Curd Clot Dehydrator

Contents

Entry

Regulatory references

1 Requirements for work

2 Process Features

3 Brief overview and analysis of equipment and services

3.1 Design Overview of Machinery for Dewatering

3.2 Automated line for traditional cottage cheese production

method-bom

3.3 Curd production line by ultrafiltration method

3.4 Line for curd production by separator method

3.5 "OLIT-PRO" curd production line

4 Upgrade of the country

5 Device and principle of operation

5.1 Clot heat treatment unit

5.2 Curd clot dehydrator

5.3 Control of equipment operation

6 Design part

6.1 Process Accounting

6.2 Power-to-Power Calculation

6.3 Kinematic account

6.4 Strength Sheet

6.4.1 Calculation of chain front

6.4.2 Calculation of drive roller sprocket

6.4.3 Calculation of gear conical front

6.5 Thermal calculation of coagulation

6.6 Constructive Account

7 Operation and maintenance

7.1 Safety requirement for curd clot dehydrator and

TOC set

7.1.1 Basic Maintenance and Repair Operations

7.1.2 Electric power supply and control of motor-s

7.1.3 Commissioning, charging

7.1.4 Operating conditions

7.1.5 Installation of equipment

7.2 FTP schedule

7.3 Table of faulty networks

8 Safety of life

8.1 Industrial sanitary service

8.2 Safety Equipment

8.3 Electrical Safety

8.4 Fire Safety

8.5 Life Safety in Emergency Situations

of equipment, premises and adjacent territory

8.6 Calculation of heat insulation of heat treatment unit

9 Business case for modernization

9.1 Definitions of Capital Investments

9.2Value analysis of designed equipment with channel

9.3 Calculation of electricity consumption

Conclusion

List of sources used

Appendix A Geometric calculation of conical transmission with

straight teeth

Appendix B Specification

Introduction

Cottage cheese is a paste-like fermented dairy concentrated protein product formed as a result of partial separation of the liquid fraction from fermented milk. Depending on the type of cottage cheese, the mass fraction of dry substances in it is 20... 35%, fat - 0.6... 18%, proteins - 15... 20%.

Cottage cheese as a product of dietary and infant nutrition owes its specific advantages to the presence of a relatively large amount of proteins, a favorable combination of minerals, vitamins and trace elements, as well as an indispensable amino acid - methionine.

The range of curd products includes the following groups:

- low-fat curd with weight fraction of fat not more than 0.6%;

- bold and fat curd (9 and 18% fat);

- soft dietary curd (9% fat);

- curd pastes and cheeses with different fat content, fruit fillers and other additives.

There are two methods for the production of cottage cheese - traditional (ordinary) and separate. Traditional method involves formation of curd from pre-prepared normalized milk mixture.

The separate method consists in the fact that milk intended for cottage cheese production is pre-separated. Low-fat cottage cheese is produced from the obtained defatted milk, to which the required amount of cream is then added, increasing curd fat content up to 9 or 18%. Separate method of cottage cheese production makes it possible to accelerate the process of whey separation and significantly reduce losses.

According to the clot formation method, two methods for the production of cottage cheese are distinguished: acid and rennet.

The first is based only on acid coagulation of proteins by fermenting milk with lactic acid bacteria, followed by heating the clot to remove excess whey.

Low-fat and low-fat cottage cheese is made in this way, since when the clot is heated, significant fat losses occur in the serum. In addition, this method ensures the production of low-fat cottage cheese of a more delicate consistency. In the rennet-acid method of milk coagulation, the clot is formed by the combined action of rennet enzyme and lactic acid.

The purpose of the degree design is to design a clot heat treatment apparatus (TOC) and a curd clot dehydrator in the curd production line in a continuous way. This equipment is an integral part of the process and is currently undergoing some design changes.

5 device and principle of operation

Line of cottage cheese production by continuous method is intended for production of cottage cheese based on milk fermentation with lactic acid bacteria in reservoirs with subsequent heat treatment of clot and its dewatering in flow.

The line produces low-fat cottage cheese, 9% fat and 5% fat "Peasant."

The following operations are performed on the line in accordance with the process instruction:

- filling of reservoirs with pasteurized, homogeneous and cooled milk to the temperature of fermentation;

- fermentation and fermentation of milk in tanks;

- mixing of milk with starter and clot in tanks;

- heat treatment of clot in flow, including:

- clot heating;

- clot maintenance;

- pre-cooling of clot;

-freezing the clot in the stream;

-cooling of curd in the flow;

-circulation washing of line equipment and pipelines.

Milk digestion and clot production are carried out in tanks having a heat jacket to supply hot and cold water to it and equipped with different stirrers and devices for circulation washing. The supply of heat-cooling agents is used to more accurately, if necessary, control the fermentation temperature of milk.

The tanks are also provided with milk and clot sampling devices.

The finished clot, after mixing with a stirrer, is supplied from the tanks by screw pumps to the channels of the TOC apparatus. Pumps have local speed control. The processing capacity of the clot is set according to the readings of flowmeters on the control panel.

5.1 Clot heat treatment apparatus

The device of the thermal treatment of a clot (TTC) [OOT 09.00.00.000 IN] is the kozhukhotrubny heat exchanger with channels of flat section, at the same time the big axis of section of the channel is located horizontally.

In the line, the TOC apparatus has two parallel working channels 7.

Each of the channels of the apparatus has three sections: heating, holding and preliminary cooling of the clot, the sections of which are located in two parallel rows and arranged according to a spiral scheme so that they provide a small rise towards the outlet upper section of the channel and are attached to the frame 8. Sections of the apparatus consist of several similar sections: the first section (in the direction of product) (heating 2) - of four sections, the second section (holding 1) - of one, the third section (preliminary cooling 3) - of two. All sections have the same length except for the last shortened section of the pre-cooling section. The sections are connected to each other by branches 6 providing rotation through 180 0C and having the same cross-sectional profile as the working channels. Water jackets of heating and preliminary cooling sections are connected by branch pipes and connected to boiler and ice water supply system, respectively, forming two circulation circuits.

The last sections of the pre-cooling sections of the clot end with cylindrical vertical sections having a glass insert passing into the branch pipe 4, through which the clot from both parallel channels of the TOC is directed to both drums of the dewatering device.

The parts of the heat exchanger in contact with the product, as well as water jackets, are made of stainless steel. The connections of the section are flanged, the seals are made of food rubber.

The clot is heated by hot water circulating in the jackets of the first section of the heat exchanger. Direction of coolant movement - counter current. Hot water is supplied to heat exchanger from two boiler units operating independently of each other.

The heated clot is maintained in the stream at the preheating temperature and enters the pre-cooling section, where it is cooled by ice water supplied to the jackets of the section of this section. In the vertical cylindrical section, temperature is maintained and equalized, after which the clot is dewatered.

The design of the heat cooler piping in the heat exchanger provides, if necessary, the possibility of heating the clot using the entire total length of the working channel, including, in addition to the heating section, also the pre-cooling section. In this case, the clot is held in the channel of the last vertical section, and no pre-cooling is carried out.

After completion of heat treatment in TOC apparatus curd clot is supplied to dehydrator.

5.2 Curd Clot Dehydrator

The dewaterer of cottage cheese [OOT 10.00.00.000 IN] is intended for dehydration of a cottage cheese clot in the course of production of cottage cheese.

Curd clot dewatering device represents non-intermittent device made in form of rotating conical drum 2 tapering to point of product outlet. Drum consists of two sections and bearing structure.

The filter material used in it is lavsan cloth 3, which is part of the shell of both sections of the drum. Fabric is fixed on flanges located on periphery and in central part of drum sections. The latter is mounted on movable rotary frame 1 mounted on bed. The drum is rotated along the drive means 3. For direction of its rotation on frame there are three support rollers 9 arranged at edges of bearing structure.

Drum and drives have enclosures (casing 15) that completely cover filtering surface. On the sides they are quickly detachable. At the bottom of the drum are whey collecting trays 13. Their location provides free access for manual sanitary treatment (dressing).

The structure of the dewatering agent allows you to obtain cottage cheese, standard in terms of weight fraction of moisture. The curled clot entering the drum still falls on the filter cloth of the dehydrator, where the whey is separated while stirring. As the drum rotates, the duration of dewatering, and hence the moisture content of the final product, is controlled by changing the tilt angle of the drum by means of a lifting mechanism 12 operating from a separate drive 10 and mounted on the dewatering bed. First, the dewatering drum is installed so that the lower (relative to the axis of rotation of the drum) generatrix of the filtering surface is located in a horizontal plane.

Dewatering device has maintenance platform providing pre-access to filter cloth.

5.3 Control of equipment operation process

The curd line automation system performs information and control functions.

Information functions:

- fermentation reserves: remote control of consumption and quantity of starter supplied to tanks; level, temperature;

-clot heat treatment apparatus (TOC): remote temperature monitoring after the holding section; clot flow rate for each of the channels; monitoring and recording of clot temperature after sections of heating and pre-cooling section; monitoring and recording of burning water temperature at outlet to jackets of heating section sections.

- curd cooler: remote control of curd temperature and recording of curd temperature at the curd cooler outlet by any channel.

At the same time, a number of parameters in place are monitored

- pressure of steam supplied to boilers; tap water; ice water; ice water and refrigerant at the line supply;

- pressure with light alarm: detergent solution at supply to the line and return to the detergent station; after the washing solution supply pump to the second channel of the TOC apparatus (at preliminary washing); hot water after the supply pumps in the heating section of the TOC apparatus; steam at supply to boilers, air at supply to control system.

In the modes of product displacement, the separation of "water milk" media is monitored at the supply of milk (starter) to the fermentation tanks and "water serum" at the inlet to the dehydrator.

There is a light alarm for actuation of electric drives of pumps, stirrers of tanks, dehydrator, curd cooler, position of all valves, limit upper and lower positions of dehydrator drums; lower level in fermentation tanks; limit levels in the dewatering tray.

The light alarm shall be used only when deviating from the permissible values of the lower limit of steam pressure supplied to the control system; upper limit level in reservoirs of fermentation and upper limit pressure of detergent solution at the inlet to the TOC apparatus.

Control functions of the system:

For all process operations, two control modes are provided - "Remote" and "Automatic."

Remote control of equipment, pumps, valves is provided for commissioning, as well as in case of problems in the automatic control system, and is carried out using toggle switches installed directly on the mnemonic diagram of the control board.

The automatic control mode provides for the group actuation required for this process of process equipment, pumps, valves with a blocking and automatic control system, which facilitates the operation of the operator. The automatic process mode is activated from the control and alarm board using the appropriate switches.

Valves with pneumatic drive are used to switch milk flows (clot), starter and detergents.

Starter supply to the tanks - using switches from the control board, the route of starter supply to the corresponding tank is opened, the starter supply pump is turned on. Required quantity of starter is determined by readings of integrating counting set-top box.

Milk supply to the tanks - with the help of switches from the control board, the route of milk supply to the corresponding tank is opened.

When the tank is filled with milk up to the specified upper level, the level indicator is activated and the light-and-sound signal is turned on.

Sanitary treatment of equipment shall be carried out after completion of work.

Washing is carried out less often than after 2 shifts of continuous operation. Equipment not used after washing and disinfection for more than 6 hours,

It is disinfected and rinsed with tap water before the start of work.

Sanitary treatment of the line equipment is carried out from the washing station of the plant along closed ring routes :

-route No. 1 - washing ring of digestion tanks;

- route No. 2 - seventh ring of pipelines washing, which includes clot supply line, clot supply pumps and serum pipelines;

- route No. 3 - the second ring of pipelines washing, which includes the milk supply line;

- route No. 4 - the third ring of pipelines washing, which includes the starter supply line;

- route No. 5 - fourth ring of pipelines washing, which includes a clot supply line from tanks to clot pumps;

- route No. 6 - washing ring of the TOC apparatus immediately after completion of the work;

- route No. 7 - clot dehydrator washing ring;

- route No. 8 - washing ring of pipelines connecting reserve-ar No. 1

Notes:

- tanks are washed as they are emptied (routes No. 1, 8);

- washing routes No. 2, 6, 7 are used after the line is completed;

- routes No. 3, 4, 5 are used after filling the tanks, since milk and starter are partially supplied to the tanks through clot supply pipelines.

Sanitary treatment of small equipment (clot supply pipes, test channels) is carried out in manual, in accordance with the "Instruction on sanitary treatment of equipment at dairy enterprises."