INTERNSHI

P
REPORT
ON
OLPERS
(ENGRO FOOD Ltd.)
MILK PROCESSING

Prepared By:
 JAWAD
AHMED
2ND YEAR
CHEMICAL
ENGINEERING
M.U.E.T Jamshoro

Contents
1 Introduction of Milk
2 Milk Reception
 1 Pasteurization Section
2 Butter & Ghee section
3 Ultra Heat Treatment
Section
4 Tetra Packing Section
5 Utility
6 Cleaning In Place Section
10 Water treatments

Introduction of Milk
History:
Milk production began 6 000 years ago or even
earlier. The dairy animals of today have been developed
from untamed animals which, through thousands of years,
lived at different altitudes and latitudes exposed to natural
and, many times, severe and extreme conditions.Practically
everywhere on earth man started domesticating animals. As
a rule herbivorous, multipurpose animals were chosen to
satisfy his need of milk, meat, clothing, etc. Herbivorous
animals were chosen because they are less dangerous and
easier to handle than carnivorous animals. The former did
not compete directly with man for nourishment, since they
ate plants which man could not use himself.

Composition of Milk from

different types of animals
.
Carbo
Anima Protein Casein Whey
Fat - Ash
l Total % protein %
% % % hydra
te
%

Cow 3.5 2.8 0.7 3.7 4.8 0.7

Buffalo 4.0 3.5 0.5 7.5 4.8 0.7

Goat 3.6 2.7 0.9 4.1 4.7 0.8

Sheep 5.8 4.9 0.9 7.9 4.5 0.8

The most widespread milking animal in the world is

the cow, which is found on all continents and in
nearly all countries.
Cow milk:
Milk is the only food of the young
mammal during the first period of its life. The substances in
milk provide both energy and the building materials
necessary for growth. Milk also contains antibodies which
protect the young mammal against infection.

Main constituent Limits of variation Mean value

Water 85.5 – 89.5 87.5
 Total solids 10.5 – 14.5 13.0
Fat 2.5 – 6.0 3.9
Proteins 2.9 – 5.0 3.4
Lactose 3.6 – 5.5 4.8
Minerals 0.6 – 0.9 0.8

Milk Reception
Tanker reception:
Tankers arriving at the dairy drive straight into a reception
hall, often large enough to accommodate several
vehicles.The milk is measured by two methods by:
(I) Weight (II)Volume

(I) Measuring by weight:

Collected milk is weighed by this way:
• by weighing the tanker before and after unloading and
then subtracting one value from the other.

(II) Measuring by volume:

 This method uses by a flowmeter. It is
placed in the Reception Unit’s by which it is measured.

After the line lab 14 tests, if the test results are negative(in
standard rang) then we receives the raw milk and if in case
the result are in positive then we will reject the tanker
because by these test we knows that, that raw milk is usefull
for our process or not.
Then we attach the flexible pipe with the reciption which
send this raw milk to the silos.
That reception unit work is to transfer flow by cooling(below
+ 4 °C) it.

Reason of the milk chilling:

The milk should be chilled to below + 4°C immediately after
milking and be kept at this temperature all the way to the
dairy.If the cold chain is broken somewhere along the way,
e.g. during transportation,the micro-organisms in the milk
will start to multiply. This will result in the development of
various metabolic products and enzymes.Subsequent chilling
will arrest this development, but the damage has already
been done. The bacteria count is higher and the milk
contains substances that will affect the quality of the end
product.
SILO
THE Large vertical tank is known as Silo.
Raw milk storage:
The untreated raw milk – whole milk – is stored in large
vertical tanks – silo tanks – There are three Silo’s, Each Silo
having capacities of 100000 litres. The Silos tanks are of
double-wall construction,with insulation between the walls.
The inner tank is of stainless steel, polishedon the inside,
and the outer wall is usually of welded sheet metal.

Silo temperature & Level indication:

The temperature & level in the tank is indicated on the silo
control panel by using an electric transmitter, which
transmits signals to a central monitoring station.
There are various methods available for measuring the milk
level in a tank.
The pneumatic level indicator measures the static pressure
represented by the head of liquid in the tank. The greater
the pressure, the higher the level in the tank. The indicator
transmits readings to an instrument.
Overflow protection:
A high-level electrode (HL) is fitted at the top of the tank to
prevent overfilling.
This electrode closes the inlet valve when the tank is full,
and the milk
supply is switched to the next tank.
Empty tank indication:
During an emptying operation, it is important to know when
the tank is
completely empty. Otherwise any milk remaining when the
outlet valve has closed will be rinsed out and lost during the
subsequent cleaning procedure.
The other risk is that air will be sucked into the line if
emptying continues after the tank is dry. This will interfere
with later treatment. Consequently an electrode, lowest low
level, (LLL) is often located in the drainage line to indicate
when the last of the milk has left the tank. The signal from
this electrode is used to switch to another tank or to stop
emptying.

Agitation in silo tanks:

These large tanks must have some form of agitation
arrangement to prevent cream separation by gravity. The
agitation must be very smooth. Too violent agitation causes
aeration of the milk and fat globule disintegration. This
exposes the fat to attack from the lipase enzymes in the
milk. Gentle agitation is therefore a basic rule in the
treatment of milk. The tank in the illustration picture has a
propeller agitator, often used with good results in silo tanks.
In very high tanks it may be necessary to fit two agitators at
different levels to obtain the required effect.
Outdoor silo tanks have a panel for ancillary equipment. The
panels onthe tanks all face inwards towards a covered
central control station.
 Silo with propeller agitator

Pasteurization Section
Pasteurisation:
Pasteurisation is one of the most important
processes in the treatment of milk. If carried out
correctly,these processes will supply milk with longer shelf
life.
Temperature and pasteurisation time are very important
factors which must be specified precisely in relation to the
quality of the milk and its shelflife requirements. The
pasteurisation temperature for homogenised,HTST
pasteurized.The setpoint of temperature is usually 75°C and
having stay time of 20 sec.
The pasteurisation process is the heat treatment must
guarantee the destruction of unwanted microorganisms and
of all pathogenic bacteria without the product being
damaged.
Pasteurization Process Description:
Balance Tank:
The raw milk introduced into balance tank by the help of
Swing Band Panel, the balance tank having two censers which helps to
maintain the flow pressure and there continuity and Other censer is
used for the avoiding to overflow.
Regeneration:The method of using the heat of a
hot liquid, such as pasteurised milk, to preheat cold
incoming milk is called regeneration. The cold milk also
serves to cool the hot, thus economizing on water and
energy. Regeneration efficiencies of up to 94 – 95 % can be
achieved in efficient modern pasterurisation plants.

Regenerator#1:
When the raw milk comes into 1 st
regenerator from the balance tank so there temperature will
rises it may be reaches 50-55°C Then the milk is flow’s to the
separator.
Separator:
The separator is used to separate the cream from
the raw milk. It works on the basis of centrifugal force law.
It seprate the cream from the raw milk because the lighter
particles of cream becomes on the surface and denser
particle will be down.
It also used for the seprate the unwanted sediment particles.
Then skimilk flows to the regenrator#2.
Regenrator#2:
When the raw milk comes into 2nd regenerator
from the Seprator so there temperature will rises it may be
reaches 60-65°C.
Then the milk is flow’s to the Dearator.
Dearator:
Dearator Is used for the removing the unwanted
gases and also used for the removing of the bed smell from
the milk.
Then the skimilk flow’s to the homogenizer.
Homogenizer:
There are two types of
homogenizer.
Single-stage and two-stage homogenization:
Homogenisers may be equipped with one homogenising
device or two connected in series, hence the names single-
stage homogenisation and two-stage homogenisation. The
two systems are illustrated .
In single-stage and two-stage homogenisation the total
homogenization pressure is measured before the first stage,
P1, and the homogenization pressure in the second stage is
measured before the second stage, P2.
The two-stage method is usually chosen to achieve optimal
homogenisation
efficiency. Best results are obtained when the relation P1 /
P2 is about 0.2.

Single-stage homogenisation may be used for

homogenisation of:
–products demanding a high viscosity (certain cluster
formation).
Two-stage homogenisation is used for:
– products with a high fat content
– products where a high homogenisation efficiency is
desired.
The formation and breakup of clusters in the second stage
is illustrated in
Effect of homogenization:
The effect of homogenisation on the physical structure of
milk has many
advantages:
• Smaller fat globules leading to no cream-line formation,
• Whiter and more appetizing colour,
• Reduced sensitivity to fat oxidation,
• More full-bodied flavour, better mouthfeel,
• Better stability of cultured milk products.
Then it sends flows to 3rd regenerator.
Regenrator#3:
The flow is introduced in regenrator 3
where it’s tepmrature is about 70°C.
Similarly the flow passes from heater and then it passes
from the flow divergence valve.
Flow divergence valve:
The flow passes from the FLV
which is used for the flow divert if any case the milk is not
heated at it’s required temprature(75+2/75-2°C)then It the
raw milk is introduced back into the balnce tank and the milk
is reprocessed until it will not reach at which teprature which
is required.
If the flow temperature is reaches at which tepmrature which
is it’s requirement the it flows to cooler.

Cooler:

When flow of skimilk is passes from the regerator 3,2

and similarly 1 towards the cooler then it’s tepmrature will
be reduces.
Then flow of pasteurized milk is sends towards the
standardized silos.
Butter & Ghee section
Cream Tank:
 These tanks are used for the storage of cream which is
introduced from pasteurization Section this cream was separated by
separator.

Butter Churner:
The stored cream introduced into the butter
churner by flexible pipe, the chilled water is added into
cream it’s 1:4 butter churner is rotated for 20-25 min at
temprature 80-85°C.
When the rotation is completed the lasi separated from
butter the lasi sends back into the pasteurization section to
use for milk process
Butter Melter:
The butter which is seprated
from butter churner it is introduced into the butter melter to
give its liquid form. It is melted at temperature 50-65^C.
Ghee Cooker:
The melted butter is
introduced into the ghee cooker where the
temperature is supplied 80-85^C by steam for 4
hours. Then it stayed for half hour because if there
having remained some lasi it will be separated in this
duration.
Then again heat is supplied for 3-4 hours at
temprature 70-75^C to remove the remaining
moisture.Then it is filtereated and sent to filling tank.
Filling tank:
When the ghee is introduced from the ghee
cooker In Filling tank the the antioxdant is added in it to
increase it’s shelf life.
Then it is filled in different size of tins.
Ultra Heat Treatment Section
UHT is the abbreviation for Ultra High Temperature. UHT
treatment is a technique for preserving liquid food products
by exposing them to brief, intense heating, normally to
temperatures in the range of 135 – 140°C. This kills micro-
organisms which would otherwise destroy the products.
UHT treatment is a continuous process which takes place in
a closed
system that prevents the product from being contaminated
by airborne micro-organisms. The product passes through
heating and cooling stages in quick succession. Aseptic
filling, to avoid reinfection of the product, is an integral part
of the process.
Two alternative methods of UHT treatment are
used:
•Indirect heating and cooling in heat exchangers,
• Direct heating by steam injection or infusion of milk into
steam and
cooling by expansion under vacuum.
Standardized silos:
The after pasteurization the milk is known as standardized milk so it is
stored in standardized silo, where we can stored it for 2 days.
The standardized milk is introduced into the balance tank.
Then it is it is flow with help of pumps. When we have to supplied ultra heat treatment to
milk then we will select to centrifugal pump. In case we have to supplied ultra heat
treatment to cream then we will select the loop pump for the maintain the flow of
milk/cream.
Then the milk/cream is flow into the 1st pre-heater where the heat is supplied at
temperature 30-40^C, in 2nd pre-heater 80-90^C,in 3rd pre-heater 120^C similarly in main
heater at temprature 139^C.
Then flow is stays for 2-4 sec by holding tube.
Then the flow is comes into 1st cooler where the flow is cooled and it’s temprature is
decreases 70-80^C.
Then the flow is introduced into the homogenizer where the flow is homogenized and
flow cames into 2nd coller where it’s further temprature is decreased about 28-30^C.
Then the flow is transferred to tetra packing section for Packing.

Tetra Packing Section

HISTORY:
Glass bottles for milk were introduced back at
the beginning of the 20thcentury. As a package, glass has
some disadvantages. It is heavy and fragile,and must be
cleaned before re-use, which causes some problems for
dairies. Since 1960 other packages have entered the milk
market, mainly paperboard packages but also plastic bottles
and plastic pouches.
A package should protect the product and preserve its food
value and
vitamins on the way to the consumer. Liquid foods tend to
be perishable, so a clean, non-tainting package is absolutely
essential. The package should also protect the product from
mechanical shock, light and oxygen. Milk is a sensitive
product; exposure to daylight or artificial light destroys some
essential vitamins and has a deleterious effect on the taste
(sunlight flavour).
Other products, such as flavoured milk, contain flavouring
matter or
vitamins that are oxygen-sensitive. The package must
therefore exclude oxygen.
A milk carton usually consists of paperboard and plastic
(polyethylene).
Paperboard comes from wood, which is a renewable
resource. The paperboard gives stiffness to the packages as
well as making them resistant to mechanical stress. The
paperboard also serves to some extent as a light barrier.
A thin layer of food-grade polyethylene on either side of the
paperboard makes the cartons leakproof. On the outside,
the plastic also protects the cartons from condensation
when chilled products are taken out of storage.
Because of its purity, this polyethylene produces minimal
environmental impact when incinerated or deposited in
landfills.
For products with a long non-refrigated shelf life and very
sensitive products, a thin layer of aluminium foil is
sandwiched between layers of polyethylene plastic. This
gives almost complete protection of the product against light
and atmospheric oxygen.
All packages end up as waste. The growing volume of
household waste could become an environmental problem in
our society. Ways of tackling this problem can be
summarized in principle under five headings :
• Reduction. Reducing the input of raw materials and
choosing materials
that are not environmentally harmful helps to conserve
natural resources.
• Recycling. Packages can be collected after use and used
again. How
ever, it should be remembered that even a refilled package
ultimately
ends up as waste.
• Recovery of materials. Packages can be collected and the
materials
used to manufacture new products, but it is important that
the new
products meet a real need.
• Recovery of energy. All packages incorporate energy,
which can be
extracted when the waste is incinerated. The potential yield
depends on
the type of packaging material.
• Landfill. Waste can be deposited as landfill and the area
can ultimately
be landscaped for recreational or other purposes.
Paperboard packages have a very low weight, and their main
component
comes from a source that is renewable. Compared to most
other packages,
the amount of waste generated is small. A one-litre Tetra
Brik pack
weighs 27 g and generates only that amount of waste.
Paperboard packages are highly suitable for energy
recovery. Wood and
oil (the raw material for the plastic) are conventional sources
of energy, and
it can be said that we simply borrow these raw materials for
packages before
using them as fuel. The incineration of two tons of packaging
material
yields as much energy as one ton of oil.
Waste as landfill is the least efficient form of waste
managament. However,
if Tetra Pak packages are deposited in this way, there are no
toxic
substances in them which could contaminate ground water.

The principal and fundamental

functions of packaging are:
- to enable efficient food distribution
- to maintain product hygiene
- to protect nutrients and flavour
- to reduce food spoilage and waste
- to increase food availability
- to convey product information

The milk is introduced into machines from other sides in the machines the
paper reels and poly is loaded for the packing & from aseptic lines, where
the milk is filled into the and reel paper packets then packed very easily and
smoothly.

Types of Tetra Brick Aseptic

Machines :
(I) TBA-08
(II) TBA-22
(III) TBA-19

(I)TBA-08:
This type of machine is packing for 1000ml.
It have a two jaws for cutting. It can be gives us 6000 packets/h.

(II)TBA-22:
This machine is latest one
machine.This type of machine is packing for 200ml. It have a TEN
jaws for cutting. It can be gives us 20000 packets/h.

(III)TBA-19:
This type of machine is packing for 250ml.
It have a two jaws for cutting. It can be gives us 7500 packets/h.
Aseptic Tank:
• If one of the packaging machines incidentally stops the
aseptic
tank take care of the surplus product during the stoppage.
• Simultaneous packaging of two products. The aseptic
tank is first filled with one product, sufficient to last for a full
shift of packaging. Then the UHT plant is switched over to
another product which is packed directly in the line of
packaging machines.
One or more aseptic tanks included in the production line
thus
offer flexibility in production planning.

Utilities
• Instrument Air(compressed air)
• Water Chilling
• Boiler
• Power Generation
• Instrument Air(compressed air):

• Water Chilling:
• Boiler:
MOST IMPORTANT FACOTORS FOR CIP:
• TEMPRATURE
• FLOW
• CONCENTRATION
• TIME
.
CIP is most important for any industry it is very usefull
Benefits of CIP
It is used to get a good quality.
It increases the shelf life of the plant instruments.
 Water treatment

PIT:
It is a point where we collect all the sewerage lines.
Screening:
It is used to seprate(removing) 5mm particles.
Duff unit:
It removes the lighter and below than 5mm particles.
Equlization basens:
These basen are used to combines the fresh air to water for
growthing bacteria.
When bacteria are growth they will eat to unwanted material small
particles.
Clarifier:
It is used to remove all dust particles.
Indus tank:
After clarifying the water, water becomes in
good condition for utilized.
This Indus tank is connected with the river, where we sends this
water.