):Cleaning done after removing parts of equipment and washing them separately.

25. Equipment Cleaning Steps Rinse with warm water
Apply detergent and scrub.
Rinse with clean water again.
Sanitize with food-grade chemical.
Air dry equipments
Check before reuse.

26. SWAP Method (Sanitation With A Purpose) Step Description S – Sweep Clean floor and remove waste. W -Wash surfaces with detergent. A – Apply Sanitizer Kill all germs. P – Put Back Return tools and record cleaning. SWAP keeps plant clean, safe, and organized daily.

27. Temperature Control Material/Product Ideal Temperature Raw Milk 4°C. Pasteurized Milk. 4°C Yogurt 5°C Butter 5–10°C Ice Cream -18°C Cheese 4–6°C Maintaining these temperatures ensures freshness and prevents spoilage.

28. Quality Control System Check milk quality at every stage.
Verify equipment cleaning records.
Maintain temperature logbook.
Test each batch in the lab before selling.
Only safe and high-quality milk goes to market.

29. Conclusion A Self-made dairy industry can work efficiently with proper layout.
Clean environment and hygiene make safe dairy products.
SWAP method and regular cleaning maintain quality.
Good teamwork and management ensure success.