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GEA contracted by Hatsun to install automated dairy plant in Dharapuram
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Saturday, 22 July, 2017, 08 : 00 AM [IST]
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Our Bureau, Mumbai
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GEA in India has been contracted by Hatsun Agro Product Limited (HAP) to install an automated dairy plant on turnkey basis at Dharapuram near Coimbatore, Tamil Nadu. This greenfield dairy project is designed to handle 6,50,000 litre of milk per day, to produce 3,00,000 litre per day of milk in pouches and 1,50,000 litre per day of curd. The plant is expected to be fully operational by early 2018.
HAP is one of the leading private sector companies in the dairy business in South India. It manufactures and markets dairy and ice cream products under various brands, including Hatsun, Ibaco, Arun and Arokya.
It believes that the dairy industry in India is ready to embrace new technologies and higher hygienic standards and chose GEA as its engineering partner because of its turnkey approach, its innovative technology and its experience of working with GEA in the past.
“So far, GEA has been supplying components to HAP, and it is a great pleasure to be able to be a partner for HAP for their turnkey project,” said Abhay Chaudhari, country managing director, India cluster, GEA.
“They are obviously happy with the quality and the service they have received from GEA in the past, as they have shown confidence in us once again, and with a larger scope. HAP is a progressive dairy company, and likes to be ahead of the curve in terms of automation, quality and hygiene standards,” he added.
Apart from specialised equipment from GEA, such as separators, homogenisers and flow components, a new and interesting feature of GEA’s offerings is the reverse osmosis (RO) plant for the concentration of skim milk.
RO, being a cold process, ensures the natural freshness of milk and curd. GEA has successful references worldwide for milk concentration with RO.
The plant is fully automated for the processing and packaging of liquid milk and curd. Management Information System (MIS) reports can be generated to capture data regarding process parameters, production and packaging making it highly responsive and efficient.
AmulFed plant
During the first quarter of 2017, GEA in India received an order from the AmulFed Dairy (formerly Mother Dairy) in Gandhinagar, a unit of Gujarat Co-operative Milk Marketing Federation (GCMMF).
The order, said to be for a lower double-digit, million-euro amount, is for a new turnkey dairy plant for the production of 150 tonne per day of skim milk powder and 120 tonne per day of dairy whitener or baby food. The milk powder plant is scheduled to commence production in 2018.
When completed, the plant will be the largest skim milk powder and dairy whitener plant in Asia. The company markets its milk and milk products under the Amul brand, and its baby milk powder under the name of Amul Spray.
The plant, to be installed on a turnkey basis by GEA, will process around 90,000 litre per hour of milk to produce multiple value-added products.
AmulFed already has two milk powder plants in the same location supplied by GEA. Together, they make AmulFed the largest plant in Asia at a single location.
The new plant features GEA’s most advance safety system and uses hygienic architectural design principles to make it one of the most advanced GEA has built to date.
Some other interesting features to be included in the AmulFed plant are:
• The use of a mechanical vapour recompression (MVR) system from GEA within the evaporation plant. MVR continuously recycles energy by recompressing the vapour within the evaporator. This reduces energy costs and the carbon dioxide (CO2) footprint to minimise the environmental load
• The use of a reserve-osmosis (RO) polisher to treat the milk condensate from the evaporation plant and recycle the water for reuse within the plant. This significantly reduces water usage and approaches the zero liquid discharge concept
• The application of a GEA clarifying separator to remove the entire life cycle of bacteria from the milk, thereby ensuring a supply of bacteria-free healthy milk throughout the process cycle
• The inclusion of GEA Sanicip bag filters in series with cyclones to collect powder fines, save product and reduce emissions to the atmosphere
• The inclusion of a GEA sifter to provide a uniform distribution of the powder particles and, therefore, a more homogenous final product
• It will also be equipped with powder packing and a conveying system from GEA
• The plant will be designed to operate in fully-automated mode. This includes the powder production, conveying, storage, packing, final packed product conveying and a complete management information system
“We will provide AmulFed with a hygienically-superior plant that will deliver peak performance,” said Chaudhari, adding, “The AmulFed milk powder plant at Gandhinagar will not be just the largest in Asia, but it will also be the most environment-friendly,” he said.
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