Looking to Setup a Dairy Plant?
must known Practices...
Finding Location:
An estimated bovine population of over 300 million produces 185 million + tonnes of milk. The per capita consumption is a little less than 400 gm.
Rising income level, convenience, increased awareness of hygiene and associated health factors are the growth drivers in this business. One more factor impacting growth, particularly in major cities and urban areas, is introducing innovative milk-based products that have expanded the consumer base. The general scenario of or how to choose a location for your business.
Factors for Selecting the Location
1. Usage status of the land
Land for a dairy business usually will be available in a rural location; it (the ground) has to be finalised at the Panchayat/municipality level. It is necessary to check whether the particular area/locality has no bar on setting up the type of unit you have planned.
Though such restrictions are generally meant for polluting industries or specific types of chemical production, it is better to be clear on the land usage pattern at the planning stage itself.
2. Land infrastructure
It would help if you categorically ascertained the existing physical condition of the land. Historically, rural locations are used for agricultural activities; the ground levels may vary; you need to determine whether it requires land-filling to match the ground level with the neighboring areas; otherwise, rainwater accumulation problems may occur.
Are there water bodies within the parcel of land? This can be detrimental because there are strict rules in many parts of the country against filling up water bodies; this will reduce the actual usage area and have commercial implications.
3. Connectivity
A vital location issue surrounding infrastructure of approach roads, nearness to highways (or main roads) and straightforward accessibility need to be considered. Distances to the nearest electricity point, water source are other factors that need checking.
4. Transport
How convenient will it be to reach the place? An easy connection is essential because a large number of associates like vendors, technicians, consultants and even customers will be coming to the site.
5. Peaceful area
Is the proposed site located in a peaceful neighborhood? Is it free from all kinds of disturbances? These are some of the essential questions you need to answer and take into consideration before arriving at the final decision.
6. Special points
Is there an inherent advantage of the location? Like, closeness to a large colony or a township? Residential areas nearby can serve as a potential customer base.
There may be other factors to be considered for the location choice specific to your requirements and the piece of land. The final decision has to be taken after a thorough review of all the issues.
7. Cost budget
One issue that remains to be clarified in the finalization process is the cost of land. Your choice of location must be in line with the provision in the business plan.
Few additional points:
We have considered the primary issues that govern the selection of an ideal location and land for a dairy. In the next step, we look at the animals' specific infrastructural needs, which can influence the selection. Among the many factors contributing to the success of a business, the quality of raw materials (or input, in case of service) play a significant role.
1. In the dairy business, you have to handle living animals as the input resource. Therefore, it is imperative to plan proper shelter and other facilities for taking good care of the animals. Your location decision must consider the land requirement with the following in mind:
- Well-ventilated sheds or barns for the cattle, adequately protected from the weather.
- Irrigation system for pasture
- Milking area
- Facility for pasteurization and storage of milk
- Feed storage
- Manure storage
- Proper waste management system
2. A dairy business plan should include provision for the cultivation of fodder crops for the cattle. Growing your crop gives you control over the quality and nutritional aspects of the feed for the cattle.
3. One more from the list of experts' recommendations; locating your dairy in proximity to other farms can result in better support systems. Easy availability of inputs, veterinary support, transport arrangements, marketing can work favorably for the new entrepreneur. Besides, competition among the local units can improve both yield and quality.
4. Similarly, if there is a milk cooperative operating nearby, you can take advantage of selling additional quantities of milk (if any) to them.
The flooring of RMRD has specific requirement of good mechanical strength, resistance against the detergents, less noise problem etc. The flooring of section for fermented liquid products like, Dahi, Cheese, Yoghurt etc., requires vitreous category of tiles to maintain hygienic condition
Waterproof membrane:
One of the most important features at the time of planning and designing of the food plant floor is the use of water proof membrane in the floor to prevent liquids from penetrating to the base structure.
The material used for the membrane must be strong and yet flexible. Acid resistant asphalt laid at least 10-12 mm thick on a layer of bitumen felt is most commonly used
- Water proof membrane should be impermeable to water.
- It should be resistant to corrosive liquids and substances.
- It should be strong enough to support the required load
Asphalt or Bitumen layer in the form of a thicker layer which is applied on walls to prevent leakage of water.
Types of water proof membranes
- Plastic sheets
- Chemicals
Requirements of a food plant floor or characteristics of a food plant floor
· They should be impervious, smooth and easy to clean.
· It should be able to withstand the effect of lactic acid.
· It should be able to resist the effect of the cleaning solution, steam or hot water.
· It should be strong enough to withstand the effect of falling objects, cans, boxes (impact resistance)
· It should have high resistance to abrasion (wear and tear).
· It should have desired slope towards drains
· In processing section, the slope should be 1:80.
· In bottling section and RMRD, the slope should be 1:40.
Different types of floors:
· Cement concrete floor
· Terrazzo floor used in offices
· Tile floor having either natural stones or synthetic tiles
· Metal floor
· Grill floor
Heat Integration Of A Milk Plant:
In grass root stage, if the energy system of a milk processing plant is properly planned with heat recovery options, a good amount of electricity (power) and steam can be saved.
Energy analysis of 2,000 liters per day is shown in nutshell – along with pinch point identification for minimum energy, with respect to heating and cooling load. Modern techniques are also discussed for energy efficient milk processing. In grass root stage, if the energy system of a milk processing plant is properly planned with heat recovery options, a good amount of electricity (power) and steam can be saved
Drain and drain layout for food plant especially dairies:
The ratio of milk to water used in various dairy plants varies from 1:1 to 1:3 depending on the type of plant. The old figure of water use was quite large but now water conservation measures resulted in to considerable low level of water consumption. Water is mainly used for washing of equipment’s, floors, milk crates/cans, hot water, chilled water etc. When water is used in dairy plants, it is necessary to provide drains and piping arrangement to transfer the waste water to effluent treatment plant (ETP) of the dairy. The drains and pipeline layout should be such that it maintains hygienic conditions in the processing area and waste water containing milk resides is efficiently collected from all the sections and finally supplied to the ETP plant.
Drainage system is very important in any dairy and food plant. Therefore, it is one of the essential considerations at the stage of planning and design of processing building. It is important to provide adequate numbers of sanitary drains coupled with waste water conveying system to transfer the effluent to the treatment plant. Any shortcomings may lead to choking of drainage pipelines and unhygienic conditions in the plant. Cast iron or PVC pipelines are commonly used for conveying of effluent in dairy plants.
1. Select the most appropriate type of drains and entire system considering hygienic conditions.
2. Use the drains which can be cleaned easily.
3. Provide adequate number of drains considering the maximum flow of water.
4. Use of 4”-5” (100 mm to 125 mm) diameter pipe for drainage lines for handling milk plant wastes.
5. Regular cleaning of sanitary drains is recommended to avoid chocking of drainage system.