An Energy Efficient Design for a Mini Milk
Pasteurization Plant
HTST Milk Pasteurization Plant for 600 Litre/hour
Habib Ullah Manzoor Muhammad Umer Iqbal
University of University of
Engineering & Engineering &
Technology Lahore Technology Lahore
Faisalabad Campus, Faisalabad Campus,
Pakistan Pakistan
habibullahmanzoor@gm umer95634@gmail.com
ail.com
Abstract—Milk has been used from centuries in daily lives of
humans to add more nutrients in food. Milk is also utilized in many
barking products. Cow milk can sour in 3 hours at 30°C. To
prevent milk from souring a process named pasteurization is
performed. Where milk temperature is kept at 75°C for 15 seconds
and then cooled to 4°C. After this process milk can be stored for
21 days in refrigerator. However, this process can increase the cost
of milk. In this paper an energy efficient design of mini milk
pasteurization plant is presented. Calculations are carried out for
all the required components (electric pumps, heat exchanger,
electric heater and chillers) in detail. If plant is to run for 12 hour
in a day then 1.1 million annually can be saved.
Keywords— pasteurization; HTST; holdign tube; heat
exchanger; cost analysis.
I. INTRODUCTION
It is recommended that Mother’s own milk be fed
exclusively for the first 6 months of new-born child’s life [1]. It
is because it is necessary for the health of newborns and is
particularly importance for fragile preterm infants born of very
low birth weight. Due to certain reasons, including mother’s
illness and immaturity of mammary secretory cells, mothers do
not have a full supply of their own milk, and in this case, human
donor milk is preferred. Donor human milk provides for a
reduction in the incidence of necrotizing enterocolitis (NEC) as
well as improved feeding tolerance compared with formula
milk in this high-risk group [2]. To ensure safety from
infectious agents potentially contaminating donated milk, the
milk is typically pasteurized.
Processing of milk is done to prevent it from souring
specially in summer where temperature approaches 50 oC. So
there is a chance of rapidly souring of milk. However, milk does
not sour at temperature below 10oC, probably at 4oC, for 72
hours. If we consider the cow milk then it sour within 3 hours
at temperature 30oC [3]. As the milk business is totally
concerned with rural areas where milk storage and processing
Muhammad Haris Muhammad Bilal
University of University of
Engineering & Engineering &
Technology Lahore Technology Lahore
Faisalabad Campus, Faisalabad campus
Pakistan chohanbilal95@gmail.co
harisinam10@gmail.com m
facilities are very rare, so the milk is soured which will reduce
its economic value. In order to increase the quantity and
improve the quality of milk, better facilities and technical
knowledge is required [4].
Pakistan is the third big country of supplying milk.
Dairy industry is included in one of the major industry in
Pakistan. The popularity of processed milk is increasing day by
day as the attention to preservation through the use of
antimicrobials has been increased[21], which inhibit or destroy
the growth of microorganisms. Antimicrobials are produced by
animals, plants, and microorganisms [5]. Pasteurization is an
important process that can kill various dangerous
microorganisms in the milk like Salmonella, Listeria, Yersinia,
Campylobacter, Staphylococcus and E-Coli [6].
Pasteurization is the process in which milk is heated
up to 72ºC for a certain period of time and then it is cool down
to 4ºC [7]. Heating milk up to 72oC and then holding at that
temperature for a certain time guarantee the destruction of
unwanted microorganisms and does not affect the taste &
nutritional value of the milk[22]. When properly done, shelf life
of pasteurized milk increased to 72 hours [8]. This is a very
positive aspect of using the pasteurized milk.
A. Pasteurization:
Pasteurization is a process invented by Louis Pasteur
in 1864 [9]. He discovered that abnormal fermentation of wine
and beer could be prevented by heating these beverages to about
57oC for a few minutes [10]. In pasteurization process,
sufficient heat is applied to a food for a particular time. This
heat will kill all the germs present in the food that will cause
spoilage and disease. Fortunately, most of the harmful
microorganisms present in foodstuff are not very resistant to
heat. This process is mostly used for beer and wine. Besides
beer and wine, now this process is mostly used for milk, juices,
liquid eggs [11], milk and milk products.
 The most common type of pasteurization are Batch
pasteurization, High temperature Short time (HTST)
pasteurization and Ultra High temperature pasteurization
(UHT).
1) Batch Pasteurization:
Batch pasteurization is a type of pasteurization in
which milk is heated up to 63oC in a large container and held at
that temperature for 30 minutes. This is a very simple and oldest
method. This process is mostly used for small dairies and in
homes too. In this type, the milk is stirred constantly so that
each particle of milk is heated [16].
2) High temperature Short time Method(HTST):
HTST is a type of pasteurization in witch fresh milk is
heated up to 72oC and held at that temperature for 15 seconds
in order to insure that all germs has been killed, was introduced
in 1933, with a result of 99.999% or greater reduction in
harmful bacteria [17]. After this, milk is suddenly cool down to
4oC. Now this milk can be stored for 72 hours at temperature
less then 10oC [8]. It is very useful method and used by higher
volume processing industries. This type of pasteurization is
more beneficial then batch pasteurization because here energy
can be recovered to pre-heat the raw milk before entering to the
heat exchanger. In proposed method, HTST method is used
with improved efficiency. The HTST process used by many
other plants are like this as shown in figure 1 below [19].
Figure 1 : HTST milk overflow
3) Ultra-High temperature Method (UHT):
UHT is a pasteurization process in which milk is to be
heated at temperature 135oC and held at that temperature for a
very short time typically 2 to 3 seconds [18] and cool down
rapidly to room temperature. It is a very useful method used by
major dairy industries because its initial cost is very large. A
UHT pasteurized milk can be stored up to nine months without
any refrigerator[23].
In this paper an energy efficient milk pasteurization
plant is purposed with the milk capacity of 600 liters per hour.
Here HTST technique has been utilized. Calculations and
measurements for the required components have been discussed
in detail. The purposed design has also been compared with
already installed mini plants located in Faisalabad, Pakistan.
Cost analysis has also been carried out with and without energy
efficient model.
II. EASE OF USE
It is essential that the proposed pasteurization method
should be economical for all intended users. The main thing is
to meet the requirements of all its users and operating
requirements. Most necessary thing is that this plant has to be
portable so that it can be transported on a pick-up vehicle. Initial
start-up for this plant is to be a service provider for milk shops.
The design has been made so that it can withstand a harsh
operating environment. Design has been made by observing the
requirements of farmers because they haven’t enough
knowledge of technical things. The operation is simple to be
operated by farmers with limited technical knowledge.
III. MAIN COMPONENTS OF PROPOSED DESIGN
The main components in proposed pasteurization plant
consists of raw milk tank where raw milk is collected, a pump,
a heat exchanger, an electric instant heater, a thermally
insulated holding tube, an evaporator with second heat
exchanger, chiller, a set of diverter valves, and a control box to
control the entire pasteurization process. In the energy efficient
pasteurization plant, the raw milk flow rate is controlled by a
solenoid valve. Speed of the pump can be varied using a
variable frequency derive (VFD). A solenoid valve is required
that is to be controlled with a Programming logic controller
(PLC).
IV. PROPOSED DESIGN
To initiate the process, raw milk is pumped into
electrical heater directly (only first 2.5litters) where it is heated
to 75oC. After attending desired temperature, milk is
transferred in to holding tubes. Where the milk is kept for 15-
18 seconds. This heat treatment ensures that all micro-organism
and bacteria has been killed. Temperature of the milk is
measured again just after the holding tube with RTD pt-100
where the milk that does not meet the required temperature is
diverted back into the raw milk tank by an electric diversion
valve while the heated milk than goes to the cooling process.
This heated milk need to be cooled down to 4 oC. Sudden
cooling from 75oC to 4oC requires a very expensive chiller. The
heated milk is fed to the milk to milk heat exchanger. Purpose
of this heat exchanger is to cool the heated milk and preheat the
raw milk. Now raw milk is not sent directly to electric heater
but through heat exchanger. Heated milk at 75oC will exchange
its heat with raw milk (25oC) and raw milk will be preheated to
60oC and heated milk is precooled to 45 oC. This way heated
milk is used to heat the raw milk and raw milk is used to cool
the heated milk simultaneously. Now heated milk at 45oC is
again fed to another heat exchanger where it will exchange its
heat with water at room temperature by an evaporator, the
output of 2nd heat exchanger will provide milk at 25oC. Now we
can use a chiller which will cool down the milk from 25oC to
4oC. In this way, chiller is not very expensive and is affordable.
Figure 2 represents schematic diagram of energy
efficient mini milk pasteurization plant.

Figure 2: Energy efficient design
V. CALCULATIONS:
A. Pump:
In this project, two stain less steel electric pump is
used. One for pumping the raw milk from constant level tank
and second for evaporator. Due to the product characteristics,
special hygienic demands are placed on milk pump. The
product is highly perishable and must be protected from germs.
Generally stainless steel of 1.4404 is utilized as the preferred
material. The pumps should be self-draining and cavity-free so
that cleaning in the plant (CIP) is possible without dismantling.
It is also advantageous when a low surface roughness is ensured
[12].
Calculations are based on the basis of requirements [13]. To
obtain power requirement for pump, difference in potential
energy is to be calculated as:
∆𝑃 = 𝛿 × 𝑔 × ∆ℎ (1)
Here, 𝛿 is the density of liquid in kg/m3 ,∆ℎ is the maximum
head and 𝑔 is the gravity 9.8 ms-1 . Now the required power in
KW is calculated as
𝑃𝑢𝑚𝑝𝑖𝑛𝑔 𝑃𝑜𝑤𝑒𝑟 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑(𝐾𝑊) = 𝑄 × ∆𝑃 (2)
Here, 𝑄 is the flow rate in m3/sec, ∆𝑃 is calculated in equation
1. After the calculation, the used pump for 600 L/hr for 0.5m
head is 1.5 Hp.
B. Heat Exchanger:
In this plant, two plate heat exchangers are used. If we
increase the efficiency of plate heat exchanger then energy
consumption reduced and also it reduces the sterilization in
dairy industries [14]. Area of plates required in heat exchanger
can be calculated from the following equations [15].
𝑄 Here 𝑄 is the energy required in KW, 𝛿 is the density of liquid
𝐴= (3)
𝑈∆𝑇𝐿𝑀
Where:
Q = 𝑚𝐶𝑝 ∆𝑇 (4)
Here 𝑚 is the mass flow rate (kg/s), 𝐶𝑝 is the heat capacity of
milk (kJ/kg.K) and ∆𝑇 is the temperature difference (C°).
∆𝑇𝐿𝑀 is the log-mean temperature difference measured as
∆𝑇2 −∆𝑇1
∆𝑇𝐿𝑀 = ∆𝑇2 (5)
ln ( )
∆𝑇1
𝑈 is the Overall heat transfer coefficient.
After the calculations, required area for 600 L/hr is 40 ft 2 .A 2-
by-1 heat exchanger consisting of 20 plates is used.
C. Electric instant Heater:
Electric instant heater for proposed plant is used
which is to be placed just after the milk to milk heat exchanger.
Required power for electric heater can be calculated from the
equation 4. The required energy for a temperature difference of
10oC is 5 kwh for 600 L/hr.
D. Holding Tube:
The heated milk from electric heater output is passes
through holding tube. Holding tube should be well insulated so
that heat losses can be reduced. In holding tube, heated milk
remains at that temperature at which it is heated. The length of
the holding tube required to hold the milk for a period specific
period of time can be calculated by calculating the required
volume from equation 6.
𝑄 ×𝐻𝑇
𝑉= (6)
3600×𝑛
Where 𝑉 is the volume in litter or 𝑑𝑚3 , 𝑄 is the Flow rate of
liquid in Litter/Hour, 𝐻𝑇 is the required holding time in seconds
and 𝑛 is the Efficiency Factor. Length of the holding can be
calculated as
𝑉×4
𝐿= (7)
𝜋 ×𝐷2
Where , 𝐿 is the length of holding tube required in dm, 𝐷 is the
inside diameter of tube in dm, 𝑉 is the volume in litter or 𝑑𝑚3 .
For this plant of 600 litter per hour, the required holding tube
length is 10m and 1 inch diameter.
E. Chiller:
Required refrigeration tons for cooling of milk up to 4 oC can be
calculated as shown in equation 8 and 9.
Q = 𝛿 × 𝑉 × 𝐶𝑝 × ∆𝑇 (8)
at average temperature, 𝑉 is the volume flow rate in m3 /sec,
𝐶𝑝 is the heat capacity of milk (kJ/kg.K), ∆𝑇 is the temperature Cost analysis is carried out considering specific heat
difference (oC) of milk = 3.93 𝐾𝐽/𝑘𝑔 and density of milk = 1.03 𝑘𝑔/𝐿𝑡𝑟.
𝑄 If 75oC is achieved by using heat exchanger where milk is pre
𝑅𝑇 = (9) heated at 60oC. The required energy consumption of electric
3.517
heater is obtained by multiplying specific heat of milk, density
Here, 𝑅𝑇 is the required capacity of chiller in tons, 𝑄 is the of milk and difference of temperature = 3.93 × 1.03 × (75 −
KJ
energy required in KW. 60) = 60.7185 .
Ltr
From above equation, 5 tons chiller is need for this plant. 60.7185×600
For 600 litre per hour , Power consumption is =
3600
10.119 KW.
VI. CONTROL UNIT:
The control box is the main part of the plant and A. Without energy efficient method:
Programming Logic Controller (PLC) is the processing unit of
this control box. A PLC is basically a large microcontroller, its
working is same as microcontroller but its speed and Without the energy efficient method one pump of 1.5 ℎ𝑝 is
performance is high. In the proposed design, there are three required for pumping the raw milk and its power is 1.119 𝐾𝑊.
RTD PT-100 temperature sensors to measure the raw milk In old plants milk is to be cooled from 45 oC to 4oC directly
temperature, electric instant heater output temperature and which requires 18 ton chiller of 63.30𝐾𝑊. Here Total power
pasteurized milk temperature output after the holding tube. The required is 74.538 𝐾𝑊 (63.30 + 10.119 + 1.119). Cost per
𝐾𝑊
measured temperatures are feedback into the PLC, which make litter can be calculated as 74.538𝐾𝑊 ÷ 600𝐿𝑡𝑟 = 0.124 .
𝐿𝑡𝑟
decision on suitable control actions. Other components include Cost of electricity per tariff = 5.79 Rs [24]. Thus total cost of
the selector switch, on off LEDs and Human Machine interface 𝐾𝑊
electricity = 5.79 𝑅𝑠 × 0.1243 = 0.72 𝑅𝑠 𝑝𝑒𝑟 𝐿𝑖𝑡𝑟𝑒.
(HMI). HMI display the temperatures that are sensed during the 𝐿𝑡𝑟
process. Control box also include the magnetic connectors,
relays and circuit breaker. B. With energy efficient method:
VII. CASE STUDY:
To compute the cost of running system with using energy
In order to be a Service provider, four milk shops efficient system, cost of evaporator is added. Adding evaporator
located at Faisalabad, Punjab Pakistan are considered for the can reduce the required capacity of chiller from 18 tons to 5
case study. Table 1 shows the details of these shops. tons. Because evaporator can reduce the heat of milk from 45oC
to 25oC, however addition cost of pump will be added. Power
Table 1 : Milk Shops Surveyd
Shop Location Daily Milk Milk Chiller Gas Workers required of chiller for cooling from 25 oC to 4oC of 5 𝑡𝑜𝑛 is =
Name Consumption For
Boiling
Expense(Bill) Expense(Bill) Expense and
miscellaneous
17.58 𝐾𝑊. Here two pumps are required for pumping the raw
(liter) (liter) milk and for pumping the water in evaporator, so required
Medina Jaranwala 400 200 15000 25000/month 15000/month power for two 1.5 ℎ𝑝 pumps is = 2.238 𝐾𝑊. Hence total
Milk Road monthly/ 4.16 Rs/ltr 1.25 Rs/ltr
Shop 1.25 Rs/ltr required power is 29.9 𝐾𝑊 (17.5 + 2.238 + 10.19𝐾𝑊). Cost
𝐾𝑊
Gosia Tezab Mill 1000 400 50000/month 40000/month 80000/month per litter can be obtained as: 29.9 𝐾𝑊 ÷ 600 𝐿𝑡𝑟 = 0.05 .
Milk 1.67 Rs/ltr 2.78 Rs/ltr 2.67 Rs/ltr 𝐿𝑡𝑟
Shop
Asim Jinnah 1000 300 40000/month 25000/month 80000/month
The cost of electricity per tariff = 5.79 Rs [24].
𝐾𝑊
gujjer
Milk
Colony 1.33 Rs/ltr 2.78 Rs/ltr 2.67 Rs/ltr
Hence, total cost of electricity = 5.79 𝑅𝑠 × 0.05 =
𝐿𝑡𝑟
Shop
Ghousia Nazimabad 3000 500 1.5 lac/month 42000/month 180000/month 0.288 𝑅𝑠 𝑝𝑒𝑟 𝐿𝑖𝑡𝑟𝑒.
Milk 1.67 Rs/ltr 2.8 Rs/ltr 2 Rs/ltr
Shop

C. Savings:
From this analysis, their overall cost per liter is 7.5 𝑅𝑠 . From
energy efficient overall cost is 2 𝑅𝑠 𝑝𝑒𝑟 𝑙𝑖𝑡𝑒𝑟. By using evaporator, tremendous burden on chiller is
reduced. Hence cost on electricity is saved. Savings are
VIII. ELECTRICITY COST ANALYSIS: computed as: cost savings=per liter Rs of HTST-per liter Rs of
𝑅𝑠
Without energy efficient method, electric heater has to proposed method= 0.72 − 0.288 = 0.432 . Here per hour
𝐿𝑡𝑟
𝑅𝑠 𝑅𝑠
heat up the milk from 28oC to 72oC and chiller has to cool down saving is= 0.432 × 600 Ltr = 259.2 . If plant is
𝐿𝑡𝑟 𝐻𝑜𝑢𝑟
milk from 72oC to directly less than 10oC. But with energy
running for 12 hours a day then
efficient method electric heater has to heat up the milk from 𝑅𝑠
65oC to 75oC and chiller has to cool down milk from 26 oC to 𝑃𝑒𝑟 𝐷𝑎𝑦 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 = 259.2 × 12 = 3110.4
𝑑𝑎𝑦
directly 4oC because of the evaporator placed just before the 𝑅𝑠
𝐴𝑛𝑑 𝑝𝑒𝑟 𝑚𝑜𝑛𝑡ℎ 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 = 93,312
𝑀𝑜𝑛𝑡ℎ
chiller witch will reduce the temperature of the milk so that
And annually it saves 𝑅𝑠 1,119,744.
burden on chiller reduced. Cost analysis for both methods is
So by using energy efficient method, we can save more than
discussed in details below.
one million rupees.
So by using energy efficient method, we can save more than
one million rupees.
This analysis have been done by visiting different plants and
shops located in Faisalabad, Pakistan. Table:1 shows the places
that we have visited.
IX. CONCLUSION:
In this paper an energy efficient mini milk
pasteurization plant is presented. After the pasteurization
process milk can be stored for 21 days in refrigerator. Mini plant
consists of 2 stainless steel electric pumps, two heat exchangers,
holding tube, an evaporator and a chiller. This plant has the
capacity of 600 liters per hour. Calculation for all the required
components has been discussed in detail. After conducting a
survey in the city of Faisalabad, Pakistan, running costs of
different plant have been compared with purposed design. It is
concluded that using energy efficient design 1.1 million
annually can be saved. This cost is reduced by adding an
evaporator before chiller. Adding an evaporator reduces the
required capacity cooling system from18 tons to 5 tons.
X. FUTURE WORK:
Since the pasteurization can be used for other food
stuff like butter, cream etc. So team is hoping to install some
machines in the existing plant for the extraction of cream and
XI. REFERENCES
butter . An inspiration of our future work would be the packing
of milk in different size of pouches so that it can be delivered
reliably.

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