Payment & Shipping Terms:
|Material:||Fresh Milk, Milk Powder||Capacity:||1000l/h|
|Package:||Plastic Cup, Plastic Bottle, Plastic Bag, Gable Top Carton||Volume:||250ml-1000ml|
|Warranty:||One Year||Solution:||Turn Key Project|
500LPH Small Fresh Yogurt Processing Plant Plastic Cup / Bottle Package
The yogurt production process begins with receiving milk from local or other cooperating regional producers and its transportation in a tank . The milk is weighed and then transferred to an auto-cooling storage tank . The entire process occurs as a continuous flow system. A pre-heating stage follows where the milk is pasteurized within few seconds at 63–65 °C in the heat exchanger and then moves to a separator to standardize the fat content using centrifugation. Then, the milk moves to a pasteurizing boiler – production tank – where it is boiled to kill any contaminating micro-organisms. At the same time, yogurt rennet is added to speed up the coagulation. The filling of plastic containers (cups) in the filler machine with milk-yogurt takes place using a filling pump . The last step for yogurt production is the ripening-cooling where the filled cups move to the ripening/incubation chamber for three hrs and then to the rapid cooling chamber for two more hours. Once the production run is completed, the cleaning of all machines involved starts automatically using cleaning in place-CIP . The latter lasts for 5–7 min.
Figure 1. Flow diagram of yogurt production line where CIP is applied for cleaning purposes to all machines involved in this process.
The yogurt production line contains seven machines in series. In a serial configuration, all machines of the production line should be functioning to maintain the proper operation of the system. Thus, the failure of any machine may potentially cause failure in the entire system. Failure and repair data for the yogurt production line were collected from the files of the maintenance staff (mechanical and electrical) at the end of each shift. The records included the failures occurring per shift, the action taken to repair the failure, the downtime, and the exact time of failure. Apart from the failures occurring, the line stopped whenever alarm signals (related to quality and/or potential safety problem) were recorded. Therefore, the times related to these activities were also included in the failure data.
The failure data for the yogurt production line were also collected from the files of the technical department at the end of each shift, and a total of 759 failures were recorded. The line operates in one eight-hour shift each workday to include 6 h for yogurt production. For the rest of the time (2 h), the line is cleaned and prepared for the following day (i.e. raw materials, packing materials, etc.).
The currently applied maintenance policy of the yogurt line is both corrective (unscheduled and carried out in case of failure) and preventive maintenance (scheduled and performed periodically); this procedure requires immediate action by the maintenance staff to restore the machine into an operational state. This maintenance policy may include any or all the following steps: identification, localization and diagnosis of faults, correction actions (disassemble, remove, replace, reassemble, and adjust), and operation checkout. The corrective maintenance is applied while the line is running.