Milk Cooler

Application :

DAIRIES

ICE CREAME MANUFACTURES

MILK OUTLETS

PROVISION STORES

TEA DEPOTS

Technical Details :

Efficient and Power savor Reciprocating Compressor

Groved Copper tube Condensor with aluminium fins

Corrosion Resistance 304 grade Stainless Steel Body and Storage tank

Copper tubed static evaporator for effective and efficient colling

thicker and Dense Polyurathan (PUFF) insulation for least heat loss.

Subzero Digital Thermostate

Specifications :

General Description
Design, supply, installation& Commissioning of direct expansion type of bulk milk cooling system including all accessories & items given in the detailed scope on turnkey basis.

FunctionalRequirement
These system would be installed in village dairy co. operative society(DCS)/village milk collection center which collects the milkevery day in the morning & evening from milk producers, The milk collected shall be stored in the bulk milk cooler which is cooled from ambient temperature to 4deg. C. The stored milk shall be dispatched to dairy plant through insulated road milk tanker once in aday.

Supply
The bulk milk cooler shall be a complete unit with the refrigeration system, Agitator, lockable inlet outlet valve with line strainer (Disc Type) to dump tank out let. Also includes supply of AISI-304 balance tank with S S filter for pumped system, S S piping & milk hose unions &milk transfer pump of 5000LPH S S304 pipes& fittings, food grade quality flexible hose of adequatelength. Erection materials, pipe supports, floor plates, pipe clamps, cable conduits shall also be supplied.Earth pit CI covers&earthling as required by local electricalregulation. The indicative distances between SS collection tray to balance tank – 2 m, between balance tank to bull milk cooler – 5 m, BMC to Mains power point & DG set – 20 m may be considered for calculating cable & SS piping requirement, The exact distances for S piping, electrical cabling to panels & D G sets shall be as per site conditions and complete piping &cabling necessary for installation shall besupplied.

Constructional features
Material used for construction. BMC tank inner, outer, bottom top open able cover fabricated from stainless steel AISI 304 Material. The Skid made out of heavy M.S. box section and hot dip galvanized on which refrigeration unit is mounted. All piping ,fitting, lockablecover, agitator shaft &blade adjustable ball feet made out of AISI304 dipstick, outlet& inlet valves, blankflanges, ladder& manhole of about 45 centimeters diameter for closed type milk cooling tank etc. made out ofAISI304

Tank fittings&accessories.
The tank shall be provided with stainless steel inlet with special “no-foam” design, outlet 38mm. butter fly valve& blank union with locking arrangement, a sampling cock lockable type at outlet before butterfly valve, Inspection window/manhole with lockingarrangement. The digital type temperature indicator provided in the control panel. Temperature sensor permanently fixed at the bottom. It senses the temperature of the surface at the outlet & transmits the signal to the digital Indicator. The tank provided with S.S. calibrated dipstick to measure the volume of milk inside the tank. The dipstick graduated from 10% or less to not less than 100% of the rated volume. The tank shall be equipped with agitator capable of producing a uniform distributionof fat in the milk.
All S.S. Fittings of S M S STANDARD. BMC provided with AISI-304. Filter with S S fine wire mesh. The filter designed and installed in such way that it can frequently and easily be cleaned. STAINLESS STEEL SANITORY MILK PUMP. Alfa Laval or equivalent 5KLPH,per BMC,12MWC, 1.00 h.p.

INSULATION The insulation of the tank done by injection in situ of high density, 40kg/cub. Mtr. polyurethane foam insulation. The efficiency of insulation is such that at max. 50 deg. cent. ambient temperature the rate of rise of the mean temperature of the milk shall not exceed by 1deg.cent. In four hrs. When the rated milk volume initially at about 4deg. Cent. Is allowed to stand undisturbed when refrigeration unit is not working.

CLEANING IN PLACE (C IP) For closed type tank configuration facilities for cleaning- In-Place shall be provided which shall include C I P spray balls and piping from milk reception / balance tank through milk transfer pump to bulk milk cooler. For top open able configuration manual cleaning shall beprovided.

BALANCE TANK
Up to 2000lit. And above2000lit. 200 lit.Cap. From bmc the milk shall be transferred to road milk tanker (RMT) through food grade quality Flexible hose of adequate length. S S304 Pipes of 38 mm size will be provided from the Balance tank via in-line filter Milk Transfer by pump up to BMC.

REFRIGERATION SYSTEM
The refrigeration system shall be designed to comply with A R I Standard 520 -2004& to meet the requirements of milk collection system of I S O 5708, class2. The refrigeration system shall be of direct expansion type with Freon- 22 or CFC free environmental friendly refrigerant to cool the raw milk from reception temp. to4deg. Cent. In the prescribed period mentioned. The evaporators of the system shall form a part of the milk tank body as dimpled jacket in the bottom plate in case of rectangular open tank or at least up to 1/3 height of circular/elliptical(closed) tank. The refrigeration system shall be direct expansion type to perform cooling function in an ambient temperature of 46 deg. Cent. With air cooledcondenser.
1) COMPRESSOR
The refrigeration compressor shall be adequate enough to ensure that milk is cooled to 4deg. Cent. In the prescribed time limit &suitable to operate at 0deg. Cent. Suction temp&60deg.cent. Condensing temperature (air cooled condenser) assuming 46deg. Cent. Ambient Temperature. The refrigeration compressor(s) shall be energy efficient hermetically sealed reciprocating/rotary/scroll. The compressors selected should be energy efficient consume least power to meet the cooling load requirements. Client shall approve Make(s) of compressor from KZSDUS.
2) CONDENSER
The condenser shall be air cooled finned tube type having sufficient heat transfer area designed for extremely high ambient temperature givenabove.
3) RECEIVER
For refrigeration circuit a suitable size liquid receiver mounted on the skid near compressor to assist system to store refrigerant during pump down cycle as well as in case ofmaintenance.
4) THERMOSTATIC EXPANSIONVALVE
Suitable size & capacity Thermostatic expansion valve should be provided in the refrigeration circuit of the bulk milk cooler. TX valve should be maximum operating pressure type and of adequate capacity to feed optimum of refrigerant to the milk cooling tankevaporator.
5) REFRIGERANT PIPE , FITTINGS & CONTROLLS
All pipes, valves, fittings & controls shall comply with the latest relevant BIS code applicable. Isolation valves at suction & discharge sides of compressors is provided for compressor isolation, during maintenance of the system All the pipes shall be clamped properly with fixed support. In case of double compressor system, pipe fitting & control should be designed in such a way that both the compressors can run independently. The tubing shall be insulated wherevernecessary.

Electrical ControlPanel
1) ControlPanel
Three control panels shall be provided, one for the main power supply tapping, second for the refrigeration unit and third for the milk tank. Each panel shall be provided with MCB, S of suitable ratings for switching and protection as per the system requirement. The incoming and outgoing power supply terminals shall be covered and secured with a lead seal to prevent tampering. The door of the panels should be provided with lockable handles.
2) Main ControlPanel
This panel should be suitable to tap the incoming State Electricity Board supply and feed the refrigeration unit, agitator motor and milk unloading pump (from balance tank) and dispatch pumps. The DG set should be hooked up with this panel through a Change-over-switch in order to operate the DG set in place of state Electricity Board supply as & when required. It should be provided with necessary phase indication lamps (LED type), contactors, MCBs, ammeter, voltmeter, energy-meter, frequency-meter, push buttons, DG set running hour meter etc. A battery charger to trickle charge the battery when the DG set is in operation should be provided (charge indications to be displayed on the panel).
Note: The switch gears used in all the panels should be of reputed makes. L & T and Siemens make
3) Refrigeration ControlPanel
The panel shall be provided with motor starters, ON/OFF push buttons & necessary MCBs, control wiring, line voltage controller to guard the compressor is provided in the refrigeration system, the control panel shall be provided with a sequence controller & timer to start one compressor at a time to avoid power supply surge. The panel shall also have facility to operate refrigeration unit on auto/ manual mode. As soon as the milk temperature reaches to pre-set value, the compressor should be switched off to avoid freezing ofmilk.

Voltage Stabilizer (Servotype) and single-phasepreventer
The system should have Voltage stabilizer conforming to following features and single phase preventer of suitablerating . Individually correct the voltage of each phase.
. Auto low – high cut out
. Phase sequence Preventer.
. Stabilizer should be supplied as per BMC load (electrical) capacity.

Cables & Electrical Switchgears
All electrical switchgears, controls & electrical cables required for the complete system shall be of suitable rating & of standard company. Cables armored / Flexible should be of polycab/ finolex make Switch gears make -L&T/ SEIMENS
Earthling
The earthling should be carried as per IS: 3043-1987(reaffirmed 2001)-“code of practice for earthling”. The chassis, framework and the fixed parts of the metal casing of the tanks where used shall be provided with two separate earthling terminals, Earthing for Alternator&Panels. The earthing terminals shall be of adequate size, be protected against corrosion and shall be metallically clean. Under no circumstances shall a movable part of the enclosure be insulated from the part carrying terminal when the movable part is inplace. The earthing terminal shall be identified by means of the “[]” marked in a legible and indelible manner on or adjacent to the terminals.