Looking to Setup a Dairy Processing Plant?

on

Looking to Setup a Dairy Processing Plant?

There has been a major improvement in milk production, which increased from 17 million tonnes in 1951 to 127.9 million tonnes during 2011-12. Uttar Pradesh, Punjab, Madhya Pradesh, Rajasthan, Maharashtra, Gujarat, Andhra Pradesh, Haryana, Tamil Nadu, and Bihar contributed to the extent of 80 percent of the total milk production in the country. The per capita availability of milk has reached a level of 290 grams per day during the year 2011-12, which is more than the world average of 284 grams per day. Most of the milk in the country is produced by small, marginal farmers and landless laborers.

To meet the rapidly growing demand for milk with a focus to improve milch animal productivity and increase milk production, the Government has approved National Dairy Plan Phase-I (NDP-I) in February 2012 with a total investment of about Rs.2242 crore to be implemented from 2011-12 to 2016-17. NDP-I will help to meet the projected national demand of 150 million tons of milk by 2016-17 from domestic production through productivity enhancement, strengthening and expanding village level infrastructure for milk procurement, and providing producers with greater access to markets

Project Area:
The proposed activity would be implemented in the operational area of the Union. The new dairy Plant is proposed to be established at the LMN location for which the Union has already purchased the land. The list of villages where BMC and electronic milk adulteration testing equipment would be installed is given

Beneficiaries:
After implementation of the project, there would be an increase in sales realization, which would be passed on to the milk producers in form of increased milk procurement price. During 2016-17, the Union has passed on 78% of the sales realization to milk producers as a cost of raw material (milk), which is expected to increase to 80% by end of the project period. Further, consumers would be benefitted due to the availability of better quality milk and milk products in the market.

Manpower requirement:
Existing Manpower:
To set up the milk plant needs manpower strength of 639, of which 73 are officers, 132 are staff and 434 are workers. There are a total of 9 sections in the Union. The day-to-day operations of the Union are looked after by a Managing Director, who is on deputation from State Milk Federation.

Manpower required:
To set up an automated milk processing plant of 300 TLPD which will require minimum manpower support to operate and manage the plant. About 7 Officers and 13 staff are required to operate the automated plant. The casual labor required for the plant would be hired on a daily job work basis. The Union will manage all administrative operations through the existing manpower.

Manpower recruitment & schedule:
On approval of the project proposal, a detailed recruitment and training schedule will be prepared to deploy the technically competent trained manpower in plant operation well before the plant is handed over to the Union

Staff for Dairy processing Plant Project

Plant Manager

01

Plant operator

01

Marketing

02

Plant Supervisor

01

Mechanics

02

Driver

01

Lab Technician

02

Labour

08

Accounts Staff

02

Watch Man

02


Milk & Milk products manufacturing:
At Dairy plant present processes milk into toned milk, full cream milk, and homogenized milk. The Union also manufactures milk products like curd, lassie, buttermilk, flavored milk (Flexi pack), peda, and paneer. In the new plant along with packing of pasteurized liquid milk of the above variants, capacity for manufacturing of products like curd, buttermilk, and paneer would be set up. Flavored milk in the Flexi pouch would be packed in the liquid milk packing facilities available in the new plant.

1. Balance Tank, 2. Feed Pump, 3. Flow Controller, 4. Regenerative preheating sections, 5. centrifugal Clarifier, 6. Heating Section, 7. Booster Pump, 8. Holding Tube, 9. Hot water heating System, 10. Regenerative cooling sections, 11. Cooling sections, 12. Flow diversion valve, 13. Control Panel, A. Temperature transmitter, B. Pressure Guage

Proposed new milk processing plant details
Land and location:
The Union has about 12 acres of land at the LMN location, near the state highway in the operational area of the Union. The connecting road from the proposed location to the state highway is available. The land was purchased by the Union from the market in 2005. The land is encumbrance-free. After construction of the plant in 1/3 of the area, sufficient land will be available for its future expansion, vehicle movement, parking of tankers, and transport vehicles.

Site development:
The location has been fenced with barbed wire with a gate opening towards the road.
The land has to be leveled before the establishment of the plant and internal road and drainage facilities have to be constructed under the project.

Layout and building:
The civil works comprise of main processing building, which includes Raw Milk Reception Dock, Main processing hall, provision for the manufacture of other products, cold storage, CIP, Laboratory, quarters, office, garages, security post, etc. The factory building for the milk reception, quality control, processing, packing, and storage of milk products should be as per approved standards.

A well-designed layout must facilitate production operations, minimize material handling maintain flexibility of the operation for alteration and expansion, minimize investment in equipment, make economical use of floor area, promote effective utilization of the labor and provide for employee convenience and comfort. It is up-most important to design the optimum size of the dairy building. Some enterpriser engages an architect to prepare the plant layout for an attractive design and consult dairy equipment manufacturers for ideas regarding the latest machinery. However, the involvement of a dairy engineer in the layout is very vital to take care of all necessary requirements. It is advisable to make judicial use of the land available and optimum cost in the construction of the building. 

Important factors for the planning of dairy building:
The following are the basic factors that must be considered before planning the dairy building. 
  • Milk handling capacity and variation in milk handled every day. 
  • Method of milk collection and transportation 
  • Design of milk processing section. 
  • Method of milk packaging. 
  • Way of milk distribution to consumers 
  • Source of electric power supply, water supply, and wastewater disposal. 
  • Type of fuel for the boiler. 
  • Provision for subsequent future expansion. 
  • Transportation facilities and conditions of the road
The essential sections of a milk processing plant are given in below:
  • Raw Milk Reception Dock (RMRD) - consisting of can conveyor, can washer, weighing balance, dump tank, etc.
  • Processing Hall - cream separator, chiller, homogenizer, pasteurized, and other related machinery are installed.
  • Storage area -for milk storage tanks.
  • Products manufacturing area depends upon the type of products, the quantity of milk handled and the machinery to be installed.
  • Packing area-for packing of liquid milk and other products.
  • Cold storage-for keeps the milk and milk products before sending to market.
  • Quality Control Laboratory for testing the quality of milk and milk products.
  • Utilities area-for installing a boiler, generator set, water treatment plant, maintenance, and storage area for spares.
  • Effluent Treatment Plant area for treating the dairy effluents before releasing them to the fields
  • Office area for all the essential staff.
  • Vehicle parking area-both for the milk procurement and distribution vehicles.
  • Input supply area- for providing veterinary service, supply of feed, fodder seeds, etc.

Types of Equipments:
  • Reception Equipment
  • Chilling and processing Equipment
  • Reconstitution Equipment
  • Liquid milk Filling Machine
  • Rinse milk Recovery system
  • Butter making Equipment
  • Buttermilk handling section
  • Fat Recovery Section
  • Ghee Making Section
  • Curd Making Section
  • CIP Section
  • Process & Tankers Section
  • Milk pumps and pipes
  • Cold Storages & Deep Freezers
  • Steam Generation System
  • Water handling system
  • Compressed air handling systems