Welding and Materials in Dairy Engineering

Dairy Engineering

•  This document is a course on Dairy Engineering, developed by S. Ravi Kumar at SVVU, Tirupati.

Module 1: Sanitary pipes, fittings, and Milk handling equipment

•  Covers materials and sanitary features of dairy equipment.
•  Includes sanitary pipes, fittings, and gaskets.
•  Explains installation, care, and maintenance of pipes and fittings.
•  Discusses milk storage tanks, silos, road tankers, and rail tankers.

Module 2: Bottle & Cans Washing and CIP cleaning equipment

•  Details the description, working, and maintenance of can washers.
•  Describes bottle washers and factors affecting washing operations.
•  Includes power requirements for can and bottle washers.
•  Explains CIP (Cleaning in Place) design.

Module 3: Separation equipment

•  Explores mechanical separation fundamentals.
•  Discusses principles and rates of filtration, pressure drop calculations.
•  Explores different types of centrifuges, their applications in the dairy industry, clarifiers, tri-processors, and cream separators.
•  Explains self-disludging centrifuges and Bacto-fuges, along with their maintenance.

Module 4: Homogenizers

•  Classifies homogenizers: single and two-stage.
•  Discusses power requirements for homogenization.
•  Details care and maintenance of homogenizers, including aseptic homogenizers.
•  Includes solving calculations.

Module 5: Pasteurizers

•  Explores batch, flash, and continuous (HTST) pasteurizers.
•  Explores pasteurizer controls and flow diversion valves.
•  Includes care and maintenance, plus solving calculations.

Module 6: Sterilizing & Packing equipment

•  Explores diverse sterilizer types, including in-bottle and autoclaves.
•  Covers aseptic packaging and equipment maintenance.
•  Includes continuous sterilization plants and UHT sterilization.

Module 7: Filling equipment

•  Details the working principles and types of bottle and capping machines.
•  Explores aseptic filling methods and maintenance.
•  Discusses methods for filling pouches and bags.

Module 8: Mixing and agitation equipment

•  Explores mixing and agitation principles and equipment selection for the dairy industry.
•  Includes mixing pumps and power consumption.
•  Explores the importance of mixing equipment for different dairy products

Lesson 1: Introduction - Materials and Sanitary Features of the Dairy Equipment

•  Details the role of pipes, fittings, valves, and other milk handling components in dairy plants.
•  Highlights the importance of sanitary features for maintaining product quality and hygiene.
•  Emphasizes that equipment must be accessible for cleaning, and that all product-contact parts should be smooth, self-draining, and readily cleanable.

Lesson 2: Sanitary Pipes and Fittings, Glass Piping, Plastic Tubing, Fittings and Gaskets

•  Covers the use of sanitary piping in dairy equipment design and layout.
•  Describes general points to consider when designing and laying out sanitary pipelines.
•  Includes a table of outer diameter, thickness, and capacity details of pipes.

Lesson 3: Installation, Care and Maintenance of Pipes & Fittings

•  Explores the installation of piping systems in dairy plants, including diagrams and procedures.
•  Highlights the significance of correct pipe sizing, material selection, and connections for safety and sanitation.
•  Includes details of valve types, support systems, and sizing of pipelines.

Lesson 4: Milk Storage Tanks, Silos, Road and Rail Tankers

•  Details various types of milk storage tanks, emphasizing the need for quality construction and materials in dairy operations.
•  Details the features of and design considerations for various types of storage tanks (Vertical, Horizontal and Silos)
•  Describes design considerations of road and rail tanker operations, with respect to safety and stability, and capacity requirements for different types of dairy products.

Lesson 5: Description, Working And Maintenance of Can Washers Straight - Through Can Washer

•  Explains methods for cleaning cans in dairy plants.
•  Discusses the construction and operation of a straight-through can washer.
•  Details the operation and maintenance procedures related to the can washer.
•  Detailed operating procedures for the different stages of can washing.

Lesson 6: Bottle Washers, Factors Affecting Washing Operations, Power Requirements of Can and Bottles Washers

•  Describes the principles and types of soaker-type bottle washers.
•  Explores the operating procedures for a soaker-type bottle washer, with emphasis on the various required stages
•  Explores the impact of temperature, water pressure/flow rates on the performance of bottle washing equipment.
•  Describes the power requirements of bottle washers.

Lesson 7: CIP and Designing of System

•  Focuses on the cleaning and sanitation of dairy equipment, including the function and features of cleaning-in-place (CIP) systems.
•  Details various types of CIP systems: single-use and reusable.
•  Explores and emphasizes process design and process methodology implications
•  Discusses practical considerations for CIP systems, including automation, and efficiency.

Lesson 8: Mechanical Separation: Fundamentals Involved in Separation

•  Explores various types of mechanical separation, including sieving, filtration, and membrane separation.
•  Categorizes separation processes based on the types of materials separated (liquid-liquid, liquid-gas, solid-solid, solid-gas).
•  Explores different separation methods, such as dust removal and safety processes.
•  Explores the fundamentals of gas-solid separation and the role of cyclones.
•  Discusses industrial applications and safety or health considerations.

Lesson 9: Principals Involved in Filtration, Types, Rates of Filtration, Pressure Drop Calculations

•  Explores filtration as a unit operation in the dairy industry.
•  Details the classification of filtration on the basis of applied forces (gravity, pressure, vacuum, and centrifugal), and their applications in industry.
•  Classifies filter operations into the categories: cake filtration, clarification, and microfiltration.
•  Explores types of vertical plate pressure filters.
•  Discusses the design and operation of various filter press types.

Lesson 10: Gravity Settling, Sedimentation, Principles of Centrifugal Separation

•  Explores the principles of gravity settling and sedimentation.
•  Explores Stokes' Law as a tool for analysis of particle separation.
•  Describes centrifugal separation, its principles, and its use in the dairy industry.
•  Details power calculations and capacity concerns in centrifugal separation.

Lesson 11: Different Types of Centrifuges: Application in Dairy Industry, Clarifiers, Tri-Processors, Cream Separator

•  Categorizes centrifuges based on their physical configuration.
•  Explores the principles of operation for different types of centrifuges (clarifiers, tri-processors, and cream separators).
•  Provides the specifications and operations of different kinds of centrifuges.

Lesson 12: Self- desludging Centrifuge, Bacto-fuge, Care and Maintenance of Separators and Clarifiers

•  Details self-desludging centrifuge designs.
•  Describes processes for cleaning centrifugal equipment (bactofugation).

Lesson 13: Solving Numerical problems on Gravitational Separation

• Provides numerical problems and their solutions, including calculations for determining velocity of particle separation.

Lesson 14: Homogenization: Classification, Single Stage and Two Stage Homogenizer Pumps, Power Requirement for Homogenization

•  Explores the homogenization process in detail, the different types of homogenizers (single-stage and two-stage), and how to calculate power requirements.
•  Discusses design considerations.

Lesson 15: Care and Maintenance of Homogenizers, Aseptic Homogenizers

•  Explores ways to maintain and care for homogenizers and how to perform a proper maintenance program.
•  Explores design, maintenance, and repair aspects of valves and gauges (pressure gauges) to properly maintain homogenizers.

Lesson 16: Solving Numerical problems on Homogenizers

•  Provides different numerical problems related to homogenizers and how to solve them.

Lesson 17: Pasteurization: Batch, Flash and Continuous (HTST) Pasteurizers

•  Describes pasteurization processes, from batch to HTST (high temperature short time).
•  Explores the different types of pasteurizers and their construction.

Lesson 18: Pasteurizer Control, Flow Diversion Valve

•  Explores the instrumentation and control systems used in pasteurizers to monitor and control temperatures.
•  Describes the function of flow diversion valves (FDV).

Lesson 19: Care and Maintenance of Pasteurizer

•  Explores the maintenance aspects of pasteurizers emphasizing the need for proper maintenance to avoid contamination and ensure optimal operations.
•  Emphasizes that preventative maintenance checks and repairs are part of maintaining optimal pasteurizer function.

Lesson 20: Solving Numerical problems on Pasteurizer

•  Provides numerical problems on pasteurizer design, regeneration, flow rates, and heat transfer.

Lesson 21: Different Types of Sterilizers, In-Bottle Sterilizers, Autoclaves

•  Explores various sterilization methods and equipment used in the dairy industry.
•  Details of batch sterilization and continuous sterilization equipment.
•  Explores the design, working and maintenance of various sterilizer types: batch, in-bottle, and autoclave sterilizers.

Lesson 22: Continuous Sterilization Plant, UHT Sterilization

•  Describes UHT (ultra-high temperature) sterilization, its methods, advantages, and the specific equipment needed.
•  Details the heat exchange types (indirect heating), along with typical equipment diagrams.

Lesson 23: Continuous Sterilization Plant, UHT Sterilization

•  Details direct heating systems for sterilization, emphasizing the advantages and principles of those methods.
•  Explores different heat transfer types and equipment diagrams.

Lesson 24: Aseptic Packaging and Equipment

•  Explores aseptic packaging and handling along with the importance of filling systems and processes

Lesson 25: Care and Maintenance of Sterilizers

•  Focuses on the maintenance procedures for different types of sterilizers considering different materials for gaskets and other components.
•  Explores preventative maintenance, considering the critical components of batch and continuous sterilizers.

Lesson 26: Thermal Process Calculation: Solving Numerical

•  Explores calculations and numerical solutions related to microbiological inactivation and thermal processes.

Lesson 27: Filling Operation

•  Discusses methods and principles for filling various types of containers (bottles, pouches).
•  Explores important aspects of filling operations, including vacuum filling.
•  Explores the components and capabilities of filling machine designs and operations.

Lesson 28: Pouch Filling Machine: Form-Fill-Seal Types

•  Outlines the operations and sequential procedures of form-fill-seal (FFS) machinery, with an emphasis on the various steps of packaging
•  Describes the processes and the components involved in the design and operation of filling equipment.

Lesson 29: Aseptic Filling by Bulk Handling System, Care and Maintenance

•  Explores the principles, types, and equipment of aseptic bulk filling systems, focusing on their design, operation, and maintenance.
•  Provides detailed operational aspects and safety information.

Lesson 30: Mixing and Agitation

•  Explores different types of mixing and agitation equipment commonly used in the dairy industry
•  Describes different types of agitators, including paddle, propeller, and turbine types.
•  Discusses the importance of mixing and agitation, in different industrial operations.

Lesson 31: Power Consumption of Mixer-Impeller

•  Explores the calculation of power requirements for various types of mixing equipment.
•  Explores the importance of efficient mixing operation in terms of energy consumption.

Lesson 32: Solving Numerical on Mixing and Agitation

•  Provides numerical problems and approaches for calculating power requirements for mixing equipment.

Lesson 33: Solving Numerical on Mixing and Agitation

•  Focuses on solving numerical problems related to mixing and agitation in different industrial settings.