DAIRY PLANT DESIGN AND LAYOUT

Module 1. Introduction of dairy plant design and layout

Lesson 5
CLASSIFICATION OF DAIRY PLANTS

5.1 Introduction

The design and layout of the dairy plant depend much on the quantity of milk handled and the type of the product made. Some may need refrigerated condition for the distribution of the product, while others may not need such requirement. Some of the products may not need a daily delivery and need to be transported once a week or so. There is a wide variation in the size and type of dairy plants. Fig. 5.1 and Fig 5.2 shows broad classification of milk plants.

Fig. 5.1 Classification of dairy plants as per type of organization and capacities

Fig. 5.2 Classification of the dairy plants as per the location and type of products

The milk plants can be classified broadly into two groups :–

5.1.1 Liquid milk plant

This type of plant should be situated/located as close as possible to the consumer area i.e., generally in or on the outskirts of a large city or town. It supplies market milk in chilled condition in small retail packs.

5.1.2 Product milk plant

Here, there is the production of products like cheese, butter, ice-creams, etc. which do not require daily distribution to the consumers. So the plant should be located near the producing areas. The difference in the location areas of both plants results in the minimized transportation cost.

Milk plants can be classified based on its capacity also:

5.1.3 Small capacity milk plants

These are usually below 10,000 lpd and may need to load milk in road tankers and send to larger dairies. A very limited local sales of liquid milk could be possible, as these are essentially located in small towns.

5.1.4 Medium capacity milk plants

The capacity of the medium sized dairy plant ranges from 20,000 lit to 1,00,000 litres of milk handling per day. Layout for products like market milk, butter & ghee and cheeses can be designed. Each room should be planned separately and arranged with forward flow of product as per requirement.

5.1.5 Large capacity milk plants

Here, the plant building may have few floors having multi-product manufacture, where the reception is done at the ground floor and should have both milk treatment and tank storage on the first floor. If products like milk powder are to be manufactured, then the powder plant should placed in different building.

The classification in general may be subject to change in the capacities and there can be a certain overlap in the type and products handled. Some dairies could be handling both liquid milk as well as products, to maximize their market reach and profitability. Though there were certain restrictions in the area of operation of dairies, the same is not strictly enforced or adhered to at present.