Fluid Filling Technology by tlo18813

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									Fluid Milk Processing



Process Area                                        Operating. Low Cost/No Cost

1. Raw Milk Receiving and Tanker Wash (Raw Area) Nozzle maintenance for CIP
                                                 (Critical     Infrastructure
                                                 Protection) to ensure minimal
                                                 hot CIP use

2. Raw Milk Holding Silos (Raw Area)                Enhance silo insulation. Ensure
                                                    sufficient mixing to minimize
                                                    any temperature gradients.
3. Processing and Pasteurization System (Raw Area) Nozzle or flow restrictions to
                                                    reduce flushing water flow to
                                                    minimum necessary.
4. Homogenization                                    Nozzle or flow restrictions to
                                                    reduce flushing water flow to
                                                    minimum necessary.
5. Pasteurization using High Temperature Short Time Maintenance to ensure leakage
(HTST) Plate Heat Exchanger                         from plate-pack prevented.

6. Pasteurized Milk Storage (Pasteurized Area)
7. Filling. Product Conveying and Casing
(Pasteurized Area).
8. Case Washing

9. Product storage
10. CIP operations              Volume, rather than time, based
                                control on burst rises and CIP
                                flows to reduce water quantities.




11. Wash-up throughout plant.   1. Nozzle in hoses. Not left
                                running.
                                2. Dry ingredient spills treated as
                                solid wastes, rather than flushed.
                                Hoses should not be used as
                                brooms.
                                3. Heated water or heat
                                exchange rather than steam
                                injection for heating.
                                4. Reporting of leaks to ensure
                                chronic leakage problems
                                addressed.
Retrofit Higher Cost

1. Infrared heating for receiving bay.
2. Exterior Tanker Wash with recycled
water from elsewhere in plant.
3. CIP system improvements




CIP system improvements




1. Heated cooling water recovery.
2. Improve efficiency by addition of
plates.
CIP system improvements
CIP system improvements

 Recycled water from elsewhere in
plant for initial case wash flush.
Free cooling during winter months.
1. Optical interface unit to monitor
milk/rinse water interface and
water/CIP chemical interface.
2. Utilization of waste heat from
identified utilities and services for
heating/preheating of CIP washes and
rinses as required.
3. Utilization of thermal storage for
hot water requirements.
4. Recycle system on chemical
washing solution, especially HTST
washing chemicals, to reduce heating
requirements.
Thermal storage of recovered hot
water for wash-up purposes.
Cheese processing

Process Area                   Operating. Low Cost/No Cost


1. Raw Milk Receiving and      Nozzle maintenance for CIP to ensure minimal hot CIP
Tanker Wash (Raw Area)         use

2. Raw Milk Holding Silos      Enhance silo insulation. Ensure sufficient mixing to
(Raw Area)                     minimize any temperature gradients.
3. Processing and              Nozzle or flow restrictions to reduce flushing water
Pasteurization System (Raw     flow to minimum necessary.
Area)
4. Pasteurization using High   Maintenance to ensure leakage from plate-pack
Temperature Short Time         prevented.
(HTST) Plate Heat Exchanger


5. Cheese Vat Processing       1. Operator attention to vat levels if manually filled to
Area (Pasteurized Area)        ensure no overfilling.
                               2. Operator attention to vat temperature if manually
                               controlled, to ensure no excess cooking beyond
                               necessary, during cooking process.
6. Hoop washing
7. Aging/ Product storage
8. Whey processing (for Whey Ensure all whey collected to minimize water and hot
powder – most common)        water requirements for cleaning.

9. CIP operations              Volume, rather than time, based control on burst rises
                               and CIP flows to reduce water quantities.




10. Washup throughout plant    1. Nozzle in hoses. Not left running.
                               2. Dry ingredient spills treated as solid wastes, rather
                               than flushed. Hoses should not be used as brooms.
                               3. Heated water or heat exchange rather than steam
                               injection for heating.
                               4. Reporting of leaks to ensure chronic leakage
                               problems addressed.
Retrofit Higher Cost


1. Infrared heating for receiving bay.
2. Exterior Tanker Wash with recycled water from elsewhere in plant
3. CIP system improvements


CIP system improvements


1. Heated cooling water recovery.
2. Improve efficiency by addition of plates



1. Automated filling control to eliminate over-filling.
2. Automated temperature controls to ensure no excess cooking.
3. Membrane system for pre-concentration of milk products.
4. CIP system improvements

Recycling flush water to other uses, such as floors etc.
Free cooling during winter months.
1. Use condenser to heat cooling water for other purposes, such as
washup water.
2. Pre-concentration using membranes.
1. Optical interface unit to monitor milk/rinse water interface and
water/CIP chemical interface.
2. Utilization of waste heat from identified utilities and services for
heating/preheating of CIP washes and rinses as required.
3. Utilization of thermal storage for hot water requirements.
4. Recycle system on chemical washing solution, especially HTST
washing chemicals, to reduce heating requirements.
Thermal storage of recovered hot water for wash-up purposes.
Ice Cream and Frozen Products processing

Process Area                    Operating. Low Cost/No Cost
1. Raw Milk Receiving and       Nozzle maintenance for CIP to ensure
Tanker Wash (Raw Area)          minimal hot CIP use


2. Raw Milk and Cream           Enhance silo insulation. Ensure sufficient
Holding (Raw Area)              mixing to minimize any temperature
3. Ice Cream Milk Blending      gradients.
                                Dry ingredient spills treated as solid wastes,
(Raw Area)                      rather than flushed. Hoses should not be used
                                as brooms.
4. Processing and               Nozzle or flow restrictions to reduce flushing
Pasteurization System (Raw      water flow to minimum necessary.
Area)
5. Homogenization               Nozzle or flow restrictions to reduce flushing
                                water flow to minimum necessary.
6. Pasteurization using High    Maintenance to ensure leakage from plate-
Temperature Short Time          pack prevented.
(HTST) Plate Heat Exchanger
7. Pasteurized Ice Cream Mix
Storage (Pasteurized Area)
8. Bulk Ice Cream             1. Minimize leakage and losses of product to
Production/Filling            reduce energy requirements for manufacture.
                              2. Collect residual ice cream mix for rework.
                              3. Minimizing product line distance from
                              freezing unit to filling to reduce reheating.
9. Ice Cream /Novelty Molding 1. Ensure proper water flow controls for
                              mould cleaning to ensure water use not
                              excessive.
                              2. Ensure maintenance of brine temperature
                              and warm-up to avoid excess sticking in
                              moulds.
                              3. Ensure warm-up well-controlled to avoid
                              excessive melting.
10. Product Freezer
11. CIP operations             Volume, rather than time,based control on
                               burst rises and CIP flows to reduce water
                               quantities.




12. Wash-up throughout plant   1. Nozzle in hoses. Not left running.
                               2. Dry ingredient spills treated as solid
                               wastes, rather than flushed. Hoses should not
                               be used as brooms.
                               3. Heated water or heat exchange rather than
                               steam injection for heating.
                               4. Reporting of leaks to ensure chronic
                               leakage problems addressed.
Retrofit Higher Cost
1. Infrared heating for receiving bay.
2. Exterior Tanker Wash with recycled water from elsewhere in
plant.
3. CIP system improvements.




CIP system improvements




Heated cooling water recovery. Improve efficiency by addition
of plates.

CIP system improvements




1. Utilization of waste heat or thermal storage for hot water
requirements for mould release.
2. Recycling flush water to other uses.




Refrigeration system refrigeration.
1. Optical interface unit to monitor milk/rinse water interface
and water/CIP chemical interface.
2. Utilization of waste heat from identified utilities and services
for heating/preheating of CIP washes and rinses as required.
3. Utilization of thermal storage for hot water requirements.
4. Recycle system on chemical washing solution, especially
HTST washing chemicals, to reduce heating requirements.
Thermal storage of recovered hot water for wash-up purposes.
Cultured Products processing

Process Area                       Operating. Low Cost/No Cost
1. Raw Milk Receiving and Tanker   Nozzle maintenance for CIP to ensure minimal
Wash (Raw Area)                    hot CIP use


2. Raw Milk Holding Silos (Raw     Enhance silo insulation. Ensure sufficient
Area)                              mixing to minimize any temperature gradients.
3. Processing and Pasteurization   Nozzle or flow restrictions to reduce flushing
System (Raw Area)                  water flow to minimum necessary.
4. Homogenization                  Nozzle or flow restrictions to reduce flushing
                                   water flow to minimum necessary.
5. Pasteurization using High       Maintenance to ensure leakage from plate-pack
Temperature Short Time (HTST)      prevented.
6. Pasteurized Product Storage
(Pasteurized Area)
7. Bulk Starter Culture and Main
Culture Incubation/Holding

8. Filling/Cartoning/Casing        Ensure use of nozzles on all flushing flows.
                                   Review type and positioning of spray nozzles.
9. Product storage
10. CIP operations                 Volume, rather than time, based control on burst
                                   rises and CIP flows to reduce water quantities.




11. Wash-up throughout plant       1. Nozzle in hoses. Not left running.
                                   2. Dry ingredient spills treated as solid wastes,
                                   rather than flushed. Hoses should not be used as
                                   brooms.
                                   3. Heated water or heat exchange rather than
                                   steam injection for heating.
                                   4. Reporting of leaks to ensure chronic leakage
                                   problems addressed.
Retrofit Higher Cost
1. Infrared heating for receiving bay.
2. Exterior Tanker Wash with recycled water
from elsewhere in plant.
3. CIP system improvements


CIP system improvements




1. Heated cooling water recovery.
2. Improve efficiency by addition of plates.
CIP system improvements

Active bacterial control in starter culture area to
reduce potential contamination and losses. 2.
CIP system improvements
CIP system improvements

Free cooling during winter months.
1. Optical interface unit to monitor milk/rinse
water interface and water/CIP chemical interface.

2. Utilization of waste heat from identified
utilities and services for heating/preheating of
CIP washes and rinses as required.
3. Utilization of thermal storage for hot water
requirements.
4. Recycle system on chemical washing solution,
especially HTST washing chemicals, to reduce
heating requirements.
Thermal storage of recovered hot water for
washup purposes.
Butter processing

Process Area                       Operating. Low Cost/No Cost
1. Raw Milk and Cream Receiving    Nozzle maintenance for CIP to ensure
and Tanker Wash (Raw Area)         minimal hot CIP use


2. Can Washing (Raw Area)          Volume control rather than time control in
                                   can washing
3. Raw Milk Holding Silos (Raw     Enhance silo insulation. Ensure sufficient
Area)                              mixing to minimize any temperature
                                   gradients.
4. Processing and Pasteurization   Nozzle or flow restrictions to reduce
System (Raw Area)                  flushing water flow to minimum necessary.
5. Pasteurization using High       Maintenance to ensure leakage from plate-
Temperature Short Time (HTST)      pack prevented.
Plate Heat Exchanger
6. Pasteurized Skim Milk Storage
(Pasteurized Area)
7. Churning/Butter Making
8. Product storage
9. CIP operations                  Volume, rather than time, based control on
                                   burst rises and CIP flows to reduce water
                                   quantities.




10. Wash-up throughout plant       1. Nozzle in hoses. Not left running.
                                   2. Dry ingredient spills treated as solid
                                   wastes, rather than flushed. Hoses should
                                   not be used as brooms.
                                   3. Heated water or heat exchange rather
                                   than steam injection for heating.
                                   4. Reporting of leaks to ensure chronic
                                   leakage problems addressed.
Retrofit Higher Cost
1. Infrared heating for receiving bay.
2. Exterior Tanker Wash with recycled water from elsewhere in
plant.
3. CIP system improvements.
Diversion of hot water from other areas for can wash, especially
for initial rinsing.




CIP system improvements

1. Heated cooling water recovery.
2. Improve efficiency by addition of plates.

CIP system improvements

CIP system improvements
Free cooling during winter months.
1. Optical interface unit to monitor milk/rinse water interface and
water/CIP chemical interface.
2. Utilization of waste heat from identified utilities and services
for heating/preheating of CIP washes and rinses as required.
3. Utilization of thermal storage for hot water requirements.
4. Recycle system on chemical washing solution, especially HTST
washing chemicals, to reduce heating requirements.
Thermal storage of recovered hot water for wash-up purposes.
Evaporated/ Dried Product Processing

Process Area                              Operating. Low Cost/No Cost
1. Raw Milk Receiving and Tanker Wash     Nozzle maintenance for CIP to ensure minimal
(Raw Area)                                hot CIP use


2. Raw Milk Holding Silos (Raw Area)     Enhance silo insulation. Ensure sufficient
                                         mixing to minimize any temperature gradients.
3. Processing and Pasteurization System  Nozzle or flow restrictions to reduce flushing
(Raw Area)                               water flow to minimum necessary.
4. Pasteurization using High Temperature Maintenance to ensure leakage from plate-pack
Short Time (HTST) Plate Heat Exchanger prevented.
5. Pasteurized Milk Storage (Pasteurized
Area)
6. Evaporation

7. Post Evaporation Homogenization of     Nozzle or flow restrictions to reduce flushing
Evaporated/Condensed Product              water flow to minimum necessary – refer to
                                          manufacturers.
8. Filling/Product Conveying and Casing
(Pasteurized Area)

9. Drying and Agglomeration Spray and
Fluid Bed
10. CIP operations                        Volume, rather than time, based control on burst
                                          rises and CIP flows to reduce water quantities.
11. Wash-up throughout plant   1. Nozzle in hoses. Not left running.
                               2. Dry ingredient spills treated as solid wastes,
                               rather than flushed. Hoses should not be used as
                               brooms.
                               3. Heated water or heat exchange rather than
                               steam injection for heating.
                               4. Reporting of leaks to ensure chronic leakage
                               problems addressed.
Retrofit Higher Cost
1. Infrared heating for receiving bay.
2. Exterior Tanker Wash with recycled water from
elsewhere in plant.
3. CIP system improvements


CIP system improvements

1. Heated cooling water recovery.
2. Improve efficiency by addition of plates.
CIP system improvements

Membrane RO/NF pre-concentration to reduce thermal
load.




1. Optical interface unit to monitor milk/wash flow
rinse.
2. CIP System Improvements.
Improved higher efficiency drying technologies.

1. Optical interface unit to monitor milk/rinse water
interface and water/CIP chemical interface.
2. Utilization of waste heat from identified utilities and
services for heating/preheating of CIP washes and
rinses as required.
3. Utilization of thermal storage for hot water
requirements.
4. Recycle system on chemical washing solution,
especially HTST washing chemicals, to reduce heating
requirements
Thermal storage of recovered hot water for wash-up
purposes.
New Technologies

Name of Technology                                       Process
1. Expert Computer Control Systems.                      All (Especially Frozen Products).

2a. Non-Thermal Pasteurization Methods: Micro            Primarily Fluid Milk.
filtration
2b. Non-Thermal Pasteurization Methods: High             Primarily Fluid Milk and Cheese.
Hydrostatic pressure
2c. Non-Thermal Pasteurization Methods: Electrical       Primarily Fluid Milk.
Field Effects
3. Non-Thermal Bacterial Control: High and Low-          1. High-Intensity fir Whey (Cheese)
Intensity UV for liquids.                                2. Low-Intensity for Water (All)
4. Vacuum Superheated Steam Drying                       Dryed Milk and Whey Products.
5. Pulsed Drying Systems                                 Dryed Milk and Whey Products.
6. Enzyme-based cleaners to improve CIP                  All
operations reduce energy, caustic and water use.
7. Just-In-Time Dairy Manufacturing Concept.             Primarily Fluid Milk.

Note 1 The sole responsibility for the content of this
publication lies with the authors. It does not
represent the opinion of the Community. The
European Commission is not responsible for any use
that may be made of the information contained
therein.
Activity
1. Cooling
2. Processing
1. Pasteurization
2. Bacterial control
1. Pasteurization
2. Bacterial control
1. Pasteurization
2. Bacterial control
1. Bacterial control
2. Bacterial control
Drying
Drying
CIP

Primarily Storage Related.

								
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