Course Objectives

• To impart knowledge on different unit operations of dairy and food products.

Course Outcomes

CO1: Acquaint the students with various dairy engineerings operations such as homogenization, pasteurization, thermal processing, evaporation, freezing, and milk drying: PO1

CO2: Design of pasteurization, sterilization, and evaporations equipment: PO1, PO3, PO5, PO6

CO3: Learn to design a dairy plant layout and preparation of different dairy products: PO1, PO2, PO3, PO12

PO1: Engineering knowledge: Apply the knowledge of mathematics, science, engineering fundamentals, and an engineering specialization to the solution of complex engineering problems.

PO2: Problem analysis: Identity, formulate, review research literature, and analyze complex engineering problems reaching substantiated conclusions using first principles of mathematics, natural sciences, and engineering sciences.

PO3: Design/development of solutions: Design solutions for complex engineering problems and design system components or processes that meet the specified needs with appropriate consideration for the public health and safety, and the cultural, societal, and environmental considerations.

PO5: Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern engineering and IT tools including prediction and modeling to complex engineering activities with an understanding of the limitations.

PO6: The engineer and society: Apply reasoning informed by the contextual knowledge to assess societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to the professional engineering practice.

PO12: Life-long learning: Recognize the need for, and have the preparation and ability to engage in independent and life-long learning in the broadest context of technological change.

Course Syllabus

MODULE-I INTRODUCTION, MILK PROPERTIES (3 h)

Dairy development in India, Engineering, thermal and chemical properties of milk and milk products, Process flow chart for product manufacture, Principles and equipment related to receiving of milk.

Project (1 hr):

Write a two-page note on dairy development in India and Orissa since independence.

MODULE-II DIFFERENT PROCESSING METHODS OF MILK (8 h)

Principles, Equipment’s, Controls used in Pasteurization, sterilization, homogenization, centrifugation, cream separation. Evaporation of food products: principle, types of evaporators, steam economy, multiple-effect evaporation, vapour recompression, Thermal Compression

Project (3 hr):

1. Writing a term paper on Ultra High-Temperature Pasteurization of Milk: Kinetics of Microbial Destruction and Changes in Physico-chemical Characteristics.
2. Estimation of cream yield by using Domestic cream separator present in Mini Dairy plant in CUTM Campus.
3. Estimation of Steam Economy, Mass and Energy calculation in an Evaporator.

MODULE-III VALUE ADDITION, FILLING AND PACKAGING OF MILK (4 h)

Preparation methods and equipment for the manufacture of cheese, paneer, butter and ice cream, Different packaging material used for packaging of milk and milk products, filling of milk: Principle and Equipment for filling of Liquid milk, Pasty milk products, and power.

Project (3 hr):

1. Preparation of Paneer from different varieties of milk and compare the paneer yield.
2. Estimation of packaging capacity and efficiency of form-fill-seal machine present in the Mini Dairy plant of CUTM Campus for packaging of milk.

MODULE-IV DRYING AND SEPARATION METHODS (5 h)

Drying of liquid and perishable foods: principles of drying, vacuum tray drying, spray drying, drum drying, freeze-drying, Filtration: principle, types of filters; Membrane separation, RO, Nano-filtration, Ultrafiltration and Macro-filtration, equipment and applications. Dairy plant design and layout, Plant utilities

Project (5.5 hr):

1. Preparation of dried mushroom in the Vacuum self-dryer and compare the rehydration quality with hot air tray dryer (2hr)
2. Preparation of Freeze-dried bitter gourd and compared the rehydration quality with tray drying.
3. Estimation of refrigeration requirements of Mini dairy plant present in the CUTM Campus.
4. Prepare the layout of any dried vegetables manufacturing plant producing 100 kg product per day (1 hr)

References:

• Ahmed, T. 1997. Dairy Plant Engineering and Management. 4th Ed. Kitab Mahal.
• McCabe, W.L. and Smith, J. C. 1999. Unit Operations of Chemical Engineering.
• Mc Graw Hill. Rao, D.G. Fundamentals of Food Engineering. PHI learning Pvt. Ltd. New Delhi.
• Singh, R.P. & Heldman, D.R. 1993. Introduction to Food Engineering. Academic Press.
• Toledo, R. T. 1997. Fundamentals of Food Process Engineering. CBS Publisher.

Session Plan

Session 1

Dairy development in India, Engineering, thermal and chemical properties of milk and milk products.

PDF: Introduction to milk

PDF:Physical, Chemical and Thermal properties of milk

Lactometer reading:https://www.youtube.com/watch?v=ieI8BgPte3E

Lactoscan : https://www.youtube.com/watch?v=lO2oJ7rN2l0

Project (1 hr):

Write a two-page note on dairy development in India and Orissa since independence. (The answer should have the following:

• Development of milk production since independence (India and Orissa)
• Development of the dairy processing industry in India and Orissa.
• References

Session 2

Process flow chart for different milk and milk product manufacture: Pasteurized Milk, Sterilized Milk, Ice-cream, Cheddar Cheese etc.

PDF: Process flow charts

Cheese Making: https://www.youtube.com/watch?v=yCm___cxaEA

Session 3

Principles and equipment related to receiving milk: Milk reception for cans and bulk milk tankers, Storage tank for milk, and different accessories. 

PDF: Reception of milk

Reception for cans: https://www.youtube.com/watch?v=GXFzxHDa8b0

Reception for tankers: https://www.youtube.com/watch?v=3GvEeduTK60

Session 4

Pasteurization: Principles, VAT pasteurizer with different stages of modification, HTST Pasteurizer: Principles and operation.

PDF: Pasteurisation

HTST Pasteurizer animation: https://www.youtube.com/watch?v=6IJLVjpLPb8

HTST Pasteurizer: https://www.youtube.com/watch?v=oGzzo2aEliU&t=225s

Project (1 hr):

Writing a term paper on Ultra High-Temperature Pasteurization of Milk: Kinetics of Microbial Destruction and Changes in Physico-chemical Characteristics of milk.

Session 5

Pasteurization: Temperature, Pressure, and Flow control in HTST Pasteurization, UHT Pasteurization, Uperization, Vacreation.

PDF: Pasteurisation - Cotrols

UHT Pateurizer: https://www.youtube.com/watch?v=KlQyxqJo2IQ

Session 6

Sterilization: Conventional canning, In-Bottle sterilization process (Retorting), Aseptic Sterilization, Different types in-bottle sterilizers.

PDF: Sterilization

Hydrostatic sterilizer: https://www.youtube.com/watch?v=_e-AH89sPIU

Conventional retort : https://www.youtube.com/watch?v=1Cq7LN1tTMg

Water spray retort: https://www.youtube.com/watch?v=bWD87VVtzKU

Rotart retort: https://www.youtube.com/watch?v=iGRgYuYUOYY

Session 7

Sterilization: UHT Processing, Ways to reduce fouling in a sterilizer

PDF: UHT Processing and Fouling

UHT Sterilization: https://www.youtube.com/watch?v=pXWu40NoTZM

Session 8

Homogenization: Requirements, Single-stage homogenizer: Principles of operation and components, Double-stage homogenizer, Pressure, and temperature control.

PDF: Homogenisation

Homogenizer: https://www.youtube.com/watch?v=r5MhAK8lAmU&t=82s

Session 9

Cream Separation: Principles, Tubular bowl centrifuge, Disc bowl centrifuge

PDF: Cream Separation

Disc bowl centrifuge: https://www.youtube.com/watch?v=aq5cpTc_5dU&t=41s

Tubular bowl centrifuge: https://www.youtube.com/watch?v=mBNxntsUUME

Project (1 hr):

Estimation of cream yield by using Domestic cream separator present in Mini Dairy plant in CUTM Campus.

Session 10

Evaporation: Principles, Basic function, and construction of an Evaporator, Types: Natural and Forced Circulation.

PDF: Evaporation

Single Effect Evaporators: https://www.youtube.com/watch?v=VBaz3NIIJ9o

Rising Film Evaporators: https://www.youtube.com/watch?v=vG-ze17ADPI&t=72s

Falling Film Evaporators: https://www.youtube.com/watch?v=gFK2w4lx4i0

Session 11

Evaporation: Multiple effects evaporator, steam Economy, Mass, and Energy balance in an evaporator, Boiling point Elevation.

PDF: Mass & Energy balance in an Evaporator

Multiple Effect Evaporator: https://www.youtube.com/watch?v=kHMlLDsJqXE&t=78s

Project (1 hr)

Estimation of Steam Economy, Mass, and Energy calculation in an Evaporator.

Session 12

Preparation methods and equipment for the manufacture of cheese and ice cream.

PDF: Cheese manufacturing

PDF: Ice cream manufacturing

Cheese: https://www.youtube.com/watch?v=wxm8jTzU_8o&t=1s

Ice-cream: https://www.youtube.com/watch?v=BBTLlOF87xY&t=334s

Session 13

Preparation methods and equipment for the manufacture of butter and paneer.

PDF: Butter manufacture

Butter: https://www.youtube.com/watch?v=6m7dU3Q4Ujo

PDF: Paneer manufacturing

Paneer: https://www.youtube.com/watch?v=yV9wTbvGjHs&t=187s

Project (2 hr):

Preparation of Paneer from different varieties of milk and compare the paneer yield. 

Session 14

Milk and Milk product packaging: Role of packaging material, Functions of packaging, different packaging material used for packaging of milk and milk products.

PDF: Packaging of milk and milk products

Importance of packaging: https://www.youtube.com/watch?v=i2pnLrsMtPs

Project (1 hr):

Estimation of packaging capacity and efficiency of form-fill-seal machine present in the Mini Dairy plant of CUTM Campus for packaging of milk.

Session 15

Filling of milk: Principle and Equipment for filling of Liquid milk, Pasty milk products, and power.

PDF: Filling of milk and milk products

Gravity filler: https://www.youtube.com/watch?v=816SH-lJqx8

Piston filler: https://www.youtube.com/watch?v=UeTGE2Ag3hg

Form fill seal packaging: https://www.youtube.com/watch?v=eqBiZE9Fofo

Session 16

Drying of liquid and perishable foods: principles of drying, Drying rates and drying curve, Equilibrium Moisture content, Free Moisture, Bound Moisture, Factors affecting drying of food materials.

PDF: Drying theory and principles

Drying rate curve: https://www.youtube.com/watch?v=sxAb2PMsnQ0

Session 17

Dryers: Vaccum tray drying, Microwave drying, Spray drying, Drum drying, Freeze drying, Principles, and construction of dryers.

PDF: Dryers

Vacuum tray dryer: https://www.youtube.com/watch?v=YQ7y6Kvjd5Y

Spray dryer: https://www.youtube.com/watch?v=0o4ZCjHnaRw&t=2s

Drum dryer: https://www.youtube.com/watch?v=msGOevNYVL4&t=25s

Project (3.5 hr):

• Preparation of dried mushroom in the Vacuum self-dryer and compare the quality parameter with hot air tray dryer.
• Preparation of Freeze-dried bitter gourd and compared the rehydration quality with tray drying.

Session 18

Filtration: Principles of operation, Plate and frame filter, Shell and leaf filter, Filtration of gases: Principles of operation and construction.

PDF: Filtration

Plate and frame filter: https://www.youtube.com/watch?v=msGOevNYVL4&t=25s

Shell and leaf filter: https://www.youtube.com/watch?v=QjScaXWiq1s&t=15s

Bag filter: https://www.youtube.com/watch?v=Xl8Y2S7MW28

Session 19

Membrane separation: Reverse osmosis, Nano-filtration, Ultrafiltration and Macro-filtration, equipment, and applications.

PDF: Membrane separation

Membrane separation: https://www.youtube.com/watch?v=5qVIPUMJaRA&t=39s

Reverse osmosis: https://www.youtube.com/watch?v=-_sr7mzhVsE&t=19s

Session 20

Dairy plant design and layout, Plant utilities

PDF: Dairy Plant layout

Mini dairy plant: http://Dairy Milk Plant Animation - Dairy Milk Processing Manufacture Movie_Sdk99uB_E4g_360p

Project (2 hr):

• Estimation of refrigeration requirements of Mini dairy plant present in the CUTM Campus.
• Prepare the layout of any dried vegetable manufacturing plant producing 100 kg product per day.

Lecture Notes, MCQs, Question Bank

Lecture Notes: DFE- Lecture Notes

Question bank: DFE Question Bank

MCQ: DFE-MCQ

Case Studies