Revamping and expansion of milk chilling centre.

In this paper we have elaborated about revamping of the old refrigeration system for a milk chilling center at Lingnoor 300 km from Mumbai. This is a classic example of how old inefficient milk chilling centers can be revamped and modernized in India. The main diary process 1,500,000 lit milk every day. This chilling center is one of the four chilling center where 70000 to 80000 LPD (litter / day) milk was processed since 1985. The major problems faced were, inadequate milk handling capacity, very high energy consumptions, high discharge pressure, high milk temperature ( 3 Deg C required , actual was 5 to 7 Deg C ), and safety related issues such as frequent ammonia leak. In last twenty years the population density around chilling center increased and safety became a very critical issue. In addition, energy cost also increased substantially. Entire plant was operated manually. The approach/ methodology selected were, to carry out technical evaluation and to conduct safety audit. Study and understand day to day operation as compare to present / future milk processing requirement. Asses and evaluate route cause of problem. Find out areas of improvement to make existing chilling center energy efficient, safe and has capacity to handle 200,000 LPD milk. The entire operation was executed on fast track of six months without affecting the operation and business. Key achievements were substantial reduction in energy consumption, improved safety, and plant operation is atomized, increased milk handling capacity to 200,000LPD, Last one year no breakdown as compare to every two to three months breakdown. The return on investment as planned was achieved in first year.