Dairy Plant Design Intro:

Setting up a multi-product milk processing facility requires a clear definition of products, capacity, site constraints and operating requirements. This article focuses on those design decisions rather than historical production forecasts.

This blog will shed light upon the key considerations required by clients, engineers and project management companies commencing on the development of a multi-product milk processing facility.

Statement of Requirements:

SOR or Statement of Requirements is a prior activity before the start of the project. It is basically a definition of facility requirements. The first step before initiating a plan is to highlight the main objectives and priorities of the whole project for the better functioning and success.

Basically, the main objectives revolve around factors such as safety, capital cost, good manufacturing practice and hygienic design, project schedule, quality, etc. Capital cost helps us determine whether a project will proceed or not. Good manufacturing practice and hygiene is important because it can affect the reputation of the brand and products. The quality of the building and plant’s longevity is also one of the important factors to take into account.

It is also important to determine at the start which products are to be manufactured and what the output capacity of the plant will be. This will further help to determine what major equipment such as dryers, evaporators, etc will be required which further impact the building design and layout.

Let’s understand the 3 major sectors that should be taken under consideration before initiating a dairy plant:

1. Site layout considerations:

There are numerous options available when it comes to layout and the layout largely depends upon the requirements of the facility. Linear, L-shaped and U-shaped layouts are options to evaluate against the shape, size and flows of the overall site; none is automatically the right choice for every project.
The first is linear flow plant where the raw material is kept at one end and feeds directly into processing, then to packaging and the final good is out. It works in a continuous chain process. The labs, utility building, and the administration block are separate and this allows more space for future expansion on a phased basis.
The next option is the L shaped format which needs to fit into a narrower site. This style of the layout has the same functionality to expand.
A U-shaped flow may be considered where the site footprint is constrained. Check separation of incoming and outgoing movements, hygiene zoning and future expansion before adopting it.

2. Safety considerations:

Safety of every stage of production should be well considered during the initial stage of the design. Some of the main safety considerations include personnel access, platform design, escape routes, machine access, operability and process safety. A regular Design Risk Assessment should be carried out to ensure that all aspects of safety are considered during the design phase.
During the designing process, a Hazard and Operability Study (HAZOP), where appropriate to the process risks, can help identify problems and risks to personnel or equipment. It should be conducted by a suitably qualified team.

3. Site Selection consideration:

In order to avoid ending up with a bad site, it is highly crucial to undertake site selection exercise to maintain the stability and better functioning of the whole plant. Close attention should be given to the suitability of the site based on the proposed layout. The ground conditions should be suitable for the extensive facility to be built on.
The transportation infrastructure should also be well developed for the smooth movement of the in-house traffic.

The above mentioned are some of the important points that need close attention and consideration before initiating a dairy plant. There are several other factors that also need to be pondered upon during the plant designing process.
Seeking the guidance of a professional and experienced expert is highly recommended for the smooth and successful functioning of your dairy plant. It also helps you to avoid making major mistakes in the dairy business.

Amol Ghodke is a dairy consultant with firsthand experience in dairy projects and production. His consulting work supports entrepreneurs in defining requirements and planning their dairy facilities.
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