vasudharadairycasestudy-160816074414.pdf

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1. DAIRY PROJECT
CASE STUDY

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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2
34
5
6
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12
10
11
11
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
ThesiteislocatednearChikhliand
connectsthemainNationalHighwayNH8.
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
•TheextramilkfromtheadjacentvillagesiscollectedattheBMC.
•TheAdulterationischeckedduringthegradingprocess.
•TheRawmilkpassestothecilosat15°C-16°C.Thereare4cilos
(2cowmilk,1buffalomilkand1mix)with50,000lit.capacity
each.
•ThemilkfromthecilosisdeliveredtotheBy-productssection.
•TheDairycollects4lakhLPDmilk.
•IDMCandAlphalevalcompanyproductsareusedinthedairy.
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
•ThemilkischilledforextendeddurationintheBalancingTank.
•Pasteurizationisdoneat85°C.Themilkcapacityofpasteurizeris
10,000Lit.perhourandcreamcapacityis4000Lit.perhour.
•FDVmaintainsthetemperatureat85°C,whereitisheldfor15-
16seconds.
•Thereare8ProcessedMilkCilosof40,000Lit.capacityeach.
•Themilkgetsseparatedinthefollowingtypesintheseparator
section,andthenitisstoredintheprocessedmilkcilos:
1.SlimFatMilk
2.LowFatMilk
3.MediumFatMilk
4.NoFatMilk
5.Cream
Pasteurizer FDV

6. PROCESSING UNIT
MILK BY-PRODUCT: CURD
Raw Milk
DahiTank
Culturing
Agitation
Curd
Setting
Acidity
check
Standardization
Process
Sampling
Checked by
ISO
Packing
•TheFermentedMilkby-productsare:Plainchaas,MastiDahi,
JeeraChaasandProlifeMilk.
•CulturingisdoneinDahiTankfor15min.andthenagitationis
doneforsettlingthecurd.
•Theacidityischeckedafter4hourswhichshouldbe1.2phon
thephscale.
•JeeraChaasismadebyaddingjeeraandsalttotheabove
process.
•Thereare2thermisersof10,000Lit.and20,000Lit.eachand1
pasteurizerof1000Lit.capacity.
DahiTank Jeera ChaasTank

7. PROCESSING UNIT
GHEE AND BUTTER SECTION
Raw Milk
Jacketed type Machine
Clarifier
Packing
•TheButterispassedthroughsteamorhotwaterinthejacketed
typemachine.
•Thereare3Jacketedtypemachines.
•Packingisdonein2quantitiesof500gand200g
Raw Milk
Cream Addition
Churning
Continuous Butter
Making
Machine(CBMM)
Storage
Ghee Processing Butter Processing
Ghee Processing
Butter Processing
•TheButterisproducedthroughbatchtypeprocess.
•Thereare3creamtanksof50,000Lit.capacityeach.
•Whitebutterisproducedfromcowmilkandstoredat15°C.
Jacketed type machine

8. PACKAGING UNIT
MILK PACKING SECTION
Processed Milk
10 Huge Tanks
8 Small Tanks
Pouch Packing
Affiliated Milk
Plant
•ThePackagingisdonefrommorning7amtoevening8pm
•10Hugetanksareof10,000Lit.capacityeach.
•80pouchpermin.areproducedinsmalltanks.
•Pouchpackingisdonein500ml,300ml,200mland5Lit.
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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2
3
4
5
7
6 8
9
Plan