dairy processing plant and equipment considerations seminars and... · dairy processing plant and...

Dairy Processing Plant and Equipment

Considerations

Eric Goan Dairy Processing Specialist

Department of Food Science Technology University of Tennessee

• Considerations – Are you sure this is something you want to do? – Talk to other producers

• Visit their facility – Would they change anything? – Keep in mind you may not be approved for the exact same set up.

• Commitment to the dairy • Advantages and disadvantages • How hard and competitive is marketing the product? • If they had to do over would they begin processing? • What does it cost to process a gallon/pound of product?

Processing Considerations

http://images.google.com/imgres?imgurl=www.greygourmet.com/images/cheese.jpg&imgrefurl=http://www.greygourmet.com/&h=150&w=224&prev=/images?q=cheese&start=340&svnum=10&hl=en&lr=&ie=UTF-8&oe=UTF-8&sa=N

First Talk with Inspection Service (Tennessee Department of Agriculture) or UT Extension (Department of Food Science & Technology)

Processing Construction Requiremnets

• Bill Thompson Food Manufacturing Administrator Tennessee Department of Agriculture 440 Hogan Road Nashville, TN 37220 Phone: (615) 837-5534 Fax: (615) 837-5335 Email: [email protected]

• Eric C. Goan Director Center for Food Processing Extension Specialist Dairy Processing The University of Tennessee Department of Food Science & Technology 2510 River Drive Knoxville, TN 37996 Phone: 865-974-7287 Fax: 865-974-7332 Email: [email protected]


• First Talk with Inspection Service (Tennessee Department of Agriculture) or UT Extension (Department of Food Science & Technology)

• Order of Approval Process – Site Approval (TDA) – Facility Approval (TDA)

• Waste Water (TDEC) • Potable Water (TDEC) • Septic Tank (Health Department) • Direction of all facility Drains (TDA)

– Equipment Approval (TDA) • Prior to Purchase and Installation • After Installation

– Plant Layout and Design Approved (TDA) – Approved Lab (TDA) – Special License (TDA)

• Plant Permit • Hauler/Sampler License

– Chemical Approval (TDA)



• First Talk with Inspection Service Tennessee Department of Agriculture (TDA) or UT Extension, Department of Food Science & Technology (UTFST)









• First Talk with Inspection Service (Tennessee Department of Agriculture) or UT Extension (Department of Food Science & Technology)









• Grade “A” Pasteurize Milk Ordinance (PMO) – All Federal and State of Tennessee Rules for producing and processing grade A

milk – State rules vary state to state

• Interstate Milk Shippers List (IMS) – Allows products to be sold across state lines – Three tiered inspection program on dairy plant and dairy farm for IMS

• 1) Area inspector inspects plant every 3 months • 2) State rating officer conducts state survey every 2 years • 3) Federal rating officer conducts federal survey every 3 years

• Good Manufacturing Practices (GMPs) – Cornell online course

• Standard Operating Procedures (SOPs) • Standard Sanitation Operating Procedures (SSOPs) • Hazard Analysis Critical Control Points (HACCP)

– Certification course offered through UTFST

Processing Regulations


• Considerations – Processing Classes

• Learn processing and lab techniques • Sensory properties

– Co-Packers • Starting Point

Processing Considerations


Sources of Milk

Table 1. Gross Composition (%) of Milk from Domesticated mammals

Species Fat Protein Lactose Ash Total Solids

Cow

Ayshire 4.1 3.6 4.7 0.7 13.1

Brown Swiss 4.0 3.6 5.0 0.7 13.3

Guernsey 5.0 3.8 4.9 0.7 14.4

Holstein 3.5 3.1 4.9 0.7 12.2

Jersey 5.5 3.9 4.9 0.7 15.0

Goat 3.5 3.1 4.6 0.8 12.1

Sheep 5.3 5.5 4.6 0.9 16.3

Park, YW and Haenlein, GFW. Handbook of Milk of Non-bovine Mammals. Blackwell Publishing.

http://images.google.com/imgres?imgurl=www.greygourmet.com/images/cheese.jpg&imgrefurl=http://www.greygourmet.com/&h=150&w=224&prev=/images?q%3Dcheese%26start%3D340%26svnum%3D10%26hl%3Den%26lr%3D%26ie%3DUTF-8%26oe%3DUTF-8%26sa%3DN

Different Dairy Products

http://commons.wikimedia.org/wiki/File:Milkproducts.svg


• Test Milk • Separate Fat • Mix Ingredients • Pasteurize Milk • Bottled or Further

Processed (i.e. Cultured Products)

Processing Plant


• Milk Tests – Smell & Taste – Receiving Temperature – Titratable Acidity – Direct Microscopic Count (DMC) – Standard Plate Count – Somatic Cell Count – Drug Residue (Inhibitor Testing) – Lab Pasteurize Test – Freezing Point of Milk – Butterfat

Processing Plant

DCQI Services http://www.dqci.com/milk-microbiology-analyses.html


• Milk Storage – Refrigerated Farm Bulk Tanks

• Pasteurize Milk • Raw Milk • Cream Storage

• Separator • Blend/Mix Tanks • CIP and COP Systems

Processing Equipment



• Pasteurization – High Temperature Short Time (HTST)

• 161.5°F (72°C) for 15s

– Vat or Batch Pasteurization • 145°F (63°C) for 30m

www.shiercompany.com

www.dairyagendatoday.com


• HSTS Pasteurizer Heat Exchangers – Plate Heat Exchanger – Tube in Tube Heat Exchanger



• Homogenizer – Breaks down fat globules

• Jug Filler – Product must be mechanically

filled and sealed

• Fermentation Vat – Allows Yogurt to

ferment



• Excess Cream – Butter

• Utilizes more cream • Churn

– Ice Cream • Limitations

– Seasonal – Varieties

• Uses less cream • Ice Cream Maker • Storage freezer



• Cheese Making – Make Sheet – Vat – Drain Table

• Waste Material (Whey)

– Press

http://www.wsu.edu/creamery/phototours/phototourschz.htm



• Dairy Plant with Batch Pasteurization

Dock

Up

Dock

Up

Casing Area

Jug Filler

3'x10' C.O.P.

Vat

Homogenizer Platecooler

500 Gallon PasteurizedFarm Bulk

TankRefrigerated


TankRefrigerated

800 Gallon Pasteurized

Farm Bulk TankRefrigerated



Butter Making

1500 Gallon Raw Milk Tank


390 Seperator

800 Raw Skim Blend

800 Raw Skim Blend

500 Mix Tank

300 Mix Tank

600 Gallon Pasteurization

Vat


Vat

Sales RoomSecretary’s

Office

Manager’s Office

Raw Milk Storage

Raw C.I.P.

Women’s Locker Room

Men’s Locker Room

Chemical Storage

Mechanical

3'x10' C.O.P VatHand Wash Sink

Han

d W

ash

Sin

k

Hand Wash Sink

Hand/Eye Wash Sink

Hand W

ash Sink

Men’s Public Restroom

Women’s Public

Restroom

Finish Product Storage Cooler

Empty 25Jug Storage

Dry Storage

Dock anteroom with three 8 ft. wide unloading doors with dock

seals.

12 ½’

60'

12 ½’ 12 ½’

12 ½

’

10’10’

10’

10’ Sliding Door

10’

10’10’

10’

10’

6’

25’

25’

25’

25’

20’20’

34’

4’

4’ 4’

4’4’

4’

4’4’

4’4’

4’6’

8’

4’4’

4’

4’4’4’

6’ 6’

10’

10’

8’ Overhead

Roll U

p Door

8’ Overhead

Roll U

p Door

8’ Overhead

InsulatedR

oll Up D

oor

30'

85'

12’

10’

20’

19'

19'

19'

19'

19'

19'

19'

24'17'

12'

19'

24'

20'

40'

12' Overhead Roll Up Door

20'

12 ½

’17

½’

24’

24’

70'

70'

70'

70'

46'

46'

20'

12’

11’

120'

120'

120'

120'

4’12’

6’ 6’

6’6’

8’ Overhead

Roll U

p Door

With D

ock Seal

8’ Overhead

Roll U

p Door

With D

ock Seal

8’ Overhead

Roll U

p Door

With D

ock Seal

Up

Up

6’6’

12 ½’

12 ½’

12 ½’

4’

72'

10’

20’

Break Room

4’

Dairy Processing Plant Fluid Milk & Butter Floor Plan

Prepared by Eric Goan and Tommy Burch (University of Tennessee) and Hugh Wilson and Terry Kinser (Tennessee Department of Agriculture)

1" = 17.14'

19'

ChillerBoiler 2

Boiler 1

1

Work Bench

2

Hand Wash Sink

1 2

Hand/Eye Wash Sink

4’3'

Sales Counter

Sales Cooler 1 Sales Cooler 2

Sal

es C

oole

r 3

Sal

es S

helv

ing


Vat


Vat

200 GallonRaw Cream Vat

Refrigerated


Vat

Air Compressors

3'x8' C.O.P

Vat

Drain

Drain

Drain

Drain

Drain

Drain

Drain

Drain

Drain

Drain

Drain

Drain

Drain

Drain to Safety Box

DrainDrain

Drain

Drain

Drain

Drain

17'

Drain

Drain

Hand/Eye Wash Sink

19'

19'

Labratory

Pasteurization C.I.P. Drain

Hand/Eye Wash Sink

4’

Drain

20'


Vat

Commercial Hot Water Heater

Hand W

ash Sink

Han

d W

ash

Sin

k

10’ Overhead Roll Up Door


Up

Milk Receiving

3'

10'

Plant Considerations


• Dairy Plant with HTST Pasteurization

Dock

Up

Dock

Up

Casing Area

Jug Filler

3'x10' C.O.P.

Vat

HTST Pasteurizing Unit With Homogenizer


TankRefrigerated


TankRefrigerated





Butter Making



390 Seperator

800 Raw Skim Blend

800 Raw Skim Blend

500 Mix Tank

300 Mix Tank


Vat

Sales RoomSecretary’s

Office

Manager’s Office

Raw Milk Storage

Raw C.I.P.

Women’s Locker Room

Men’s Locker Room

Chemical Storage

Mechanical

3'x10' C.O.P VatHand Wash Sink

Han

d W

ash

Sin

k

Hand Wash Sink

Hand/Eye Wash Sink

Hand W

ash Sink

Men’s Public Restroom

Women’s Public

Restroom

Finish Product Storage Cooler

Empty 25Jug Storage

Dry Storage

Dock anteroom with three 8 ft. wide unloading doors with dock

seals.

12 ½’

60'

12 ½’ 12 ½’

12 ½

’

10’10’

10’

10’ Sliding Door

10’

10’10’

10’

10’

6’

25’

25’

25’

25’

20’20’

34’

4’

4’ 4’

4’4’

4’

4’4’

4’4’

4’6’

8’

4’4’

4’4’

4’4’

6’ 6’

10’

10’

8’ Overhead

Roll U

p Door

8’ Overhead

Roll U

p Door

8’ Overhead

InsulatedR

oll Up D

oor

30'

85'

12’

10’

20’

19'

19'

19'

19'

19'

19'

19'

24'17'

12'

19'

24'

20'

40'


20'

12 ½

’17

½’

24’

24’

70'

70'

70'

70'

46'

46'

20'

12’

11’

120'

120'

120'

120'

4’12’

6’ 6’

6’6’

8’ Overhead

Roll U

p Door

With D

ock Seal

8’ Overhead

Roll U

p Door

With D

ock Seal

8’ Overhead

Roll U

p Door

With D

ock Seal

Up

Up

6’6’

12 ½’

12 ½’

12 ½’

4’

72'

10’

20’

Break Room

4’

Dairy Processing Plant Fluid Milk & Butter Floor Plan

Prepared by Eric Goan and Tommy Burch (University of Tennessee) and Hugh Wilson and Terry Kinser (Tennessee Department of Agriculture)

1" = 17.14'

19'

ChillerBoiler 2

Boiler 1

1

Work Bench

2

Hand Wash Sink

1 2

Hand/Eye Wash Sink

4’3'

Sales Counter

Sales Cooler 1 Sales Cooler 2

Sal

es C

oole

r 3

Sal

es S

helv

ing

200 GallonRaw Cream Vat

Refrigerated

Air Compressors

3'x8' C.O.P

Vat

Drain

Drain

Drain

Drain

Drain

Drain

Drain

Drain

Drain

Drain

Drain

Drain

Drain

Drain to Safety Box

DrainDrain

Drain

Drain

Drain

Drain

17'

Drain

Drain

Hand/Eye Wash Sink

19'

19'

Labratory

Pasteurization C.I.P. Drain

Hand/Eye Wash Sink

4’

Drain

20'

Commercial Hot Water Heater

Hand W

ash Sink

Han

d W

ash

Sin

k

10’ Overhead Roll Up Door

300 Gallon

Past Vat


Up

Milk Receiving

3'

10'



• Milking Parlor with Plant Attached

Drain

Water Heater

IceBuilder

Bulk Milk Tank 100 or 200 Gallon

Air Compressor

100 or 50 GallonVat Pasteurizer

Cheese Vat Cheese Press

COP Vat

Up

Laboratory

Mechanical Room

Dry Storage Crate Storage

Chemical Room

Manager’s Office

Office

Refrigerator

Store Bathrooms

Milking Parlor

Tank Room

Milk Processing

Drain Table

Casing Area

Viewing Hallway

Anteroom

Locker Room

Crate Washer

Vacu

um

Seal

er

COP Vat

Plate Cooler andHomogenizer

Drain

DrainDrain

Drain

Drain

Drain

Drain

Drain

Jug Filler

Drain

Drain

Drain

Drain

Drain

Drain

Drain



• Goat/Sheep Processing Facility


Up

200 gallonVat Past.

Jug Filler

Drain

Drain

Drain

200 Gallon Cheese Vat

Crate Washer

Lab/Locker Room

Tank RoomMilk ParlorBathrooms

Processing

Cooler

Cooler/ Dry Storage

Shipping/ReceivingDry Storage

Mechanical

Office

Loading Dock

Hot Water HeaterBoiler

Air Compressor

Chemical Storage

Bulk Tank

Drain

DrainDrain

3'x8' COP Vat

Chill Water Tank


Questions


dairy processing plant and equipment considerations seminars and... · dairy processing plant and...

Documents