Greenfield 1 LLPD liquid milk dairy
Turnkey execution of a one lakh litre per day liquid milk plant with an attached curd and paneer section, from feasibility study through to a demonstrated rated-capacity run.
This describes how we approach a project of this shape. It is not an account of a completed installation, and no client is named.
The brief
A brand with an established procurement network but no processing of its own is buying pasteurised milk from a third party, and losing both margin and control of quality. It needs a one lakh litre per day plant of its own, with a value-added section from day one rather than as a later retrofit.
What decides the outcome
Two things, both settled before any equipment is ordered.
The first is whether the mass balance was built from real milk data or from a capacity figure. Feasibility notes that size equipment from a headline capacity almost always miss the flush-season peak, which commonly runs 25 to 35 per cent above the annual average. Size the pasteurisation stream on the average and the plant is short exactly when the milk is there.
The second is whether the CIP room and its circuit lengths were in the layout from the start. Retrofitting a CIP return path into a finished floor is expensive, and a circuit that cannot hold 1.5 m/s return velocity will produce bacteriological problems for the life of the plant.
How we engineer it
We rebuild the mass balance from your own milk analysis and pouring data, then size the pasteurisation stream against the flush peak. The layout follows: three separated hygienic zones, drainage falling away from the process floor, and the CIP room placed so no return leg is starved.
Civil coordination drawings — plinths, floor loading, drain slopes, service penetrations, clear heights — are issued to your contractor well before equipment arrives. That single sequencing decision is what keeps trenches out of finished floors.
Equipment is specified line by line and tendered to several fabricators. Offers are compared on plate area against calculated duty, material of construction, surface finish and inspection terms, not on headline price.
How it is verified
Water trials, then chemical trials, then CIP validation against conductivity and return temperature, then milk trials. Rated capacity is demonstrated over a continuous run with pouch weights sampled at fixed intervals, and the result is documented as the acceptance record.
Design basis
The figures this scope is engineered to. They are design targets and industry benchmark bands, not results claimed for a completed plant.
- ≥ 90%
- Pasteuriser regeneration specified
- 10–14 months
- Typical DPR to commissioning
- ≤ 0.5%
- Process loss target at handover