KITs COLLEGE OF ENGINEERING

An
INDUSTRIAL TRAINING REPORT
AT
KOLHAPUR ZILLA SAHAKARI DUDH UTPADAK SANGH LTD.
GOKUL
SUBMITTED TO THE
SHIVAJI UNIVERSITY, KOLHAPUR
IN PARTIAL FULLFILLMENT OF THE REQUIREMENT FOR THE
DEGREE OF
BACHELOR OF ENGINEERING (MECHANICAL ENGINEERING)
SUBMITTED BY,
Mr. Pise Saiprasad Rajendra
Mr. Saygaonkar Swanand Suhas
Mr. Kadam Rohan Shrikant
Mr. Wagavekar Vikas Rajendra
Mr. Sutar Sandip Dilip
Mr. Sutar Tejesh Balasaheb
Mr. Patil Suraj Ramchandra
Mr. Patil Pandurang Niwas
Mr. Manole Pranav Ashok
Mr. Janwadkar Giridhar Vyankatesh
UNDER THE GUIDANCE OF
Prof. S. M. Pise
Prof. P. B. Mutalik
DEPRTMENT OF MECHANICAL ENGINEERING
K.I.T's COLLEGE OF ENGINEERING,
KOLHAPUR

KITs COLLEGE OF ENGINEERING

INDEX
Sr.No.

Title

Page No.

Introduction

03

Overall preview

07

RMRD

09

Boiler department

11

Refrigeration Department

15

Pasteurization department

21

E.T.P department

24

Case study

27

References

33

KITs COLLEGE OF ENGINEERING

INTRODUCTION
Kolhapur Zilla Sahakari Dudh Utpadak Sangh Ltd. well known with its
popular brand Gokul is a Cooperative Dairy Project established on 16 March 1963. Since then,
Gokul achieved many land marks in Milk Procurement, Extension, Animal Health, Breeding,
Milk Processing, Product making and Marketing. At present Gokul has modern 7 Lakh
Litres/day capacity dairy plant with 4 owned and 1 hired chilling centers having 4.25 Lakh
Liters/day milk

handling

capacity with

modern

Packing

Unit

at

Navi

Mumbai.

For milk production enhancement, in milk shed they have presently 41 Mobile
veterinary routes , 430 Cluster and 17 static A. I. Centers, Along with this new 300 MT/day
capacity Cattle Feed Plant with popular Mahalaxmi brand is operational at KagalHatkanangale Five Star MIDC. The old cattle feed plant with 200 MT/day capacity plant is
simultaneously operational.

SPECIAL FEATURES:
Quality Management and Food Safety System is under implementation at Gokul.
Union continues renewal of Export Inspection License in July 12, 2012 for Product
Exports.
Undertaken DPM Study from 1990 for Plant improvement, Refrigeration, Plant Losses
etc. with help of NDDB/FAO. First plant to start Quality Assurance Program in country
in 1992
14 times winner of National Productivity Awards from 1988/89 to 2006/07.
Gokul bags PATENT for its innovation Milk Replacer.
Gokul pay back 76 to 82% for every sale rupee generated in form of price and services to
the Milk Producer.
Turnover for financial year 2012-2013: Rs. 1205 Crores.
Plant commissioned in 1986 with 2 Lac process capacities. Average growth rate in last 24
years is 10 to 11%.
Highest handling - 11 Lakh Litre/day. Average handling in Dairy Plant - 7 Lakh Ltr. /day.

KITs COLLEGE OF ENGINEERING

ABOUT GOKUL:

The Kolhapur District Co-operative Milk producers Union Ltd. Kolhapur was
established on 16 March 1963 under the Co-operative Act. It made a moderate beginning by
collecting 500 liters of Milk per day from 22 societies. Most success stories have a humble
beginning & so has been with Kolhapur Zilla Sahakari Dudh Utpadak Sangh Ltd.
On 16thMarch 1963 a spark stormed a fire to help the White Revolution revolt
heavily, when on this day came into being the Kolhapur Zilla Sahakari Dudh Utpadak Sangh
Ltd with the introduction of its popular brand of Gokul Milk & its wide range of Dairy
products into the market.

KITs COLLEGE OF ENGINEERING

GOKULS PRESENT SETUP:

A)

Milk Reception Capacity

3.2 Lakh Ltrs/Day (Raw)

3.8 Lakh Ltrs/Day Lakh(Chilled)

B)

Milk Process capacity

7.0 Lakh Ltrs/Day

C)

Powder Manufacturing

D)

DesiLoni ( Desi Butter ) Manufacturing

(Union handled 1 Million Ltr. in Flush 2001/02)

C. B. M. M.

32 MT/Day

Top Churn

8 MT/Day

E)

Ghee Manufacturing

F)

Packaging Lines :
Milk Packaging
Powder

40 MT/Day

Packing-Nichrome (Pouch)

6 MT/Day
1 Lakh Ltr/day
10 MT/day

Rollatainer Machine (Cartoons)

10 MT/day

Ghee Packaging (Pouch)

4.5 MT/Day

Table Butter Packaging

G)

In 500 gm

3 MT/day

In 100 gm.

1 MT/day

Total

4 MT/day

Storage Capacity :
Milk (Packed Milk)

1 Lakh Ltr

DesiLoni ( Desi Butter )

800 MT

Powder

1400 MT

Ghee

20 MT to 30 MT

Milk (Raw/Process)

9.25 Lac Ltrs.

Total Project Investment :

OF- I/II

12 Crore

1978-1986

33 Crore
---------------45 Crore

1995-1998

OF-III

AWARDS:
Activities at Gokul are always towards giving best quality and test to consumer by
effective resource utilization and keeping best hygiene practices.
The plant has been awarded 14 times in dairy & animal feed processing segment since
1994-95 by National Productivity Council of India.
The Union also received the license from Export Council of India to export the products.
Awarded for Sahakar Bhushan by Government of Maharashtra.
First prize for Energy Conservation in Dairy Vertical by Government of Maharashtra.

KITs COLLEGE OF ENGINEERING

Here are some details of the awards that we have won over past years.

The image on the left

denotes 1st
Prize for National
Productivity Council
Award. The 1st Prize was
won for the following
years: 89-90, 91-92 & 9394(won for both Dairy &
Cattle feed categories)

Above
images
denotes 2nd
Prize for Nat
ional
Productivity
Council
Award. The 2nd Prize was won for the following
years.
o
o

92-93 (won for both Dairy & Cattle feed categories)

94-95 (won for both Dairy & Cattle feed categories)

KITs COLLEGE OF ENGINEERING

OVERALL PREVIEW
The milk coming from various dairies is first of all collected to the dock department.
Sample is taken from milk collected from each institute to measure fat and water percentage.
Whole stock of milk is then cooled to 4C and stored in storage containers.

As per the

requirement the milk is then taken to pasteurization department where it is pasteurized and then
stored again in separate tanks. Major part of this pasteurized milk is then sent to Thane and
Vashi for packaging. Remaining part is used to produce local packaging as well as other
products like- paneer, shrikhand, milk powder, curd, flavored milk, ghee, butter.
Produced products are first stored in the Cold Storage room and then distributed to
the market according to the needs.
All the vessels, cans and truck containers are sterilized or cleaned with help of hot
water produced by boiler. Also plate heat exchanger which is located at pasteurization unit is
cleaned after every 8hr. shift by hot water and acid C.I.P. is done after every 24hrs.
All the waste water along with mixed pollutants is then drained using drainage
system to E.T.P. where it is digested aerobically and anaerobically to produce Biogas and
Fertilizer so that water is purified and then let for agricultural use.

Overall View of Gokul

Plant

KITs COLLEGE OF ENGINEERING

Total layout of GOKUL PLANT

(AutoCAD Drawing)

KITs COLLEGE OF ENGINEERING

RMRD
All dairies dispatch their collected milk to plant from cans or from large truck
containers (from BMC).

MILK COMING FROM

CANS: Cans are received and unloaded from trucks at the dock department. These
cans are let on the roller chain conveyer. Lids of these air tights cans are opened using
can opening machine while moving along the conveyer. After opening lids of cans smell
testing is done. This is the first type of testing done on the incoming raw milk. Special
persons are appointed for this kind of skilled work. The acceptance or rejection of the
whole lot of milk send by each institute depends on this test. If any foul smell is found
then whole lot is rejected to avoid anything that will hamper quality of plant. The
accepted milk cans are then emptied into the collecting vessels. The milk collected from
each institute is given separate sample number while collecting in the vessel. Total
quantity of milk poured by each institute is measured electronically and recorded into
computer. Samples of milk of each institute according to their sample number are taken
into small sample bottles automatically, while pouring into the collecting vessels. The
sample bottles are made of plastic and are used again and again for cost saving. These
samples are then sending to dock lab using belt conveyer. These sample bottles are first
kept under stirrer, for homogenisation of sample, for at least 30sec. After
homogenisation, they are checked for Fat and water percentage. The data of each milk
sample is recorded against their sample number. The prices or rate of milk depends on
their fat and water percentage. The money to be given to each institution is calculated
automatically depending upon following factors: Quantity of milk
Fat present in the milk
Water percentage in the milk
Market rate
After checking milk samples, the sample bottles are washed using hot
water and resend back to the belt conveyer to collect new samples.
The emptied cans are kept inverted on the Chain-Roller conveyer for
collecting the remaining milk adhered inside of cans. The path of Chain-Roller conveyer
is increased for this is intended purpose. This is the best method for optimization.

KITs COLLEGE OF ENGINEERING

The inverted cans kept on conveyer are then conveyed to the sterilizing
machine. In sterilizing machine hot water is pumped from below, so that it is spread
inside the inverted can kept on the roller. This hot water is supplied from the boiler. The
hot water temperature is about 70cel, as sterilization temperature is about is 66cel. The
waste water is send to E.T.P. via drainage system. The advantage of keeping the cans
inverted is that the hot water is drained automatically due to gravity effect. After dripping
of all the water the cans are erected vertically using ratchet arrangement, which gets
locked into mouth of cans. The erected cans are then conveyed to the dispatch unit.
While all this process is done, a simultaneous process of sterilizing of lids
takes place. These lids are washed manually by hot water and brought to dispatch unit.
Before dispatching, the lid is assembled on the can and loaded in the truck.

TRUCK CONTAINER:The milk in the container is first stirred using stirrer manually for about
5minutes. Then 5 to 6 samples are taken and send to Dock testing lab where its fat and
water percentage is measured and accordingly the rates are fixed. Then using pump the
milk is transferred to storage container where it mixes with the milk from cans. After
empting the tank completely the truck is send for sterilisation. Hot water from overhead
tanks is spread throughout internally and all the remaining milk is washed out. Again the
waste water mixes with sewage water and flows through drainage system to ETP.

Truck

Container

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KITs COLLEGE OF ENGINEERING

BOILER DEPARTMENT
A boiler is a closed vessel in which water or other fluid is heated. The fluid does not
necessarily boil, which is used for various purposes. Boilers manufactured by IAEC are used in
GOKUL plant. Three boilers are used for accomplishing the requirement of hot water. Capacity
of boiler is 5ton i.e. 5ton of steam can be generated per hour. The type of boiler used is FIRE
TUBE boiler. At a time two boilers can handle the requirement of steam generation, so that
maintenance of the third can be done simultaneously. The ignition time for boiler is about 30min.
The hot water generated in the boiler is used for: Pasteurisation.
Sterilisation.
Butter/ ghee melting.
Can washing.
Tanker washing.
Operating pressure of boiler is about 17.5Kg/cm2. Old boilers were used to have only
mechanical ON/OFF system. There was no intermediate stage in oil feeding system. Recent
boilers have a stepper motor to control the stages of boiler. The stepper motor arrangement
controls the flame in small steps so that pressure does not decrease tremendously.

Boiler Department

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KITs COLLEGE OF ENGINEERING

FUEL SYSTEM:
Fuel used is furnace oil. Flash point of this oil is 66C burning of 1liter of fuel produces
13liter of steam under standard operating condition.
There are 3 furnace oil tanks having capacity of 35000 liters each. The oil from these
tanks is fed to the 2 service tanks provided in the boiler section. From these service tanks oil is
fed to the boiler. This oil is filtered for the 3 times: firstly while passing in tank through tanker,
then while transferring it from the main tank to the service tank and at the entry in the boiler. The
unit cost of Furnace oil is 50Rs./ltr.
Before entering into the boiler oil is preheated using air preheater. Then it is fed to the
combustion chamber. In the chamber firstly a spark is created which causes burning of oil.
WATER SYSTEM:
Water is supplied to the plant from MIDC tank. It is stored in overhead tank having
capacity of 100000 liters. Then the water is passed to the 2 day tanks placed in the boiler section.
Then it is fed to the boiler by using feed pump. Lastly outlet steam of the boiler is fed to the
process.
CHIMNEY:
A chimney is a structure which provides ventilation for hot flue gases or smoke from a
boiler, stove, furnace or fireplace to the outside atmosphere. The height of a chimney influences
its ability to transfer flue gases to the external environment via stack effect. Additionally, the
dispersion of pollutants at higher altitudes can reduce their impact on the immediate
surroundings.
CHIMNEY SPECIFICATION
Standards for emissions of Air-pollutants from a factory are given below: a) SPM not to exceed 150mg/Nm3.
b) SO2 not to exceed 1.3T/day.
Chimney attached to
Boiler 1 and 2
Boiler 3
Air heater 1 and 2
DG set(250KVA3)
DG set(625KVA2)

Height in meter
25.50
30.00
30.00
3.5*
3.5*

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KITs COLLEGE OF ENGINEERING

ACCESSORIES:1. WATER LEVEL INDICATOR:

Water level indicator indicates level of water in the boiler. It also has provision of
automatic operation of feed water pumps. When water level in the boiler gets reduced below a
certain level then feed water pump starts automatically and after a predetermined level is been
reached pump stops automatically.
To achieve such automation a floating valve is provided. a small balance tank is
provided besides water level indicator in which this floating valve is provided. when water level
goes down the floating valve dips along with water level and electrical contact for feed pump is
established using bell crank lever. When water level rises above certain level, electrical contact
is broken and feed pump stops automatically.
2. SAFETY VALVE:
There is one spring loaded safety valve provided on the upper side of boiler shell
which is used to regulate the pressure. If pressure in the boiler increases beyond operating
pressure safety valve acts and releases excess amount of steam into atmosphere. Operating
pressure of safety valve used for boiler is 19 bar.
3. FUSIBLE PLUG:
Fusible plug is one of the safety device used on boiler. As the boiler has large
dimensions two fusible plugs are provided. As one fusible plug cannot take care of whole boiler
another fusible plug is provided. This provision is also useful when one of the fusible does not
operates. When pressure in the boiler increases beyond certain limit, the fusible plug operates. It
has a metal having low melting point which melts when steam reaches to a particular pressure
and at the same instant water is sprayed in the boiler which reduces amount of steam resulting
in reduction in pressure. Although operating pressure of boiler is 17.5 bar fusible plug operates
at 20-21 bar. This is one of the most important accessories in order to avoid blast of the boiler.

13

KITs COLLEGE OF ENGINEERING

4. STEAM TRAP:
Steam trap is a device which is spaced equally throughout the pipeline carrying
steam. It is used to separate water particles from the steam and to provide completely dry steam
at the point of application.
BOILER PROBLEMS:
Nozzle choke up
Burner choke up
Oil temperature increases/ decreases
Vapour formation in furnace chamber
Filter choke up
Oil pressure increases/ decreases

Fuel Tank

14

KITs COLLEGE OF ENGINEERING

REFRIGERATION
Refrigeration is reduction of temperature of the body below the surrounding temperature.
It further implies maintenance of the temperature body below the surrounding temperature. In
Gokul Dairy Refrigeration is mainly used for chilling the milk, also for storing different milk
products. As the time passes after milking, growth of bacteria increases in exponential manner.
To avoid this milk is to be cooled to 4cel.instantly. The bacteria become inactive below this
temperature. This cooling effect is achieved by using refrigeration system.
Basic refrigeration cycle diagram
Components of basic refrigeration cycle
Compressor
Condenser
Expansion device
Evaporator

Compressor: The low pressure and low temperature vapour refrigerant from evaporator is drawn into
the compressor then it is compressed to high pressure and temperature then discharges to
condenser.
Following are the compressors that we had seen:
1. Screw compressors
2. Reciprocating compressors
3. Bitzer compressor

Condenser:Condenser is device in which high pressure and temperature vapour refrigerant is cooled
by rejecting the latent heat to cooling medium and change of phase takes place from vapour to
liquid. condenser is a type of heat exchanger. Type of condenser that we had seen in plant is
plate type heat exchanger (PHE). Plant uses 3 Plate heat exchanger.

Receiver:The condensed liquid from condenser is stored in a vessel known as receiver from where
it is supplied to evaporator through expansion valve.

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KITs COLLEGE OF ENGINEERING

Expansion valve:The function of expansion valve is to allow the liquid refrigerant under high pressure and
temperature to flow to evaporator by reducing its pressure and temperature.

Evaporator:Actual refrigeration effect produced by the refrigeration cycle is at the evaporator. In this,
cold liquid refrigerant reject its latent heat and converts into a vapour form.

0C & -10C Vessels

PHE Condenser

16

KITs COLLEGE OF ENGINEERING

REFRIGERATION CYCLES IN GOKUL

1) MAIN AMMONIA CYCLE:

Ammonia (NH3) from storage tank is supplied to screw compressor in form of vapour. In
compressor, the pressure and temperature of ammonia increases. 3 screw compressors are used
for this purpose.

17

KITs COLLEGE OF ENGINEERING

Then this ammonia supplied to Plate Heat Exchanger (PHE) condenser. In condenser,
vapour ammonia condensed in to liquid form. This liquid ammonia is then stored in accumulator.
In the expansion valve, pressure and temperature decreases up to -10C. From -10C vessel, the
ammonia is supplied to Ice Bank Tank (IBT) where it is used to cool the water. This cooled
water is used for pasteurisation purpose.
After cooling the milk, warm water is then supplied to chiller for the purpose of
precooling. From IBT, ammonia is supplied to storage tank and cycle repeats.
This particular refrigeration cycle produces refrigeration effect of 225 TR.
Specifications of screw compressor used are:
Type: OH04131
Year of fabrication: 1995
Vessel number: 97674
Design code: DS 320
Media: R717
Maximum operating pressure: 28 bar
Test pressure: 35 bar
Maximum operating temperature: 130o C
Volume: 610 lit.
Actual working condition:
Suction pressure: 2.1 bar
Discharge pressure: 10.9 bar
Suction temperature: -3.5oC
Discharge temperature: 62oC
Oil pressure: 6.5 bar

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KITs COLLEGE OF ENGINEERING

2) CHILLER CYCLE:

Ammonia coming out of deep freezer is supplied to Bitzer compressor in the form of
vapour. In compressor, pressure and temperature of vapour NH3 is increased. This high pressure
and high temperature NH3 is passed through condenser. In condenser, vapour NH3 is condensed
to liquid NH3. This liquid ammonia is passed through expansion valve where its temperature
decreases to 0C. This liquid ammonia is stored in 0C vessel. Liquid ammonia is entered in
chiller, where it absorbs heat from warm water. Because of this, liquid ammonia converted into
vapour. This vapour is then supplied to NH3 storage.
In pasteurisation process, chilled water is supplied which becomes hot. This warm water
is precooled in the chiller and supplied to IBT. Due to which performance of cycle gets
improved.

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KITs COLLEGE OF ENGINEERING

3) DEEP FREEZER CYCLE:

Ammonia vapour from storage is supplied to screw compressor. In compressor, this

vapour is compressed to high pressure and temperature. This compressed vapour is then
condensed. Due to this vapour ammonia is converted into liquid ammonia. Liquid ammonia is
supplied to accumulator. This liquid ammonia is passed through expansion valve where its
temperature decreases up to -10C and stored in -10C vessel. The temperature is further reduced
to -30C by passing through second expansion valve. This -30C liquid is circulated in deep
freezer.
Different products like Butter, shrikhand, Ghee are stored in this deep freezer. These
products are at room temperature. Because of this, liquid ammonia gets converted into vapour
ammonia. Due to this, -26C is actually maintained in deep freezer. This ammonia vapour again
passed to NH3 storage.

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KITs COLLEGE OF ENGINEERING

PASTEURIZATION
Pasteurization is a process of heating food, which is usually a liquid, to a
specific temperature for a predefined length of time and then immediately cooling it after it is
removed from the heat.
Louis Pasteur was a scientist who developed this technique for
enhancing life of food. Hence to honor him this process is known as pasteurization.
Unlike sterilization, pasteurization is not intended to kill all microorganisms in the food. Instead, it aims to reduce the number of viable pathogens so they are
unlikely to cause diseases.
In olden days after milking it was possible to store milk only for some
time, so it was to be consumed immediately. Thus milk was available for a short period only
after milking. Due to pasteurization process now it is possible to store milk for about two days
(at low temperature).
There are two processes of pasteurization:
1. LTLT: Low Temperature Long Time
In this pasteurisation process milk is heated up to 63cel. using hot
water, then it is maintained at that temperature for about 30min. this hot milk
is then cooled to 4cel. i.e. below the growing temperature of bacteria.
2. HTST: High Temperature Short Time
In this pasteurisation process milk is heated up to 78cel. using hot
water, then it is maintained at that temperature for about 15sec. this hot milk is
then cooled to 4cel.

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KITs COLLEGE OF ENGINEERING

PASTEURISATION FLOW CHART

Balance Tank
Pump

Duplex Filter
Regeneration 1
Separator

Regeneration 2
Homonizer

Regeneration 3
Flow Direction
Valve (FDV)

Heating

Holding

To storage
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KITs COLLEGE OF ENGINEERING

ICE BANK:A bulk tank using an Ice Builder or Ice Bank immerses the bottom of the inner
milk chamber in an open pool of water with copper tubes containing refrigerant suspended in the
water. Between milking, a small low-power cooling system slowly builds up a coating of ice
around the copper tubes, and prevents icing of the pool over by continuously circulating the
water in the pool. After the ice has achieved a thickness of 2-3 inches, the cooling system stops
running.
During milking, the milk entering the tank is primarily cooled by circulating the
water in the pool around the walls of the inner milk chamber, and the melting of the ice. After
the ice has melted sufficiently the cooling system restarts to assist the ice bank and restart the ice
building.
Ice bank bulk tanks are better suited for small family farm operations where only
single-phase electric power is available, and high-power cooling systems would be either too
expensive or difficult to install.

Refrigeration Plant

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KITs COLLEGE OF ENGINEERING

Effluent Treatment Plant

The word ETP implies Effluent Treatment Plant i.e. it is an industrial structure
designed to remove biological or chemical waste products from water, so that permitting the
treated water to be used for other purposes like agriculture.
The effluent treatment plant at gokul includes the following units:Raw Effluent Tank or Slag removal tank.
Fat Removal Unit.
Equalisation Tanks.
UASB (Up flow anaerobic sludge blanket digestion).
Aeration Tanks.
Clarifier.
Treated Effluent Tank.
The complete ETP cycle can be shown as below:-

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KITs COLLEGE OF ENGINEERING

1) SLAG REMOVAL TANK: In this tank the slag or the solid particles mixed with waste water are
removed by filtration. Then slag is separated manually from water and water is send to
fat removal tank by pump. The slag is send to sludge drying bed for drying so that it can
be used as fertiliser for agriculture.
2) FAT REMOVAL TANK: In this tank FAT from mixture of milk and water is separated so that only
water is let for further use like agriculture purpose. GOKUL plant contains two FAT
removal tanks. Some specific type of bacteria is let into the tank which carries the process
of aerobic degradation. This removes the fat in the mixture. For proper aerobic conditions
stirrer is used. Water from slag removal tank enters first FAT removal tank where the
bacteria removes some amount of fat, then it is send to second fat removal tank where the
bacteria again carries process of degradation second time. Then the water is send to
Equalisation tank by gravity.

3) EQUALISATION TANK: Equalisation is the process of removing the waste by equalising flow.
During turbulent flow the fluid tends to carry heavy solid particles which are also a
waste. So in equalisation tank, the speed of fluid is reduced in order to settle the solid
particle. In GOKUL plant there are two equalisation tanks. The water coming from FAT
REMOVAL TANK is send to first equalisation where some of the solid particles are
separated and then it is send to second equalisation tank where the remaining solid
particles are separated. Water is then sending to USAB by pump.
4) UASB: UPFLOW ANAEROBIC SLUDGE BLANKET DIGESTER is an
anaerobic type of digester which mainly produces methane. UASB uses an anaerobic
process whilst forming a blanket of granular sludge which suspends in the tank.
Wastewater flows upwards through the blanket and is processed (degraded) by the
anaerobic microorganisms. Biogas with a high concentration of methane is produced as a
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KITs COLLEGE OF ENGINEERING

by-product, and this may be captured and used as an energy source, to generate electricity
for export and to cover its own running power. The technology needs constant monitoring
when put into use to ensure that the sludge blanket is maintained, and not washed out
(thereby losing the effect). The heat produced as a by-product of electricity generation
can be reused to heat the digestion tanks. If the treatment is unsatisfactory, then it is again
send to Equalisation tank, else it is send to Aeration tank by gravity.
5) AERATION TANK: The main purpose of an aeration tank is to facilitate the biological
treatment of wastewater by pumping or inducing air into it. There are two aeration tanks
in the GOKUL plant. Two stirrers are used to aerate the water present in these tanks. An
aeration tank should be leak-proof, and sufficiently large to enable aeration to take place
without overflowing. A typical aeration tank comprises an aerator, a wastewater inlet, a
treated water outlet and a sludge outlet. In general, wastewater should be continuously
aerated so as to maintain a dissolved oxygen level of 1-2mg/L for 18 to 20 hours. This
should be followed by at least an hour of settling in order to achieve the required quality
for discharge. The settled sludge should be drained off to a drying unit after each aeration
cycle. It must be stressed that excessive aeration could also result in very poor treated
water quality. Then water is send to clarifier by gravity force.
6) CLARIFIER: Clarifiers are settling tanks built with mechanical means for continuous
removal of solids being deposited by sedimentation. A clarifier is used in waste water
treatment. It works by separating solids and water. They are large circular open air tanks.
The clarifier works by having the waste water enter through the center tower. The flow of
the water slows down allowing for solids to settle on the floor. The solids are then
directed to the center of the clarifier by using slow moving collection scrapers. The clear
water then exists the tank and is treated for use. If the treatment is unsatisfactory then the
water is again send to aeration tank, otherwise it is send to Treated effluent tank.
7) TREATED EFFLUENT TANK: Before leaving the processed to water to agricultural field, it is first send to
a small treated effluent tank. The size of treated effluent tank is about 4m 3. Two baffles

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KITs COLLEGE OF ENGINEERING

are used so that flow becomes steady and any remaining impurities are trapped so that
only clear is delivered.

CASE STUDY
BULK MILK CHILLER:To maintain the quality of procured milk, it must be cooled to 4 degrees within a
short time of milking. It results in limited bacterial build-up resulting in better quality of milk for
processors resulting in better prices to Dairy Farmers. BMCs mostly installed in India are of
capacity 1000L to 5000L. Off late, 10000L BMCs are also becoming popular. Sometimes, each
BMC even caters to a cluster of 15-20 Villages around it and serves the purpose of a chilling
center working at low cost of operation. Chilled Milk from these BMCs is then transported to
processing plants by Milk Tankers.
As per International Standards for Bulk Milk Coolers, ISO 5708, Bulk Milk
Cooler should be designed in such a way that for the first milking, the raw milk at temperature of
35 deg Centigrade must be cooled to 4 deg Centigrade within 4 hours when BMC is running at
ambient temperature of 38 deg Centigrade.
In dairy farming a bulk milk cooling tank is a large storage tank for cooling and
holding milk at a cold temperature until it can be picked up by a milk hauler. The bulk milk
cooling tank is an important piece of dairy farm equipment. It is usually made of stainless steel
and used every day to store the raw milk on the farm in good condition. It must be cleaned after
each milk collection. The milk cooling tank can be the property of the farmer or be rented from a
dairy plant.
TANK CONSTRUCTION:A milk cooling tank, also known as a bulk tank or milk cooler, consists of an
inner and an outer tank, both made of high quality stainless steel.
The space between the outer tank and the inner tank is isolated with polyurethane
foam. In case of a power failure with an outside temperature of 30C, the content of the tank will
warm up only 1C in 24 hours.

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To facilitate an adequate and rapid cooling of the entire content of a tank, every
tank is equipped with at least one agitator. Stirring the milk ensures that all milk inside the tank
is of the same temperature and that the milk stays homogeneous.
On top of every closed milk cooling tank is a manhole of about 40 centimeters
diameter. This enables thorough cleaning and inspection of the inner tank if necessary. The
manhole is covered by a lid and sealed watertight with a rubber ring. Also on top are 2 or 3 small
inlets. One is covered with an air-vent; the other(s) can be used to pump milk into the tank.

A milk cooling tank usually stands on 4, 6, or 8 adjustable legs. The built-in tilt of
the inner tank ensures that even the last drop of milk will eventually flow to the outlet.
At the bottom, every milk cooling tank has a threaded outlet, usually including a
valve. All tanks have a thermometer, allowing for immediate inspection of the inner temperature.
Most tanks include an automatic cleaning system. Using hot and cold water, an
acid and/or alkaline cleaning fluid, a pump and a spray lance will clean the inner tank, ensuring a
hygienic inner environment each time the tank is emptied.
Almost every tank has a control box. It manages the cooling process by use of a
thermostat. The user can turn the system on and off, allow for extra and immediate stirring, start
the cleaning routine, and reset the entire system in case of a failure.
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New and bigger milk cooling tanks are now being equipped with monitoring and
alarm systems. These systems guard temperature of the milk inside the tank, check the
functioning of the agitator, the cooling unit and temperature of the cleaning water. In case of
malfunctioning of any of these functions, the alarm will activate. The monitoring system will
also keep a record of the temperature and of all malfunctions for a given period.
MANUAL SCRUBBING:Manual scrubbing requires the bulk tank to have large hinged covers that can be
lifted open to permit easy access to the interior surfaces of the tank. It tends to be much more
thorough than automatic methods since it permits the tank to be carefully inspected during the
washing process. If the tank is not found to be cleaned well enough, a troublesome area can be
given additional cleansing attention.
Manual Scrubbing Limitations
This job is difficult to perform for very large tanks, and becomes more difficult as
the overall cross-section or diameter of the tank increases, requiring either a longer brush or a
raised work platform around the tank to lift the cleaning worker to reach over the side of a tall
tank.
AUTOMATIC WASHING:
Automatic bulk tank washing systems are used in closed tanks and are normally
activated by the milk collection truck driver after each milk collection. The cleaning system
operates similar to a consumer dishwasher and consists of one or more free-spinning highpressure spray nozzles with tangential jets, with the spray nozzle mounted on the end of a
flexible whip suspended down into the center of the interior. As the cleaning solution sprays out
of the jet, the force of the expelled water causes the jet to spin around and the whip to wildly
swing back and forth, spraying the cleaning solution randomly all over the interior of the tank.

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Automatic Washing Limitations

Because no physical scrubbing occurs with automatic wash systems, the cleanser
relies on surfactants and detergents to dissolve the fats left on the interior of the tank by the
cream in the milk. However, this is not sufficient to remove milk stone buildup, and the tank may
need to be washed occasionally with milk stone remover to remove this scale buildup that can
harbor bacteria and contaminants.
Automatic scrubbing only cleans the interior of the tank. It is not capable of
cleaning the exterior of the tank, and it does not do a good job of washing around the cover seals.
While it is possible to just clean the interior and call it good enough, it does not provide the
maximum sanitation of manually washing down the exterior of the tank following or during the
automatic wash process. Also, some components that contact the milk such as the drain valve
cannot be properly cleaned automatically without disassembling the valve and retaining washer
and directly scrubbing in soapy water.

Operating costs
Substantial reductions in running costs can be made when an ice builder is used in
conjunction with off-peak electricity. Pre-cooling milk using a plate or a tube cooler supplied
with mains or well water can also reduce costs and add to the cooling capacity of the tank.
Bulk tank condenser units, which are not an integral part of the tank, should be
fitted in an adjacent, suitable and well ventilated place.
If at all possible, condenser units should not be fitted on a wall facing the sun.
They should be installed in a way which allows them to draw in and discharge adequate
quantities of air for efficient operation.
Bulk tank should be easily accessible by large bulk collection tankers and
positioned so that the tanker approaches can be kept clean and free from cow traffic at all times.
Although tanks have been calibrated when first installed, bulk tank mis-calibration is not
uncommon and in some cases it can result in significant loss of income. Milk tanks calibrated on

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the low side can cheat raw milk producers by up to 22 liters on each shipment. It is therefore
advisable to re-calibrate a bulk tank.

CHUYE:
The plant consists of dump tanks of 250lit.capacity and 3000lit.tank both for cow
milk. It also consist a 2000lit. tank for buffalo milk. Collection of cow milk on an avg. is
between 1600 to 1750lit. and of buffalo milk is about 900 to 1200lit.

VADKASHIWALE:
The plant consists of dump tanks of 200lit.capacity and 5000lit.tank both for cow
milk. It also consist a 1000lit. tank for buffalo milk. Collection of cow milk on an avg. is
between 1600 to 1750lit. and of buffalo milk is about 700 to 900lit.
Milk is collected in 2 stages at 6 a.m. and 6.30 p.m. Tanker arrives at 10 a.m.
and milk collected in both stages is transferred to it. After emptying the BMC tank it is
washed thoroughly with hot water. Water is heated with the help of electric heater or by
means of LPG gas (in situation of power failure). The temperature of hot water is about
67c.

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First cycle of BMC starts in the evening. Samples of incoming milk are taken to measure fat and
water per cent and accordingly rates are fixed. After sampling is done, milk is poured into a
vessel from where it is send to dump tank. When the dump tank is about to be filled, it is send to
BMC tank with the help of pump. When 2-3 dump tanks are poured to BMC tank, cooling of
BMC tank is started. After about an hour or so, the milk in BMC attains required temperature of
4c. then the cooling of BMC is stopped. In this cycle BMC is about half filled.
The second cycle is similar to first cycle only the difference is; milk is added to
the milk in the previous cycle.

Observation table for BMC tank is shown below:

CHUYE:
Sr. No.

BMC ON

BMC OFF

Temp.(C)

Voltage(V)

Current(A)

Power(KW)

01

6:35 AM

8:05 AM

8.5

405

57.5

24

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02

7:15 PM

8:45 PM

11.5

489

57.5

28

03

6:55 AM

8:20 AM

10.5

406

57.5

24

04

7:20 PM

9:00 PM

11.0

394

57.5

23

VADKASHIWALE:
Sr. No.

BMC ON

BMC OFF

Temp.(C)

Voltage(V)

Current(A)

Power(KW)

01

6:30 AM

8:00 AM

7.5

409

57.5

24

02

7:10 PM

8:40 PM

11.0

398

57.5

23

03

6:35 AM

8:10 AM

7.5

397

57.5

23

04

7:00 PM

8:35 PM

9.0

405

57.5

24

Suggestions:
1. Air blower can be used to take out all the adhered milk.
2. Evaporator location should be changed in order to increase heat transfer rate.
3. More local dairies should be equipped with BMC.

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REFERENCES
Kolhapur zilla sahakari dudh utpadak sangh ltd.
Gokul Dairy,
Gokul Shirgaon MIDC,
Kolhapur.
Principles of refrigeration Roy J. Dossat
Refrigeration and Air Conditioning Arora Domkundwar
Refrigeration and Air Conditioning V.K.Jain
Heat & Mass Transfer R.C.Sachdeva

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