1

CHAPTER 1

INTRODUCTION

Powdered milk or dried milk is a manufactured dairy product made by

evaporating milk to dryness. 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, due to its low moisture content. Another purpose is to reduce its bulk for
economy of transportation. Powdered milk and dairy products include such items as
dry whole milk, nonfat (skimmed) dry milk, dry buttermilk, dry whey products and
dry dairy blends.

1.1 HEAT TRANSFER

Heat transfer is classified into various mechanisms, such as thermal conduction,

thermal convection, thermal radiation, and transfer of energy by phase changes.

1.1.1. LIMITATION FACTORS FOR HEAT TREATMENT

Intense heat treatment of milk is desirable from the microbiological point of

view. But such treatment also involves a risk of adverse effects on the appearance,
taste and nutritional value of the milk. Proteins in milk are denatured at high
temperatures. This means that the cheese making properties of milk are drastically
impaired by intense heat treatment. Intense heating produces changes in taste; first
cooked flavour and then burnt flavor. The choice of time/temperature combination is
therefore a matter of optimization, in which both microbiological effects and quality
aspects must be taken into account. Since heat treatment has become the most
important part of milk processing, and knowledge of its influence on milk better
understood, various categories of heat treatment

1.1.2 REGENERATIVE OF HEATING AND COOLING

In many cases, a product must first be heated for a certain treatment and then
cooled. Pasteurization of milk is an example. Chilled milk is heated from perhaps 4
°C to a pasteurization temperature of 72 °C, held at that temperature for 15 seconds
and then chilled to 4 °C again.The heat of the pasteurized milk is utilized to warm the
cold milk. The incoming cold milk is preheated by the outgoing hot milk, which is
simultaneously pre-cooled. This saves heating and refrigeration energy.The process
takes place in a heat exchanger and is called regenerative heat exchange or, more
commonly, heat recovery. As much as 94 – 95% of the heat content of the pasteurized
milk can be recycled.

HEATING

Hot water, or occasionally low-pressure steam, is used as the heating medium

to heat milk. A certain amount of heat is transferred from the heating medium to the
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milk so that the temperature of the latter rises and the temperature of the heating
medium drops correspondingly.

COOLING

Directly after arrival at the dairy, the milk is often cooled to a low temperature (5
°C or lower), to temporarily prevent growth of microorganisms. Following
pasteurization, the milk is also cooled again to about 4 °C. If naturally cold water is at
hand, it may be utilized for pre-cooling after pasteurization and regenerative heat
exchange. In all cases, heat is transferred from the milk to the cooling medium. The
temperature of the milk is reduced to the desired value and the temperature of the
cooling medium rises correspondingly. The cooling medium may be cold water, ice
water, brine solution or an alcohol solution, such as glycol.

1.2 PASTEURIZATION

Pasteurization is the process of heat processing a liquid or a food to kill

pathogenic bacteria to make the food safe to eat. The use of pasteurization to kill
pathogenic bacteria has helped reduce the transmission of diseases, such as typhoid
fever, tuberculosis, scarlet fever, polio, and dysentery.

1.2.1 TYPES OF PASTEURIZATION

LTLT PASTEURIZATION

The original type of heat treatment was a batch process in which milk was
heated to 63 °C in open vats and held at that temperature for 30 minutes. This method
is called the holder method or low temperature, long time (LTLT) method.
Nowadays milk is almost always heat treated in continuous processes like
thermization, HTST pasteurization or UHT treatment.

HTST PASTEURIZATION

HTST is the abbreviation of High Temperature Short Time. The actual

time/temperature combination varies according to the quality of the raw milk, the type
of product treated, and the required storage properties.The HTST process for milk
involves heating it to 72 – 75 °C with a hold of 15 – 20 seconds before it is cooled.
The phosphatase enzyme is destroyed by this time/temperature combination. The
phosphatase test is therefore used to check that milk has been properly pasteurized.
The test result must be negative; there must be no detectable phosphatase activity.

ULTRA PASTEURIZATION

Ultra pasteurization can be utilized when a particular shelf life is required. For
some manufacturers, two extra days are enough, whereas others aim for a further 30 –
40 days on top of the 2 – 16 days that are traditionally associated with pasteurized
products. The fundamental principle is to reduce the main causes of reinfection of the
product during processing and packaging, so as to extend the shelf life of the product.
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This requires extremely high levels of production hygiene and a distribution

temperature of no more than 7 °C; the lower the temperature, the longer the shelf life.

UHT TREATMENT

UHT is the abbreviation for Ultra High Temperature. UHT treatment is a

technique for preserving liquid food products by exposing them to brief, intense
heating, normally to temperatures in the range of 135 – 140 °C. This kills
microorganisms that would otherwise destroy the products.UHT treatment is a
continuous process that takes place in a closed system that prevents the product from
being contaminated by airborne microorganisms. The product passes through heating
and cooling stages in quick succession. Aseptic filling, to avoid reinfection of the
product, is an integral part of the process.

Two alternative methods of UHT treatment are used:

Indirect heating and cooling in heat exchangers. Direct heating by steam

injection or infusion of milk into steam and cooling by expansion under vacuum.

STERILIZATION

The original form of sterilization, which is still in use, is in-container

sterilization, usually at 115 – 120 °C for some 20 – 30 minutes.After fat
standardization, homogenization and heating to about 80 °C, the milk is packed in
clean containers; usually glass or plastic bottles for milk, and cans for evaporated
milk. The product, still hot, is transferred to autoclaves in batch production or to a
hydrostatic tower in continuous production. Heating and cooling are the most
important operations in the dairy.

THERMIZATION

In many large dairies, it is not possible to pasteurize and process all the milk
immediately after reception. Some of the milk must be stored in silo tanks for hours or
days. Under these conditions, even deep chilling is not enough to prevent serious
quality deterioration.Many dairies therefore pre-heat the milk to a temperature below
the pasteurization temperature, to temporarily inhibit bacterial growth. This process is
called thermization. The milk is heated to 63 – 65 °C for about 15 seconds, a
time/temperature combination that does not inactivate the phosphatase enzyme.
Double pasteurization is forbidden by law in many countries, so thermization must
stop short of pasteurization conditions. Types of pasteurization are given in table 1.1
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Process °C Time
Thermization
LTLT pasteurization of 63 30min
milk
HTST pasteurization of 72 – 75 15-20sec
milk
HTST pasteurization of > 80 1-5sec
cream
Ultra pasteurization 125 – 138 2-4sec
UHT (flow sterilization) 135 – 140 Few sec
normally
Sterilization in container 115 – 120 20-30 min
Table 1.1 Types of pasteurization
1.3 MILK FLOWING IN HEAT EXCHANGER
Thermal processing is an energy-intensive process in the dairy industry
because every product is heated at least once. Fouling-related costs are additional
energy, lost productivity, additional equipment, manpower, chemicals, and
environmental impact.

1.3.1 MECHANISM OF MILK FLOW

Milk is a complicated biological fluid and contains a number of species.

Average composition of milk (Bylund 1995) Constituents Average concentration (%)

 Water - 87.5
 Total solids - 13
 Proteins - 3.4
 Lactose - 4.8
 Minerals - 0.8
 Fat - 3.9
 Proteins - 3.4
 Lactoglobulin - 0.32
 Lactalbumin - 0.12

Fouling in a heat exchanger depends on bulk and surface process. The deposition
is a result of a number of stages (Belmar-Beiny and Fryer 1993). The 1st stage
involves denaturation and aggregation of proteins in the bulk followed by the
transport of the aggregated proteins to the heat-transfer surface. Then surface
reactions take place and resulting in incorporation of the proteins into the deposit
layer. The deposit layer is subjected to fluid hydrodynamic forces and as a result there
is possible re-entrainment or removal of the deposits.The step controlling the overall
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fouling may either be related to physical/chemical changes in the proteins or the mass
transfer of the proteins between the fluid and the heat-transfer surface.

1.3.2 ASPECPTS OF MILK FLOWING

Protein denaturation is reversible Protein denaturation is irreversible Ruegg

and others Protein aggregation is irreversible Mulvihill and Donovan (1987), Anema
and McKenna (1996), Changani and others (1997), Chen and others (1998) Protein
denaturation is the governing reaction Lalande and others (1985), Hege and Kessler
(1986), Arnebrant and others (1987), Kessler and Beyer (1991), de Jong and others
(1992) Protein aggregation is the governing reaction Lalande and René (1988),
Gotham and others (1992), Delplace and others (1997) Formation of protein
aggregates enable to de Jong and others (1992), Delplace and others (1997), van
Asselt and others (2005) reduce fouling Only protein aggregates cause fouling
Toyoda and others (1994) Fouling is considered to depend on protein de Jong and van
del Linden (1992), de Jong and others (1992), Belmar-Beiny and others
(1993),reactions only Delplace and others (1994, 1997), Schreier and Fryer (1995),
Grijspeerdt and others (2004), Sahoo and others (2005), Nema and Datta (2005)
Fouling is considered to depend on protein Toyoda and others (1994), Georgiadis and
others (1998), Georgiadis and Macchietto (2000),reactions as well as mass transfer.
 6

CHAPTER 2
LITERATURE REVIEW

2.1 MILK POWDER PRODUCTION

2.1.1 COLLECTION OF RAW MILK

Raw milk on arrival at the factory is rapid tested for temperature, hygiene,
antibiotics, water addition and adulteration.

2.1.2 ADULTERATION OF RAW MILK

Adulteration of raw milk in some countries is prolific and a real barrier to

globally operating companies establishing facilities due to the high brand risk
involved. When the raw milk arrives at the manufacturing plant it is usually separated
into cream and skimmed milk to enable standardization of the fat content prior to
spray drying. High volume manufacturers will automate this cream fat standardization
using an inline “standomat” which doses cream back into the skim to give the correct
fat % in the milk to be processed.

2.1.3 HEAT TREATMENT OF SKIMMED MILK

The skimmed milk heat treatment temperature coupled with the holding time
determines the heat classification of the powder produced. For skim milk powder
classified as “low-heat”, the milk is low temperature pasteurized with little or no
holding required, while heat treatment for a “high-heat” method requires heating milk
to 85-88 C and holding at this temperature for 15 to 30 seconds..There is no
requirement to homogenize skimmed milk for powder production because of its low
fat content. High heat, heat stable powders are also produced by varying the
evaporation conditions.

2.1.4 MILK POWDER COLLECTION

Viscosity is generally maintained below 250 centipoise at the atomizer. The

most efficient way to reduce viscosity is to increase the feed temperature. This will
also increase the milk powder spray dryer capacity. A high pressure pump feeds the
liquid to nozzles or atomiser and the dryer chamber. Nozzles typically produce a
powder with a high bulk density, a narrow particle size distribution and, in the case of
fat containing powders a low free-fat content due to the homogenizing effect. The
bulk density of the milk powder is mostly affected by the density of the concentrate.
A good process control system is essential to ensure a consistent product.Milk powder
specification is given in Table 2.1
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2.2 MILK POWDER SPECIFICATIONS

S.NO. PARAMETERS SPECIFICATIONS

ADPIEXTRA GRADE

1 Total milk solids % min 96.0

2 Insolubility Index ,ml,max 1.2

3 Total ASH % max 8.2

4 Fat % max 1.25

Table 2.1 Milk powder specifications

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CHAPTER 3
TECHNICAL DETAILS OF T-SERIES
3.1 INTRODUCTION

BlazeCut “T” Series system is a simple and cost effective fire protection of
small enclosures. The system consists of a heat sensitive tube made of special plastic
which is closed by a stainless steel fitting on each end. The tube has both storage and
detection function which means that the extinguishing agent is stored directly in the
tube and no additional storage device like cylinder is needed. BlazeCut system
operates automatically independent of any power supply by detecting higher
temperatures. When the temperature in the protected enclosure rises to a critical
threshold, the detection tube melts down at the point where the affecting temperature
is the highest. Melting the tube creates a hole releasing the entire extinguishing agent
stored in the tube onto the source of the fire. Blazecut is shown in fig 3.1

Fig 3.1 Blazecut

3.2 HFC Clean Agent

The HFC clean extinguishing agent is liquefied gas used for volume fire
suppression. The HFC clean extinguishing agent is discharged as a stream of gas and
liquid droplets that penetrate into the fire area, ceasing the combustion process
through heat absorption and chemical interaction. The HFC clean extinguishing agent
is considered environmentally accepted substitute for Halon extinguishing agents
harmful to the ozone layer used in the past.
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3.2.1 TYPES AND APPLICATIONS

Types of HFC clean extinguishing agents used:

 HFC-227ea
 HFC-236fa

Application

The HFC clean extinguishing agent is an agent of choice for protection of

enclosures where residue may be harmful to the protected sensitive devices. The agent
is suitable for Class A (creating flames), Class B, and Class C.

3.3 AUTOMATIC FIRE SUSPENTION SYSTEM

When the System is Installed the Fire Breakout occurred is detected by the
Fire Detection system and the Extinguishing Fire is Quenched.

3.3.1 ELECTRIC ENCLOSURE

 Electrical cabinets
 Fuse boxes
 Racks
 Audio-video equipment
 Battery spaces
 Network and cable installations

Fig 3.2 Electric enclosure

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CHAPTER 4

PRODUCTIVITY ENHANCEMENT
4.1 TECHNICAL ENHANCEMENT

4.1.1 BULK DENSITY (ρ)

When powders are shipped over long distances it is important that they have a
high bulk density to reduce the volume, since in most cases transportation costs are
calculated by volume. A high bulk density also saves packaging material. However, in
some instances the producers may be interested in low bulk density to supply
optically larger amounts of powder than that of their competitors. Low bulk density,
as influenced by agglomeration, is also an important characteristic of instant powders.

DEFINITION

Bulk density is the weight of a unit volume of powder; in practice it is

expressed as g/ml, g/100 ml or g/l.

Factors influencing bulk density

The bulk density of milk powders is a very complex property; it is the result of
several other properties and is influenced by a number of factors. The primary factors
determining bulk density are:

The particle density, given by

1. powder material density

2. The content of the occluded air inside the particles
3.The content of interstitial air, i.e. the air between the particles.

4.1.2 POWDER MATERIAL DENSITY

The powder material density is given by the composition of the powder. It

depends on the contents and densities of the individual components, and can be
calculated according formula:
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4.2 DOMESTIC ENHANCEMENT

4.2.1 FIRE BREAKOUT

Disasters happen for many reasons, often because managers and employees
aren’t aware of the risks that surround them at work every day.

Here are five of the most common causes of industrial fires and explosions.

1. Combustible dust

Overlooked, and highly deadly, combustible dust is a major cause of fire in

food manufacturing, The reason is that just about everything, including food, dyes,
chemicals, and metals even materials that aren’t fire risks in larger pieces has the
potential to be combustible in dust form. And these explosions aren’t easy to contain.
In the typical incident, a small fire will result from combustible material coming into
contact with an ignition source. This may be a dust explosion, but it doesn’t have to
be. In fact, it could be most any other type of explosion on this list.

How to prevent combustible dust incidents

The key ingredient in combustible dust fires and explosions is the presence of
the dust itself. While you probably won’t be able to eliminate dust entirely, you can
make sure it doesn’t accumulate to a dangerous level simply

2. Hot work

Hot work is one of the leading causes of industrial fires across all industries.
Although hot work is commonly equated with welding and torch cutting, there are
many other activities including brazing, burning, heating, and soldering that pose a
fire hazard. This is because the sparks and molten material, which reach temperatures
greater than 1000°F, can easily travel more than 35 feet.

How to prevent hot work incidents

Like combustible dust incidents, hot work disasters are preventable by

following proper safety procedures. Avoid hot work if possible. This isn’t always a
feasible solution, but if there’s an alternative, take it. Train personnel on the hazards
associated with hot work, any site-specific hazards, the proper policies and
procedures, and the use of safety equipment. Ensure that the area is clear of
flammable or combustible materials including dusts, liquids, and gasses. Use a written
permit system for all hot work projects, even where permits aren’t required. Better
safe than sorry! Supervise the work. Especially if you use outside contractors, make
sure a safety professional is on hand to provide supervision.
 12

3. Flammable liquids and Chemicals

These fires, which often occur at chemical plants, can be disastrous. To see
what these look like, check out this post at Industry Tap. It features videos from five
chemical plant explosions that were the result of explosions of flammable materials,
such as rocket fuel (which produces a flammable gas), acrylic acid, and crude oil.

How to prevent flammable liquid and gas incidents

There is certainly some danger inherent in any work involving flammable

liquids and gasses, but all available safety precautions should be taken to mitigate
these risks. Know the hazards. One major component of prevention is simply
knowing the safety information for every liquid on your premises. This information is
available on the material safety data sheet (MSDS) that comes with such products.
Store flammable liquids properly. Make sure all hazardous materials are stored
according to OSHA-compliant procedures. Control all ignition sources. Except for
when you’re intentionally heating the flammable materials, keep ignition sources as
far away from them as possible. Provide personal protective equipment. This is a must
across all categories of fire hazards but especially when liquids and gasses are
involved.

4. Equipment and machinery

Faulty equipment and machinery are also major causes of industrial fires.
Heating and hot work equipment are typically the biggest problems here — in
particular, furnaces that aren’t properly installed, operated, and maintained. In
addition, any mechanical equipment can become a fire hazard because of friction
between the moving parts. This risk can be brought down to practically zero simply
by following recommended cleaning and maintenance procedures, including
lubrication.

Awareness

You can’t prevent risks you don’t know exist. Neither can your employees.
Provide safety awareness training so everyone in your facility knows what risks to
watch out for and what to do if they find one.

5.Electrical hazards

Electrical fires are one of the top five causes of fires in manufacturing plants.
Here a non-exhaustive list of specific electrical hazards: Wiring that is exposed or not
up to code Overloaded outlets Extension cords Overloaded circuits Static discharge
The damage caused by these fires can quickly compound thanks to several of the
other items on this list. Any of the above hazards can cause a spark, which can serve
as an ignition source for combustible dust, as well as flammable liquids and gasses.
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How to prevent electrical fire incidents

As with the previous risks, the key to preventing electrical fires is awareness
and prevention. This involves training, maintenance, and following best practices.
Here are a few to put into practice right now: Don’t overload electrical equipment or
circuits. Don’t leave temporary equipment plugged in when it’s not in use. Avoid
using extension cords, and never consider them permanent solutions. Follow a regular
housekeeping plan to remove combustible dust and other hazardous materials from
areas that contain equipment and machinery. Implement a reporting system so that
anyone who observes an electrical fire risk can report it without consequences.
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4.3 PROJECT LAYOUT

4.3.1 CREAM PASTEURIZATION

4.3.2 PMS SYSTEM

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CHAPTER 5

RESULT AND DISCUSSION

5.1 FIRE CONTROL & PROTECTION

 Material handling safety related to mechanical and manual material handling,

lifting applications, transport, earth moving and material handling equipments
required like cranes, conveyors and lifts.
 Fixed fire fighting the fire service organization should identifies the sprinkler
system of fire and should care, maintain, operational procedure, drenchers,
down-comers and automatic fire alarm system
 Water relayit should identify the communication of fire system, calculation of
hose, turn out area, area topography, radio communication and use of VHF
sets.
 Rural fire the fire hazards in rural areas which causes fire, mist, gasses, dust,
smoke, chemicals and aerosols
 Ship fires elemental knowledge about the ship fire protection action is
required rescue and fire fighting, special equipment and training is required.
 Hazardous chemical dangerous chemical and substances which introduce to
transportation and handling of dangerous chemical and explosives should be
under take a corrective measures

5.2 FIRE PRODUCTION SOLLUTION IN SPRAY DRYER

Before spray-drying, milk concentrate is heated at a temperature in the range
of 65 °C to 80°C to reduce its viscosity. This is to optimize atomization of the
concentrate in the spray-dryer, thereby improving spray-drying efficiency and powder
properties (such as solubility index and coffee sediment).Any heat-sensitive
microorganisms present are also destroyed by the concentrate heating step .Heating
under vacuum requires low temperature for drying .As the temperature of drying is
lowered, there is an increase in the solubility and a decrease in the free fat content of
milk powder. The bulk density of milk powder decreases with an increase in the
temperature of concentration . A combination of high homogenization pressure and
high temperature treatment of the concentrate before spray-drying results in poor
reconstitution properties of the powder, particularly when heating is carried out after
homogenization (Singh and Aiqian 2010). Homogenization of the whole milk
concentrates before spray-drying helps to reduce the presence of free fat in the
powder.
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5.3 MILK POWDER MATERIAL DENSITY

One of the main risks in a spray dryer is material build-up inside the dryer.
Over time, this material will over-dry and can start to smoulder. this smouldering fire
continues without detection, a fire can break out. Many milk products will self-ignite
at 100˚C over time, if the build-up thickness is around 100-150mm. This is very
critical since all dryers have an inlet temperature of more than 100˚C. Another risk is
mechanical friction in any of the mechanical moving parts in the area of the spray
dryer. Firefly’s solution for the protection of milk powder spray dryers consists of
flame detection and suppression as well as spark and hot particle detection and
extinguishing. Firefly also offers a fire protection solution for the fluid bed,
minimizing the risk for a fire in the fluid bed and downstream the production flow.
The codes for the use of equipment in the food industry are very strict. Firefly
therefore tailors a protection system to accommodate these parameters. Firefly
equipment for the food industry contains of stainless steel and other food-approved
materials. To provide effective protection against fires and explosions, Firefly uses
IR-radiation detection and flame detection in combination with either CO2
suppression or water spray extinguishing and water mist suppression if possible.
 17

CONCLUSION

The aspect that the project is to Improve the productivity and to reduce the
heat explotion and fire breakthrough during the process . The many solution are been
analyzed to improve the rate of the production and reduce the breakout of the fire.T-
series Blaze cut is one of the which is used to extinguish the firebreak through. This is
the one of the remedy which has been analyzed to install in the mechanism of cream
pasteurization, MVR evaporation ,PMS System and stages of spray dryer. Where the
heat exchanger are used in these stages and heat expolation are exploits more during
this process. The research on the fatigue behaviors of hot-end components such as
turbine disks have become a research hotspot. Thus, cracks begin to initiate after a
large number of fatigue cycles. The material deformation during the heat treatment
should be studied.
 18

REFERENCE

JOURNALS

1. Harrison, W.; Whittaker, M.; Williams, S. Recent advances in creep modelling of

the nickel base superalloy, alloy 720Li. Materials 2013, 6, 1118–1137

2. Mr.V.K.Garg,Chairman, Fire Technology and Industry safety management, 2013,

6,10

BOOKS

1. Fire Engineers published by Institution of Fire Engineers(INDIA) ISO 9001-2008

2. Indian Dairyman published by Indian world milk org. July 2017

WEBSITE

1. http://www.worksafe.govt.nz/worksafe/information-guidance/all-guidance-
items/acop-fire-and-explosion-in-nz-dairy-industry-spray-drying-plant/dairy-ac.pdf

2. http://www.aidic.it/cet/13/31/119.pdf

3. http://www.chemistry.nus.edu.sg/_file/PSSO/RiskAssessment/cm2166-
Expt%201B%20-%20Ion%20Selective%20(Milk%20Powder).doc

4. http://www.anval.net/downloads/bulk%20density%20chart.pdf

5.http://onlinelibrary.wiley.com/store/10.1111/j.15414337.2006.tb00080.x/asset/j.154
14337.2006.tb00080.x.pdf?v=1&t=j96nzdkn&s=f7685c91b8f639fb398e93680fce669
894b0d729

6. http://www.mdpi.com/1996-1944/8/9/5299/pdf

7. http://askagroup.com/wp-content/uploads/2016/08/electrical_enclosures_2a.jpg

8. https://www.rotronic.com/en/rotronic-cases-read?id=364/