Small-Scale Dairy Processing Plant Description
A comprehensive dairy processing plant uses fresh milk as the main raw material to produce a wide range of dairy products, including pasteurized milk, UHT milk, ESL milk, yogurt, cheese, cream and butter through one integrated processing system.
For many dairy investors in Africa, establishing a large-scale dairy factory requires significant capital investment, stable milk supply and complex infrastructure. Therefore, a small-scale multi-product dairy processing plant has become an ideal solution for emerging dairy businesses that want to start production with limited investment while maintaining flexibility and profitability.
Small dairy processing plants are increasingly popular in African markets such as Ethiopia, Burundi, Kenya, Algeria, Nigeria and other developing dairy regions due to their:
- Flexible production capability
- Short investment return cycle
- Lower initial investment
- Small fresh milk requirement
- Easy operation and maintenance
This type of dairy plant is especially suitable for investors, dairy cooperatives, milk collection centers and farmers who have limited budgets or relatively small quantities of available fresh milk.
This small-scale dairy processing plant is involved in milk receiving and storage system, milk preparation and blending system, milk pasteurizing or UHT treatment and homogenizing system, yogurt fermentation system, cheese processing system, cream separation system and butter processing system, filling and packing system, CIP system and utility system, each systems are modular design and skid mounted, easy for installation and equipment maintenance
All of the processing machines are made of SUS304/SUS316L material to ensure producing the high-quality products.
A 5T/D-30T/D multi-product dairy processing plant provides an economical and flexible solution for dairy investors who want to produce multiple dairy products with one integrated production line.
By combining milk processing, yogurt fermentation, cheese production, cream separation and butter processing in one system, dairy businesses can maximize the value of fresh milk and gradually expand their production capacity.
For African markets with growing dairy consumption and increasing demand for locally produced dairy products, this type of small-scale dairy plant offers an efficient pathway to build a sustainable dairy processing business.
Small-Scale Dairy Processing Plant Production Process and End Products
Pasteurized Milk: Fresh milk is received, filtered, standardized, homogenized, and pasteurized to ensure product safety while maintaining its fresh taste and nutritional value. After cooling, the pasteurized milk is filled into various packages, such as plastic pouches or gable top cartons.
UHT Milk: After fresh milk receiving and storage, the milk is homogenized and processed through an ultra-high-temperature (UHT) sterilization system to achieve a longer shelf life. The treated milk is then cooled and filled into aseptic pouches or other suitable packaging formats.
Yogurt: Fresh milk is homogenized and pasteurized at approximately 95℃ for 300 seconds to improve stability and ensure microbiological safety. After cooling to the fermentation temperature, yogurt cultures are added, and the milk is incubated and fermented into yogurt. The finished yogurt products are then filled into cups, cartons, or bottles.
Milk Cream: Cream is a high-fat dairy product separated from fresh milk by a cream separator. It mainly consists of milk fat, with small amounts of water and milk solids. Depending on the application, the cream fat content can typically range from 18% to 40%. After separation and processing, the cream is filled into pouches, cartons, or other suitable containers.
Butter: Butter is a solid dairy product produced by churning cream to separate butterfat from buttermilk. It typically contains around 80% milk fat and is further processed, shaped, and packaged in food-grade paper wrapping or other retail packaging formats.
Cheese: Cheese is a solid dairy product produced by coagulating milk, separating the curds from whey, and further processing or aging the curds to develop different flavors and textures. Depending on the cheese variety, the fat content generally ranges from 20% to 30%. The finished cheese products can be packaged in boxes, vacuum bags, plastic bags, or other customized formats.
Small Scale Dairy Processing Plant Process Introduction
Fresh milk receiving and storage unit
This system mainly includes a milk receiving tank, milk filter, milk plate cooer and milk storage tank, centrifugal milk pump, and flowmeter. Fresh milk after filtration, then it will be cooled down to 4℃, and then milk will be stored in a milk storage tank for further processing.
The milk storage tank is SUS304, three-layer tank, inner layer 3mm, outer layer 2mm, dimple jacket (feed ice water), PU heat preservation, sealed manhole, vertical eccentric stirring 36r/min, feeding from the lower side, digital display thermometer, lamp hole Sight glass, built-in scale, glass tube liquid level gauge, breathable cover, CIP cleaning head, material inlet and outlet, electrode type high and low liquid level gauge, climbing ladder, sampling valve, adjustable feet.
Milk preparation and blending system
This system includes one emulsification tank to dissolve the ingredients, 2-3 sets of blending tanks for milk preparation, a centrifugal milk pump, a milk plate heat exchanger and a preparation system platform.
The emulsification tank is SUS304, PU heat preservation, outer layer 2mm, inner layer 3mm, bottom emulsification head, 1450r/min, electrode type high and low liquid level gauge, sealed manhole, CIP cleaning head, breathable cover, digital display thermometer, built-in scale, light hole sight glass, adjustable feet.
The blending tank is SUS304, outer layer 2mm, inner layer 3mm, PU heat preservation, sealed manhole, vertical eccentric stirring 60r/min, lower side feeding, digital display thermometer, light hole sight glass, built-in scale, breathable cover, CIP cleaning head, materials Import and export Φ38, glass tube liquid level gauge, sampling valve, tie rod valve, adjustable feet.
The plate heat exchanger is for heating and cooling, two-stage type, one stage of 2 ℃ ice water cooling medium, and one stage of hot water heating medium, heating adopts a brazed plate to heat hot water, hot water heats materials, and the heating system includes a brazed type Plates, hot water barrels and a southern hot water circulation pump, Spirax Sarco pressure reducing valve, German Burkert temperature regulating valve, JK steam trap, overall bracket, including control cabinet.
Milk pasteurization and homogenizing system
The milk pasteurizer is mainly for producing pasteurized milk and yogurt products. SUS304, multi-functional automatic plate pasteurizer, feed 4°C/20°C, pasteurizing temperature and time 72°C/85°C/115°C, 15S, 95°C, 300S, discharge 4°C/45°C. material flow, pasteurizing temperature and time are all automatic controls. Spirax Sarco steam pressure reducing and draining system, Samson steam regulating valve. Paperless recorder. Siemens PLC, touch screen, Schneider electric components, Danfoss frequency converter, three color alarm light, paperless temperature recorder, Shanghai Yuan’an material pump, Nanfang brand hot water pump.
The milk homogenizer has a maximum pressure of 25MPa and working pressure of 18-20MPa, including a stainless steel starter cabinet, the electrical components in the cabinet are mainly Schneider brand, frequency conversion speed regulation, handle pressure, and pressure reduction.
Yogurt fermentation system
The yogurt fermentation system includes 2-4 sets of fermentation tanks, a rotor pump for transferring yogurt to the filling system, and a fermentation tank platform.
The fermentation tank is SUS304, insulation tank, 3mm inner thickness, out layer 2mm, upper and lower heads and barrel body PU insulation, bottom feed, conical head, sealed manhole, lamp hole sight glass, respirator, CIP cleaning head, built-in scale, equipped with central large paddle suspension stirring 18-36rpm/min, horizontal worm gear reduction motor, mechanical seal. Frequency conversion speed regulation, electrode type high and low liquid level gauge, digital display thermometer, adjustable feet, the discharge port is about 1.2 meters above the ground.
Milk cream separation system
This cream separation system mainly includes a plate heater and a cream separator.
The plate heater is a SUS304 stainless plate, Hasp type sealing pad,△T=50degc, equipped with a temperature control system, temperature sensors, regulating valve, and temperature control meter, the temperature is automatically controlled, combined with a milk pump.
The cream separator is a fully automatic control box, with 3 phases separating, starting with frequency convertor, auto discharge dregs, with friction when starting, pressure at outlet ≤ 2 bar, fat content in skimmed milk≤0.1%.
Butter production system
This butter production unit mainly includes a cream storage tank, milk pump and butter churner.
The cream storage tank SUS304, with heat insulation, dimple jacket, the speed of vertical agitator with scraper is 15-30rpm. Digital show thermometer, CIP cleaning ball.
The butter churner is SUS304 material, Using a cone cylinder as a drum, the outcome of oil splashing is better, and efficiency is higher. Under the centrifugal action, milk will gather around the drum wall and be thrown upward along the conical inner wall of the drum, oil splashing is full. With a view window easy to inspect inside; from the manhole to take out the ready butter, with manual brake, electric power cabinet, etc; Working speed: about 35-45RPM.
Cheese production system
The cheese production system mainly includes cheese vats and cheese pressers.
The cheese vat is material contact parts is SUS316L,three-layer design, honeycomb jacket, rock wool insulation, steam heating, long oval straight cylinder, special design for stirring, detachable (with a set of stirring), can be used for whey cutting, Stirring can be moved left and right to ensure that all materials can be stirred. The cheese tank can be partially lifted and discharged, and the stirring speed can be adjusted by frequency conversion (18-40rpm). The detachable half-open cover can seal the container during fermentation. Comes with an SUS304 electric cabinet, touchscreen operation, and one imported temperature sensor. The cheese vat is also equipped with a cheese cutter, long handle type, used for cutting cheese curds, the length of the knife is 900mm, the length of the knife handle is 400mm.
The cheese presser is batch pressing 200KG, each box 50KG, rectangular, food-grade filter, food-grade plastic cover, hydraulic extrusion (including hydraulic station).
