i

PRODUCTIVITY IMPROVEMENT
IN MILK POWDER PLANT

A PROJECT WORK - PHASE I REPORT

submitted by

ANDREW CHARLES.R
ASHMITHRAJ.S
DINESH.R
KAVIN.T

in partial fulfillment of the requirement

for the award of the degree

of

BACHELOR OF ENGINEERING

in

MECHANICAL ENGINEERING
 ii

K.S.RANGASAMY COLLEGE OF TECHNOLOGY

TIRUCHENGODE – 637 215
(An Autonomous Institution, Affiliated to Anna University Chennai and Approved by AICTE, New Delhi)

OCTOBER 2017
 iii

K.S.RANGASAMY COLLEGE OF TECHNOLOGY

TIRUCHENGODE - 637 215

BONAFIDE CERTIFICATE

Certified that this Project Work - Phase I report titled “PRODUCTIVITY

IMPROVEMENT IN MILK POWDER PLANT” is the bonafide work of
ANDREW CHARLES.R (1411110), ASHMITHRAJ.S (1411124), DINESH.R
(1411145), KAVIN.T (1411209), who carried out the project under my supervision.
Certified further, that to the best of my knowledge the work reported herein does not
form part of any other project report or dissertation on the basis of which a degree or
award was conferred on an earlier occasion on this or any other candidate.

SIGNATURE
Dr. A. Kumaravel, M.Tech., Ph.D.
HEAD OF THE DEPARTMENT
Professor
Dept. of Mechanical Engineering
K.S.Rangasamy College of Technology
Tiruchengode - 637 215
SIGNATURE
T.T.Rameshkumar Raja M.E., M.B.A
SUPERVISOR
Assistant Professor
Dept. of Mechanical Engineering
K.S.Rangasamy College of Technology
Tiruchengode - 637 215
 iv

DECLARATION

We jointly declare that the project report on “PRODUCTIVITY

IMPROVEMENT IN MILK POWDER PLANT” is the result of original work
done by us and best of our knowledge, similar work has not been submitted to
“ANNA UNIVERSITY CHENNAI” for the requirement of Degree of
BACHALOR OF ENGINEERING. This project report is submitted on the partial
fulfilment of the requirement of the award of Degree of BACHALOR OF
ENGINEERING.

Signature

ANDREW CHARLES R
____________________

ASHMITHRAJ S
____________________

DINESH R
____________________

KAVIN T
____________________

Place: Tiruchengode

Date:
 v

ACKNOWLEDGEMENT

We wish to express our sincere gratitude to our honourable correspondent

Lion Dr. K. S. RANGASAMY, M.J.F., for providing immense facilities in our
institution.

We are very proudly rendering our thanks to our principal

Dr. K. THYAGARAJAH, M.E., Ph.D., SMIEEE, MISTE, for the facilities and the
encouragement given by him to the progress and completion of our project.

We regard our sincere and heartfelt thanks to our Director of the Department
Mr. SIVAMALAI RANGASAMY, M.E., M.B.A., (Ph.D.), who has been the key
spring of motivation to us throughout the completion of our course and project work.

We proudly render our immense gratitude to the Head of the Department

Dr. A. KUMARAVEL, M.Tech., Ph.D., for his effective leadership, encouragement
and guidance in the project.

We are highly indebted to provide our heart full thanks to our guide Assistant
Professor T.T.RAMESHKUMAR RAJA, M.E.,M.B.A., for his valuable ideas,
encouragement and supportive guidance throughout the project.

We wish to extend our sincere thanks to all faculty members of our

Mechanical Engineering Department for their valuable suggestions, kind co-operation
and constant encouragement for successful completion of this project.

We wish to acknowledge the help received from various Departments and

various individuals during the preparation and editing stages of the manuscript.
 vi

ABSTRACT

The sharp rise in fire related accident has been attributed to a spurt in serious
fire accidents, which went up by 50 percent last year. A total of 36 serious fire
accident occurred in 2014 and the number rose to 53 last year and productivity of the
industry has reduced upto 50%. This is due to outbreak of heat from stage dryers. An
analysis of the fire and explosion risk in spray dryers is presented by consideration of
the potential ignition sources and the flammability of materials (powders, dust clouds,
vapours). "Milk powder is a fine dust when mixed with air, "Because it's being dried
at reasonably high temperature you only need a spark in there and you will get a dust
explosion."Explosions are an occupational hazard in milk processing plants."That is
why we modified the drier to provide for explosion protection, "Powdered milk or
dried milk is a manufactured dairy product made by dehydrating liquid milk through
several drying processes until it is a powder. One purpose of drying milk is to
preserve it. Milk powder has a far longer shelf life than liquid milk and does not need
to be refrigerated. This is used for the more effective production of the milk powder.
During the heat treatment the heat generated in the mechanism causes the accidents in
the production and even it's causes the collapse in the production and even it's causes
the less effective in the product efficiency. This is due to the material assure in the
fatigue damage .The study of fatigue behaviors for materials which is very significant
because fatigue damage results in serious consequences. In this paper, two kinds of
heat treatment procedures were taken to investigate the effect of heat treatment on
micro-structures and fatigue behaviors of a nickel-base super alloy. Fatigue behaviors
were studied through total strain controlled mode at 650 °C. This paper explains the
heat treatment which involved in the production of the milk powder to improve the
efficiency of the Milk Powder Plant.
 vii

TABLE OF CONTENTS

PAGE
CHAPTER TITLE
NO.

ABSTRACT Iv

LIST OF TABLES Vii

LIST OF FIGURES Viii

LIST OF SYMBOLS AND ABBREVIATIONS Ix

INTRODUCTION 1
1
1.1 HEAT TRANSFER 1

1
1.1.1 Limitation factor for heat treatment
1
1.1.2 Regenerative of heating and cooling
2

1.2 PASTEURIZATION 2

1.2.1 Types of pasteurization 3

1.2.2 Thermization 4

1.3 MILK FLOWING IN HEAT EXCHANGER 4

1.3.1 Mechanism of milk flowing 5

1.3.2 Aspects of milk flowing

 viii

2 LITERATURE REVIEW 6

2.1 MILK POWDER PRODUCTION 6

2.1.1 Collection of Raw milk 6

2.1.2 Adulteration of raw milk 6

2.1.3 Heat treatment of skimmed milk 6

2.1.4 Milk Powder Collection 6

2.2 MILK POWDER SPECIFICATION 7

3 TECHNICAL DETAILS OF T-SERIES 8

3.1 INTRODUCTION 8

3.2 HFC CLEANING AGENT 8

3.2.1 Types and application 9

3.3 AUTOMATIC FIRE SUSPENSION SYSTEM 9

3.3.1 Electrical enclosure 9

4 PRODUCTIVITY ENHANCEMENT 10

4.1 TECHNICAL ENHANCEMENT 10

4.1.1 Bulk Density 10

4.1.2 Powder material density 10

4.2 DOMESTIC ENHANCEMENT 11

4.2.1 Fire breakout 11

4.3 PROJECT LAYOUT 14

4.3.1 Cream Pasteurization 14

4.3.2 PMS System 14

 ix

5 RESULT AND DISCUSSION 15

5.1 FIRE CONTROL AND PROTECTION 15

5.2 FIRE PRODUCTION SOLLUTION IN SPRAYER 15

5.3 POWDER MATERIAL DENSITY

15

6 CONCLUSION 17

7 REFERENCES 18
 x

LIST OF TABLES

TABLE NAME OF THE TABLE PAGE

NO. NO.

1.1 Types of pasteurization 4

2.1 Milk powder specification 7

 xi

LIST OF FIGURES

FIGURE NAME OF THE FIGURE PAGE

NO. NO.
3.1 Blaze cut 8

3.2 Electric enclosure 9

4.1 Cream pasteurization 14

4.2 PMS system 14

 xii

LIST OF SYMBOLS AND ABBREVIATIONS

SYMBOLS

A - Area m2

T - Temperature °C

Q - Heat transfer rate W

h - Heat transfer coefficient W/m 2 K

ν - Kinematic viscosity m 2 /s

L - Length M

M - Mass flow rate kg/s

Nu - Nusselt number -

U - Overall heat transfer coefficient W/m 2 K

Pr - Prandtl number -

Re - Reynolds number -

Cp - Specific heat J/kgK

K - Thermal conductivity W/mK

 xiii

GREEK SYMBOLS

ρ - Bulk density kg/ m3

ABBREVIATIONS

LTLT Low Temperature Long Time

HTST High Temperature Short Time

UHT Ultra High Temperature

HFC Hydro Fluorocarbon