Small Turn Key Project Milk Processing Line

A "small milk processing plant turnkey project" refers to a comprehensive solution designed and implemented by a service provider for establishing a fully functional milk processing facility from scratch. 

Here's a detailed breakdown of what such a project typically entails:

Project Feasibility and Planning:
• Market research and demand assessment to determine the viability of setting up a small-scale milk processing plant in the target area.• Site selection and analysis, considering factors like proximity to raw milk sources, transportation access, utilities, and environmental regulations.• Development of a detailed business plan, including financial projections, investment requirements, and operational strategies.

Design and Engineering:
• Conceptual design and layout of the processing plant, ensuring efficient flow of materials, personnel, and utilities, as well as adherence to food safety and hygiene standards (e.g., HACCP, GMP).• Detailed engineering drawings, specifications, and equipment lists for all aspects of the plant, such as milk reception, storage, processing, packaging, and utilities (water, electricity, waste management).

Equipment Supply and Installation:
• Procurement of milk processing equipment, including: 
• Milk reception and pre-treatment systems (weighing, sampling, filtering, chilling)• Pasteurization or UHT treatment units• Homogenization equipment• Separation equipment for cream or skim milk production• Standardization equipment for adjusting fat content• Fermentation tanks for yogurt or cheese production (if applicable)• Packaging machinery (fillers, cappers, labelers, cartoners)• Refrigeration systems, storage tanks, and conveying systems• Professional installation and commissioning of all equipment, ensuring proper integration and adherence to manufacturer guidelines and industry standards.

Utilities and Infrastructure:
• Installation of electrical, plumbing, and ventilation systems tailored to the specific needs of the milk processing plant.• Construction or modification of building structures to accommodate the processing lines, storage areas, and administrative spaces.• Implementation of waste management solutions, such as wastewater treatment plants, solid waste disposal systems, and air pollution control measures.

Quality Assurance and Regulatory Compliance:
Assistance with obtaining necessary permits, licenses, and certifications from local authorities and regulatory bodies, such as food safety inspections, dairy product registrations, and environmental clearances.• Development and implementation of quality management systems (QMS), including standard operating procedures (SOPs), sanitation programs, and record-keeping systems.• Training of staff on Good Manufacturing Practices (GMPs), Hazard Analysis and Critical Control Points (HACCP), and other relevant food safety standards.• Training and Technical Support:• Provision of operator training for all installed equipment, focusing on safe and efficient operation, maintenance, and troubleshooting.• Ongoing technical support and after-sales service, including warranty coverage, spare parts supply, and assistance with process optimization or capacity expansion.

By opting for a turnkey solution, the investor or entrepreneur can benefit from a streamlined project execution, reduced coordination efforts, and a single point of responsibility for the entire project. This approach ensures a faster time-to-market and minimizes potential risks associated with setting up a complex industrial facility like a small milk processing plant.

     

The technical points of a milk processing plant cover the entire process from receiving raw milk, pretreatment, standardization, sterilization, homogenization, filling to packaging.

Here are some key technical steps and points:

Raw milk reception and storage: • Quality testing: Firstly, strict quality inspection is carried out on the raw milk, including fat content, protein content, microbial indicators (such as total bacterial count, somatic cell count), and antibiotic residues, to ensure that the raw milk meets food safety standards Cooling storage: Raw milk should be quickly cooled to below 4 ° C for storage to inhibit microbial growth and maintain freshness Pre treatment: • Filtering and purification: Remove impurities such as soil, hair, etc. from milk through filters Degassing: removes oxygen from milk, reduces oxidation, maintains flavor, and extends shelf life.

• Standardization: Adjust the fat content in milk to meet the needs of different products (such as whole milk, low-fat, or skim milk) Pasteurization: • High temperature short-term sterilization (HTST): Usually maintained at 72-75 ° C for 15-20 seconds, it can effectively kill most harmful microorganisms while preserving the nutritional content and taste of milk as much as possible Ultra high temperature sterilization (UHT): Instantaneous heating at 135-150 ° C for a few seconds to achieve commercial aseptic state, allowing milk to be stored for a long time without the need for refrigeration Homogenization: • Reduce the size of fat globules in milk through high pressure, so that fat is evenly distributed in lotion, prevent fat from floating, and improve taste and appearance.

• Filling and sealing: • Using aseptic filling technology, the processed milk is poured into pre disinfected packaging containers in a sterile environment and immediately sealed to ensure the sterility of the product Packaging: • Choose appropriate packaging materials, such as cardboard boxes, plastic bottles, or glass bottles, taking into account shelf life, transportation convenience, and environmental factors Adopting automated packaging lines to improve efficiency and reduce pollution risks Quality control and tracking system: • Implement full process quality monitoring, including online monitoring, finished product testing, and traceability system, to ensure product quality and safety Environmental and Energy Management: • Optimize production processes, use energy-saving equipment, reduce water and energy consumption, and treat wastewater and waste effectively to meet environmental requirements.

The continuous progress of milk processing technology, the improvement of automation and intelligence levels, and the application of new processing technologies (such as membrane filtration technology, low-temperature short-term sterilization technology, etc.) are all continuously improving the quality, safety, and production efficiency of milk products.

Product storage system

A turnkey project for a small milk processing plant involves the complete design, engineering, procurement, construction, installation, and commissioning of the facility. 

This type of project is called "turnkey" because it means that the client can simply "turn the key" to start operations, as everything is provided and tested by the contractor.Here are the general steps involved in such a project:

1. Project Planning: This includes market analysis, site selection, and feasibility studies to determine the scope and size of the plant.

2. Design and Engineering: The layout and detailed design of the plant are created, including process flow diagrams, equipment selection, and architectural plans.

3. Procurement: All necessary equipment and materials are sourced and purchased. This includes pasteurizers, homogenizers, tanks, packaging machines, and any other specialized dairy processing equipment.

4. Construction: The physical construction of the facility takes place, which may include building the structure, installing utilities (water, electricity, steam), and setting up the infrastructure.

5. Installation: Equipment is delivered to the site and installed according to the engineering plans. This involves setting up machinery, piping, and electrical connections.

6. Commissioning and Testing: Once all equipment is installed, it undergoes testing to ensure it operates correctly and meets performance standards. This includes system integration testing and operational trials.

7. Training: Personnel are trained on how to operate and maintain the equipment properly.

8. Start-up Assistance: During the initial operation phase, experts from the contractor may be present to assist with troubleshooting and to ensure smooth operations.

9. Documentation and Handover: All relevant documentation, such as operating manuals, maintenance schedules, and warranties, are provided to the client. The plant is then officially handed over.
 

The installation and debugging of a milk processing plant involves several stages, from site preparation to final commissioning.

Here's a comprehensive overview:Installation Process

1. Site Preparation:•Choose a location that meets health, safety, and environmental regulations.•Ensure proper drainage, water supply, and waste disposal facilities are in place.•Prepare the floor for heavy machinery and equipment, which may include laying concrete foundations and providing electrical, water, and compressed air connections.

2. Equipment Delivery and Unloading:•Coordinate with suppliers to schedule delivery of all components such as tanks, pasteurizers, UHT sterilizers, separators, homogenizers, filling machines, and packaging equipment.•Use appropriate lifting gear to unload and position each piece safely.

3. Infrastructure Setup:•Install utilities like electricity, water, steam, and cooling systems according to equipment specifications.•Connect pipelines for raw milk intake, product transfer, and CIP (Clean-in-Place) systems.

4. Processing Equipment Assembly and Installation:•Assemble modular equipment sections if necessary.•Install processing equipment such as reception tanks, storage tanks, heat exchangers, pasteurizers, homogenizers, and UHT sterilizers.•Mount supporting systems like pumps, valves, filters, and instrumentation.

5. Quality Control Systems:•Set up quality control labs with testing equipment for parameters like fat content, protein, acidity, and bacterial counts.•Install inline sensors and automated sampling systems.

6. Cleaning and Sanitation:•Integrate CIP systems for automatic cleaning of process lines.•Ensure proper drainage and access points for manual cleaning where required.

7. Automation and Controls:•Configure and integrate PLCs (Programmable Logic Controllers), SCADA (Supervisory Control and Data Acquisition) systems, and HMI (Human Machine Interface) panels.•Program the automation systems to manage processes, alarms, and interlocks.

8. Filling and Packaging Lines:•Install and align conveyor belts, filling machines, capping devices, labeling machines, and packaging equipment.•Set up vision systems for quality checks on filled containers.

9. Utilities and Energy Management:•Install energy-efficient refrigeration units, boilers, and chillers.•Implement energy management software to optimize power consumption.

Debugging and Testing

1. Electrical and Pneumatic Checks:•Test all electrical and pneumatic connections, ensuring they meet safety standards and function correctly.•Calibrate sensors and instruments for accurate readings.

2. System Functionality Tests:•Conduct individual tests on each piece of equipment to ensure it operates as expected.•Run integration tests to verify seamless interaction between different parts of the production line.

3. Sterilization and Pasteurization Validation:•Validate that heating and cooling cycles meet regulatory requirements for effective sterilization or pasteurization.•Check temperature uniformity throughout the process.

4. Product Quality Assurance:•Test samples at various stages of processing to confirm compliance with food safety standards and desired product attributes.•Fine-tune equipment settings based on test results.

5. Cleaning and Sanitization Verification:•Perform multiple CIP cycles and visually inspect cleaned surfaces to ensure no residue remains.•Confirm sanitation levels through ATP swab tests or other microbial analysis methods.

6. Alarms and Safety Interlocks:•Test all alarm systems and safety interlocks to guarantee immediate shutdowns when triggered.

7. Performance Optimization:•Monitor and analyze system performance data to identify areas for improvement and adjust settings accordingly.

8. Operator Training:•Train personnel on how to operate and maintain the new equipment, including emergency procedures and troubleshooting guidelines.

9. Documentation and Record Keeping:•Document every step of the installation and debugging phases, including any adjustments made.•Maintain records for regulatory compliance and future reference.

Once all equipment is installed, tested, and verified to be working optimally, the milk processing plant can proceed to a trial run using actual raw milk before moving into full-scale production. Regular maintenance and monitoring are essential to ensure continued efficiency, food safety, and regulatory compliance.
 

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FAQ

 

1 ) Q: How can we visit your factory?
A: If you come from abroad, air to shanghai airport, then we can pick you up at airport.

 

2) Q: How do you ensure the quality of your products?
A: Our Company is a state owned enterprise with more than 16 years experience , strict operation policy is performed, advanced processing machines guarangtee the precision of all components, workers with operation license, parts get multiprocessing, transmission& electrical parts are of international famous brand. Series of test and inspection are done in the whole producing state.

 

3) Q: What payment methods your company accept?
A: We accept most of the payment methods , but mainly accept T/T, L/C at sight .

 

4) Q: How long is the warranty time for your products?
A: Our officially promised warranty time is 12 months after commissioning .

 

5) Q: I am new in this field,can you supply us turnkey services?
A: YES.We can supply all the system including Market Analysis/Product Analysis/Location Choice/Processing Flow Design/Equipment Layout Design/Building Design direction/Equipment mode selection/Equipment Manufacturing/Equipment Mounting/Equipment Debugging/Worker Training.

 

6) Q: What ' s the shipment terms and delivery time of your company?
A: Well, the delivery time depend on the quantity of your order. Usually is 20 days . For some customized machine 30 days is necessary.

 

7) Q: Can you supply OEM services?
A: Yes,we have our R&D team,and we have more than 400 workers with workshop area 75000 square meters.

 

8) Q: Do you give any Discount?
A: I will surely try my best to help you get those by the best price and good service at the same time.