Dairy Plant

Plant Process Overview:

The production begins with the reception and storage of raw milk, which is collected from local dairy farmers. The milk is then rapidly cooled and stored in bulk milk coolers and storage tanks. Afterward, the milk undergoes pasteurization, a process that eliminates harmful pathogens, ensuring the safety of the product.

Following pasteurization, the milk is processed into various products like paneer, cheese, butter, and ghee through specialized processes such as coagulation, churning, and clarification. For curd and yogurt production, the milk is fermented in a controlled incubation environment, creating a smooth and consistent product.

Once the products are processed, they are packaged using automated filling and sealing systems for retail distribution. Finally, the finished dairy products are stored in both hot and cold storage rooms to preserve their quality and flavor before they are delivered to consumers.

Equipment Specifications

1. Milk Storage & Cooling System:

Bulk Milk Cooler (BMC)

    • Capacity: 1,000 – 5,000 liters.
    • Cooling Range: 37°C to 4°C.
    • Material: Food-grade stainless steel.
    • Cooling Method: Plate heat exchangers for rapid cooling.
    • Features: Automatic milk temperature control, alarm system for temperature deviation, and easy-to-clean surface.

Storage Tanks

    • Capacity: 1,000 to 10,000 liters (depending on the size of the batch).
    • Material: Insulated stainless steel.
    • Temperature Control: Insulation with refrigeration for maintaining milk at 4°C.
    • Features: Hygienic design, easy-to-maintain components, and a built-in cleaning system (CIP).

2. Paneer Making System:

Milk Pasteurizer

    • Capacity: 1,000 to 5,000 liters per hour.
    • Temperature Control: Adjustable, typically 85-90°C.
    • Material: SS304 or SS316 (food-grade stainless steel).
    • Features: High-efficiency heat exchangers, fully automatic control system for temperature and time.
    • Additional Feature: Heat recovery system for energy savings.

Paneer Pressing Machine

    • Capacity: 50-200 kg of paneer per batch.
    • Pressure System: Hydraulic or pneumatic with adjustable pressure.
    • Material: Food-grade stainless steel.
    • Features: Uniform pressing, adjustable pressure, minimal manual intervention.

Paneer Molding & Cutting System​

    • Mold Size: Adjustable to different block sizes.
    • Cutting Mechanism: Automatic cutting with precision blades.
    • Material: Stainless steel and high-quality food-grade plastics.
    • Features: Easy operation, consistent product shape, low maintenance.

3. Cheese Making System

Milk Pasteurizer

    • Capacity: 1,000 to 5,000 liters per hour.
    • Temperature Control: Adjustable (85-90°C).
    • Features: Automated cleaning system (CIP), energy-efficient heat exchangers.

Cheese Vat

    • Capacity: 500 – 2,000 liters.
    • Temperature Control: 30-35°C for coagulation.
    • Material: Stainless steel with a smooth surface.
    • Features: Mechanical stirrer for curd formation, automatic agitation, precise temperature control.

Curd Cutting Machine

    • Capacity: Cuts curd into 5-25mm cubes.
    • Material: Stainless steel blades and frame.
    • Features: Adjustable blade size, quick operation, easy maintenance.

Curd Stirring & Whey Draining System​

    • Capacity: 1,000 – 5,000 liters per batch.
    • Features: Continuous stirring for even curd texture, automatic whey separation, hygienic design for easy cleaning.

Cheese Press

    • Pressure Range: 0 to 150 kg per block.
    • Material: Stainless steel with adjustable plates.
    • Features: Hygienic design, easy-to-adjust pressure, robust construction.

4. Butter Making System

Milk Separator

    • Capacity: 1,000 – 5,000 liters per hour.
    • Features: Continuous cream separation with high efficiency, low energy consumption, food-grade stainless steel.
    • Adjustable Cream Separator: To separate cream content for butter production.

Butter Churner

    • Capacity: 100 – 500 liters per batch.
    • Material: Stainless steel.
    • Features: Fully automated churning process with adjustable speeds, designed for continuous butter production.

Butter Salt Mixing Machine

    • Capacity: 10 – 50 kg per batch.
    • Features: Consistent salt distribution, hygienic design, easy-to-clean components.

5. Ghee Making System

Ghee Boiler

    • Capacity: 100 – 500 kg per batch.
    • Heating System: Steam or electric heating for uniform clarification.
    • Material: Stainless steel with thermal insulation.
    • Features: Adjustable heat settings, built-in stirring mechanism to prevent scalding.

Clarification Tank

    • Capacity: 50 – 200 liters.
    • Material: Stainless steel.
    • Features: Insulated, with temperature control to maintain ideal cooling conditions.

6. Khuwa (Khoya) Ketlee System

Khuwa Making Vessel (Khoya Ketlee)

    • Capacity: 100 – 500 liters per batch.
    • Material: Stainless steel.
    • Features: Efficient heat distribution, temperature control system for evaporation.

Stirring System

    • Capacity: 100 – 500 liters per batch.
    • Material: Stainless steel with high-temperature resistance.
    • Features: Automated stirring for even evaporation, speed control for uniform consistency.

7. Sweet and Plain Curd Making System

Yogurt Incubation Tank

    • Capacity: 100 – 1,000 liters.
    • Temperature Range: 40-45°C.
    • Material: Stainless steel.
    • Features: Precision temperature and time control for consistent fermentation.

Yogurt/Curd Filling Machine

    • Capacity: 500 – 2,000 cups per hour.
    • Material: Stainless steel with food-grade plastic parts.
    • Features: Automated portioning, sealing, and labeling.

8. Hot and Cold Storage Rooms

Cold Storage Room (4°C)

    • Capacity: 5,000 – 20,000 liters of dairy products.
    • Cooling System: High-efficiency refrigeration.
    • Temperature Control: Precise control for maintaining 4°C.
    • Features: Humidity control, adjustable shelves, insulated structure.

Hot Room (35-45°C)

    • Room (35-45°C):
    • Capacity: 2,000 – 10,000 liters.
    • Heating System: Electric or steam heating system.
    • Features: Temperature and humidity control, proper ventilation.

9. Other Auxiliary Equipment

Milk Transfer Pumps

    • Capacity: 1,000 – 5,000 liters per hour.
    • Material: Stainless steel with food-grade materials.
    • Features: Adjustable flow rate, easy to maintain.

Filtration System

    • Type: Multi-stage filtration system.
    • Features: High-efficiency filters, replaceable cartridges, low maintenance.

Automated Packaging System​

    • Capacity: 500 – 5,000 units per hour (depending on the product).
    • Features: Automatic sealing, labeling, and packaging with high-speed operation.

10. Cleaning and Sanitation Equipment

CIP (Clean-in-Place) System

    • Capacity: 1,000 – 5,000 liters per cycle.
    • Features: Automated cleaning and sanitizing for tanks, pipes, and equipment.
    • Efficiency: Uses hot water and chemicals for cleaning, ensuring no manual intervention.

Sterilizer for Equipment

    • Temperature Control: 80-90°C for effective sterilization.
    • Features: Quick sterilization cycle, minimal water usage.
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