Welding and Materials in Dairy Engineering

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Questions and Answers

Which material is difficult to weld and considered brittle?

Mild Steel

Cast Iron (correct)

Wrought Iron

Stainless Steel

Which grade of stainless steel is primarily used for pipes and fittings?

AISI 205

AISI 304 (correct)

AISI 316

AISI 430

Mild steel possesses which of the following properties?

Highly brittle

Cannot be forged

Easily welded and magnetic (correct)

Difficult to work with

What distinguishes AISI 316 from AISI 304 stainless steel?

AISI 316 is suitable for heat exchangers needing higher corrosion resistance Signup and view all the answers

What types of applications is wrought iron typically used for?

Shock loading parts Signup and view all the answers

Which type of stainless steel is categorized as martensitic?

440 series Signup and view all the answers

What is a characteristic feature of the 300 series stainless steel?

Is non-hardenable except by cold working Signup and view all the answers

In which applications are iron and steel primarily used in the dairy industry?

Structural components not in contact with milk Signup and view all the answers

Which type of stainless steel is known to be semi-austenitic?

201 series Signup and view all the answers

What composition defines stainless steel?

More than 10.5% chromium Signup and view all the answers

Which material is commonly used for insulation in dairy equipment?

Plastics Signup and view all the answers

Which statement about ferritic stainless steels is correct?

They are non-hardenable. Signup and view all the answers

Which alloy series is known for its high chromium content and is non-hardenable except by cold working?

300 series Signup and view all the answers

What is a key feature of sanitary pipes and fittings used in dairy engineering?

They must be non-porous and easy to clean. Signup and view all the answers

Which component in AISI 316 SS primarily increases resistance to corrosion?

Molybdenum Signup and view all the answers

What is a significant disadvantage of aluminum when used for making milk cans?

It is difficult to weld Signup and view all the answers

Which type of pasteurization involves holding milk at a specific temperature for a short period?

Flash pasteurization Signup and view all the answers

What type of plastic is primarily used for pump shaft seals in the dairy industry?

PTFE Signup and view all the answers

What is the primary purpose of a can washer in dairy processing?

To ensure sanitary cleaning of containers before use. Signup and view all the answers

Which method is NOT involved in the mechanical separation of milk?

Pasteurization Signup and view all the answers

Which property is improved by adding chromium to the stainless steel compositions AISI 304 and AISI 316?

Hardenability Signup and view all the answers

What is one of the key factors affecting the performance of a bottle washer?

The water temperature used during washing. Signup and view all the answers

What is a distinguishing feature of thermoplastics compared to thermosetting plastics?

They can be reshaped upon heating. Signup and view all the answers

Which type of centrifuge is specifically designed for separating bacteria from milk?

Bacto-fuge Signup and view all the answers

Which of the following is a function of nickel in AISI 304 and AISI 316?

Improves toughness and corrosion resistance Signup and view all the answers

What is a significant maintenance requirement for homogenizers in dairy engineering?

Regular calibration of the homogenization pressure. Signup and view all the answers

What is one major characteristic of thermosetting plastics?

They undergo permanent changes when heated. Signup and view all the answers

How does the presence of manganese affect stainless steel composition?

It enhances machining properties Signup and view all the answers

Which type of sterilizer is commonly used for sterilizing milk in its container?

In-bottle sterilizer Signup and view all the answers

Which feature is essential for ensuring the sanitary design of dairy equipment?

Equipment must be easily accessible and readily cleanable. Signup and view all the answers

What is a key consideration for joints in dairy equipment?

All permanent joints must be welded and grounded to a smooth finish. Signup and view all the answers

Why is it important for product contact surfaces to be self-draining?

To prevent the accumulation of residual product that can lead to contamination. Signup and view all the answers

Which of the following is a benefit of avoiding the use of gaskets in dairy equipment?

Gaskets can contribute to off flavors in the product. Signup and view all the answers

What is the purpose of pre-heating the product with external devices in dairy processing?

To reduce the risk of external contamination during processing. Signup and view all the answers

What effect does effective velocity of flow have in dairy equipment?

It helps achieve optimum agitation to prevent surface film formation. Signup and view all the answers

Why is having smooth and even interior surfaces important in dairy equipment?

It eliminates crevices and projections that could harbor bacteria. Signup and view all the answers

What is a critical aspect of equipment design in the dairy industry related to pressure?

Processing under vacuum reduces the risk of external contamination. Signup and view all the answers

Which material is commonly specified for sanitary pipes used in the dairy industry?

Stainless Steel grade 304 Signup and view all the answers

What is an essential design feature of pipes for handling milk?

Pipes should be seamless and preferably cold drawn Signup and view all the answers

Why must pipes in the dairy industry be polished internally and externally?

To avoid surface defects that can harbor bacteria Signup and view all the answers

Which of the following is an important consideration when designing sanitary pipe lines for the dairy industry?

Flow capacity should minimize pressure loss Signup and view all the answers

What should be done to the surface of pipes before use in the dairy industry?

They should be softened, descaled, and pickled Signup and view all the answers

What type of fittings should be used with sanitary pipes in the dairy industry?

Material for fittings should be the same as that of the pipe Signup and view all the answers

What characteristic should the pipes NOT have in the dairy industry?

Surface defects Signup and view all the answers

What is a characteristic of the carrying capacity of a 25.4 mm outer diameter pipe?

It has a size variant that allows less than 2000 Kg/h Signup and view all the answers

Signup and view all the answers

Study Notes

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.

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Description

Test your knowledge on the properties and applications of various metals, particularly in the dairy industry. This quiz covers welding challenges, stainless steel grades, and common materials used in dairy equipment. Perfect for students and professionals in engineering and materials science!