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Pasteurization Plant
HTST Milk Pasteurization Plant for 600 Litre/hour
Habib Ullah Manzoor Muhammad Umer Iqbal Muhammad Haris Muhammad Bilal
University of University of University of University of
Engineering & Engineering & Engineering & Engineering &
Technology Lahore Technology Lahore Technology Lahore Technology Lahore
Faisalabad Campus, Faisalabad Campus, Faisalabad Campus, Faisalabad campus
Pakistan Pakistan Pakistan chohanbilal95@gmail.co
habibullahmanzoor@gm umer95634@gmail.com harisinam10@gmail.com m
ail.com
Abstract—Milk has been used from centuries in daily lives of facilities are very rare, so the milk is soured which will reduce
humans to add more nutrients in food. Milk is also utilized in many its economic value. In order to increase the quantity and
barking products. Cow milk can sour in 3 hours at 30°C. To improve the quality of milk, better facilities and technical
prevent milk from souring a process named pasteurization is knowledge is required [4].
performed. Where milk temperature is kept at 75°C for 15 seconds
Pakistan is the third big country of supplying milk.
and then cooled to 4°C. After this process milk can be stored for
21 days in refrigerator. However, this process can increase the cost Dairy industry is included in one of the major industry in
of milk. In this paper an energy efficient design of mini milk Pakistan. The popularity of processed milk is increasing day by
pasteurization plant is presented. Calculations are carried out for day as the attention to preservation through the use of
all the required components (electric pumps, heat exchanger, antimicrobials has been increased[21], which inhibit or destroy
electric heater and chillers) in detail. If plant is to run for 12 hour the growth of microorganisms. Antimicrobials are produced by
in a day then 1.1 million annually can be saved. animals, plants, and microorganisms [5]. Pasteurization is an
important process that can kill various dangerous
Keywords— pasteurization; HTST; holdign tube; heat microorganisms in the milk like Salmonella, Listeria, Yersinia,
exchanger; cost analysis.
Campylobacter, Staphylococcus and E-Coli [6].
I. INTRODUCTION Pasteurization is the process in which milk is heated
up to 72ºC for a certain period of time and then it is cool down
It is recommended that Mother’s own milk be fed
to 4ºC [7]. Heating milk up to 72oC and then holding at that
exclusively for the first 6 months of new-born child’s life [1]. It
temperature for a certain time guarantee the destruction of
is because it is necessary for the health of newborns and is
unwanted microorganisms and does not affect the taste &
particularly importance for fragile preterm infants born of very nutritional value of the milk[22]. When properly done, shelf life
low birth weight. Due to certain reasons, including mother’s of pasteurized milk increased to 72 hours [8]. This is a very
illness and immaturity of mammary secretory cells, mothers do
positive aspect of using the pasteurized milk.
not have a full supply of their own milk, and in this case, human
donor milk is preferred. Donor human milk provides for a
reduction in the incidence of necrotizing enterocolitis (NEC) as A. Pasteurization:
well as improved feeding tolerance compared with formula Pasteurization is a process invented by Louis Pasteur
milk in this high-risk group [2]. To ensure safety from in 1864 [9]. He discovered that abnormal fermentation of wine
infectious agents potentially contaminating donated milk, the and beer could be prevented by heating these beverages to about
milk is typically pasteurized. 57oC for a few minutes [10]. In pasteurization process,
Processing of milk is done to prevent it from souring sufficient heat is applied to a food for a particular time. This
specially in summer where temperature approaches 50 oC. So heat will kill all the germs present in the food that will cause
there is a chance of rapidly souring of milk. However, milk does spoilage and disease. Fortunately, most of the harmful
not sour at temperature below 10oC, probably at 4oC, for 72 microorganisms present in foodstuff are not very resistant to
hours. If we consider the cow milk then it sour within 3 hours heat. This process is mostly used for beer and wine. Besides
at temperature 30oC [3]. As the milk business is totally beer and wine, now this process is mostly used for milk, juices,
concerned with rural areas where milk storage and processing liquid eggs [11], milk and milk products.
The most common type of pasteurization are Batch II. EASE OF USE
pasteurization, High temperature Short time (HTST) It is essential that the proposed pasteurization method
pasteurization and Ultra High temperature pasteurization should be economical for all intended users. The main thing is
(UHT). to meet the requirements of all its users and operating
1) Batch Pasteurization: requirements. Most necessary thing is that this plant has to be
Batch pasteurization is a type of pasteurization in portable so that it can be transported on a pick-up vehicle. Initial
which milk is heated up to 63oC in a large container and held at start-up for this plant is to be a service provider for milk shops.
that temperature for 30 minutes. This is a very simple and oldest The design has been made so that it can withstand a harsh
method. This process is mostly used for small dairies and in operating environment. Design has been made by observing the
homes too. In this type, the milk is stirred constantly so that requirements of farmers because they haven’t enough
each particle of milk is heated [16]. knowledge of technical things. The operation is simple to be
2) High temperature Short time Method(HTST): operated by farmers with limited technical knowledge.
HTST is a type of pasteurization in witch fresh milk is
heated up to 72oC and held at that temperature for 15 seconds
in order to insure that all germs has been killed, was introduced III. MAIN COMPONENTS OF PROPOSED DESIGN
in 1933, with a result of 99.999% or greater reduction in The main components in proposed pasteurization plant
harmful bacteria [17]. After this, milk is suddenly cool down to consists of raw milk tank where raw milk is collected, a pump,
4oC. Now this milk can be stored for 72 hours at temperature a heat exchanger, an electric instant heater, a thermally
less then 10oC [8]. It is very useful method and used by higher insulated holding tube, an evaporator with second heat
volume processing industries. This type of pasteurization is exchanger, chiller, a set of diverter valves, and a control box to
more beneficial then batch pasteurization because here energy control the entire pasteurization process. In the energy efficient
can be recovered to pre-heat the raw milk before entering to the pasteurization plant, the raw milk flow rate is controlled by a
heat exchanger. In proposed method, HTST method is used solenoid valve. Speed of the pump can be varied using a
with improved efficiency. The HTST process used by many variable frequency derive (VFD). A solenoid valve is required
other plants are like this as shown in figure 1 below [19]. that is to be controlled with a Programming logic controller
(PLC).
Where:
𝐶𝑝 is the heat capacity of milk (kJ/kg.K), ∆𝑇 is the temperature Cost analysis is carried out considering specific heat
difference (oC) of milk = 3.93 𝐾𝐽/𝑘𝑔 and density of milk = 1.03 𝑘𝑔/𝐿𝑡𝑟.
𝑄 If 75oC is achieved by using heat exchanger where milk is pre
𝑅𝑇 = (9) heated at 60oC. The required energy consumption of electric
3.517
heater is obtained by multiplying specific heat of milk, density
Here, 𝑅𝑇 is the required capacity of chiller in tons, 𝑄 is the of milk and difference of temperature = 3.93 × 1.03 × (75 −
KJ
energy required in KW. 60) = 60.7185 .
Ltr
From above equation, 5 tons chiller is need for this plant. 60.7185×600
For 600 litre per hour , Power consumption is =
3600
10.119 KW.
VI. CONTROL UNIT:
The control box is the main part of the plant and A. Without energy efficient method:
Programming Logic Controller (PLC) is the processing unit of
this control box. A PLC is basically a large microcontroller, its
working is same as microcontroller but its speed and Without the energy efficient method one pump of 1.5 ℎ𝑝 is
performance is high. In the proposed design, there are three required for pumping the raw milk and its power is 1.119 𝐾𝑊.
RTD PT-100 temperature sensors to measure the raw milk In old plants milk is to be cooled from 45 oC to 4oC directly
temperature, electric instant heater output temperature and which requires 18 ton chiller of 63.30𝐾𝑊. Here Total power
pasteurized milk temperature output after the holding tube. The required is 74.538 𝐾𝑊 (63.30 + 10.119 + 1.119). Cost per
𝐾𝑊
measured temperatures are feedback into the PLC, which make litter can be calculated as 74.538𝐾𝑊 ÷ 600𝐿𝑡𝑟 = 0.124 .
𝐿𝑡𝑟
decision on suitable control actions. Other components include Cost of electricity per tariff = 5.79 Rs [24]. Thus total cost of
the selector switch, on off LEDs and Human Machine interface 𝐾𝑊
electricity = 5.79 𝑅𝑠 × 0.1243 = 0.72 𝑅𝑠 𝑝𝑒𝑟 𝐿𝑖𝑡𝑟𝑒.
(HMI). HMI display the temperatures that are sensed during the 𝐿𝑡𝑟
process. Control box also include the magnetic connectors,
relays and circuit breaker. B. With energy efficient method:
VII. CASE STUDY:
To compute the cost of running system with using energy
In order to be a Service provider, four milk shops efficient system, cost of evaporator is added. Adding evaporator
located at Faisalabad, Punjab Pakistan are considered for the can reduce the required capacity of chiller from 18 tons to 5
case study. Table 1 shows the details of these shops. tons. Because evaporator can reduce the heat of milk from 45oC
to 25oC, however addition cost of pump will be added. Power
Table 1 : Milk Shops Surveyd
Shop Location Daily Milk Milk Chiller Gas Workers required of chiller for cooling from 25 oC to 4oC of 5 𝑡𝑜𝑛 is =
Name Consumption For
Boiling
Expense(Bill) Expense(Bill) Expense and
miscellaneous
17.58 𝐾𝑊. Here two pumps are required for pumping the raw
(liter) (liter) milk and for pumping the water in evaporator, so required
Medina Jaranwala 400 200 15000 25000/month 15000/month power for two 1.5 ℎ𝑝 pumps is = 2.238 𝐾𝑊. Hence total
Milk Road monthly/ 4.16 Rs/ltr 1.25 Rs/ltr
Shop 1.25 Rs/ltr required power is 29.9 𝐾𝑊 (17.5 + 2.238 + 10.19𝐾𝑊). Cost
𝐾𝑊
Gosia Tezab Mill 1000 400 50000/month 40000/month 80000/month per litter can be obtained as: 29.9 𝐾𝑊 ÷ 600 𝐿𝑡𝑟 = 0.05 .
Milk 1.67 Rs/ltr 2.78 Rs/ltr 2.67 Rs/ltr 𝐿𝑡𝑟
Shop
Asim Jinnah 1000 300 40000/month 25000/month 80000/month
The cost of electricity per tariff = 5.79 Rs [24].
𝐾𝑊
gujjer
Milk
Colony 1.33 Rs/ltr 2.78 Rs/ltr 2.67 Rs/ltr
Hence, total cost of electricity = 5.79 𝑅𝑠 × 0.05 =
𝐿𝑡𝑟
Shop
Ghousia Nazimabad 3000 500 1.5 lac/month 42000/month 180000/month 0.288 𝑅𝑠 𝑝𝑒𝑟 𝐿𝑖𝑡𝑟𝑒.
Milk 1.67 Rs/ltr 2.8 Rs/ltr 2 Rs/ltr
Shop
C. Savings:
From this analysis, their overall cost per liter is 7.5 𝑅𝑠 . From
energy efficient overall cost is 2 𝑅𝑠 𝑝𝑒𝑟 𝑙𝑖𝑡𝑒𝑟. By using evaporator, tremendous burden on chiller is
reduced. Hence cost on electricity is saved. Savings are
VIII. ELECTRICITY COST ANALYSIS: computed as: cost savings=per liter Rs of HTST-per liter Rs of
𝑅𝑠
Without energy efficient method, electric heater has to proposed method= 0.72 − 0.288 = 0.432 . Here per hour
𝐿𝑡𝑟
𝑅𝑠 𝑅𝑠
heat up the milk from 28oC to 72oC and chiller has to cool down saving is= 0.432 × 600 Ltr = 259.2 . If plant is
𝐿𝑡𝑟 𝐻𝑜𝑢𝑟
milk from 72oC to directly less than 10oC. But with energy
running for 12 hours a day then
efficient method electric heater has to heat up the milk from 𝑅𝑠
65oC to 75oC and chiller has to cool down milk from 26 oC to 𝑃𝑒𝑟 𝐷𝑎𝑦 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 = 259.2 × 12 = 3110.4
𝑑𝑎𝑦
directly 4oC because of the evaporator placed just before the 𝑅𝑠
𝐴𝑛𝑑 𝑝𝑒𝑟 𝑚𝑜𝑛𝑡ℎ 𝑠𝑎𝑣𝑖𝑛𝑔𝑠 = 93,312
𝑀𝑜𝑛𝑡ℎ
chiller witch will reduce the temperature of the milk so that
And annually it saves 𝑅𝑠 1,119,744.
burden on chiller reduced. Cost analysis for both methods is
So by using energy efficient method, we can save more than
discussed in details below.
one million rupees.
So by using energy efficient method, we can save more than
one million rupees.
This analysis have been done by visiting different plants and
shops located in Faisalabad, Pakistan. Table:1 shows the places
that we have visited.
IX. CONCLUSION:
In this paper an energy efficient mini milk
pasteurization plant is presented. After the pasteurization
process milk can be stored for 21 days in refrigerator. Mini plant
consists of 2 stainless steel electric pumps, two heat exchangers,
holding tube, an evaporator and a chiller. This plant has the
capacity of 600 liters per hour. Calculation for all the required
components has been discussed in detail. After conducting a
survey in the city of Faisalabad, Pakistan, running costs of
different plant have been compared with purposed design. It is
concluded that using energy efficient design 1.1 million
annually can be saved. This cost is reduced by adding an
evaporator before chiller. Adding an evaporator reduces the
required capacity cooling system from18 tons to 5 tons.
X. FUTURE WORK:
Since the pasteurization can be used for other food
stuff like butter, cream etc. So team is hoping to install some
machines in the existing plant for the extraction of cream and
XI. REFERENCES
butter . An inspiration of our future work would be the packing
of milk in different size of pouches so that it can be delivered
reliably.
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