ACKNOWLEDGEMENT

At first we would like to express our gratitude to Er. Khem Narayan Poudel, our subject teacher for motivating us for this case study. Also, we would like to express our special thanks to The Head of Electronics and Computer Department Er. Manish Aryal for his immense support during our case study. We would also like to express our deepest gratitude to Industrial Engineer Ravi Shrestha for giving us his valuable time and giving us all the information about the technology implemented in Sitaram Gokul Milks Pvt. Ltd. We thereby express our heartfelt gratitude to all the people who directly and indirectly helped us, and also expect the same from their side throughout the successful completion of our case study. At last but not least, we would like to acknowledge our all friends who helped to make this case study report complete.

TABLE OF CONTENT

1. 2. 3. 4.

5. 6. 7. 8.

INTRODUCTION OBJECTICES OF THE STUDY MILK TRANSFORMATION PROCESS OPERATION OF PLANT A. MILK RECEPTION (RMRD) SECTION B. STNDARDISATION OF MILK C. HOMOGENITY OF MILK D. PASTEURISATION OF MILK E. DEODORISER F. CHILLING OF MILK G. PACKING H. COLD STORAGE EFFLUENT TREATMENT PLANT CLEAN-IN-PLACE (CIP) SYSTEM RECOMMENDATIONS CONCLUSION

INTRODUCTION
Pertaining to the context of Nepal's economy and uplifting the living standard of Nepalese farmers, Nepal's dairy sector is providing handsome contribution. It is one of the nation's small industrial sectors that are contributing for paving the path of economic growth. And Sitaram Gokul Milks Kathmandu Limited is helping in concreting the backbone of nation's economy. It is one of the branch organizations of leading Kedia Group. Sitaram Gokul Milks Kathmandu Limited embarked its career in 2052 B.S. as mediator for social welfare and development of Nepalese farmers. It was lead by Late Shankar Lal Kedia with an investment about 26 corers, whose main objective was to act as mediator in transferring the milk of farmers to the Nepalese homes. As the time changed, it established itself as one of the emerging commercial organization by introducing product line of milk, ghee, butter, peda etc. keeping the objective uniform. Regarding organization's configuration, it is structured with line-staff organization forming seven departments as well as concreted by the sources like

100 government operatives 30 cooperatives

And about 4 lakhs of farmers are directly dependent on this organization for their livelihood. At present organization is supplying the milk and various products to Nepalese homes by collection raw milk mainly from the district Chitwan, Nawalparasi, Kavre, Nuwakot and Rupendehi. It is providing goods and services from 13 chilling centres among which 11 are run by the organization itself and the remaining by the co-operatives. It has 7 road tankers that start delivering the milk in the market from 4:30 A.M. Its average sales are about 35000 litres per day. The main targeted area is capital city and nearby places that includes 60% of middle class consumers and 40% of others. For all this social and economical service, it has got workforce of 100 people (skilled and semi-skilled) and 48 sales forces through which milk is being marketed. It has occupied 20% of the total market share and stands second to the leading competitor of DDC.

Location:
Location refers to the place where the organization is located. Generally, organization locates in a place where different types of facilities are available like labour supply, water facility and various others factors. Regarding the location of the Sitaram Gokul Milks Kathmandu Limited is located in Kirtipur, ward no. 4, Kathmandu. It is near Dudhpokhari (famous for water resources during Rana regime) named after water tastes like milk. And it is also near to the Kathmandu so it has provided benefit to the organization. TABLE 1: WORKFORCE QUANTITY AND CONSTITUENTS CONSTITUENTS NAME Chilling Centres Staffs Sales Forces Road Tankers Raw Materials From Districts Average Daily Sales WORKFORCE/QUANTITY 13 100 48 7 5 35000 Litres/Day

A PIE CHART SHOWING THE MARKET SHAR E OF THE DIFFERENT DAIRY ORGANIZATION

20 20 60

DDC Sita Ram Others

History of Dairy Organization in Nepal

Nepal's first milk processing plant was built in Lainchaur 40 years ago with help from New Zealand and the UN. Until then, even in Kathmandu, people kept cows at home and had no reason to buy processed milk. The Dairy Development Corporation (DDC) was formed in 1969 and as Kathmandu became urbanised, demand for processed milk soared. Another plant capable of processing 5,000 litres and hour was set up in 1978 in Balaju. Two more plants were built in Hetauda and Pokhara with Danish assistance. Veterinarian Heramba Rajbhandari oversaw the DDC's expansion during those heady days. But he understood that the government would never be able to meet Kathmandu's growing demand for milk and dairy products. In fact, by the early 1980s, Nepal had a milk deficit. Rajbhandari dreamt of starting his own dairy and remembers calling a pledging conference of his friends in 1981 to finance the launch of private dairy. "Each person promised to loan me Rs. 10,000" Rajbhandari recalls. This wasn't enough to cover the cost, so he built a small shed in his garden and started producing yogurt. That was where Nepal Dairy was born. Today Nepal Dairy employs 200 people directly in its Khumaltar plant and has seven outlets in Kathmandu, Pokhara, Hetauda and Biratnagar. Nepal Dairy does not penalise farmers with milk holidays but buys all oversupply and has made product diversification and value addition its twin mantras. It has followed this up with professional marketing, investing in the attractive 'ND' logo and branding milk bars and dairy outlets. ND has also branched out into products that make extensive use of milk with bakery products, Nepali sweets and cheese.

OBJECTIVES OF CASE STUDY

Case study in the industry is a research work where the existing system are modified and porposed for the efficient design of the factory. The main objective of our visit are: To understand about the organizations operation under supervision of senior engineers and technicians. To study the existing system and technology used in company. To learn about existing system and proposed an automatic system using microcontrollers and other electronics components To extract practical experiences and comparing it with the theoretical knowledge.

MILK TRANSFORMATION PROCESS

RAW MILK RECEIVING NMMDDDDdDOCK WEIGHING & RECORDING QUALITY TEST OF MILK

PLATFORM TEST CLUT ON BOILING ETHYL ALCOHOL

PHYSIO CHEMICAL TEST PHYSICAL ANALYSIS TEST SENSORY TEST FAT TEST SOLID NOT FAT TEST

STANDARDIZATION OF MILK HOMOGENEITY OF MILK PASTEURIZATION OF MILK DEODORISER CHILLING OF MILK PACKING COLD STORAGE

OPERATION 1. Raw milk receiving dock(RMRD) section: 1.1

Raw Milk Receiving:

The insulated tanker is used for receiving the raw milk from all the chilling centres. They have eleven chilling centres of their own and two with association with corporate chilling centre. The raw milk is unloaded at the dock section where three storage tanks are available which stores the milk at 4.

1.2 Weighing And Recording Of Received Milk:

After receiving the milk it is weighted and recorded.

1.3 Quality Test Of Milk:

Quality test of milk undergoes testing like platform test and physic chemical test. Under platform test two types of testing is done i.e. 1.3.1 Platform test: Under this test two types of tests are performed i.e. Cult on boiling test: Under it, milk is tested whether it cults or not. Ethyl Alcohol test: Under it, using Ethyl Alcohol checks the milk. If it cults again then it is not used. 1.3.2 Physic Chemical test: It is also followed by the following respective tests. Physical analysis test: Under this test milk is tested for its purity. Sensory test: Under it, the sensitivity of milk i.e. clotting and taste is checked.

 Fat test: Under it, the fat presented in the milk is tested. Solid Not Fat (SNF) test: Under it, SNF is tested which should not be not be less as per Nepal Food Act.

2.

Standardization of Milk:
In this step the required amount of water in the milk is checked and cream separation from milk is done. . At this stage the milk is standard
condition with 3% fat and 8% S.N.F (Solid Not Fat)., which is legal standard.

Fig:- Cream separator 4. Homogeneity of Milk:

This is done to make the mixture homogenous by dissolving the coagulated solid fat uniformly.

5.

Pasteurisation of Milk:

Homogenization is followed by pasteurisation. . The main objective

of pasteurising the milk is to destroy the pathogenic organisms present in the milk. Pasteurisation process is conducted by using three steps i.e. regenerating, preheating and heating. Under this technology, milk is heated for fifteen seconds at 70-80 degree centrigade and the milk is pasteurised. This process is termed as
continuous pasteurization and is high temperature short time pasteurization (H.T.S.T.).

Fig:- Pasteurisation of Milk

6.

Deodoriser:

This system was 1st introduced in Nepal. It is used to remove the moisture content in the milk and to remove the off odour from the milk. 7. Chilling of Milk:
The main objective of chilling milk is to preserve it at low temperature and make it very cold so it may not destroy. Chilling of milk at 3-5 degree centigrade. After chilling, the milk is stored in tank.

Fig:- chilling machine

8. packing of milk:
The milk is packed in standard plastic package of one-litre volume. Packing takes place through following series of steps that is carried out automatically.
Plastic supply section Shaping section Filling section Cutting section

Fig:-Packing of milk
9. Cold Storage:
The organization has cold storage called chilling fan room under which the packets of milks are stored under low temperature about 2-4 degrees centigrade.

Fig:-chilling fan room

10. Effluent treatment plant(ETP): The dairy manages its wastes in efficient way using a well developed ETP. For the treatment of effluents, it has built 60000 litres

tank which is supposed to expand to 120000 litres within a period of 2 months. It produces three types of wastes:
i) Solid Waste: The Organization produces poly film and it is collected and dumped. Liquid Waste: Liquid waste like caustic soda, nitric acid, sulphuric acid, amyl alcohol, which is produced by the organization has no effect on the surroundings. Gas Waste: As the gas pipe is erected as per Nepal Company act, it also creates no effect on the surroundings.

ii)

iii)

11.

Clean in place (CIP) system:

Containers and machines working on milk are subject to the gradual growtof bacteria with the passage of time. So in order to ensure the proper processing of milk is done and no bacteria passes to the processed milk the milk containers i.e. the silos and the plants have to be cleaned after eight hours of use with milk. So in order to ensure proper cleaning a proper CIP plant is required. This plant is used to clean the silos and the plants in their own place. Further the CIP process is dependent on the type of the machine/container and there are only slight variations to the general procedure.

The cleaning process in general contains the following steps:

FLUSH WITH FRESH WATER TO RECOVERY FLUSHING WITH HOT WATER

FLUSH TO DRAIN WITH RECUP WATER ACID RINSE BY HNO3

LYE RINSE

FLUSHING WITH HOT WATER

STERILISATI ON WITH HOT WATER

FLUSH WITH FRESH WATER TO RECUP TANK

RECOMMENDATION:
The sub-committee on labour, transport, industry, commerce and supplies under the parliaments Finance and Labour Relations Committee inspected the milk processing units of two companies, Kathmandu Dairy and Sitaram Gokul Milks Kathmandu, on Monday. Suspecting the companies of selling adulterated milk containing hazardous chemicals, the lawmakers and government officials has confiscated 11 sacks of caustic soda and five sacks of sodium bicarbonate (baking soda) from them. This might have caused due to the manual system of CIP(clean in place) adopted by the industry which is inefficient one. Hence we recommend to use microprocessor controlled automated CIP system for higher efficiency and help
food processors achieve utmost performance from their investment and ensure end-use products meet safety and quality standards.

An automated clean-in-place (CIP) system delivers a standard number of wash and rinse cycles to the internal surfaces of a closed system. microprocessors and computers are commonly used to control CIP systems and to validate

exposure times and cleaning temperatures providing traceability and security for the process. A processing line with a highly automatic CIP system includes following six measure components. A solid, welded, product circulation system A solid, welded, CIP circulation system CIP nozzles installed in series, in the storage tanks and process equipment One or more automatically controlled CIP systems that can be used to clean the whole system Air operated valves for controlling the flow of processed products and cleaning solutions through the various elements of processing line A central control system for process and CIP operations placed at the certain point in line and monitored by the operator.

Also at the present there is manual packing system for the butter thus we recommended the automatic packing system, where microprocessor control the timer to set for the belt to move and to stop in which fixed number of cup are placed. There is use of sensor in the pipe of the butter which senses the packet for the butter and opens the valve which is controlled by the microcontroller. If there is no packet then it doesnt sense the packet so valve remains close. The quantity and the time for the but to butter is calculated before the design.As the filled packet move then there is automatic covering system which can be designed similarly and is controlled by the microcontroller.

Fig:-proposed concept for the automatic packing of butter

CONCLUSION
As the whole world is now automated through embedded system. In our field visit we explored that, most of the systems used in Sitaram Gokul Milks were electromechanical being operated manually. So we recommend automated system for clean-in-place and packing of butter. Our proposed system can be expensive at the time of installation but this cost can be recovered in few years as it reduces the man power cost. There are other system too controlled manually such as pasteurization, cleaning, cream separation etc which can also be automated but we have not included in our design.