POSITIVE PRESSURE MONITORING IN DAIRY PROCESSING/PRESSURE MONITORING/DIFFERENTIAL PRESSURE MONITORING/CPM VALVES/CONSTANT PRESSURE MODULATOR

POSITIVE PRESSURE MONITORING

THE PASTEURIZER/STERILIZER IS THE HEART OF  MILK PROCESSING,IN ORDER TO MAINTAIN QUALITY IN PROCESSING THE EQUIPMENT SHOULD BE DESIGNED IN WAY THAT THE PRODUCT SHOULD BE TREATED IN SAFER WAY.

THE HEAT TREATMENT AND COOLING IN PASTEURIZER/STERILIZER IS DONE BY INDIRECT HEATING AND COOLING THROUGH DIFFERENT TYPE OF HEAT EX CHANGER, (TUBE  IN TUBE/PLAT,ETC)

IN HEAT EX-CHANGER THE HEAT OF MEDIA LIKE HOT WATER/STEAM/COOLING WATER/COLD WATER/CHILLED WATER/BRINE WATER ETC WILL TRANSFER TO PRODUCT LIKE LIQUID MILK/SOYA MILK/ICE CREAM MIX ETC,INDIRECTLY

THEIR IS AN INCREASED CHANCE FOR MIXING THE MEDIA IN TO  PRODUCT THAT LEAD TO BE POOR PRODUCT QUALITY OR STERILITY.

HERE WE HAVE SOLUTION FOR MONITORING THEES POSSIBILITY, AS LIQUID WILL FLOW FROM HIGH PRESSURE REGION TO LOW PRESSURE REGION.

KEEPING A HIGHER PRESSURE ALWAYS IN PRODUCT SIDE THAN MEDIA IS THE BEST PRACTICE AND CONTROL STRATEGY.


"MAINTAINING THE POSITIVE PRESSURE IN PRODUCT SIDE THAN MEDIA OR IN CASE OF REGENERATION SECTION PROCESSED MILK AND UNPROCESSED MILK  IS CALLED POSITIVE PRESSURE MONITORING"

There are two different types of construction for  Constant Pressure Modulating valves.

The CPMI-2 and CPMO-2 valves consist of a valve body with valve seat, cover, a

valve plug with a special diaphragm and a clamp. The diaphragm consists of two flexible EPDM diaphragms supported by 12 stainless steel sectors in between them.

The cover and the valve body are clamped together. The valve body and the seat are welded together.

The CPM-I-D60 consists of a CPMI-2 valve with additional piping.

Operating principle

The CPMI-2, CPMO-2 and CPM-I-D60 valves are controlled remotely by means of compressed air. The valves operate without a transmitter in the product line and only require a pressure-

regulating valve for the compressed air and a pressure gauge in the product line (see below).

Where modulating back pressure is required (i.e., to maintain a fixed flow in and out of the CPM valve), the air supply to the valve can be provided by an I/P converter (typically 3-15 psi) and a booster valve. The product pressure dictates the pressure ratio of the booster valve.

A diaphragm reacts immediately to any alteration of the product pressure and changes position so that the preset pressure is maintained.

Inlet side: The Constant Pressure Modulating Inlet (CPMI-2) valves and the Constant Pressure Modulating Inlet D60 (CPM-I-D60) valves maintain constant pressure in the process line at the inlet sid

e of the valve. CPMI-2 and CPM-I-D60 open when product pressure increases and close when product pressure decreases. These are often installed downstream from separators and heat

exchangers, and may also be used as overflow valves.

Outlet side: The Constant Pressure Modulating Outlet (CPMO-2) valves maintain constant pressure in the process line at the outlet side of the valve. CPMO-2 closes when product pressure increases and opens when product pressure decreases (see illustration below). It is often installed upstream from pasteurizers, separators and filler systems of filtration units.

Options

·         Fittings in accordance with required standard

·         Air pressure regulating valve kit, 0-8 bar

·         Diaphragm in PTFE covered in EPDM or PTFE

·         Seals in NBR, FPM or PTFE

·         Air throttling valve for adjustment of regulating speed for the CPM-2 valve

·         Booster for product pressure exceeding the available air pressure (Product pressure = 1.8 x air pressure)

3A version available on request for CPMI-2 and CPMO-2 valves only 

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INDIA CHEESE INDUSTRY/INDIAN CHEESE/CHEESE EATING/CONSUMPTION PATTERN

The Indian Cheese Industry

Except for the popular Indian variety of cottage cheese-Paneer, India is not traditionally a 'cheese nation'. Why then are we doing this report on the Cheese Industry in India? The reason is this - with the growing saturation of cheese consumption in the West and encouraging successes in other 'non-cheese' Asian countries like Japan and China; overseas cheese producers are eyeing the Indian market for its huge promise.
The organised cheese industry in India is at best in its nascent stage, accounting for under 1% of total dairy production and largely limited to urban consumption. Though cheese was first marketed under the brand name 'Amul', from the popular Amul butter stable in the late 1970s, it attained an

identity of its own only as late as 1990s.
The organized cheese industry in the country as of 2006, is valued at Rs 250 crore (US$ 50 million), with a volume in excess of 8000 tonnes. The industry growth rate is estimated at about 10%-12% per year in terms of volume and 16%-17% per year in value terms. Current household cheese penetration is 5%, with about 50% of consumption being limited to cities. Mumbai and Delhi together capture half of the cheese market. Within cheese products, around 60% of the market is dominated by processed cheese, 30% by cheese spreads and the remaining 10% by flavoured and specialty cheese.

here have been two significant changes in consumption patterns, affecting each end of the spectrum. In the mass consumption category,

Indian consumers are more ready to buy off the shelf. Paneer, which all the major cheese producers are marketing as a branded product, was traditionally home made. Secondly, with greater international exposure, rising incomes and brand affiliation; the demand for niche cheese products has increased. Amul was an early mover in capitalizing on the demand for specialized cheeses like Gouda and Emmental. However, cheese consumption continues to be an urban phenomenon, with processed cheese and cheese spreads accounting for about 80% of the total cheese consumption. Also, cheese is mostly consumed by children and is yet to be part of the mainstream adult diet on a mass scale.

Increasing and Widespread Demand
Based on a multi-year study of dairy consumption patterns in China, Mckinsey predicts a growth in the demand for Cheese by 40% by 2011. With India having similar consumer trends- namely, growing incomes, westernization and urbanization - Indian demand is likely to mirror Chinese patterns. Two conspicuous

outcomes are: i) There is likely to be a 25%-30% increase in demand in the metros and ii) There is likely to be a 5%-10% growth in demand in tier 2 cities as urbanization and modern consumption patterns extend to these cities.
In the past couple of years, for example, Mother Dairy has already been pursuing aggressive advertising strategies. One successful promotion in Delhi and Mumbai was the "Cheese khao superhero ban jao" (Eat Cheese to become a Superhero) event, where kids buying cheese at retail outlets were invited for a photo- op - dressed as superheros with a framed photograph presented to them. Another, helped the company bond better with its retailers. In November 2005, retailers in Delhi displayed banners proclaiming, "Cheese ke saath bees ki cheez" (Buy Cheese and get Rs. 20 worth of freebies), a proposal where, if a consumer bought Mother Dairy cheese, the retailer would offer her free purchases worth Rs 20 from the store. Both these innovative campaigns were hugely successful in brand awareness and sales.
'Indianization' of processed cheese
Dabon, in acknowledgement of customer preferences for indegenous cheese, has customized their portfolio to include paneer.
The next three years will see new Indian flavours of cheese being introduced in the processed cheese and

cheese spread market. The Indian consumer has unique tastes with variations even across regions. Both Indian and International brands are likely to 'Indianize' their cheese products with Indian flavours to attract a larger customer base.
Consumption Patterns
The product mix and consumption pattern is unlikely to change drastically in the next few years. The largest

demand will continue to be for processed cheese and cheese spreads. Children will continue to be the largest consumers of cheese.
Of the predicted increase in demand, children will contribute to the largest proportion in tier 2 cities while it will be adults in the metros. To cater to this increase, it is also likely that cheese producers introduce new varieties of specialty cheese in the metros.

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ENJOY CHEESE../MOZZARELLA/PIZZA CHEESE/PROCESSED CHEESE/CHEDDAR CHEESE/CREAMY CHEESE/STRING CHEESE/RICCOTTA

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UHT PLANT/ASEPTIC STERILIZER/ASEPTIC HOMOGENIZER/DEGASER/ASEPTIC TANK/CIP/SIP/HOW/WHAT/variable capacity/ASEPTIC PROCESS/ASEPTIC FILLING

The UHT treatment (Ultra High Temperature) is a modern and innovative technological process that consists in carrying a foodstuff fluid to a high temperature and after a short holding time cooled quickly up to room temperature.The product, sterilized, is then filled in aseptic conditions with use of Aseptic pouch filling machines
So treated products keep freshness, taste, and nutritional value similar to the fresh products but with the very great advantage that can be kept at room temperature forconservancies. 

A UHT LINE CONSIST OF 

1.RAW MILK RECEPTION DOCK

2.RAM MILK STANDARDIZATION UNIT

3.ASEPTIC STERILIZER

4. ASEPTIC/NON ASEPTIC HOMOGENIZER

6.DEGASER WITH AROMA RECOVERY SET UP

7.ASEPTIC TANK

8.ASEPTIC FILLING MACHINE

RAW MATERIALS/UTILITY REQUERD 

1. FILM FOR FILLING MACHINE(MATERIAL&TYPE SUITABLE FOR SHELF LIFE OF PRODUCT REQUIRED),

2.SATURATED STEAM,

3.COOLING TOWER WATER,

4.CHILLED WATER,

5.COMPRESSED AIR

6.RO WATER,

7.HYDROGEN PEROXIDE

8.ELECTRIC CITY

A.WHAT IS ASEPTIC STERILIZER

(Example of a Indirect heating uht sterilizer for Milk)

Sterilization Temperature :140Deg.C
Holding Time :4s
Capacity of sterilizer can be variable but the maximum and minimum should be fixed and pre designed,
advanced sterilizers are multy product treatment ,with fully automated instrumentation included holding time and capacity variation & Positive pressure measurement and control.

• Milk
• Cream
• Vla
• Custard
• Pudding
• Soft ice mix
• I ce cream mix
• Condensed milk
• Baby food
• Processed cheese

• Sauces

The thermal treatment in corrugated tubular steriliser is very quick and effective, since

the corrugated tube heat exchangers increase the thermal transference coefficient reducing

the required time for the thermal process.

This process make easier the elaboration of a much more natural product, avoiding the thermal

degradation and keeping the properties of the product.

Advantages

• Less vulnerable to fouling giving long production runs

• High operating pressures are acceptable

• Processes products with fibres and particulates

• Processes high viscosity products

• Low shear characteristics for cream

• Low requirement for gasket material and easy gasket exchange

• Very robust design

• Low maintenance costs

• Can be designed as a multi-purpose plant

B.ASEPTIC HOMOGENIZER

  LOCATION OF HOMOGENIZER VARIES WITH EACH SYSTEM, BUT IN UHT PROCESS THERE ARE MAY BE AN ADVANTAGE AFTER HEATING.

  HOMOGENIZATION CAN BE CARRIED OUT BEFORE AND AFTER THE UHT HEATING.

 IF AFTER ARRANGEMENT IS ADOPTED, HOMOGENIZATION WILL COST MORE SINCE THE PROCESS CARRIED OUT ASEPTICALLY.

IT PREVENTS OR REVERS PROTIEN –PROTIEN AND FAT GLOBULE –PROTIEN AGGREGATION.IT ALSO RETRAVES THE FORAMATION OF SEDEMENTS OF HEAT PRECIPITATED PROTIEN.

 ALSO IT IS ADVANTAGEOUS TO HOMOGENIZE THE PRODUCT AFTER STERLIZATION SINCE THIS ORDER PROVIDES ADDED HEAT STABILIT Y TO THE PROTIEN SYSTEM.

 WHEATHER OR NOT HOMOGENIZER IS BEFORE OR AFTER THE HEATING SECTION THE MILK IS HOMOGENIZED IN THE SAME TEMPERATURE RANGE 70-80deg.C (158-185F)

http://milkyworlds.blogspot.in/2014/08/aseptic-and-non-aseptic-homogenizer.html

(Example:UHT PLANT BY REDA.S.p.A Itali,Including Sterlizer,Homogenizer,Degaser & Aseptic Tank,M/S Repute India is the Indian agent)

C.DEGASER

Vacuum Degasser
The vacuum degasser is an indispensable device in juice, milk and tea drink production line. It’s mainly used to degas for products after homogenizing in vacuum state. Thus can prevent fruit juice oxidization and extend fruit juice storage life 

Vacuum Degasser Features
• Vacuum degasser working hours and period can be adjusted as required

• Several vacuum degassers can operate together in parallel
• Convenient installation, full-automatic working
• High corrosion resistance and security
• Minimal moving parts for reliable operation
• Unique design assures reliable continuous operation
• Easy maintenance and service

Effects of Vacuum Degasser
1. The vacuum degasser can remove the air (mainly oxygen) from the feed liquid, to restrain oxidization of pigment, vitamin, flavoring component and other materials, keep the product quality; 
2. To dislodge particle gas that adhere to feed liquid, stop the float of fine particles, keep the good appearance; 
3. To decrease foaming influence to sterilization in filling or high temperature sterilization process; 
4. To reduce corrosion of container internal surface.
C.ASEPTIC TANK

As an asecptic tank unit, the sterile tank is the link between process and packaging. The sterile tank guarantees a consistent product quality over the entire production time, since multiple heating of the product due to production stop or capacity failure on the filler lines can be avoided. Another advantage is, that the sterile intermediate storage of the aseptic product ensures the non-stop production of the filler lines even during CIP operations carried out on the process equipment. 
Depending on the production volume, tank capacities are available from 500 l to 100.000 l. Sterile tank units allow for aseptic, flexible connections of one or more process lines and packaging lines, so that different products can be filled at the same time without manual coupling

C.ASEPTIC PROCESS AND ASEPTIC FILLING

Aseptic packaging systems fill sterile product into sterile packages within the confines of

the sterile zone of the filler. The aseptic zone/sterile zone extends from the point where sterilized

packaging enters the sterile zone to where the sealed package is evacuated. Common attributes to

all aseptic packaging systems include:

1. The sterile product, sterile package, and sterile zone prevent post-processing

contamination.

2. The food contact surfaces of the package are sterile.

3. Product is filled aseptically into the package.

4. Packages are sealed hermetically.

5. Automation exists in monitoring and controlling the critical points

RELEVANCE OF ASEPTIC PROCESS?

 The demand for ultra high temperature processed and aseptically packaged dairy foods is growing throughout the U.S. The technology provides value-added food preservation for many foods including flavored milks, puddings, custards, creams, ice-cream mixes, whey-based drinks, sports drinks, and yogurt. Ultra high temperature nonfat milk, milk, light cream, and 18% cream are used throughout the U.S. by the restaurant and food service industries. There are several advantages to aseptic processing and packaging over traditional pasteurization. Advantages include extended shelf life, lower energy costs, and the elimination of required refrigeration during storage and distribution. Challenges are present in all aspects of dairy

processing. Major challenges associated with ultra high temperature processing and aseptic packaging of dairy foods include product quality loss, such as age gelation, fat separation, and flavor loss, as well as manufacturing issues such as limited production capacity, potential contamination, slow packaging speeds, and limited shelf life knowledge.

EFFECT ON FLAVOR AND AROMA!!

Less severe

Natural flavors and aromas of mlk, juices and vegetables are better maintained

EFFECT ON NUTRITION!!

Minimal nutritional losses

Heat and vegetables lose thiamin and pyridoxide(other vitamins are not really affected)

There are several advantages to aseptic processing and packaging over traditional

pasteurization. Advantages include extended shelf life, lower energy costs, and the elimination of

required refrigeration during storage and distribution. Challenges are present in all aspects of

dairy processing. Major challenges associated with ultra high temperature processing and aseptic

packaging of dairy foods include product quality loss, such as age gelation, fat separation, and

flavor loss, as well as manufacturing issues such as limited production capacity, potential

contamination, slow packaging speeds, and limited shelf life knowledge. 

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INDIA MOVES TO ROBOTICS DAIRY PLANT!!

ROBOTICS DAIRY PLANTS

India’s first robotic dairy plant was opened in Virar, in suburban Mumbai, today by Amul Dairy, the largest food brand in India for milk and milk products.

The Kaira District Co-operative Milk Producers Union Limited, known generally as Amul Dairy, launched the Virar plant, the sixth facility for Amul in the country, on the birth anniversary of Sardar Vallabhbhai Patel, India’s first home minister.

Built with a total investment of Rs1.8billion (Dh108million), the Virar plant, with an installed capacity of 1 million litre of milk processing per day, covers an area of 4.5 hectare and is the first across the globe with a fully automatic traffic management system for milk packing operations.

Its many firsts in India include a 50,000 litre/hour integrated milk reception facility, energy conservation by utilisation of hot water generator and water conservation through introduction of rain water harvesting system.

LOOKING FOR AN AUTOMATED PRODUCTION LINE?

Equipped with the largest ice cream manufacturing facility in the country — at 200,000 litres per day— Amul will ensure Mumbai doesn’t run short of ice cream in summer.

Operations such as conveying of crates, packed pouches from high-speed packing machines and filling of pouches in crates are fully automated and controlled through a centralised computer monitoring system. The high-speed packing machines have been integrated with online check weighers and robotic operations to avoid human touch of products.

           COMPLETELY  AUTOMATED  PRODUCTION             INCLUDES INTERMEDIATE CLEANING AND STERILIZATION WITHOUT HUMAN INTERFACE.  

FOR ADVANCED AUTOMATED,ROBOTIC DAIRY PLANTS

(Eg.One of REPUTED process equipment manufacturer

visit:http://www.reputeindia.com)

    

        

[SPECIAL THANKS:

 Mr.Sunil Paul,Robotics expert from India,My Teacher ,CEO of Techjeeva,who brings many people includes me to ' think different than syllabus,the result many of my colleges and others in front line of technical squad for many organization like Kukka Robotic System.Thank you sir for introducing ROBOTICS] 

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MOZZARELLA CHEES SPREAD AT_UAE_USA_INDIA/HOW TO START A CHEESE PLANT/WHAT IS CHEESE/COST OF CHEESE PLANT

MOZZARELLA CHEESE SPREAD AT_UAE_USA_INDIA

1000L COW MILK    =100KG OF CURD=120KGOF MOZZARELLA

Mozzarella cheese is a mild flavoured and unripened variety of cheese. The origin of the mozzarella cheese is Italy and it was traditionally manufactured from buffalo milk. But the manufacture of mozzarella cheese is now spread throughout the length and breadth of the Europe and USA and modifications have been made to produce the mozzarella cheese from cow milk.

The mozzarella belongs to the pasta-filata class of cheese. It involves the technique of stretching the curd under hot water to get a smooth texture and stringiness in the end product. Hence, this type of cheese possesses good melting and stretching properties. It is one of the best options for producing pizza

Cheese contains calcium, protein, and phosphorus in large quantities because of the cheese is concentrated milk.

Protein content in 100 grams of cottage cheese can provide the daily needs of 25%. Amino acid profile is also complete the sort of BCAAs (Isoleucine, leucine, and Valine) that play a role in the synthesis of protein for building muscle tissue, metabolism of body cells, and bone.  Rich useful riboflavin helps metabolize carbohydrates and maintain healthy mucous membranes.  Rich in vitamin B12 and folic acid are beneficial in the cheese helps DNA synthesis, cell maturation of red blood cells and maintain nerve function.  Rich in vitamin B6 which helps the metabolism of amino acids and fats, maintain the nervous system and skin health.  Rich in vitamin A are important for the sense of sight, skin, surface tissue, and protection against infection.  Selenium-rich essential for synthesis of an antioxidant enzyme  Useful phosphorus-rich as the formation of ATP for energy production, bone and teeth formation, and acid base balance.  Rich in calcium is important for the formation of bones and teeth, blood clotting in the wound, maintaining nerve function, muscle, and heart rhythm  Some studies also show if the consumption of cheese can prevent tooth decay.  Cheese also contain tryptophan, a type of amino acids that can relieve stress and help you sleep.  Calories and carbohydrates are also very low making it suitable as a diet food. Except for the popular Indian variety of cottage cheese-Paneer, India is not traditionally a 'cheese nation'. Why then are we doing this report on the Cheese Industry in India? The reason is this - with the growing saturation of cheese consumption in the West and encouraging successes in other 'non-cheese' Asian countries like Japan and China; overseas cheese producers are eyeing the Indian market for its huge promise. The organised cheese industry in India is at best in its nascent stage, accounting for under 1% of total dairy production and largely limited to urban consumption. Though cheese was first marketed under the brand name 'Amul', from the popular Amul butter stable in the late 1970s, it attained an identity of its own only as late as 1990s. The organized cheese industry in the country as of 2006, is valued at Rs 250 crore (US$ 50 million), with a volume in excess of 8000 tonnes. The industry growth rate is estimated at about 10%-12% per year in terms of volume and 16%-17% per year in value terms. Current household cheese penetration is 5%, with about 50% of consumption being limited to cities. Mumbai and Delhi together capture half of the cheese market. Within cheese products, around 60% of the market is dominated by processed cheese, 30% by cheese spreads and the remaining 10% by flavoured and specialty cheese. here have been two significant changes in consumption patterns, affecting each end of the spectrum. In the mass consumption category, Indian consumers are more ready to buy off the shelf. Paneer, which all the major cheese producers are marketing as a branded product, was traditionally home made. Secondly, with greater international exposure, rising incomes and brand affiliation; the demand for niche cheese products has increased. Amul was an early mover in capitalizing on the demand for specialized cheeses like Gouda and Emmental. However, cheese consumption continues to be an urban phenomenon, with processed cheese and cheese spreads accounting for about 80% of the total cheese consumption. Also, cheese is mostly consumed by children and is yet to be part of the mainstream adult diet on a mass scale. Towards the end of the review period as the economy of the United Arab Emirates recovered from the economic crisis, there was an increase in immigration from Europe and North America which fuelled demand for premium, European unpackaged hard cheese such as Parmesan, Cheddar and Gouda. Consumers from these locations are accustomed to consuming these types of cheese in their home countries and they have the disposable income to purchase these imported products in the United Arab Emirates. Thus, unpackaged hard cheese was one of the two strongest categories of cheese in terms of current retail value growth in 2013, with growth of 8%. This strong growth was supported by the wide product portfolio in unpackaged hard cheese offered in hypermarkets and supermarkets in the United Arab Emirates. The cold chain distribution and current retail value sales of these retailers increased in 2013 due to the expansion of cheese counters in these outlets. LOOKING FOR A BEST QUALITY CHEESE PLANT??? INVEST 65LAKH..LOOK FOR AN ITALIAN CHEESE PROCESSING EQUIPMENT MANUFACTURER & HAVE THE BEST CHEESE VISIT:http://www.reputeindia.com/cheese-processing-plant.html

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