dairy factory
Dairy Factory Design

Dairy factory design - continued

MILK RECEPTION – example only

All tankers on entering the factory premises will pass over a weighbridge.
Milk reception will consist of 4 x milk unloading / loading bays, each with 30,000 liter per hour capacity feeding through a filter, air eliminator, chiller and flow meter (4 x independent but interlinked lines). Milk refrigeration capacity is based on 15°c milk in maximum temperature being reduced to <5c)

Tankers will unload and move to a separate location on site for CIP.

Milk will be pumped into one of 4 x 160,000 litre capacity raw milk silos (insulated + agitated) all silos will have agitation, temperature and level indication and alarm.

This line will also have the ability to circulate and cool the milk in the silos, cool milk, cream, concentrate or skim for dispatch in bulk or transfer to liquid plant.

All raw milk silos and lines will be cleaned using CIP

Silos and tanks are to be constructed locally with supplier to provide design and details of fittings

Staff working in this area will be required to follow a change procedure prior to entering the high-risk areas of the factory. (details)

Silo filling logic will automatically switch to the next available clean silo, if none selected then stop pump and sound alarm.

Processing
Milk will be pumped from any one of the raw milk silos to the separator balance tank (pump capacity 30,000 l/hr). With automatic change over selection when empty. The separator has a capacity to separate 30,000 liter per hour of liquid milk producing approximately 27,000 liter of skimmed milk and 3,000 liter of cream of 40% FAT. The milk is fed into a pre heater and heated to some 45°c prior to separation, the skim is pasteurized at min > 75°c 15 seconds (preferably 25 seconds) and cooled to less than 5°c and fed with one of 4 x 160,000 insulated, agitated skim silos.

Cream is pasteurised at some 85°c for 15 seconds (preferably 25 seconds) at 3,000 litres/hr. Fat percentage for butter making is 40% but other fat percentages are possible.

The cream is cooled to some 8°c and pumped into one of 2 insulated cooled and agitated tanks with level and temperature indication. The cream is aged prior to butter making and then fed into the butter maker. If cream is required for dispatch or for retail filling this should also be possible.

BUTTER MANUFACTURE

Cream at 8 to 10 degree c is taken from the cream storage tank by gravity to a 200 litre balance tank from where it is pumped by positive pump through a jacketed tempering line where the cream temperature can be raised or reduced by some 2°c as required by the butter making plant.

The butter maker speed can be adjusted to give the required body and texture and moisture content and also salt addition in the form of slurry takes place to give some 2% salt and 16% moisture. Butter passes to the 25 kg bulk butter packer where butter is filled into a polythene lined cardboard box, which is sealed with tape, passes through a metal detector and is date and batch coded, palletised and moved into the freezer using a hand pallet truck. 200 gm partion packing

  • CREAM CHEESE manufacture and packing - Details
  • Yogurt manufacture and packing – Details
  • Processed Cheese manufacture and packing – Details
  • Lactose manufacture and packing – Details
  • Whey manufacture and packing – Details
  • Milk Powder manufacture and packing – Details
  • Infant Formula manufacture and packing – Details
CONTROL Logic

It is envisaged that a central control room serving the processes will be the provided for the plant.

Milk reception control room.
Separation and pasteurization / UHT and packing local control.
Where practical data will be fed back to the main control room.

7. CIP
CIP 1 Raw milk tanks and lines
CIP 2 High-risk areas, processed milks and juices areas
CIP 3 Tanker wash
CIP 2 Butter
CIP Separation area will be integral
CIP UHT – integral
Evaporator – Integral
Spray Dryer – Use CIP 2 and allow for higher capacity
Bulk acid / caustic storage silos
Chemical storage area
Safety showers

8. Finished product storage - detailed design required
Butter freezer store sufficient for some 15 days at full production – 21c
Powder storage / finished goods – detail required

9. Dry goods storage – detailed design required
Sufficient for some 3000 pallets

10. Air filtration - detailed design required
Main factory air will be filtered, pressure controlled and temperature conditioned

11. Staff facilities - detailed design required

Canteen and toilets may be separate to the main building which will necessitate a change prior to entering or leaving the main production building.

Lockers and wash facilities provided in main factory building

12. Utilities - consumptions to be specified by supplier
Boilers
Air
Water
Ice water
Waste water
Electricity
Nitrogen (Aseptic)
Gas
Oil

Further areas requiring detailed consideration
  • Grounds / parking etc
  • Administration buildings / offices – staffing plan
  • Sales and Marketing
  • Packing lines
  • Distribution
  • Milk collection / contracts
  • Staffing / recruitment plan
  • Product costing
  • Purchasing
  • Laboratory
  • Engineering / maintenance
  • Production and planning
  • Accounting
  • IT / communication
  • HR

For more information or to discuss your requirements please contact us.

button1
Contact John Watson

John Watson
Office: +44 1224 861 507
Mobile: +44 7931 776 499
jw@dairyconsultant.co.uk

Testimonials

We are a longstanding member of the Society of Dairy Technology and have Fellowship of the Institute of Food Science and Technology.

 

Dairy Consultant Locations
Copyright © 2017 - JWC Services Limited Registered in Scotland No. SC246124