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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ICE CREAM !!! PROFITABLE BUSINESS_SMALL SCALE ICE CREAM PRODUCTION PLANT 100LPH

PROCESS EQUIPMENT FOR ICE CREAM PRODUCTION

SMALL SCALE START UP

• ·   2 numbers of 100l ice cream mix preparation & batch pasteurization tanks with all accessories. 
• ·         Liquid milk will be provided to the mix preparation tank & will heat up to 80 Degree C.
• ·         The powder, sugar ingredients will be added by the same mixing tank.
• ·         Ice Cream Mix homogenizer
• ·         Ice cream aging Tanks
• ·         Flavor Addition Tanks
• ·         Ice cream Mix Freezer.
• ·         Ice cream filling machine

"INVEST A AROUND 65LAKH FOR A HIGH QUALITY ITALIAN ICE CREAM PROCESS LINE FOR ABOVE CAPACITY "

Investment Required

Infrastructure

Financial Assistance

Business Insurance

Licenses and Incorporations
 Most of the processed food items are exempt from the purview of licensing under the Industries (Development and regulation) Act, 1951. Items reserved for small-scale sector and alcoholic beverages are an exception.
 Automatic approval for foreign equity of up to 100 percent is available for most of the processed food items. Approval for alcohol, beer and items reserved for small-scale sector is subject to certain conditions.
 Food processing industries are included in the list of priority sector for bank lending.
 Excise duty on processed fruit and vegetables has been brought down from 16 percent to zero level in the Budget of 2001-2002.
 Income tax holiday and other concessions have been announced in the Budget of 2004-2005 for certain food processing sectors.
 Licensing powers have been delegated to regional offices under Full Product Order, 1955.

Basic needs
 Sales tax registration—VAT No.
 PAN card for the business.
 Trade license.
 Food license from the health department.

Competition
The food processing sector is a highly fragmented industry. Many entrepreneurs in this industry are small in terms of production and operations and largely concentrated in the unorganized segment. This segment accounts for more than 70 percent of the output in terms of volume and 50 percent in terms of value.

Though the organized sector seems comparatively small, it is growing at a very fast pace. For a first generation entrepreneur to succeed, it’s critical to find the product gap in the market, offer differentiated products and packaging, and distribute and visualize. With the advent of organized retail, there is better opportunity to place the product closer to the consumer.

Word of mouth and first few happy customers/retailers will be the biggest advertisers. Attention to detail and listening to them will determine the success rate. While newspapers, radio and television will spread awareness about the product quickly, having a website
and a page on Facebook is a must. However, nothing can match ground promotion and product trials at outlets.

You Must Know
 All India Food Processing Association.
 Food Safety and Standards (Food Import) Regulations, 2011.
 Draft Food Safety and Standards Regulations, 2010.
 Manuals of methods of analysis for different food products.
 Standard for potable water.
 Food Safety and Standards Rules, 2011.
 Highlights of Legal Metrology Act, 2009.
Legal Metrology (Packaged Commodities) Rules, 2011.
 Plastic Waste (Management and Handling) Amendment.

Rules 2011
Gestation period for setting up a food processing unit is around six months to a year. It takes about three years to break even EBIDTA.
With an investment of Rs.20 to 40 lakh, a unit can generate a revenue of about Rs.1-5 crore in three to five years. Net profit of 10-15 percent can be expected during the initial period.

I

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ASEPTIC AND NON 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)

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SHELL & TUBE HEAT EXCHANGER_DAIRY APLICATION

Shell and Tube Heat Exchangers are one of the most popular types of exchanger due to the flexibility the designer has to allow for a wide range of pressures and temperatures
A shell and tube exchanger consists of a number of tubes mounted inside a cylindrical shell.  illustrates a typical unit that may be found in a petrochemical plant. Two fluids can exchange heat, one fluid flows over the outside of the tubes while the second fluid flows through the tubes. The fluids can be single or two phase and can flow in a parallel or a cross/counter flow arrangement.

The shell and tube exchanger consists of four major parts:

• Front Header—this is where the fluid enters the tubeside of the exchanger. It is sometimes referred to as the Stationary Header.
• Rear Header—this is where the tubeside fluid leaves the exchanger or where it is returned to the front header in exchangers with multiple tubeside passes.
• Tube bundle—this comprises of the tubes, tube sheets, baffles and tie rods etc. to hold the bundle together.
• Shell—this contains the tube bundle.
  
  
  
  
  
  
  
  
  
  

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5S -LEAN METHODOLOGY FOR BETTER WASTE MANAGEMENT & WELL ORGANIZATION

A corporation is a living organism; it has to continue to shed its skin. Methods have to change. Focus has to change. Values have to change. The sum total of those changes is transformation

The most dangerous kind of waste is the waste we do not recognize

Continuous improvement is not about the things you do well — that’s work. Continuous improvement is about removing the things that get in the way of your work. The headaches, the things that slow you down, that’s what continuous improvement is all about

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