Design of a lactose free milk plant with the annual productivity of 30 million liters

HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY FACULTY OF CHEMICAL ENGINEERING DEPARTMENT OF FOOD TECHNOLOGY TP.HCM PROJECT ON FOOD PLANT DESIGN DESIGN OF A LACTOSE-FREE MILK PLANT WITH TH

HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY

FACULTY OF CHEMICAL ENGINEERING DEPARTMENT OF FOOD TECHNOLOGY

TP.HCM

PROJECT ON FOOD PLANT DESIGN

DESIGN OF A LACTOSE-FREE MILK PLANT

WITH THE ANNUAL PRODUCTIVITY OF

Dairy products, especially fresh milk, have been one of the most important

daily necessities worldwide However, lactose in milk is the main factor that

limit the consumption of milk while it is an excellent nutritious product

Therefore, lactose-free milk is introduced to encourage consumers to have

more milk in their daily diet

The project called “Design of a lactose-free milk plant” has provided an

great opportunity to gain knowledge about milk production technology as well

as the method to eliminate lactose from the milk product and apply learned

knowledge from subject of Food Plant Design to design a plant that is suitable

for the technology

I would like to thank the Faculty of Chemical Engineering of Ho Chi Minh

City University of Technology in general and Department of Food Technology

in particular for giving a chance to participate in the plant designing project

Moreover, I would like to express my gratitude to Prof Dr Le Van Viet Man

for his helpful guidance and advice to carry out this project sucessfully

Besides, I would like to give very special thanks to my friends and seniors who

giving me inspiration and several supports

The project is a result of applying learned knowledge from a period of

studying, the deficiency is not completely prevetable Thus, I would like to

express my gratefulness to your comments to further improve my project as

well as my study journey

CHAPTER 2: MATERIALS AND CRITERIA FOR SELECTING

3.1 Block diagram of the lactose-free milk production line 14

3.2 Technological operations explanation -+-<<<<e<<S2 15

3.2.7 Disolving (Lacfase prepardfiO') -«c«ececcecxeccce 18

3.2.6 Micro-fitration (Lactase preparafionl) -« <~<e« 19

4.1.1 Standardization

4.1.2 Dissolving (cream part)

4.1.3 Mixing 1

4.1.5 Homogenization

4.1.6 Cooling

4.1.7 Mixing 2

4.1.8 Dissolving (CHzZyH€ pF€DAđTfÍOHI) à.ằẶẰSSĂ SH

4.1.9 Micro-filfration (enzyme prepardfi0ri) c -««c.c-«

CHAPTER 5: EQUIPMENT

5.1 Plate heat exchanger

5.2 Dairy milk cream separator

5.3 Jacketed heating mixing tank

5.4 Continuous liquid - lỉquid mixer 55 57S<<<5<<<+<<<<<x+

5.5 UHT sterilizer

5.6 Hiph pressure automatic homiogeniZer -<<5<<<-

5.7 Aseptic milk carton box filling machine - -

5.8 Automatic labeling machine

5.9 Carton box packaging machine

5.14 Conveyor belt system

5.16 CIP system

CHAPTER 6: WATER - ENERGY - ELECTRICITY

6.2.] Heating energy caÌlculation ~ce~ccce

6.2.2 Selectfiont @ƒ ĐOiÏ€T - TH Hư

6.3 Cooling

6.3.2 Selection of compressor

6.4 Electricity

7.1.2 Powder ingredi€Hfs SÍOFAg€ ĂàĂĂĂeeieere

7.1.3 Packaging maferidÏ SÍOFđĐ€ à àcẶSĂe Hee

L9 1T nnỄ 6h66 66 6TT A

7.1.7 Locker room, hygiene room, and CIP room

CHAPTER 8: SAFETY REGULA TIONS à c.i.i.e

8.1 Potential causes of accidents

CHAPTER 9: CONCLUSION

REFERENCES

Table 1.1 Nutritional information per 1ÔỞmLL of prodUct - «<< «<<<<+<<<+ 2

Table 1.2 Sensory criteria for sterilized milk 3

Table 1.3 Physico-chemical criteria for sterIlized mÏK .-5- 5555555 <<<<s+<<e+ 3

Table 1.4 Contaminant standards for sterilized miÏK .- «555 «5< << << eees 3

Table 1.5 Microbial criteria for sterilized milk 3

Table 1.6 Evaluation of Tan Phu Trung Industrial Park .- «+< «<<<<<+<+<<+ 7

Table 1.7 Evaluation of Xuyen A Industrial Park - «5< cS< sexy 8

Table 1.8 Evaluation of Vĩnh Loc Industrial Park 555555 sex eeersees 9

Table 2.1 Sensory criteria for raw milk 10

Table 2.2 Physico-chemical criteria for raw mmiÏK «5c ss< sec eereeeee 10

Table 2.3 Contaminant standards for raw miÏK - 5 sSĂ se cư 10

Table 2.4 Microbial criteria for raw milk 11

Table 2.5 Technical standards for INS 471 11

Table 2.6 Technical standards for lactase 12

Table 2.7 Tan Phu Trung industrial park water supply station and Kenh Dong Water

Plant water quality analysis results 13

Table 4.1 Summary of loss in operations 21

Table 4.2 Summary of input, output, and by-product by operations for 10000 kg of

raw milk and 1 kg of lactase powder 25

Table 4.3 Summary of materials, by-product, products, and packaging units for

producing lactose-free milk product from 10000 kg of raw milk eee 26

Table 4.4 Summary of input and output by operations ín 1 batch 27

Table 4.5 Summary of materials, by-products, products, and packaging units per batch,

day, month, and year 28

Table 5.1 Summary of input by operations in 1 batch -c«c<c sec ce 30

Table 5.2 Plate heat exchanger BRO12 specifications .c.ceeeeieeeiee 31

Table 5.3 Dairy milk cream separator DHNZ470 specification 31

Table 5.4 Jacketed heating mixing tank KQ specifications -<< «+ 32

Table 5.5 Continuous liquid - liquid mixer DLUM/M-3 KB specifications 33

Table 5.6 UHT sterilizer HH-UHT-XGZ-8 specifications - << «+ 33

vi

Table 5.8 Aseptic milk carton box filling machine YF-ZH-B specifications 34

Table 5.9 Automatic labeling machine RE-CMT specifications -«« 35

Table 5 10 Carton box packaging machine XY-K450 specificatlons 35

Table 5.11 Mixing tank KQ specifications 36

Table 5.12 Ceramic membrane micro-filtration system BONA-GM-M22

specifications 36

Table 5.13 Tank RTS specifications 37

Table 5.14 Outdoor raw milk silo tank Ucan-120000L specifications 38

Table 5.15 Conveyor belt system T-2§00 specificatlons . c«cceceecex 38

Table 5.16 Centrifugal pump DJ-KLX specifications s- sec 39

Table 5.17 CIP system OK specifications 39

Table 5.18 List of equipment 40

Table 6.1 Summary of cleaning mode for equipimeTi -o- +5 5< c+< sex ceeeseeee 45

Table 6.2 Summary of volume of washing solutions in each step for CIP 1 in

1 day 47

Table 6.3 Summary of volume of washing solutions in each step for CIP 2 in

1 day 48

Table 6.4 Summary of volume of washing solutions for CIP 1 and CIP 2 in 1 day .49

Table 6.5 Summary of materials for CIP in Ì day «5 s« se ceeeeree 50

Table 6.6 Summary of water consumption 51

Table 6.7 Summary of heating energy 54

Table 6.8 Boiler WNS3 specifications 55

Table 6.9 Summary of cooling energy 57

Table 6 10 Compressor HWALR500 spec1fications sec He, 57

Table 6 11 Summary of electricity for operating equipmen( -« <<<<<+ 58

Table 6.12 Summary of electricity 61

Table 6.13 Transformer SM-M-630 specifications

Table 7.1 Summary of area needed for equipment and number of workers in

production area 67

production area 68

vill

market 1

tigure 3.1 Flow chart of lactose-free milk production line c<«<c-<ees 14

Figure 4.1 Mass diagram for centrifugation and standardization -.-‹ « 22

Figure 7.1 Powder ingredients storage design 64

Figure 7.2 Packaging material storage đes1gn «Ăn HH re 65

Figure 7.3 Product storage design 66

Figure 10.1 Tan Phu Trung industrial park detailed plan map - 74L_ { Commented [1]: CAP NHẬT SAU KHI CÓ ĐỦ REF

1.1 Economic - technical analysis

The dairy industry in Vietnam has been actively developing in recent years A

variety of dairy products has been introduced to the market for meeting the diverse

domestic demand The development has improved the model and quality of domestic

products that gradually replace imported dairy products and meet the requirements for

export Currently, there are several famous milk brands in the Vietnam market which

are shown in Figure 1.1, and most Vietnamese choose to use the products from

domestic brands such as Vinamilk and TH True Milk

VThitiies

90> oooeoos 0G * OH es

Figure 1.1 Top 15 milk brands in terms of awareness and usage in the Vietnam market

(Unit: %) Source: Chemlinked, May 20", 2021

As dairy products are one of the consumer daily necessities, although the national

economy has been affected by the Covid-19 pandemic situation recently, the dairy

industry has a constant development Additionally, the demand is predicted to be

further increased because of the increases in population growth rate, personal income,

and health care awareness For health care awareness, from 2016-2020, a School Milk

Program approved by the Vice Prime Minister Vu Duc Nam was introduced to

improve the nutrition and health situation of children by giving the children consume

milk daily and raising the awareness of parents and children's carers and giving advice

about the importance of milk nutrition on children growth 1

Although milk is one of the foods and drinks having the most sufficient and

balanced nutrition, the average consumption in Vietnam is still lower than the global

one Specifically, it has been estimated that the average milk consumption in Vietnam

global average consumption is 106-107 liters/year/person BI This could be explained

by the tradition that the Vietnamese does not consume frequently milk from cattle and

the high level the lactose intolerance problem The level of lactose intolerance in the

Vietnamese culture is 98% according to the statistics by ProCon.org BI Therefore,

large dairy brands such as Vinamilk and TH True Milk developed a new kind of fresh

milk called lactose-free milk and introduced it to the Vietnam market for encouraging

the Vietnamese to consume milk more frequently in their daily life Vinamilk was the

pioneer introducing to the Vietnam market the lactose-free milk named Flex in 2013

However, lactose-free milk remains a new type of dairy product in the Vietnam

market

Despite the improved growth of domestic demand, the current national supply has

not fully met the demand According to the General Statistic Office, in 2021, the

national supply produced 1770.1 million liters of fresh milk but could afford only 42%

of the domestic demand 141

Therefore, the project of designing a lactose-free milk plant is carried out to

enhance the domestic supply capability for the domestic demands of fresh milk in

general and lactose-free milk in particular, which gradually reduces the dependence on

imported dairy products

Total Carbohydrates 42¢

Dietary Fiber 0g Lactose < 0.015 g

The quality must follow the National technical regulation for fluid milk products

(QCVN 5-1:2010/BYT) and National Standard for sterilized fresh milk (TCVN

Color Ivory white, creamy white

Odor, taste Characterized for natural fresh milk

Condition Homogeneous solution

Visible contaminant None

Regarding the packaging and size, the lactose-free milk product is packed with a

net volume is 1 liter by a multi-layer paper-plastic packaging with an additional

aluminum layer as primary packaging The product is then packed with a set of 12

cartons in a secondary paper carton packaging for transportation The primary

packaging must be food grade, light-proof, gas-proof, non-toxic, no off-flavor and

off-odor effects on the milk product, be able to withstand aseptic packaging

pre-treatment procedure, and hermetic sealing The product after packaging must not

be deformed, creased, dented, or have crushed corners

The lactose-free milk product can be stored at room temperature for 6 months

Once the packaging is opened, the product should be stored at refrigerated temperature

(3-5°C) and consumed within 3 days

The brand name and label are essential elements that should be invested to be

distinctive, authentic, memorable, and impressive to attract the attention of customers

In addition, the information must follow the Decree for product labeling

established by the Government (89/2006/ND-CP) Some basic information must be

expressed on the packaging such as brand name, name of the product, product

quantification (net volume), manufacturing date, expiring date, ingredients/ingredients

quantification, nutritional information, allergy warning, instruction for use, storage

condition, name and address of the manufacturer, and country of origin The languages

used are Vietnamese and English

Packaging size (L x W x H): Primary packaging (9 x 6 x 20 cm) Secondary

packaging (18 x 36 x 20cm)

1.3 Factory productivity

Currently, the total consumption is estimated by the average milk consumption in

Vietnam (27 liters/year/person) and the total Vietnam population (approximately 99

million people), which is 2673 million liters of milk Meanwhile, according to the

General Statistic Office, in 2021, the national supply produced 1770.1 million liters of

fresh milk but could afford only 42% of the domestic demand (4)

Therefore, the lactose-free milk plant is designed with 30 million liters annually

for increasing the domestic supply capability to 43% of the domestic demand and

market

1.4 Location and site

As many other food plants, the location of the lactose-free milk plant must be

carefully selected and evaluated via some specific criteria to minimize the

transportation cost and losses of raw milk supplied from farms and easily distribute the

product to the markets

As the product of the lactose-free milk plant is aimed to Ho Chi Minh City as the

main market and adjacent provinces such as Long An and Binh Duong, it would be

suitable to be constructed near these regions In addition, the plant must be located

near farms raising cows that can supply milk for the plant

There are three industrial parks that are potential for the plant construction: Tan

Phu Trung (Cu Chi District - Ho Chi Minh City), Xuyen A (Duc Hoa District - Long

An Province), and Vinh Loc (Binh Chanh District - Ho Cho Minh City)

Site 1: Tan Phu Trung industrial park

Distance from the material sources to the park:

Cu Chi - Hoang Yen Dairy Farm: 6.4 kin

Tra Van Duong Dairy Farm: 12.9 km

Distance to the markets:

Ho Chỉ Minh City: 17.Ikm

The industrial park is located on National Road 22 that connects Ho Chi Minh

City and Cambodia border The National Road 22 also connects with National Road

1A - the trans-Vietnam traffic route and Provincial Road 8 connecting the economic

triangle including Long An, Binh Duong and Ho Chi Minh City

Electricity is supplied by Ho Chi Minh City Power Corporation The cost is 1685

VND/kWh

Water is supplied from the Water Supply Station of the industrial park (3000

m*/day-night) or Kenh Dong Water Plant (200000 m?/day-night) The cost is 9600

VND/n3

Water waste is treated to meet the requirements (QCVN 40:2011) before

discharging by transferring to the Water Waste Treatment Factory of the industrial

park (4000 m?/day-night) The cost is 7820 VND/m?

Telecommunication services include ADSL, fireber, and telephone line

Policies:

The Cu Chi District government also has plans and funds for agricultural

development, which would be a benefit for cow farms and ensure the long-term

development of the plant

The park has been planned as a large industrial space that is always available and

prioritized for smokeless industries such as food and beverage industries (the total area

is 539 hectares while 359 hectares are planned for industrial space)

The park also has juridical support and an active investment method for

production

Preferential tax rate in 10 years

Tax exemption 100% for the first 2 years and 50% for the following four years

No Factor Scale | Score

coefficient score contribution

Site 2: Xuyen A industrial park

Distance from the material sources to the park:

Cu Chi - Hoang Yen Dairy Farm: 14.8 km

Tra Van Duong Dairy Farm: 19.5 km

Distance to the markets:

Ho Chi Minh City: 14.3 km

The industrial park is located near Highway 9 connecting to Nguyen Van Bua

Road and Asian Highway

Infrastructure and services

Electricity is supplied by Duc Hoa Power Corporation The cost is 1646

VND/kWh

Water is supplied from the Water Supply Station of the industrial park (5000

m*/day-night) The cost is 8000 VND/m? (not included VAT)

discharging by transferring to the Water Waste Treatment Factory of the industrial

park (10000 m?/day-night) The cost is 6440 VND/m?

Telecommunication services include ADSL, fireber, and telephone line

Policies:

Preferential tax rate in 10 years

Tax exemption 100% for the first 2 years and 50% for the following four years

No Factor Important Scale | Score Standardized Score of

coefficient score contribution

Site 3: Vinh Loc industrial park

Distance from the material sources to the park:

Cu Chi - Hoang Yen Dairy Farm: 21.3 km

Tra Van Duong Dairy Farm: 27.8 km

Distance to the markets:

Ho Chi Minh City: 5.4 km

The park is located near Dai Han Highway connecting to Asian Highway In

addition, the traffic network is diverse which provides an easier transportation to

important destinations

Infrastructure and services

Electricity is supplied by Ho Chi Minh City Power Corporation The cost is 1350

VND/Kwh

Water is supplied from the Water Supply Station of the industrial park (12000

m*/day-night) The cost is 8800 VND/m*

Water waste is treated to meet the requirements (QCVN 40:2011) before

discharging by transferring to the Water Waste Treatment Factory of the industrial

park (6000 m?/day-night) The cost is 9200 VND/m?

Telecommunication services include ADSL, fireber, and telephone line

Policies:

The Cu Chi District government also has plans and funds for agricultural

development, which would be a benefit for cow farms and ensure the long-term

development of the plant

Preferential tax rate in 10 years

Tax exemption 100% for the first 2 years and 50% for the following four years

No Factor Important Scale | Score Standardized Score of

coefficient score contribution

Tan Phu Trung industrial park would be the most suitable for the plant destination

2.1 Main material - Raw milk

The quality of raw milk used in the production line must follow the National

MATERIALS

technical regulation for raw milk (QCVN 01-186:2017/BNNPTNT)

The raw milk suppliers for the plant are Cu Chi - Hoang Yen Dairy Farm (30 Road

22, Tan Thong Hoi, Cu Chi District, Ho Chi Minh City) and Tra Van Duong Dairy

Farm (04 Road 609, Trung Viet, Phuoc Hiep, Cu Chi District, Ho Chi Minh City)

Criteria Standard quantity

Color Ivory white, creamy white

Odor, taste Characterized for natural fresh milk

Condition Homogeneous solution

Visible contaminant None

Table 2.2 Physico-chemical criteria for raw milk

Criteria Standard quantity

Table 2.3 Contaminant standards for raw milk

Contaminants Maximum quantity

Lead (mg/kg) 0.02

Criteria Maximum quantity

The emulsifier used for milk is usually INS 471 (Mono- and diglycerides of fatty

acids) The emulsifier stabilizes the water-oil system within the milk and forms a

uniform texture for the final product The quality must follow the National technical

regulation on Food Additive - Emulsifiers (QCVN 4-22:2011/BYT) INS 471 needed

is 4g/kg of milk

The emulsifier suppliers for the plant are Lime VN Co., Ltd (95 4B Street, Binh

Hung Hoa B Ward, Binh Tan District, Ho Chi Minh City) and Navico Development

Investment Trading Co., Ltd (394 Nhi Binh 15, Hamlet 2, Nhi Binh, Hoc Mon, Ho Chi

Solubility Insoluble in water, soluble in ethanol,

chloroform, and benzene

Lactase is used to hydrolyze the lactose in milk into two simpler sugars - glucose

and galactose and ensure the milk product after being processed is lactose-free

The lactase suppliers for the plant are Southern International Pharma - Chemical

JSC (71-71A-71B, Road TAO8, Thoi An Ward, District 12, Ho Chi Minh City) and

Biogreen JSC (A24/D7 Moi Cau Giay Urban area, Cau Giay District, Ha Noi City)

The lactase powder is dissolved with a ratio of 1g enzyme in 400mL of water

The lactase concentration used in the production line is 135 U/kg of milk

Solubility Soluble in water, insoluble in organic solvents

Enzyme concentration 10,000 U/g

2.2.3 Water

Water is used for dissolving powdered ingredients (lactase) before mixing, which

increases the mixing efficiency and the homogeneity of the mixed product The water

must have the same quality as potable water and follow the National technical

regulation on drinking water quality (QCVN 01:2018/BYT) and characterized

standard of water hardness for beverage production (less than 1.5 mg CaCO3/L)

The water is supplied by the water suppliers of the industrial park, which are

Water Supply Station of the Tan Phu Trung industrial park and Kenh Dong Water

Plant (Tan Thong Hoi, Cu Chi, Ho Chi Minh City)

Criteria Quantity Standard

Kenh Dong Water Supply Station (QCVN

pH 7.6 7.01 6.5 - 8.5

Taste - Odor No strange taste No strange taste & No strange taste &

& odor odor odor Turbidity (NTU) 0.32 <01 <2

N.A: Not available; N.D: Not detectable

Although the national regulation has a specific requirement for the water hardness,

there is no result for the hardness of water from the water supply station of the

industrial park currently In addition, the water from the Kenh Dong water plant has a

relatively high excess chlorine content despite remaining within the standard range

Therefore, to meet the water hardness standard for beverage production which

must be lower than 1.5 mg CaCO3;/L and ensure the safety, the water must be treated

by ion exchange technology and activated carbon filtration technology before

supplying for the production line

3.1 Block diagram of the lactose-free milk production line

3.2.1 Standardization

Technological purpose

Improvement: To adjust the fat content of the milk to the designed content by

separating the skim milk and cream from raw milk by centrifugation and recombining

the skim milk and a portion of cream while the excess cream is removed from the

production line

Method of implementation

The feed is firstly heated to 40°C before inserting continuously into the equipment

Under the influence of centrifugal force, the milk tendency to move towards the

wall of the equipment By the difference in density, the components are affected by the

force differently and then distributed inside the equipment by layers, in detail, the

component with higher density (skim milk) is distributed closer to the wall while the

other with lower density (cream) is distributed closer to the central axis

The components after being centrifuged are collected separately by two outlets

designed corresponding to the positions of the components

The skim milk flow is transferred completely to the standardization while the

cream flow is divided into two flows A portion of the cream is transferred to the

standardization and the rest is collected in the excess cream tank The standardization

occurs inside the pipeline system, the intermediate product (standardized milk) is

stored in a balance tank before mixing with emulsifier

The process is operated automatically by the control program through the data

received from density measuring instruments and flow meters

Technological parameters

Operating temperature: 40°C

Technological requirements

Fat content: skim milk (0.1%), cream (40%), and standardized milk (2%)

The solutions must not have any sediments

Technological purpose

Preparation: To dissolve the emulsifier before mixing with the milk for enhancing

the stability of the emulsion system in milk

Method of implementation

The excess cream from standardization is partially transferred to the mixer for

dissolving the emulsifier After mixing, the solution is mixed with the standardized

milk before sterilization

Preparation: To add the dissolved emulsifier into the standardized milk before

sterilization with a controlled flow rate to meet the concentration requirement

Method of implementation

The dissolved emulsifier is directly added to the standardized milk continuously

Technological requirements

Total emulsifier content: 4 g/kg of milk

The solutions must not have any sediments

3.2.4 UHT treatment

Technological purpose

Preservation: To extend the shelf life of the milk by eliminating the

microorganisms existing in the milk through rapid heating and cooling treatments

Method of implementation

Firstly, the milk is preheated to 80°C before infusing steam into the milk flow for

direct heating to 145°C

The mixed steam-milk flow is held in the holding tube for 3 - 5 seconds for

sterilization which destroys most of the microorganisms and enzymes, except for

thermolabile microorganisms

about 80-85°C for eliminating the thermolabile microorganisms by sudden temperature

change and preparing for homogenization

The biological and sensory criteria must meet the requirement

The solution must not have any sediments

3.2.5 Homogenization

Technological purpose

Improvement: To increase the homogeneity and stability of the emulsion system of

the milk by breaking down the large fat droplets and clusters into smaller and

separated ones by high pressure and evenly distributing them in the emulsion system,

which eventually prevents the phase separation and extends the shelf life of the milk

product

Method of implementation

The warm milk is fed into the equipment by the piston pump

The homogenization applies the decreasingly narrow space width and high flow

rate to gradually increases the flow pressure and breaks the droplets The flow hits the

valve, then leaves at the narrow gap made by the seat, impact ring, and valve, and then

hit the impact ring with high pressure

The hit helps the clusters and large droplets to partially break down, then further

broken down by the high pressure when leaving the narrow gap and hitting the impact

ring

The process has two stages for better efficiency The flow after leaving the first

stage goes through the second stage with the same principle

The milk after being homogenized is then transferred to the cooling system to cool

down to the ambient temperature

Preparation: To cool the treated milk flow to an appropriate temperature for

adding the lactase to the product

Method of implementation

The milk after being homogenized is partially cooled by water to 45°C and then be

cooled indirectly by the plate heat exchanger with the cooling agent to room

temperature

Technological parameters

Cooling agent temperature: 4°C

Technological requirements

Temperature: Milk outlet (27°C - room temperature)

The solution after leaving the equipment must be homogeneous and must not have

any sediments

3.2.7 Dissolving (Lactase preparation)

Technological purpose

Preparation: To dissolve the powdered lactase and prepare an enzyme solution for

the enzyme mixing process

Method of implementation

The enzyme is dissolved in water to make an enzyme solution preparing for the

mixing and increasing the mixing efficiency

Technological parameters

Dissolving ratio: 1 g of enzyme per 400 mL of water

Technological requirements

Enzyme concentration: 25 U

Technological purpose

Improvement: To eliminate any sediments from the solution and increase the

purity of the enzyme solution

Preservation: To eliminate the microorganisms from the solution which makes the

solution aseptic for the post-sterilization procedures

Method of implementation

The enzyme solution is fed to the equipment by the pump and flows into the

vessels containing porous membranes with a diameter of pores is 0.4 tm

The solution is filtered out the microscopic particles that have a larger size than

the pores The permeate then flows out and collected in a balance tank before using,

while the retentate is washed out and discharged out of the production line

Technological requirements

The solution after leaving the equipment must be free from any microbial

contamination and must not have any sediments

The enzyme solution is directly added to the milk continuously in an aseptic

condition with a controlled flow rate to meet the enzyme concentration requirement

Enzyme concentration: 135 U/kg of milk

Technological requirements

The product must be processed in an aseptic condition

3.2.10 Filling

Technological purpose

Improvement: To fill the milk product in the primary packaging and isolate the

product from post-sterilization contamination and environmental factors degrading the

quality

The milk is directly filled in aseptic packaging in an aseptic condition and then

sealed to isolate the product from post-sterilization contamination and environmental

factors degrading the quality

Technological parameters

Temperature: 30°C

Technological requirements

The product must be sealed completely to avoid any post-sterilization

contamination and environmental factors degrading the quality

The milk cartons are manually arranged into a secondary carton packaging in a set

of 12 cartons per packaging

Technological requirements

The packaging must be firmly sealed to prevent falling during transportation The

information on the printed packaging must be clear for the customers to read

20

4.1 Working plan

Working days of the plant are planned as below:

24 hours divided into 3 shifts: shift 1 (from 7:00 to 15:00), shift 2 (from 15:00 to

23:00), and shift 3 (from 23:00 to 7:00 of the next day)

6 days per week from Monday to Saturday

Not working days: Sundays and holidays (about 13 days per year)

Therefore, the plant works 25 days per month and 300 days per year by subtracting

52 Sundays and 13 holidays from 365 days

The capacity of the plant is 30,000,000 liters per year or 33,333 liters per day

4.2 Mass balance

Assume the initial quantity of raw milk is 10000 kg

The specific loss in each operation of the production line are summarized in Table

4.1

Table 4.1 Summary of loss in operations

Loss

Operation (% based on Explanation

output)

Lactose-free milk production line

Standardization 2 Stuck in the equipment and tubes

Dissolving (cream part) 0.5 Stuck in the equipment and tubes

Mixing 1 0.5 Stuck in the equipment and tubes

UHT treatment 1 Stuck in the equipment and tubes

Homogenization 0.5 Stuck in the equipment and tubes

Cooling 0.5 Stuck in the equipment and tubes

Mixing 2 0.5 Stuck in the equipment and tubes

Filling 1 Stuck in the equipment and tubes

milk (4%) fat Í Centrifugation ‘Skim milk {0.1% fat) >| Standardization Standardized milk (2% fat)

c mite 9) > Excess cream (40% fat)

26 kg

Centrifugation

The initial raw milk (4% fat) input: 10000 kg

The mass of skim milk and the mass of cream after centrifugation are determined

by the following equations:

[Mass equation] m(skim) + m(cream) = m(raw)

[Fat equation] 0.1 m(skim) + 40 m(cream) = 4 m(raw)

From the equations, we have

Skim milk: m(skim) = 9023 kg

Cream: m(cream) = 977 kg

Standardization

The skim milk input: 9023 kg

The mass of cream needed for standardization and the mass of standardized milk

are determined by the following equations:

[Mass equation] m(skim) + m(cream) = m(standardized)

[Fat equation] 0.1 m(skim) + 40 m(cream) = 2 m(standardized)

From the equations, we have

Additional cream: m(cream) = 451 kg

Standardized milk: m(standardized) = 9474 kg

The loss in operations 1% is calculated, the final mass of standardized milk: 9474

x (1 - 0.01) = 9379 kg

4.1.2 Dissolving (cream part)

The mass of standardized milk: 9379 kg

The emulsifier is dissolved by a portion of cream from the excess cream of

standardization before mixing with a ratio of 1 kg emulsifier with 1.5 kg cream

The quantity of cream used to dissolve: 37.52 x 1.5 = 56.28 Kg

Therefore, the total mixed cream with emulsifier: 37.52 + 56.28 = 93.8 kg

The loss in operations 0.5% is calculated, the final mass of standardized milk: 93.8

x (1 - 0.005) = 93.3 kg

4.1.3 Mixing 1

The mass of standardized milk: 9379 kg

The mass of cream with emulsifier: 93.3 kg

The total mass of standardized milk after mixing: 9379 + 93.3 = 9472 kg

The loss in operations 0.5% is calculated, the final mass of standardized milk:

9472 x (1 - 0.005) = 9422 kg

4.1.4 UHT treatment

The initial mass of milk: 9422 kg

The loss in operation 1% is calculated, the final mass of milk:

9422 x (1 - 0.01) = 9327 kg

4.1.5 Homogenization

The initial mass of milk: 9327 kg

The loss in operation 0.5% is calculated, the final mass of milk:

9327 x (1 - 0.005) = 9281 kg

4.1.6 Cooling

The initial mass of milk: 9281 kg

The loss in operation 0.5% is calculated, the final mass of milk:

9281 x (1 - 0.005) = 9234 kg

4.1.7 Mixing 2

The initial mass of milk: 9234 kg

The quantity of lactase 25 U used is 5.4 g/kg of milk to reach 135 U/kg of milk:

9234 x 5.4 = 49864 g = 49.864 kg

The total mass: 9234 + 49.864 = 9284 kg

The loss in operation 0.5% is calculated, the final mass of milk:

4.1.8 Dissolving (enzyme preparation)

Assume the initial quantity of lactase powder is 1 kg

Dissolving ratio: 1 kg of enzyme in 400 kg of water

The total mass of enzyme solution: 1 + 400 = 401 kg

The loss in operation 0.5% is calculated, the final mass of milk:

401 x (1 - 0.005) = 399 kg

4.1.9 Micro-filtration (enzyme preparation)

The initial mass of enzyme solution: 399 kg

The loss in operation 3% is calculated, the final mass of enzyme solution:

399 x (1 - 0.03) = 387 kg

4.1.10 Filling

The initial mass of milk: 9238 kg

The loss in operation 1% is calculated, the final mass of milk:

9238 x (1 - 0.01) = 9145 kg

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raw milk and 1 kg of lactase powder

Operation Input Output | By-product

(kg) (kg) (kg)

Lactose-free milk production line (Initial quantity of raw milk: 10,000 kg)

Standardization 10,000 9,379 526

Emulsifier: 37.52 Dissolving (cream part) Croan: 5698 93.8 93.3 -

Milk: 9,379 Mixing 1 Mixed cream: 9472 9,422 -

93.3 UHT treatment 9,422 9,327 -

Homogenization 9327 9,281 -

Milk: 9,234 Mixing 2 Enzyme solution: | 9284 | 9,238 -

Cream (kg) 469.72 Product

Single milk carton 8,913 Set of 12 cartons 742 Packaging

Primary milk carton box 8,913 Secondary carton box 742

Table 4.4 Summary of input and output by operations in 1 batch”

Table 4.5 Summary of materials, by-products, products, and packaging units per batch,

day, month, and year

Materials/Product Batch Day Month Year

(3 batches) | (25 days) | (300 days) Materials

Primary milk carton box 33,333 100,000 | 2,500,000} 30,000,000

Secondary carton box 2,775 8,324 208,101 2,497,210

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