TRAINING REPORT

AT

MOTHER DAIRY

PATPARGANJ NEW DELHI-92

Submitted By:-Name : Mirza Mohd. Rashid & Avinash Rawat

KRISHNA INSTITUTE OF ENGINEERING & TECHNOLOGY

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

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ACKNOWLEDGEMENT

This project is done as a semester project, as a part of course titled “MOTHER DAIRY”. I’m really thankful to my instructor Mr. Sachin Rohtagi, Assistant Professor, for Financial Management, International Institute of Business studies, Noida, for his valuable guidance and assistance, without which the accomplishment of the task would have never been possible.

I would also like to thank him for giving this opportunity to explore into the real world and realize the interrelation of Dairy Industry and Economics, without which a society can never progress. In my project I have chosen the topic- “Potential and Future of the dairy Industry” and as the study of the same, done for Delhi-NCR Region, one of the famous and most populous regions of India.

This report contains an over view of Dairy industry of North West Region and the Various Development and planning by co-operative societies and national dairy development board, for a better understanding of the various steps implemented by the government to overcome the growing demand of the dairy requirements of the country. I’m also thankful to all those working for Mother Dairy for providing me with relevant information and necessary clarifications.

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TABLE OF CONTENT:

S. NO. TOPIC Page No.

1. Introduction to dairy industry 4

2. Introduction to NDDB 5

3. About company 7

4. Processing of Milk (pasteurizer plant) 9

5. Swot 11

6. Air Compressor 12

7. Boilers 15

8. Refrigeration plant 17

9. Nano Water Treatment Plant 21

10. Reverse Osmosis plant 23

11. Effluent Treatment Plant (ETP) 25

12. Conclusion 29

13. References 30

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CHAPTER 1ABOUT DAIRY INDUSTRY

Introduction:

The dairy sector in the India has shown remarkable development in the past decade and India has now become one of the largest producers of milk and value-added milk products in the world. The dairy sector has developed through co-operatives in many parts of the country. During 1997-98, the States (Delhi-Haryana-Uttar Pradesh) had 17574 million tones production capacity, which rose to 29719 million tons by the year 2012. In addition to many processing plants, many government co-operative societies and chilling centers have being made.

About the Indian dairy Industry:

In India, the dairy sector plays an important role in the country’s socio-economic development and constitutes an important segment of the rural economic. Dairy industry provides livelihood to millions of homes in village, assuring supply of quality of milk and milk products to both urban and rural areas. With view to keeping pace with the country’s increasing demand of milk and milk products, the industry has being growing rapidly.

According to research report “Indian Dairy Industry Analysis” India is world’s largest milk producers accounting of around 17% of the global milk production. Besides, India is also one of largest consumers of milk and milk products. Due to rich nutritional qualities, the consumption of dairy product has being growing exponentially in the country, and considering such facts and figures, my study anticipates that the milk production in India will grow at a CAGR of around 4% during 2012 to 2015.With rising use of dairy product, the secondary market of dairy product has been flourishing, my report observed. Covering the necessary aspects of the Indian dairy industry, the study facilitates knowledge about its current market scenario and future growth. Analyzing the past and current state of the industry, the report tries to find out how trends like the entry of international companies and packaging are attracting the consumers and heeding towards further growth in the market. This way, it present a clear picture of the direction, in which the industry is likely to proceed in the coming years.

The government is taking several initiatives and running plans and programs like National Diary Plan and Intensive Dairy Development Program to meet the growing demand for milk in the country. Our report talks about such schemes, and government regulations to present an objective and balanced picture of the industry. The study also discusses the opportunities and strengths of the dairy market in a complete SWOT analysis, and provides an insight into the competitive landscape. We hope that our comprehensive research will help clients align their business strategies as per market dynamics, and make sound investment decisions.

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CHAPTER 2

ABOUT NDDB:

Fig 2.1 National Dairy Development Board logo

National Dairy Development Board (NDDB) was founded to replace.

Exploitation with empowerment. Tradition with modernity. Stagnation with growth.

An instrument for the development of India’s rural transforming dairying into an instrument for the development of India’s rural people. Prior to NDDB, the milk market was vastly governed by local private dairy and these dairies were neither producing milk nor they were animal breeders and hence law of demand and supply was unheard by those

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whose intentions were purely to make more money from both the sides – that is from producers of milk (farmers) and consumers at large. Establishment of NDDB broke that spell and traders were side lined in due course.

The National Dairy Development Board was created in promote, finance and support producer-owned and controlled organizations. NDDB’s efforts are co-operative principles and the Anand Pattern of Co-operation

Philosophy of NDDB:

Co-operation is the preferred form of enterprise, giving people control over the resources, through democratic self-governance.

All beneficiaries, particularly women and under privileged, must be involved in co-operative management and decision making.

Technological and evolution search for better way to achieve the objective in the dynamic market.

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CHAPTER 3ABOUT THE COMPANY

"Mother Dairy" is the single largest brand of milk in India as well as in Asia, marketing about 4.45 million litres of milk per day. Mother Dairy commands 62% market share in the organized sector in and around Delhi, primarily because of consistent quality and service – whatever be the crisis - floods, transport, strike, curfew etc. Mother Dairy, Patparganj, Delhi, is presently manufacturing & selling around 8.5 lakh litres of toned milk through bulk vending shops.

Mother Dairy, Delhi is an IS/ISO - 9001:2000 and Hazard Analysis Critical Control Points (HACCP) and IS-14001:1996 Environment Management System (EMS) Certified organisation.

Mother Dairy was the first Dairy in the country to implement ISO-14031 (Environment Performance Evaluation) project. The company’s Quality Assurance Laboratory is ISO/IEC- 17025:1999 certified by NABL (National Accreditation Board for Testing and Calibration Laboratory), Department of Science & Technology, India.This provides assurance to consumer in respect of Quality and Safety of products manufactured and marketed by Mother Dairy. The National Dairy Development Board (NDDB) commissioned Mother Dairy in the first phase of Operation Flood in 1974. Considering the success of Dairy industry NDDB established Fruit & Vegetable Project in Delhi in 1988 with "SAFAL" as its umbrella brand. With a view to separating the commercial activities from developmental activities, the NDDB merged Mother Dairy and the Fruit & Vegetable project into a wholly owned company named Mother Dairy Fruit & Vegetable Ltd (MDFVL) in April 2000. This becomes the holding company of Mother Dairy India Ltd (MDIL) – a marketing company and Mother Dairy Foods Processing Ltd (MDFPL) – a processing company. MDFPL is a multi unit company, with units at various locations in India. Mother Dairy, Delhi is one of the units of MDFPL.

The company is a highly trusted house hold name for its wide range of milk products like Milk, Flavoured Milk, Ice-Cream, Dahi, Lassi, Table Butter, Dairy Whitner, Ghee etc. The application for the award is being made for Mother Dairy, Delhi unit.Mother dairy has taken up the concept of Total Productive Maintenance (TPM) wholeheartedly.The number of employees involved in KAIZENS and the no. of KAIZENS per employee are very encouraging. Mother Dairy is a member of CII-TPM Club and the KAIZENS done by Mother Dairy employees have been selected and presented in 2nd, 3rd, 4th and 5th National Kaizen Conferences held from time to time during the last three years. Our TPM efforts have resulted in increase in MTBF and decrease in MTTR, quality improvement, Cost reduction and reduction in accidents.

Mother Dairy has received "Best Productivity Performance" award for three consecutive years starting from1987-88 to1989-90 and again from1995-96 to1997-1998 from National productivity Council and a commendation Certificate for Rajiv Gandhi National Quality Award, National Energy Conservation Award - 2004, Oil and Gas

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Conservation Award - 2004, Indian Innovation Award - 2004 and Safety Initiative Award - 2005.Over the years, Mother Dairy has not only served the daily need of milk of the consumers of Delhi, it has also extended its milk to other States like Haryana, Uttar Pradesh, Maharashtra, Andhra Pradesh & Gujarat and is expanding its wings rapidly to serve the masses.

Strategically located Mother Dairy booths across Delhi and NCR make it convenient for you to pick up your daily requirement of Milk, Flavoured milk, Butter, Dahi, Lassi, Cheese, Chaas….mouth-watering Ice Creams. The focus is on key markets for each of the categories. In the curd category, they have been in Delhi for a while now and launched in Mumbai just three months back. They hold a 60 per cent market share in Delhi, but it is too soon to gauge where we stand in Mumbai.

Objectives and Business Philosophy of Mother Dairy :

The main stakeholder of Mother Dairy was the farmer member for whose welfare it existed. Unlike other organizations, their objective is not to maximize the profit. They are more interested in giving the best price for the farmers for their milk than in making a large profit. Thus they look at the price given to their suppliers as not a cost but as an objective. Mother Dairy had, as its main objective, “carrying out activities for the economic development of agriculturists by efficiently organizing marketing of milk and dairy produce, agricultural produce in raw and/or processed form and other allied produce”. This was to be done through:· Common branding· Centralized marketing· Centralized quality control· Centralized purchases and· Pooling of milk efficiently

Mother Dairy had declared, as its business philosophy, the following: ensure that milk producers and farmers regularly and continually receive market prices by offering quality milk, milk products and other food products to consumers at competitive prices and; uphold institutional structures that empower milk producers and farmers through processes that are equitable. The biggest strength of Mother Dairy was the trust it had created in the minds of its consumers regarding the quality of its products.

NDDB and its brand Mother Dairy stood for guaranteed purity of whatever products it had produced. Adulteration was simply not done in any of its products. In India, where such trust was hard to come by, this could provide a central anchor for

Mother Dairy’s future business plans. For more than 40 years' Mother Dairy helping to create a national network has been adapted and extended to other commodities and areas. Their constant effort to learn and to enrich experience is central to their approach and capacities. In times to come, Mother Dairy shall strive to become a leading player in the food industry in India.

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CHAPTER 4PROCESSING OF MILK (PASTERUIZER PLANT)

The Process Flow of the Mother Dairy:

Raw.

Fig 4.1 Process Flow of milk

Raw Milk Reception:

Raw milk received through insulated road/rail tankers at a very low temperature thus retaining the freshness of milk. The milk goes for more than 15 stringent quality tests before it is accepted for the processing of milk.

Milk achieved from individual producers is checked for all basic quality parameters meeting the company specification and required norms at respective collection and chilling centres.Milk is then supplied to the dairy units through insulated milk tankers at <4 degree C.

Processing of Milk:

Processing of milk is done in basically 4 steps

Clarification Standardization Homogenization Pasteurization

Clarification:

The chilled milk from the silos goes to the clarifier after pre-heating. The clarifier spins the milk at very high speed, removing all the dust particles that are invisible to naked eyes.

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Raw Milk Reception Clarification Standardization

Processed Milk Pasteurization Homogenization

Deep Chilling Dispatch

Standardization:

Milk from different breeds of cow and buffalo may vary in its composition. Hence, to make Milk uniform in composition, before supply to the market, it is standardized by raising or lowering its fat and SNF percentage present in the milk to a desired level, so as to deliver the milk to consumers as per prescribed norms of FSSAI.

Homogenization:

In this process, the milk is processed at very high pressure during which the large fat globules presently in milk are broken down into tiny droplets. The milk fat gets evenly distributed in the milk and milk become whiter and thicker. Milk is homogenized for consumers who do not like cream layer on top.

Pasteurization:

The milk is then pasteurized, named after Louis Pasteur, a French Scientist who invented the process to use in wine. Pasteurization was first applied by Dr. Soxhiet of Germany. This involves heating of milk to 72 degree Celsius for 15 second and then cooling it down to 4 degree Celsius. The process kills all pathogenic bacteria present in the milk making.

Milk production in India:

1991-9293-94

95-9697-98

99-2000

2001-02

2003-04

2005-06

2007-08

2009-2010

2011-20120

50

100

150

200

250

300

350

Production (Million Tonnes)Per Capita Avaiblity (gms/day)

Fig.4.2 Milk production in India

Conclusion: Rise In total production capacity- 5% Rise in Consumption (gms/day)- 3.55%

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CHAPTER 5SWOT

Strength: Different Variety of Milk. Recognized brand name. 66% of Delhi-NCR market share Trust of customer

Weakness: No Of Outlets are less. Pays less to Farmers as compared to Amul. This in return causes difficulties in engaging farmers.

Opportunity: As the dairy industry is rising with rate of 5%, whereas population is rising

by 17% making vast scope for expansion. As the rise in Index of Wholesale price of Milk roused by 10.85%, thus

there is huge potential in Milk industry. Rise in Index no of Wholesale Price of Dairy Product from year 2010 to

2011 by 12.78%, thus making it profitable for Dairy Industry.

Threats: Facing tough competition from competitors like AMUL. Pricing policy for procuring milk is far less than its competitors, causing

loss in faith of farmers Supply chain management of competitors are much better.

Recommendations: Must focus on growing market opportunity. Must revise its strategy of procurement of milk from farmers in regards to

payment of price/litres. Overseas market have huge capacity, must work aggressively on global

expansion.

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CHAPTER 6Air compressor

An electric motor, a diesel engine or a gasoline engine) into kinetic energy by compressing and pressurizing air, which, on command, can an air compressor is a device that converts power (usually from be released in quick bursts. There are numerous methods of air compression, divided into either positive-displacement or negative-displacement.

Fig 6.1 Air Compressor

Types of air compressor:

According to the design and principle of operation:1. Reciprocating compressor2. Rotary screw compressor3. Turbo compressor

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Positive displacement:

Positive-displacement air compressors work by forcing air into a chamber whose volume is decreased to compress the air. Piston-type air compressors use this principle by pumping air into an air chamber through the use of the constant motion of pistons. They use one-way valves to guide air into a chamber, where the air is compressed. Rotary screw compressors also use positive-displacement compression by matching two helical screws that, when turned, guide air into a chamber, whose volume is decreased as the screws turn. Vane compressors use a slotted rotor with varied blade placement to guide air into a chamber and compress the volume. A type of compressor that delivers a fixed volume of air at high pressures. Common types of positive displacement compressors include piston compressors and rotary screw compressors.

Negative displacement:

Negative-displacement air compressors include centrifugal compressors. These use centrifugal force generated by a spinning impeller to accelerate and then decelerate captured air, which pressurizes it.

Fig 6.2 Cut-sectional view of Air Compressor

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Cooling:

Due to adiabatic heating, air compressors require some method of disposing of waste heat. Generally this is some form of air- or water-cooling, although some (particularly rotary type) compressors may be cooled by oil (that is then in turn air- or water-cooled) and the atmospheric changes also considered during cooling of compressors.

Applications:

• To supply high-pressure clean air to fill gas cylinders• To supply moderate-pressure clean air to a submerged surface supplied diver• To supply moderate-pressure clean air for driving some office and school building pneumatic HVAC control system valves• To supply a large amount of moderate-pressure air to power pneumatic tools, such as jackhammers• For filling tires• To produce large volumes of moderate-pressure air for large-scale industrial processes (such as oxidation for petroleum coking or cement plant bag house purge systems).

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CHAPTER 7Boiler

A boiler is a closed vessel in which water or other fluid is heated. The fluid does not necessarily boil. (In North America the term "furnace" is normally used if the purpose is not actually to boil the fluid.) The heated or vaporized fluid exits the boiler for use in various processes or heating applications, including central heating, boiler-based power generation, cooking, and sanitation.

Fig 7.1 Boiler

Materials:

The pressure vessel of a boiler is usually made of steel (or alloy steel), or historically of wrought iron. Stainless steel, especially of the austenitic types, is not used in wetted parts of boilers due to corrosion and stress corrosion cracking. However, ferrite stainless steel is often used in superheated sections that will not be exposed to boiling water, and electrically-heated stainless steel shell boilers are allowed under the European "Pressure Equipment Directive" for production of steam for sterilizers and disinfectors. In live steam models, copper or brass is often used because it is more easily fabricated in smaller size boilers. Historically, copper was often used for fireboxes (particularly for steam locomotives), because of its better formability and higher thermal conductivity; however, in more recent times, the high price of copper often makes this an uneconomic choice and cheaper substitutes (such as steel) are used instead. For much of the Victorian "age of steam", the only material used for boiler making was the highest grade of wrought iron, with assembly by riveting. This iron was often obtained from specialist ironworks, such as at Creator Moor(UK). In the 20th century, design practice instead moved towards the use of steel, which is stronger and cheaper, with welded construction, which is quicker

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and requires less labour. It should be noted, however, that wrought iron boilers corrode far slower than their modern-day steel counterparts, and are less susceptible to localized pitting and stress-corrosion. This makes the longevity of older wrought-iron boilers far superior to those of welded steel boilers. Cast iron may be used for the heating vessel of domestic water heaters. Although such heaters are usually termed "boilers" in some countries, their purpose is usually to produce hot water, not steam, and so they run at low pressure and try to avoid actual boiling

Fuel:

The source of heat for a boiler is combustion of any of several fuels, such as wood, coal, oil, or natural gas. Electric steam boilers use resistance- or immersion-type heating elements. Nuclear fission is also used as a heat source for generating steam, either directly (BWR) or, in most cases, in specialized heat exchangers called "steam generators" (PWR). Heat recovery steam generators (HRSGs) use the heat rejected from other processes such as gas turbine.

Fig 7.2 Cut-section view of boiler

Application:

It is mainly used in production industry as well as manufacturing industry, where there is requirement of hot water and steam.

Maintenance:

1. Daily inspection2. Washout 3. Periodic examination4. General overhaul.

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CHAPTER 8Refrigeration plant

A refrigeration plant uses gas, liquid, and mechanical energy to move heat from one place to another. A liquid, such as ammonia, which has a low boiling temperature is allowed to pass into a space via tubing. As the pressure in the ammonia drops, the liquid begins to boil, and enter a phase transition from liquid to gas. In doing so, there is a great absorption of heat energy by the liquid in the tubing to create this phase change. The heat energy is absorbed from the space, and as the liquid boils off, it forms a gas. The gas is pulled through the tubing in the space into a suction header outside the space to the suction of a compressor. The compressor repress rises the gas, and discharges the liquid through cold water heat exchangers or cooling fans, exhausting the heat absorbed from the space, into the outside atmosphere. By pressurizing and cooling the gas, the gas returns to a liquid stage, where it is stored and reintroduced to the space to be cooled.

Fig 8.1 Refrigeration plant

Methods of refrigeration:

Methods of refrigeration can be classified as Non-cyclic Cyclic Thermoelectric Magnetic.

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Non-cyclic refrigeration:

In non-cyclic refrigeration, cooling is accomplished by melting ice or by subliming dry ice (frozen carbon dioxide). These methods are used for small-scale refrigeration such as in laboratories and workshops, or in portable coolers. Ice owes its effectiveness as a cooling agent to its melting point of 0 °C (32 °F) at sea level. To melt, ice must absorb 333.55 kJ/kg (about 144 Btu/lb) of heat. Foodstuffs maintained near this temperature have an increased storage life. Solid carbon dioxide has no liquid phase at normal atmospheric pressure, and sublimes directly from the solid to vapour phase at a temperature of -78.5 °C (-109.3 °F), and is effective for maintaining products at low temperatures during sublimation. Systems such as this where the refrigerant evaporates and is vented to the atmosphere are known as "total loss refrigeration”.

Cyclic refrigeration:

This consists of a refrigeration cycle, where heat is removed from a low-temperature space or source and rejected to a high-temperature sink with the help of external work, and its inverse, the thermodynamic power cycle. In the power cycle, heat is supplied from a high-temperature source to the engine, part of the heat being used to produce work and the rest being rejected to a low-temperature sink. This satisfies the second law of thermodynamics. A refrigeration cycle describes the changes that take place in the refrigerant as it alternately absorbs and rejects heat as it circulates through a refrigerator. It is also applied to HVACR work, when describing the "process" of refrigerant flow through an HVACR unit, whether it is a packaged or split system. Heat naturally flows from hot to cold. Work is applied to cool a living space or storage volume by pumping heat from a lower temperature heat source into a higher temperature heat sink. Insulation is used to reduce the work and energy needed to achieve and maintain a lower temperature in the cooled space. The operating principle of the refrigeration cycle was described mathematically by Sadi Carnot in 1824 as a heat engine. The most common types of refrigeration systems use the reverse-Rankine vapour-compression refrigeration cycle, although absorption heat pumps are used in a minority of applications.

Cyclic refrigeration can be classified as:

1. Vapour cycle, and2. Gas cycle

Vapour cycle refrigeration can further be classified as:

1. Vapour-compression refrigeration2. Vapour-absorption refrigeration

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Vapour-compression cycle:

Fig 8.2 Vapour-compression cycle

The vapour-compression cycle is used in most household refrigerators as well as in many large commercial and industrial refrigeration systems. Figure 1 provides a schematic diagram of the components of a typical vapour-compression refrigeration system. Vapour compression refrigeration the thermodynamics of the cycle can be analysed on a diagram. In this cycle, a circulating refrigerant such as Freon enters the compressor as a vapour. From point 1 to point 2, the vapour is compressed at constant entropy and exits the compressor as a vapour at higher temperature, but still below the vapour pressure at that temperature. From point 2 to point 3 and on to point 4, the vapour travels through the condenser which cools the vapour until it starts condensing, and then condenses the vapour into a liquid by removing additional heat at constant pressure and temperature. Between points 4 and 5, the liquid refrigerant goes through the expansion valve (also called a throttle valve) where its pressure abruptly decreases, causing flash evaporation and auto-refrigeration of, typically, less than half of the liquid.

Vapour absorption cycle:

In the early years of the twentieth century, the vapour absorption cycle using water-ammonia systems was popular and widely used. After the development of the vapour compression cycle, the vapour absorption cycle lost much of its importance because of its low coefficient of performance (about one fifth of that of the vapour compression cycle).

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Gas cycle:

When the working fluid is a gas that is compressed and expanded but doesn't change phase, the refrigeration cycle is called a gas cycle. Air is most often this working fluid. As there is no condensation and evaporation intended in a gas cycle, components corresponding to the condenser and evaporator in a vapour compression cycle are the hot and cold gas-to-gas heat exchangers in gas cycles. The gas cycle is less efficient than the vapour compression cycle because the gas cycle works on the reverse Brayton cycle instead of the reverse Rankine cycle. As such the working fluid does not receive and reject heat at constant temperature. In the gas cycle, the refrigeration effect is equal to the product of the specific heat of the gas and the rise in temperature of the gas in the low temperature side. Therefore, for the same cooling load, a gas refrigeration cycle needs a large mass flow rate and is bulky.

Thermoelectric refrigeration:

Thermoelectric cooling uses the Peltier effect to create a heat flux between the junction of two different types of materials. This effect is commonly used in camping and portable coolers and for cooling electronic components and small instruments.

Magnetic refrigeration:

Magnetic refrigeration, or adiabatic demagnetization, is a cooling technology based on the magneto caloric effect, an intrinsic property of magnetic solids. The refrigerant is often a paramagnetic salt, such as cerium magnesium nitrate. The active magnetic dipoles in this case are those of the electron shells of the paramagnetic atoms. A strong magnetic field is applied to the refrigerant, forcing its various magnetic dipoles to align and putting these degrees of freedom of the refrigerant into a state of lowered entropy. A heat sink then absorbs the heat released by the refrigerant due to its loss of entropy. Thermal contact with the heat sink is then broken so that the system is insulated, and the magnetic field is switched off. This increases the heat capacity of the refrigerant, thus decreasing its temperature below the temperature of the heat sink.

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CHAPTER 9NANO WATER TREATMENT PLANT

Nano filtration is a relatively recent membrane filtration process used most often with low total dissolved solids water such as surface water and fresh groundwater, with the purpose of softening (polyvalent caution removal) and removal of disinfection by-product precursors such as natural organic matter and synthetic organic matter. Nano filtration is also becoming more widely used in food processing applications such as dairy, for simultaneous concentration and partial (monovalent ion) demineralization.

Fig 9.1 Nano water treatment plant

General:

Nano filtration is a membrane filtration based method that uses nanometer sized cylindrical through-pores that pass through the membrane at a 90°. Nano filtration membranes have pore sizes from 1-10 Angstrom, smaller than that used in microfiltration and ultrafiltration, but just larger than that in reverse osmosis. Membranes used are predominantly created from polymer thin films. Materials that are commonly used include polyethylene terephthalate or metals such as aluminum. Pore dimensions are controlled by pH, temperature and time during development with pore densities ranging

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from 1 to 106 pores per cm2. Membranes made from polyethylene terephthalate and other similar materials, are referred to as “track-etch” membranes, named after the way the pores on the membranes are made. “Tracking” involves bombarding the polymer thin film with high energy particles. This results in making tracks that are chemically developed into the membrane, or “etched” into the membrane, which are the pores. Membranes created from metal such as alumina membranes, are made by electrochemically growing a thin layer of aluminium oxide from aluminium metal in an acidic medium.

Range of applications:

Historically, nanofiltration and other membrane technology used for molecular separation was applied entirely on aqueous systems. The original uses for nanofiltration were water treatment and in particular water softening. Nano filters can “soften” water by retaining scale-forming, hydrated divalent ions (e.g. Ca2+, Mg2+) while passing smaller hydrated monovalent ions. In recent years, the use of nanofiltration has been extended into other industries such as milk and juice production. Research and development in solvent-stable membranes has allowed the application for nanofiltration membranes to extend into new areas such as pharmaceuticals, fine chemicals, and flavour and fragrance industries. Development in organic solvent nanofiltration technology and commercialization of membranes used has extended possibilities for applications in a variety of organic solvents ranging from non-polar through polar to polar aprotic.

Industry Uses:

Fine chemistry and Pharmaceuticals Non-thermal solvent recovery and management Room temperature solvent exchange Oil and Petroleum chemistry Removal of tar components in feed Purification of gas condensates Bulk Chemistry Product Polishing Continuous recovery of homogeneous catalysts Natural Essential Oils and similar products Fractionation of crude extracts Enrichment of natural compounds Gentle Separations Medicine Able to extract amino acids and lipids from blood and other cell culture.

Advantages and Disadvantages:

One of the main advantages and reasons for why Nano filtration is considered a prime method softening water is that during the process of retaining calcium and magnesium ions while passing smaller hydrated monovalent ions is performed without adding extra sodium ions, as used in ion exchangers. Many separation processes that do not operate at room temperature. Performing gentle molecular separation is linked with Nano filtration that is often not included with other forms of separation processes (centrifugation). These are two of the main benefits that are associated with Nano filtration. Nano filtration has a very favorable benefit of being able to process large volumes and continuously produce streams of have a Nano filtration is the least used method of membrane filtration in industry as the membrane pores sizes are limited to only nanometers. Anything smaller, reverse osmosis is used and anything larger is used for ultrafiltration. Ultrafiltration can also be used in cases where Nano filtration can be used, due to it being more conventional. A main disadvantage associated with nanotechnology, as with all membrane filter technology, is the cost and maintenance of the membranes used.

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CHAPTER 10 Reverse Osmosis Plant

A reverse osmosis plant is a manufacturing plant where the process of reverse osmosis takes place. An average modern reverse osmosis plant needs six kilowatt-hours of electricity to desalinate one cubic metre of water. The process also results in an amount of salty briny waste. The challenge for these plants is to find ways to reduce energy consumption, use sustainable energy sources, improve the process of desalination and to innovate in the area of waste management to deal with the waste. Self-contained water treatment plants using reverse osmosis, called reverse osmosis water purification units, are normally used in a military context. A 1000 Lph commercial Reverse Osmosis Plant fitted with ultraviolet treatment system.

Fig 10.1 Reverse Osmosis Plant

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Examples of reverse osmosis plants

In operation

• In Israel at Ashkelon on the Mediterranean coast, the world's largest reverse osmosis plant is producing 320,000 cubic metres of water a day at around possibly $0.50 USD per cubic meter.• In western Saudi Arabia at Yanbu, production started in 1999 at 106,904 cubic meters of water a day. Later in 2009 with some expansion the production reached to 132,000 cubic meters of water a day.• In Sindh Province Pakistan the provincial government has installed 382 reverse osmosis plants in the province out of which 207 are installed in backward areas of Sindh which includes districts of Thar, Thatta, Badin, Sukkur, Shaheed, Benazirabad, Noshero, Feroz, and others while 726 are on the final stage of their completion.

Under construction

• In China a desalination plant will be built for Tianjin, to produce 100,000 cubic metres of desalinated seawater a day.• In Spain 20 reverse osmosis plants will be built along the Costas, expecting to meet slightly over 1% of Spain's total water needs.• In Pakistan South Asia's biggest reverse osmosis plant is Under Construction in Dadu to treat the effluent of RBOD for irrigation and drinking purposes

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CHAPTER 11EFFLUENT TREATMENT PLANT (ETP)

Effluent treatment is the process of removing contaminants from wastewater, including household sewage and runoff. It includes physical, chemical, and biological processes to remove physical, chemical and biological contaminants. Its objective is to produce an environmentally safe fluid waste stream (or treated effluent) and a solid waste (or treated sludge) suitable for disposal or reuse (usually as farm fertilizer). With suitable technology, it is possible to re-use sewage effluent for drinking water, although this is usually only done in places with limited water supplies, such as Windhoek and Singapore.

Fig 11.1 Effluent treatment plant

Origins of sewage:

Sewage is generated by residential, institutional, commercial and industrial establishments. It includes household waste liquid from toilets, baths, showers, kitchens, sinks and so forth that is disposed of via sewers. In many areas, sewage also includes liquid waste from industry and commerce. The separation and draining of household waste into grey water and black water is becoming more common in the developed world, with grey water being permitted to be used for watering plants or recycled for flushing toilets. Sewage may include storm water runoff. Sewerage systems capable of handling

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storm water are known as combined sewer systems. This design was common when urban sewerage systems were first developed, in the late 19th and early 20th centuries.119 combined sewers require much larger and more expensive treatment facilities than sanitary sewers. Heavy volumes of storm runoff may overwhelm the sewage treatment system, causing a spill or overflow. Sanitary sewers are typically much smaller than combined sewers, and they are not designed to transport storm water. Backups of raw sewage can occur if excessive infiltration/inflow (dilution by storm water and/or groundwater) is allowed into a sanitary sewer system. Communities that have urbanized in the mid-20th century or later generally have built separate systems for sewage (sanitary sewers) and storm water, because precipitation causes widely varying flows, reducing sewage treatment plant efficiency. As rainfall travels over roofs and the ground, it may pick up various contaminants including soil particles and other sediment, heavy metals, organic compounds, animal waste, and oil and grease. Some jurisdictions require storm water to receive some level of treatment before being discharged directly into waterways. Examples of treatment processes used for storm water include retention basins, wetlands, and buried vaults with various kinds of media filters, and vortex separators (to remove coarse solids).

Process overview:

Fig 11.2 Water treatement flow diagram

Sewage can be treated close to where the sewage is created, a decentralized system (in septic tanks, bio filters or aerobic treatment systems), or be collected and transported by a network of pipes and pump stations to a municipal treatment plant, a centralized system

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(see sewerage and pipes and infrastructure). Sewage collection and treatment is typically subject to local, state and federal regulations and standards. Industrial sources of sewage often require specialized treatment processes (see Industrial wastewater treatment).Sewage treatment generally involves three stages, called primary, secondary and tertiary treatment.• Primary treatment consists of temporarily holding the sewage in a quiescent basin where heavy solids can settle to the bottom while oil, grease and lighter solids float to the surface. The settled and floating materials are removed and the remaining liquid may be discharged or subjected to secondary treatment.• Secondary treatment removes dissolved and suspended biological matter. Secondary treatment is typically performed by indigenous, water-borne micro-organisms in a managed habitat. Secondary treatment may require a separation process to remove the micro-organisms from the treated water prior to discharge or tertiary treatment.• Tertiary treatment is sometimes defined as anything more than primary and secondary treatment in order to allow rejection into a highly sensitive or fragile ecosystem (estuaries, low-flow Rivers, coral reefs,). Treated water is sometimes disinfected chemically or physically (for example, by lagoons and microfiltration) prior to discharge into a stream, river, bay, lagoon or wetland, or it can be used for the irrigation of a golf course, green way or park. If it is sufficiently clean, it can also be used for groundwater recharge or agricultural purposes.

Filtration:

Sand filtration removes much of the residual suspended matter.22–23 Filtration over activated carbon, also called carbon adsorption, removes residual toxins.19.

Lagooning:

A sewage treatment plant and lagoon in Everett, Washington, United States. Lagooning provides settlement and further biological improvement through storage in large man-made ponds or lagoons. These lagoons are highly aerobic and colonization by native macrophytes, especially reeds, is often encouraged. Small filter feeding invertebrates such as Daphnia and species of Rotifera greatly assist in treatment by removing fine particulates.

Nutrient removal:

Wastewater may contain high levels of the nutrients nitrogen and phosphorus. Excessive release to the environment can lead to a buildup of nutrients, called eutrophication, which can in turn encourage the overgrowth of weeds, algae, and cyanobacteria (blue-green algae). This may cause an algal bloom, a rapid growth in the population of algae. The algae numbers are unsustainable and eventually most of them die. The decomposition of the algae by bacteria uses up so much of the oxygen in the water that most or all of the animals die, which creates more organic matter for the bacteria to decompose. In addition to causing deoxygenating, some algal species produce toxins that contaminate drinking water supplies. Different treatment processes are required to remove nitrogen and phosphorus.

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Nitrogen removal:

Nitrogen is removed through the biological oxidation of nitrogen from ammonia to nitrate (nitrification), followed by denitrification, the reduction of nitrate to nitrogen gas. Nitrogen gas is released to the atmosphere and thus removed from the water. Nitrification itself is a two-step aerobic process, each step facilitated by a different type of bacteria. The oxidation of ammonia (NH3) to nitrite (NO2) is most often facilitated by Nitrosomonas spp. ("nitroso" referring to the formation of a nitroso functional group). Nitrite oxidation to nitrate (NO3), though traditionally believed to be facilitated by Nitrobacter spp. (nitro referring the formation of a nitro functional group), is now known to be facilitated in the environment almost exclusively by Nitrospira spp. Denitrification requires anoxic conditions to encourage the appropriate biological communities to form. It is facilitated by a wide diversity of bacteria. Sand filters, lagooning and reed beds can all be used to reduce nitrogen,but the activated sludge process (if designed well) can do the job the most easily.:17–18 Since denitrification is the reduction of nitrate to dinitrogen gas, an electron donor is needed. This can be, depending on the wastewater, organic matter (from faeces), sulfide, or an added donor like methanol. The sludge in the anoxic tanks (denitrification tanks) must be mixed well (mixture of recirculated mixed liquor, return activated sludge [RAS], and raw influent) e.g. by using submersible mixers in order to achieve the desired denitrification. Sometimes the conversion of toxic ammonia to nitrate alone is referred to as tertiary treatment. Many sewage treatment plants use centrifugal pumps to transfer the nitrified mixed liquor from the aeration zone to the anoxic zone for denitrification. These pumps are often referred to as Internal Mixed iquor Recycle (IMLR) pumps. The bacteria Brocadia anammoxidans, is being researched for its potential in sewage treatment. It can remove nitrogen from waste water. In addition the bacteria can perform the anaerobic oxidation of ammonium and can produce the rocket fuel hydrazine from waste water.

Phosphorus removal:

Each person excretes between 200 and 1000 grams of phosphorus annually. Studies of United States sewage in the late 1960s estimated mean per capita contributions of 500 grams in urine and feces, 1000 grams in synthetic detergents, and lesser variable amounts used as corrosion and scale control chemicals in water supplies. Source control via alternative detergent formulations has subsequently reduced the largest contribution, but the content of urine and feces will remain unchanged. Phosphorus removal is important as it is a limiting nutrient for algae growth in many fresh water systems. (For a description of the negative effects of algae, see Nutrient removal). It is also particularly important for water reuse systems where high phosphorus concentrations may lead to fouling of downstream equipment such as reverse osmosis.

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CONCLUSIONMother diary is one of the largest liquid milk plants in Asia. It sells more than 32 lakh litres of milk per day, out of which approximately 11.5 lakh litres of milk is sold as bulk vended milk and another 19 lakh litres of milk is sold in sachets in 5 different variants i.e. full cream, standardized, toned, double, toned, skim milk across 6 states.

Mother diary not only takes care of people’s health by providing good quality milk and milk products but also cares a lot for the environment.

In an effort to conserve fuel, mother diary utilizes the abundant solar energy to preheat the water going into boilers.

For maintaining ground water level, a rain water harvesting plant has been installed in the diary premise.

There is an effluent treatment plant in which the water used for cleaning the equipment and tankers is treated before being discharged into sewage system.

Strategically located mother diary managed more than 1000 milk shops across Delhi and NCR make it convenient for the consumers to pick up their daily requirement of milk, flavoured milk, butter, dahi, lassie, mouth-watering ice cream etc. Mother’s dairy‘s state of the art processing and stringent quality management system ensure that the consumers get the best quality products from its large range of products portfolio.

I understand all the working of the plant and the department and the interconnection associated between them. I felt very honoured and privileged on doing my training from such a reputed firm country India.

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REFERENCES

http://en.wikipedia.org/wiki/Mother_Dairy http://www.mannventures.com/mother-dairy-ice-cream-division.html http://www.motherdairy.com/MotherDairyPages/home.aspx http://www.motherdairy.com/MotherDairyPages/branddetailpage.aspx?

HLID=7 http://www.deccanherald.com/content/224908/mother-dairy-expand-

operations.html http://www.hrgms.com/news.html

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