bihar state milk co-operative federation ltd

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Bihar State Milk Co-Operative Federation Ltd. DAIRY DEVELOPMENT COMPLEX,

P.O. - BIHAR VETERINARY COLLEGE, PATNA-800014(BIHAR) Phone No- 2224083,2228953,2228347,2220387, Fax No-0612-2228306

E-Mail: [email protected], Website: www.compfed.co.in

Corrigendum – 1

Modified Specification for 2.00 LLPD Milk Reception

1. There will be two set of Can Conveyor system each measuring 50 ft as mentioned in the BOQ.

(Make – Not specified as it is considered to be fabrication item) 2. The capacity of Raw Milk Silo will be 60 KL & specification is enclosed. (Annexe- I) 3. Sour Milk separator should be ISI Mark. 4. Make of weighbridge – Avery/Sataurious/ Essaeteroka (Specifically mentioned in the Tender

Documents) Milk Processing & Storage Section 1. There shall be one set of Milk Pasteurization plant modules, however one set of Pasteurizer under

stand by arrangement will be supplied departmentally out of available stock. 2. The capacity of Milk Storage Silo will be 60 KL of two numbers. 3. Rate for 5 KL capacity RCM tank is required but rate for 2 KL cap RCM is optional. Cream Processing Section 1. The capacity of cream transfer pump is 2 KLPH. 2. Cream pasteurizer cooling tower should be considered as accessories of cream pasteurizer. 3. Technical Specification of 10 KLPH Homogenizer is enclosed & Make of the Homogenizer will be

Tetra Pack/ APV Gullin.(Annex- II) 4. Technical Specification of desired Dairy plant equipment is enclosed. 5. Bidders may quote VFD control drive for Butter Churn as optional item. 6. Bidders should quote the rate as per BOQ, Sr. No. - 1 Dahi/Lassi Section. Milk Packing Section 1. Capacity of Crate Washer will be 800 CPH. 2. SS packing table for pouch packing should be considered in BOQ as per standard specification. Paneer Section 1. Rate for both vertical Milk Coagulation tank cap – 1 KL/open type Paneer Vat cap- 2 KL may be

quoted as optional. 2. Citric acid preparation tank capacity will be 01 KL. 3. Paneer Hoops qty- 16 Nos. only 4. Paneer cold room size – 4000 CFT, Paneer Production cap- 5 TPD 5. Paneer Vacuum packing machine quantity will be one no. only. 6. Bidders may quote the rate of Paneer press as per BOQ item no- Sr. No.- 12

Curd/ Lassi Section

1. Vertical Curd Inoculation tank as mentioned in final supply list is required. 2. Curd Milk Homogeniser specification is enclosed. 3. Curd pasteurizer specification is enclosed.(Annex -III) 4. The cup filling machine capacity should be 1800 CPH. 5. Horizontal Lassi storage tank will be 01 KL 6. Lassi pouch packing M/C capacity will be 5000 PPH. 7. Curd room will be of standard size & curd production will be 5 TPD.

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Steam Generator 1. Steam generator pressure should be 10.5 kg/cmsq. 2. For steam piping – Seamless pipes for IBR piping & MS C-class for non IBR piping must be

considered.

Refrigeration 1. Only Frick Vilter/ Kirloskar make high speed Ammonia compressor should be considered. 2. The super heater may be included as an optional item for heat recovery & energy saving. 3. Cold Store Capacity:

Milk Cold Store- 60 KL capacity. Curd cold store – 5 MT Paneer cold store- 5 MT Cold store will be conventional with ALU & Ammonia system. Separate R 404 Compressor should not be considered.

4. Refrigeration plant capacity should be considered as per BOQ. CIP 1. CIP heater capacity should be 20 KLPH. 2. Acid,lye,hot water & Recuperation tank capacity should be as per final supply list but the rate for 3

KL cap. As per specification may be quoted as optional item. In light of the reply the BOQ for 2.00 LLPD Dairy Plant should stand to be amended upto this extent. Tanker Loading/ Unloading Facility should be considered for the safe RMT loading/unloading facility under hygienic condition. Tanker Bay 1. Provision should be made for separate RMT loading/ unloading backed up with CIP arrangement

atleast for 4 vehicles at a time for 4.00/5.00 LLPD dairy plant. Arrangement should be made for deep chilling of Milk prior to the loading of RMT in the Tanker Bay.

2. Provision should be made for separate RMT loading/ unloading backed up with CIP arrangement atleast for 2 vehicles at a time for 2.00 LLPD dairy plant.

MODIFIED SPECIFICATION FOR ICE- CREAM PLANT Ice- Cream Mix Preparation System 1. If the desired make not available in the market then the system could be made after assembly of

only Tetrapack/GEA make.

2. Make of Homogenizer should be strictly as per list mentioned.

3. The Rotary Ice- Cream cup Freezer must be considered as per BOQ. (Make – Tetrapack/ Catta/ Gram

4. Rate of Optional Items required

1. Rotary Ice- Cream Cup filling Machine – Cap- 10000 Cones/hrs 2. Ice- Cream Cone filling Machine - Cap 6000 Cons/hr 3. Ice- Cream Cold Room Panels mentioned in BOQ. Sr. No- 13

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5. Refrigeration Plant for Ice- Cream mix section should be backed up with KC- 4 Compressor. Only

Ammonia system should be considered for Cream hardening Room (12 X 12 x 2.6 Meter) & Cold store.

6. Optional Rate may be quoted for BOQ SL. No. - 12 & 13.

Modified Specification for Cattle Feed Plant Cap. - 300 TPD

1. Rotary distributors (A.110) - Rate is to be quoted as per B.O.Q. 2. Capacity of Pre weighing is 35 & 15 CUM 3. Pre weighing bin (A2.2) will be mild steel construction.

4. You are advised to quote the rate for gravity feeder as per B.O.Q. and the rate for alternative

mechanical feeder with drive may be mentioned as optioned item.

5. Cascade magnets (A 3.1) cleaning arrangement is manual.

6. Mineral dosing hopper capacity should be 100 Kg.

7. Pelleting Bin (A5.1) is required as per B.O.Q.

8. Feed Hopper of pellet mill (A.5.3) Rate for 1.0 MT as well as 5MT capacity hopper is required.

9. The capacity of pellet mill should be considered 20 TPH in 8 to 10 mm pellet size of feed.

10. Two no. of pellet sieve in required

11. Bagging station (A6.7) means automatic bag feeding, auto bag lifting to the mouth of bagging spout, auto clamping, auto filling and release, conveying in the conveyor and stitching than to the slate conveyor. The bag will be HDPE only.

12. M.S. air piping may be considered.

13. The quantity of steel structured required for the construction of production block is to be

specifically mentioned in the bid, however rate is to be quoted on per MT basis.

14. Incoming power from state electricity board well be 11 KV.

15. The capacity of boiler will be 2 TPH however the rate of 1.0 TPH capacity boiler should be quoted as optional item.

16. The capacity of DG set / Transformer/ Electrical panel along with accessories varies as per

equipments design, it is advised to quote the rate of aforesaid item as per load detail. Bidders are expected to attach load detail of the plant.

Electrical Capacity of DG set / Distribution Transformer/ Electrical accessories may varies as per equipment design. Bidders have to specify the load calculation to justify the rate of aforesaid Electrical items.

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Modified Specification for Civil Works 2.00 LLPD

1) Specification for the civil works to be followed as per PWD, Bihar. 2) The following specifications are subject to any change during drawing & design.

Civil work will consist of:-

a) Dairy Block. b) Service/ Utility Section (Refrigeration/ Boiler) c) Electric Panel Room/ DG Set Room d) General Store e) Workers Amenity Block f) Administrative Block. g) Overhead RCC Water Tank with pump room of size (4mx3m). h) Road & Hard Park. i) E.T.P. of suitable capacity to treat up to 3.0 lakh liters per day of dairy effluent. j) Internal/ External electrification work including street lighting all along road and hard park.

a) DAIRY BLOCK

i) Raw milk reception dock - 20 m x15 m x4.5 ii) Process Hall with C.I.P. - 40 m x16.5m x 7.1m iii) Product packing and cold store - 30 m x 30 m x 4.5 m with mezzanine floor for Keeping 4x10 KL capacity milk tank iv) Laboratory on 1st floor - (15m x 6m)

b) UTILITY BLOCK:- (Size of Room/Block/Store)

i) Boiler house ( Roofing will be - 21m x 10 m x 7.1 Corrugated Galvanized sheet)

c) Electrical panel room with refrigeration - 30 m x 15 x 6.00 m d) General Store (RCC Roof) - 13m x 10m x 6m e) Workers Amenity - 200 Sq Mtr area f) Admn. Block (Double Story) - 300 m2 area

With Water Supply, Sanitary, Electrification all complete.

g) RCC overhead water tank in two compartments with pumping station and pump room. In size (4m x 3m) with electrification work - 50 KL Capacity. Civil work for machine foundation for IBT condenser tank, and all other required machines are to be in RCC foundation.

h) Hard park & tanker Bay – 2500 sq m

This will include

i. RCC Road - 300 sqm ii. Main Road - 9.00 m wide. iii. Other Roads - 6.00 m wide.

This work will consist of:-

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i. Earthwork in excavations ii. Sandfilling iii. Brick on edge soling iv. 150 mm thick stone metal laying with compaction by roller v. 100 mm thick PCC (1:4:8) with stone metal vi. 200 mm thick RCC M 20 in panel vii. Joint Filling with hot Bitumen & mixed with sand

(i) E.T.P. of suitable capacity to treat 3.0 lakhs ltr.per day dairy effluent.

Note- There should be provision for the expansion of R.M.R.D processing section), Product section & utility etc.

SPECIFICATION OF WORK (Subject to change during Des ign/Drawing):- Brick work: - All brick work will be of Ist class bricks in cement worker (1:6).

RCC Work/PCC work : All concrete Work will be in M 20 mix

Plaster work: - All internal plaster will be 12mm thick (1:6) in wall and 600m thick in C.M.(1:4) in

ceiling External plaster will be in two layers 15mm thick with cement motor (1:6) and top layer spatter dash plaster in cement motar (1:3) mixed With stone grits.

Glazed tiles :-White glazed tiles in walls of dairy building in process hall, product/ packing/

corridor etc. upto 7 ft height. Flooring work :-Red Mandana Stone tiles over 5” thick RCC M 20 concrete over brick flat soling

in dairy building and kota stone flooring in office/workers amenity building. In utility section the flooring will 5” thick RCC M 20 with 20 mm thick IPS mixed with iron dust.

Roofing work : All roofs will be RCC M 20 except boiler House including water proofing course.

Doors/ Windows : All doors & windows will be of Aluminum frame and glass panes of suitable

thickness. Finishing/Painting Work -Weather coat painting on external plastered surface and Emulsion paint on internal surface.

Road & Hard Park - 0’8”Thick RCC M20 road over 6” thick stone metal duly composed with roller over sand filling and one brick on edge soling and sand filling for all blocks separately. Note:-1 . Rate will be quoted on plinth area basis. A rough layout plan of dairy building may be

seen in our office for reference. Based on this, bidder has to submit the complete design/ plan and elevation of all buildings along with the bid.

Note:-2 For Road/ Hard Park the rate should be quoted in M². For RCC overhead water tank,

the rate may be quoted in per litre of tank capacity. Note:-3 Civil Work specifications to be carried out as per Bihar Schedule of Rate

Building/Roads & Code. Note:4 The specification are subjected to change as per deign/drawing.

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Modified Specification for Civil Works 4.00 LLPD

1) Specification for the civil works to be followed as per PWD, Bihar. 2) The following specifications are subject to any change during drawing & design.


a) Dairy Block. b) Service/ Utility Section (Refrigeration/ Boiler) c) Electric Panel Room/ DG Set Room d) General Store e) Workers Amenity Block f) Administrative Block. g) Overhead RCC Water Tank with pump room of size (4mx3m). h) Road & Hard Park. i) E.T.P. of suitable capacity to treat up to 6.00 lakh liters per day of dairy effluent. j) Internal/ External electrification work including street lighting all along road and hard

park. a) DAIRY BLOCK i) Raw milk reception dock - 21m x 21m x 4.5m ii) Process Hall with C.I.P. - 63m x 16.5m x 7.1m iii) Product packing and cold store - 42 m x 42 m x 4.5 m with mezzanine floor for Keeping 5x10 KL capacity milk tank iv) Laboratory on 1st floor - (15m x 6m)

b) UTILITY BLOCK : - (Size of Room/Block/ Store) i) Boiler house (Roofing will be - 21m x 21m x 7.1 m Corrugated Galvanized sheet) c) Electrical panel room with refrigeration - 49 m x 28 m x 6.0 m d) General Store (RCC Roof) - 13m x 10m x 6m e) Workers Amenity - 200 Sq Mtr Area f) Admn. Block (Double Story) - 500 m2 Area With Water Supply, Sanitary, Electrification all complete. g) RCC overhead water tank in two compartments with pumping station and pump room. In size

(4mx 3m) with electrification work - 50 KL Capacity.

Civil work for machine foundation for IBT condenser tank, and all other required machines (all work in RCC foundation).


This will include


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This work will consist of:

i. Earthwork in excavation ii. Sandfilling iii. Brick on edge soling iv. 150 mm thick stone metal laying with compaction by roller v. 100 mm thick PCC (1:4:8) with stone metal vi. 200 mm thick RCC M 20 in panel vii. Joint Filling with hot Bitumen & mixed with sand

i) E.T.P. of suitable capacity to treat 6.00 lakhs ltr.per day dairy effluent. Note:- There should be provision for the expansion of R.M.R.D processing section & Product section

& utility etc.

SPECIFICATION OF WORK:- (Subject to change during D esign/Drawing) Brick work :- All brick work will be of Ist class bricks in cement worker (1:6). RCC Work/PCC work : All concrete Work will be in M 20 mix Plaster work :- All internal plaster will be 12mm thick (1:6) in wall and 600m thick in C.M.(1:4) in


Glazed tiles : - White glazed tiles in walls of dairy building in process hall, product/ packing/ corridor

etc. upto 7 ft height. Flooring work :-Red Mandana Stone tiles over 5” thick RCC M 20 concrete over brick flat soling in

dairy building and kota stone flooring in office/workers amenity building. In utility section the flooring will 5” thick RCC M 20 with 20 mm thick IPS mixed with iron dust. Roofing work : All roofs will be RCC M 20 Except boiler House including water proofing course. Doors/ Windows : All doors & windows will be of Aluminum frame and glass panes of suitable thickness. Finishing /Painting Work -Weather coat painting on external plastered surface and Emulsion paint on internal surface. Road & Hard Park - 0’8”Thick RCC M 20 road over 6” thick stone metal duly compacted with roller over and one brick on edge soling and sand filling for all blocks separately. Note:- Rate will be quoted on plinth area basis. A rough layout plan of dairy building may be seen in our office for reference. Based on this, bidder has to submit the plan and elevation of all buildings along with the bid. For Road/ Hard Park the rate should be quoted in m². For RCC overhead water tank, the rate may be quoted in per litre of tank capacity. Note:-1 . Rate will be quoted on plinth area basis. A rough layout plan of dairy building may be seen

in our office for reference. Based on this, bidder has to submit the complete design/ plan and elevation of all buildings along with the bid.

Note:-2 For Road/ Hard Park the rate should be quoted in M². For RCC overhead water tank, the

rate may be quoted in per litre of tank capacity.

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Note:-3 Civil Work specifications to be carried out as per Bihar Schedule of Rate Building/Roads &

Code. Note:4 The specification are subjected to change as per deign/drawing.

Modified Specification for Civil Works 5.00 LLPD 1) Specification for the civil works to be followed as per PWD, Bihar. 2) The following specifications are subject to any change during drawing & design.


a) Dairy Block. b) Service/ Utility Section (Refrigeration/ Boiler) c) Electric Panel Room/ DG Set Room d) General Store e) Workers Amenity Block f) Administrative Block. g) Overhead RCC Water Tank with pump room of size (4mx3m). h) Road & Hard Park. i) E.T.P. of suitable capacity to treat up to 8.00 lakh liters per day of dairy effluent. j) Internal/ External electrification work including street lighting all along road and hard

park.

a) DAIRY BLOCK i) Raw milk reception dock - 21m x 21m x 4.5m ii) Process Hall with C.I.P. - 63m x 16.5m x 7.1m iii) Product packing and cold store - 42 m x 42 m x 4.5 m with mezzanine floor for Keeping 5x10 KL capacity milk tank iv) Laboratory on 1st floor - (15m x 6m)

b) UTILITY BLOCK : - (Size of Room/Block/ Store)

Boiler house (Roofing will be - 21m x 21m x 7.1 m Corrugated Galvanized sheet) c) Electrical panel room with refrigeration - 49 m x 28 m x 6.0 m d) General Store (RCC Roof) - 13m x 10m x 6m e) Workers Amenity - 200 Sq Mtr Area f) Admn. Block (Double Story) - 500 m2 Area With Water Supply, Sanitary, Electrification all complete. g) RCC overhead water tank in two compartments with pumping station and pump room. In size

(4mx 3m) with electrification work - 50 KL Capacity.

Civil work for machine foundation for IBT condenser tank, and all other required machines (all work in RCC foundation).


This will include

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This work will consist of:

i. Earthwork in excavation ii. Sandfilling iii. Brick on edge soling iv. 150 mm thick stone metal laying with compaction by roller v. 100 mm thick PCC (1:4:8) with stone metal vi. 200 mm thick RCC M 20 in panel vii. Joint Filling with hot Bitumen & mixed with sand

i) E.T.P. of suitable capacity to treat 8.00 lakhs ltr.per day dairy effluent. Note:- There should be provision for the expansion of R.M.R.D processing section & Product section

& utility etc.

SPECIFICATION OF WORK:- (Subject to change during D esign/Drawing) Brick work :- All brick work will be of Ist class bricks in cement worker (1:6). RCC Work/PCC work : All concrete Work will be in M 20 mix Plaster work :- All internal plaster will be 12mm thick (1:6) in wall and 600m thick in C.M.(1:4) in


Glazed tiles : - White glazed tiles in walls of dairy building in process hall, product/ packing/ corridor

etc. upto 7 ft height. Flooring work :-Red Mandana Stone tiles over 5” thick RCC M 20 concrete over brick flat soling in

dairy building and kota stone flooring in office/workers amenity building. In utility section the flooring will 5” thick RCC M 20 with 20 mm thick IPS mixed with iron dust. Roofing work : All roofs will be RCC M 20 Except boiler House including water proofing course. Doors/ Windows : All doors & windows will be of Aluminum frame and glass panes of suitable thickness. Finishing /Painting Work -Weather coat painting on external plastered surface and Emulsion paint on internal surface. Road & Hard Park - 0’8”Thick RCC M 20 road over 6” thick stone metal duly compacted with roller over and one brick on edge soling and sand filling for all blocks separately. Note:- Rate will be quoted on plinth area basis. A rough layout plan of dairy building may be seen in our office for reference. Based on this, bidder has to submit the plan and elevation of all buildings along with the bid. For Road/ Hard Park the rate should be quoted in m². For RCC overhead water tank, the rate may be quoted in per litre of tank capacity. Note:-1 . Rate will be quoted on plinth area basis. A rough layout plan of dairy building may be seen


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rate may be quoted in per litre of tank capacity. Note:-3 Civil Work specifications to be carried out as per Bihar Schedule of Rate Building/Roads &

Code.

Modified Specification for 300 MTPD Cattle Feed Pla nt

Specification for the civil works to be followed as per PWD, Bihar. The following specifications are subject to any change during drawing & design. Civil work will consist of:- i) Boiler House & Electrical Panel Room (21 M X 21 M) ii) Administrative Block (250 M2 Double Story Building) iii) Store/ Godown {44 M X 15 M (6 Nos.)} & {44 M X 10 M (2 Nos) } vi) General Store viii) Road & Hard Park. x) Internal/ External electrification work including street lighting all along road and hard park. SPECIFICATION OF WORK:- Brick work:- All brick work will be of Ist class bricks in cement worker (1:6). RCC Work/PCC work: All concrete Work will be in M 20 mix Plaster work:- All internal plaster will be 12mm thick (1:6) in wall and 600m thick in C.M.(1:4) in

ceiling External plaster will be in two layers 15mm thick with cement motor (1:6) and top layer spatter dash plaster in cement motar (1:3) mixed With stone grits. Glazed tiles: White glazed tiles in walls of buildings/ product/ packing/ corridor etc. upto 7 ft height. Flooring work:-Red Mandana Stone tiles over 5” thick RCC M 20 concrete over brick flat soling in Cattle Feed building and kota stone flooring in office. In utility section the flooring will 5” thick RCC M 20 with 20 mm thick IPS mixed with iron dust. Roofing work:All roofs will be RCC M 20 except boiler House & Raw material Godown including water proofing course. Doors/ Windows: All doors & windows will be of Aluminum frame and glass panes of suitable

thickness. Finishing/ Painting Work-Weather coat painting on external plastered surface and Emulsion paint on internal surface. For Road/ Hard Park the rate should be quoted in m2. For RCC overhead water tank, the rate may be quoted in per litre of tank capacity.

Note:- Rates will be quoted on plinth area basis. A rough layout plan of dairy building may be seen in our office for reference. Based on this, bidder has to submit the plan and elevation of all buildings along with the bid. For Road/ Hard Park the rate should be quoted in m². For RCC overhead water tank, the rate may be quoted in per litre of tank capacity.

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Note:-1 . Rate will be quoted on plinth area basis. A rough layout plan of dairy building may be seen



rate may be quoted in per litre of tank capacity. Note:-3 Civil Work specifications to be carried out as per Bihar Schedule of Rate Building/Roads &

Code. Note:4 The specification are subjected to change as per deign/drawing.

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Annex- I

TECHNICAL SPECIFICATION AND SCOPE OF SUPPLY OF MILK STORAGE SILO

CAPACITY: 60 KL SCOPE OF SUPPLY Supply of 60 KL Vertical Milk Storage Silo with Side entry agitator. FUNCTIONAL REQUIREMENT The milk silo would be used to store chilled raw / pasteurized milk at 4 0C temperature and shall be installed outside. DESIGN REQUIREMENTS Capacity: 60,000 Liters. The volume of the tank shall be such that after filling it up to the rated capacity, the level would be 100 mm below the line where cylindrical shell joins the conical top. Constructional Features: The tank shall be vertical, double walled, Insulated and welded construction of sanitary design. The vessel shall be made of SS conforming to AISI 304. Slope: The bottom of the silo shall have 1:15 slope towards inlet cum outlet for free and complete drainage of liquid. Metal Contact: The only metal-to-metal contact between the inner and outer shells shall be at the places where fittings for the tank are provided. At the places where mild steel stiffeners are provided, insulated padding shall be fixed between the inner stainless steel shell and stiffeners. Finish: Internal Surface : Original 2B Mill Finish / 150 Grit Finish External Surface : Original 2B Mill Finish with all burs removed. Weld-joint : Ground smooth & finished to 150 Grits. MS Stiffener : Two coats of epoxy primer after proper de-rusting. Joint Curvatures: The radius of all welded and permanent attachment joints shall be at least 6 mm. where the conical top and flat bottom join the cylindrical shell and radii shall not be less than 25 mm. Installation: It shall be suitable for outside installation. Accessories mounted on top shall be weather proof. SCOPE OF SUPPLY: Inner cylindrical body:

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The inner shell & conical top shall be fabricated from 3mm thick stainless steel conforming to AISI 304. The inner flat bottom shall be fabricated from 4mm thick stainless steel conforming to AISI 304. Outer cylindrical body: The outer shell & conical top shall be fabricated from 2mm and 3mm thick stainless steel respectively conforming to AISI 304. Insulation: The entire inner shell (including alcove portion), conical top and flat bottom shall be insulated as follows: Inside of Outer shell & Outside of Inner shell shall be coated with two coats of Black Bituminous Paint: 1st layer- 15 mm thick Polyurethane having density 30-35 Kg/m3 each longitudinally. 2nd layer - 50 mm thick Expanded Polystyrene foam having density of 16- 20 Kg/m3 applied redially in staggered joint with CPRX compound Sealing. 3rd layer - 50 mm thick Expanded Polystyrene foam having density of 16- 20 Kg/m3 applied longitudinally in staggered joint with CPRX compound Sealing. 4th layer – 42 SWG (0.1mm thick) Aluminum foil shall be covered over the insulation on shell. This is for the Moisture control. Suitable stiffeners shall be providing as per approved design. All the cladding joints shall be welded in design. 5.0 Accessories Alcove: The alcove arrangement shall be of size 1800 mm X 1500 mm and projecting 900 mm from the silo with bottom plate. The alcove shall accommodate thermometer pocket, level transmitter, inlet cum outlet, low level switch, sampling cock and man-way. The Alcove shall be provided in welding construction. Inlet cum Outlet: 100mm diameter cup type inlet cum outlet with manual operated butterfly type valve (size 76.1mm) stainless steel (AISI 304) flanged valve ending in complete stainless steel union. Air Vent: Stainless steel (AISI 304) 450 mm dia. Standard design air vent to prevent formation of particle vacuum during CIP and pressure during filling. Man-way: Stainless steel (AISI 304) side elliptical man-way of 405mm x 550mm diameter and located at the bottom of the silo and provided with air tight hinged insulated stainless steel (AISI 304) door with tightening and locking device. The man-way door gasket shall be neoprene or nitrile rubber of food grade quality. Light Glass:

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Stainless steel (AISI 304) light glass assembly shall be provided with toughened glass and stainless steel lamp shade for mounting 24V, 100 watt bulb. The lamp holder shall be made from brass. Side Agitator: Side mounted mechanical agitator with 3 blade propeller type impeller having sweep dia. of ~300mm. Agitator shall provide with 7.5HP @ 6 or 8 Pole motor of BBL / ABB Make, single dry mechanical seal of Burgmann Make & Bearing Housing. The agitation system to ensure uniform mixing & agitation of the milk. The agitator shaft shall be made of SS rod. The motor shall be provided with SS weather proof cover for protection. 1 Set Level Indication: Sanitary type liquid level indicator and transmitter shall be provided. All the milk contact parts shall be of SS 304 material. The liquid level indicator shall be diaphragm type. Suitable level indicators shall be provided to indicate the leveling the silo. It shall work on 24 V DC, two wire type. It shall be duly calibrated and shall have an accuracy of ± 0.25%. 1 No. Spray Ball: Removable stainless steel (AISI 304) cleaning device located at the apex of the conical tope to provide for flooding of liquid over the complete interior surface during CIP. The spray ball shall be of 100mm dia. stationary type with holes 180 deg. This shall be connected to 51mm dia. SS pipe and with stainless steel SMS union at the outer end connection with blind end. 1 No. Sampling Cock: Sampling cock shall be provided on the Inlet, cum Outlet and will be stainless steel constructions of sanitary design. 1 No. Level Probe and socket: High level, Medium Level (Agi. Cutt off Sensor) and Low level probe with provision shall be provided of E & H make. Thermo well: 200 mm long stainless steel (AISI 304) inclined pocket suitable for monitoring stem type dial thermometer / temperature sensor shall be suitably located in the alcove. It shall have 21mm BSP male threads. Thermometer / PT 100 (Temperature sensor) of radix make shall be provided. The temperature indicator shall be housed in SS control panel. Drain Hole: The outer shell shall be provided with one or more drain holes at the lowest point. Any aperture in the shell shall be designed so as to prevent ingress moisture. Lifting Lug: Stainless steel (AISI 304) lifting lugs shall be provided at top. 4 Nos. Anchor Points: Anchor points, pipes and socket shall be provided on top of the tank so that safety railing and platform shall be welded to them after installation. Sight Glass:

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Stainless steel (AISI 304) sight glass assembly shall be provided with toughened glass. It shall be provided in such a way that one can easily read from the lowest level up to the highest level marks. Railing: The necessary railing of 900mm height in SS 304 shall be provided with the help of 38.1mm & 25.4mm OD tube which is 1.6mm thick. The toe guard of 150mm x 2mm thick in SS 304 shall also be provided. The railing pipe shall be supplied loose and shall be assembled / welded at the site as per the requirement. Sand blasted Level Marking: It shall be calibrated at 500Ltrs. Interval provided on the inner shall at opposite side of sight glass. Paintings: All the mild steel stiffeners used in the construction of the silo shall be painted with two coats of epoxy primer after thorough de-rusting. Control Panel: SS 304, 2mm thick control panel shall be provided comprising with Level indicator, Temperature indicator, cyclic timer & soft starter for agitator, Push buttons, On/off buttons, Alarm & internal wiring of panel. TESTS The following tests shall be conduct by supplier at their works. Dye penetration test for weld joints. Water fill-up test of inner vessel for water tightness before insulation. Final inspection prior to dispatch including agitator trial needs to be provided. When man-way is closed and covered tightened without gasket then the gap at any place between the man-way neck and cover shall not exceed 0.5mm.

Sr. No.

Description Qty. Make

1 Hydrostatic type Level Transmitter of DN 65 DRD flange 1 E & H 2 Level Indicator, suitable for level transmitter. 1 West 3 Tuning fork type High, Medium (Agi. Cutt off sensor) &

Low Level Switches. 3 E & H

4 Temperature Sensor – PT 100, 12” Long ½” BSP end conn., Range : 0 to 150 deg. C

1 Radix

5 Temperature indicator 1 Radix 6 Control panel 1

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Annex- II

Specification for Butter Milk StorageTank, Past Wat er Storage Tank, Pre- stratification Tank, Ghee Settling Tank

Sl.

No.

Description Butter Milk Storage

Tank

Past Water Storage

Tank

Pre-

stratification

Tank

Ghee Settling

Tank

1 Purpose Store Chilled Butter Milk Pasteurised Chilled

water

Store Molten

Butter

Store Ghee

2 Qty 1 1 2 2

3 Capacity 15 KL 15 KL 2 KL 2 KL

4 Location Butter Making Butter Making Ghee Making Ghee Making

5 Construction Vertical , double walled ,

insulated

Vertical , double

walled , insulated

Vertical , double

walled , insulated

Vertical / Double

walled / insulated

Material of

Construction

6 Inner Shell 2,5 mm , AISI 304 2,5 mm , AISI 304 2,5 mm , AISI 304,

3 mm conical

bottom

2 mm , AISI 304

7 Inner Shell Finish 150 Grits 150 Grits 150 Grits 150 Grits

8 Inner mediate shell - _ _ _

9 Outer Shell 2 mm, AISI 304 2 mm, AISI 304 _ 2 mm, AISI 304

10 Outer Shell finish Mill finish Mill finish Mill finish Mill finish

11 Insulation layers 1st layer 15 mm PUF 35

kg/cum density , 2 nd &

3 rd layer each of 50 mm

EPS 20 kg /cum density

1st layer 15 mm PUF

35 kg/cum density ,

2 nd & 3 rd layer

each of 50 mm EPS

20 kg /cum density

12 Jacket drain outer shell shall have

weep holes at bottom

outer shell shall

have weep holes at

bottom

SS drain with

GM valve at the

bottom of jacket

13 Inlet 63. 5 mm SMS union 63. 5 mm SMS

union

No foam 63.5 mm

Top inlet with SMS

union

No foam 38.5

mm Top inlet

with SMS union

14 Outlet

Side outlet 51 mm

with angular valve

of AISI 304

Side outlet 51

mm with angular

valve of AISI 304

15 Sampling port Sampling cock, sanitary

design before stop valve

Sampling cock,

sanitary design

before stop valve

16 Drain ____ Bottom outlet - 51

mm with inline

sight glass and

valve of AISI 304

Bottom outlet –

51 mm with

valve of AISI 304

17 Overflow ____ 38 mm at type

top of bottom

18 Airvent 150 mm dia 150 mm dia 76 mm dia

19 Manway Ovel shaped 550 x 405

mm with Neoprene/

Nitrile rubber food grade

gasket

Ovel shaped 550 x

405 mm with

Neoprene/ Nitrile

rubber food grade

gasket

Half openable

three piece covers

of 2 mm thick of

AISI 304 at the top

Half openable

three piece

covers of 2 mm

thick of AISI 304

at the top

20 Level probe ,

sensor, transmitter

port

Yes Yes

21 Temperature sensor Yes, thermowell Yes, thermowell Yes, thermowell Yes,

17




port thermowell

22 CIP Port Spray ball AISI 304 Spray ball AISI 304 ____ ____

23 Light Port 140 mm dia AISI 304

with toughened glass &

fly nuts, 24 V 100 W

lamp

140 mm dia AISI

304 with toughened

glass & fly nuts, 24

V 100 W lamp

24 Sight Port 140 mm dia AISI 304 with

toughened glass & fly nuts

140 mm dia AISI

304 with toughened

glass & fly nuts,

Side window

25 Agitator / Drive Vertical type (AISI 304 )/

Geared motor , Motor shall

be as per IS 12615- 2004

Eff- 1

26 Level Marks Sand blasted with 500 L

intervals

Sand blasted with

500 L intervals

Controlls &

Instrumentation

27 Level Transmitter Provision for Diaphgram

type

Provision for

Diaphgram type

28 Level

Tarnsmitters

Yes Yes

29 Low level Yes Yes

30 High Yes Yes

31 Temperature

sensor

Yes Yes

32 Temperatue

Transmitter

Yes Yes

33 Temperature

Display

Yes Yes

34 Manhole Sensor

35 Alcove

Accessories

36 Approach ladder Vertical ladder AISI 304

and AL top platform

Vertical ladder AISI

304 and AL top

platform

Common Plateform

with railing for

each group

Common

Plateform with

railing for each

group

37 Top Railing 900 mm high , 38 mm dia

AISI 304 pipe - with SS kick

900 mm high , 38

mm dia AISI 304

pipe –

with SS kick

38 Liting lugs Yes 4 Nos. AISI 304 Yes 4 Nos. AISI 304

39 Test DP test, water fill test DP test, water fill

test

DP test, water fill

test

DP test, water fill

test

18




Specification for Butter Melting Vat, Concentrated Acid, Concentrated lye Tank, CIP tanks for acid /lye/ hot/water tank

Sl.

No.

Description Butter Melting Vat Concentrated Acid Concentrated lye Tank CIP tanks for acid

/lye/ hot/water

tank

1 Purpose Melting of Butter Store concentrated

acid

Store concentrated

LYE

Store Acid

2 Qty 2 1 1 3

3 Capacity 2 KL 2 KL

4 Location Ghee Making Outdoor Outdoor CIP

5 Construction Rectangular double

walled , insulated

with heating pipe

network

Vertical uninsulated Vertical uninsulated Vertical / Double

walled / insulated

Material of

Construction

6 Inner Shell 2 mm , AISI 316 3 mm , AISI 316 3 mm , AISI 316

7 Inner Shell Finish 150 Grits 150 Grits 150 Grits

8 Jacket _ _ _ _

9 Outer Shell 2 mm, AISI 304

10 Outer Shell finish Mill finish Mill finish Mill finish Mill finish

11 Insulation layers 50 mm PUF of 42 KG/

cum density

50 mm thick (each

layer) resin bonded

crown 150 bigre

glass insulation in 2

layers

12 Heating system

drain

Condensate outlet with

strainer , float type

steam trap , sight glass

and by

13 Inlet Top cover in three

pieces of of 2mm tgick

AISI 304

14 Outlet 51 mm cup type with 2

way plug valve of AISI

316

Side outlet 51 mm

AISI 304 for UHT &

Powder Plant

system, Bottom

dosing outlet for 15

mm for metering

pump for dairy

system

Side outlet 51 mm AISI

304 for UHT & Powder

Plant system, Bottom

dosing outlet for 15

mm for metering pump

for dairy system

76 mm

15 Sampling port

16 Drain ____ ____ ____ 63.5 mm

17 Overflow ____ 51 mm AISI 304 51 mm AISI 304 63.5 mm

18 Airvent Suitable Suitable 100 mm

19




Technical Specification of Milk Homogenizer Cap- 10 KL

Make : APV Gaulin / IDMC / FBF / Tetra Pak Only.

Execution : Sanitary Version

Product : Milk

Viscosity : Up to 5 cP at Homogenization temperature

Capacity : 10,000 LPH

Homogenizing Pressure : Up to 180 bar peak pressure

Homogenizing Stages : Two stages, Ist Stage: 180 Bar

IInd Stage: 50 Bar

Machine Model : to be specified by bidder

Installed Motor Rating : to be specified by bidder

Speed : to be specified by bidder

Bore : to be specified by bidder

Stroke : to be specified by bidder

Basic Configuration : 3 Nos. piston pumps system with pulsation dampeners on suction and discharge sides.

Lubrication System : Forced Lubrication System

CIP : Suitable for CIP Caustic (2%) at 85oC and Nitric acid (2%) at 72oC, Hot water at 95oC

Utility Requirements : Electrical Power : to be specified by bidder

: Earthing : Suitable

: Process Quality water : to be specified by bidder

: Compressed Air : At 5 bar

: Inlet Product Pressure : 2 bar (min.)

Inlet Connection : to be specified by bidder

Outlet Connection : to be specified by bidder

20




SUMMARY OF TECHNICAL SPECIFICATIONS OF HOMOGENISER

TECHNICAL SPECIFICATIONS OF MILK HOMOGENIZER – 10 KLPH

1. Compression head should be manufactured from single forged of special AISI 316.

2. Homogenizing chamber shall be manufacture in SS 316 with pressure stabilizers on 1st stage and 2nd stage to transmit constant pressure.

3. Suction/Discharge valve and valve seats of Poppet type suitable for liquids like Milk.

4. Suction and Discharge Valves and Valve seats should be interchangeable type made of Stellite material.

5. Homogenizing valves shall be made of tungsten Carbide material to sustain high abrasion

and cavitations. 6. Over pressure safety valve shall be provide on machine, which shall open if higher pressure

is taken than maximum designed pressure OR developed by intrusion of some foreign particle.

7. Forced lubrication ensuring lubrication of all mating parts. 8. Tube in Tube type heat exchanger for cooling lubrication oil with the help of oil pump.

9. Oil level safety switch shall be provided to ensure proper level of lubricating oil. 10. Thermo- Electric (Solenoid) valve is provided to ensure proper flow of cooling water. 11. Anti - vibration pad with adjustable ball feet.

12. Pulsation dampeners on Inlet and outlet to be provided to dampen the vibration because

of entrapped air in line OR Fluctuating Flow. 13. Automatic disconnection gauge at the inlet of Homogeniser should be provided which

disconnects the homogenizing pressure if the feed pressure is less than 2 bar thereby avoiding damages to Suction/Discharge valves due to starving/ dry running.

14. Main switch and starter provided separately and external to the machine along with all the

auto switches and Relays. 15. Blower should be provided to remove hot air inside the cabinet. 16. Remote control Panel should be provided near the Homogenizer with the indicators as given

below. a. Indication Lamp for Water / Air Failure. b. Indication Lamp for Irregular Lubrication Oil Pressure. c. Indication Lamp for Protection Intervention (For any electrical Problem) d. Indication Lamp for Product Failure e. Start and Stop Push Buttons with indication lamp. f. Pressure adjusting knob for 1st & 2nd with Push Locking arrangement. g. Emergency Stop h. Reset Push Button with indication lamp. i. 1st and 2nd Stage selector switches with indication lamp. j. Hour meter to note the total running hours, which will help to follow the maintenance

schedule. k. Ampere meter to show the current drawn by the motor

21




17. Sanitary design Diaphragm type Pressure Gauge on 1st Stage having range of 0 – 400 Bar.

18. Oil level indicator and Lubrication oil pressure gauge on front side of the Homogenizer. 19. Air Pressure gauge on front side to indicate the pressure on 1st and 2nd Stage. 20. Easily removable type SS enclosure along with bolting arrangement and handles.

21. Arrangement for tightening the V Belts to maintain the required tension.

SPECIFICATIONS AND SCOPE OF SUPPLY:

Homogenizing Heads: The valve, valve seat and impact ring in high wear Tungsten Carbide.

Compression Head: Suction and Discharge Valve seats interchangeable, in Stellite material with high wear resistance properties pumping pistons, in stainless steel AISI 316 covered with hard chrome plated.

Inlet and outlet unions: Standard type SMS inlet/outlet terminating in unions

Main motor: 4 poles, “ F” class standard for insulation, squirrel cage induction motor suitable for 415 V, 50 Hz, 3-phase power supply.

Drive System: Positive transmission with Gear Box, pulleys and rubber belts

Pneumatic pressure: Min. 6.0 bar at the incoming connection of the machine

Cleaning: Maximum temp. less than 90 Deg.C designed suitable for CIP

SCOPE OF SUPPLY :

Basic Machine : Complete with following:

a) Compression head formed by a single forged block of special type checked with ultra sound and designed to contain the suction and delivery valves with pumping systems and relevant seals.

b) Pump body shall be manufactured by spheroidal cast iron housing crankshaft and counter shaft. The crankshaft and counter shaft shall be made in thermally treated steel with rectified surface and obtained from a single solid work piece. The connecting rod is in forged steel complete with relative bearings and pins. The drive piston shall be spheroidal cast iron with surface chromed.

The drive system shall be positive type using Gearbox, Pulley and rubber belts.

c) Homogenization head shall be two-stage homogenization valve with seat valves of inter changeable type manufactured in SS alloy at wear resistance.

d) Control system comprising protection for lubricating oil level or pressure switch, solenoid valve for water flow protection, oleo pneumatic cylinder with necessary adjuster arrangement, over pressure safety valve of spring type mounted on compression head.

A control board provided on the machine consists of emergency stop, start/stop buttons indication for electrical fault, pressure selector switch for stages with locking arrangement

The machine shall be integrally built and provided with SS coverings duly tested at our principal’s works. The test certificate shall be provided along with the machine.

22




Electrical Panel: Electrical panel in stainless steel cubical execution complete with main switch and circuit breaker of suitable rating and star delta starter of Siemens / equivalent reputed make. The panel shall be complete with internal wiring. The remote control push button arrangement shall be provided to facilitate start/stop of the machine. The electrical panel shall be installed near the Homogeniser.

1 set. of special tools and light spares for commissioning and maintenance as recommended by our principal shall also be supplied.

One set of spares sufficient for 2000 hours of operation of homogenizer shall also be supplied along with the machine. The list of spares is given in next page.

23




TECHNICAL SPECIFICATIONS AND SCOPE OF SUPPLY FOR HOMOGENISER 2.00 KLPH

Make: IDMC/Tetra Pak/APV/FBF

Execution : Sanitary Version

Product : Milk

Viscosity : Up to 5 CP at Homogenization temperature

Capacity : 2,000 LPH

Homogenizing Pressure : Up to 230 bar peak pressure

Homogenizing Stages : Two stages, Ist Stage: Maximum -230 Bar

IInd Stage: Maximum- 50 Bar

Machine Model : Bidder to specified

Installed Motor Rating : Bidder to specified

Speed : < 200 rpm (Slow Speed)

Bore : 30 mm

Stroke : 45 mm

Basic Configuration : 3 Nos. piston pumps system with pulsation dampeners on suction and discharge sides.

Lubrication System : Splash Lubrication System

CIP : Suitable for CIP Caustic (2%) at 85oC and Nitric acid (2%) at 72oC, Hot water at 95oC

Utility Requirements : Electrical Power : Bidder to specified

: Earthing : Suitable

: Process Quality water : 200 LPH

: Compressed Air : At 5 bar

: Inlet Product Pressure : 2 bar (min.)

Inlet Connection : Union SMS Suitable size

Outlet Connection : Union SMS Suitable Size

SUMMARY OF TECHNICAL SPECIFICATIONS OF MILK HOMOGEN ISER

• Alloy Cast Iron Crank Case for proper surface hardness, strength, grain structure and graphitization to dampen and absorb noise and vibration.

• Plasma Nitrided Crank Shaft for highest possible surface hardness with tough core. • Monoblock Forged 316L Liquid block design is adopted for easy maintenance and operation. • Full Stellite Suction and Discharge Valves and Valves Seat ensure constant throughput over

operational life of the equipment.

24




• Homogenizing Valves are made of Tungsten Carbide material to sustain high abrasion and cavitation.

• Hydro Pneumatic Homogenization System: Very handy and easy Hydro-Pneumatic operation. Pressure is required to be set once during commissioning by turning on the pressure-adjusting knob from operator’s panel. Pressure setting is locked after it is set at the desired value. The operator has to just put on 1st and 2nd stage switches for regular operation that actuates the pneumatic cylinder, and homogenizing pressure will automatically develop to the preset value.

• Forced Lubrication System with oil pressure switch ensures proper lubrication at exact locations. • External Oil Cooling System provided to avoid any possible contamination and emulsification of oil

by water in the crank case. • Electronic Water Flow Sensor is provided to assure proper flow of cooling water and ensures air

supply. • Starter Panel shall be provided near the machine along with all the electrical switchgears and

relays. The power and earthing connections to the main panel are to be made by the buyer. Interconnecting power and control cable are to be carried out by the customer. The panel shall have hour meter to record total running hours that helps follow periodic maintenance schedule. It shall have digital ammeter on the front panel.

• Heavy Duty Structural and Sturdy Feet to minimize vibration of machine. • Blower is provided to remove hot air inside the cabinet.

Instruments: The following controls, indications and instruments shall be provided on the machine.

i) Indication of homogenization pressure with sanitary design diaphragm type pressure gauges of 4” dial.

ii) Sanitary diaphragm type pressure gauge on the product inlet with electrical disconnection for low pressure.

iii) Indication of air pressure for hydro-pneumatic system for 1st and 2nd stage homogenization with pressure gauges.

iv) Electronic solid stage pressure switch for lubrication oil pressure. v) Lubrication oil pressure gauge.

Operator Panel and Instruments: The operator panel is provided on front side of the Homogeniser at eye level. The following controls, indications and instruments shall be provided on the machine.

i) Indication lamp product pressure failure ii) Indication Lamp for water / air failure. iii) Indication lamp for lubrication pressure failure. iv) Indication lamp for electrical tripping and faults. v) Start, Reset, and Stop push buttons with indication lamps. vi) Emergency Stop push buttons vii) 1st and 2nd stage homogenization switches with indication lamps. viii) 1st and 2nd stage homogenization pressure regulating knobs.

DETAILED SPECIFICATIONS

Liquid Block: Liquid block is formed from a heat treated single AISI 316L forged block that is checked with ultra sound. This monoblock unit houses suction and discharge valves, pistons and gaskets in a convenient easy to maintain design layout.

Interchangeable suction and discharge non-return valves are made from full Stellite material having good wear resistance properties for long trouble free operation. Full Stellite lapped valves hold the product efficiently without any leakage thus yielding full designed capacity constantly that does not drop with machine running life.

Pumping pistons in stainless steel AISI 316L are hard chrome coated for long piston and piston gasket life.

Power Block: Power Block is manufactured from alloy Cast Iron that houses crankshaft, connecting rods and crossheads. The crankshaft is made from alloy steel that undergoes multistage heat treatment and stress relieving. The crank shaft is plasma treated to obtain highest possible surface

25




hardness for a crank shaft that generally finds application in marine and small aircraft engines. Heavy design connecting rods are used with big end journal bearing and small end bushes. The crosshead shaft is hard chrome plated and ground for better surface finish, longer seal and wiper life.

Homogenization Block: Homogenization blocks are made from forged AISI 316L steel. Homogenization is carried out in two stages. Homogenization pressure is set with turn of a knob from operator panel with the help of hydro-pneumatic pressure booster system.

Homogenizing Heads: Homogenizing valve, valve seat and impact ring are made from Tungsten Carbide material. Impact ring is of reversible design.

Lubrication System: Forced lubrication system is provided for connecting rod big end journal bearings. The system delivers filtered lubricating oil with pressure at exact locations. This dampens the cyclic force on crank shaft, eliminates vibrations and ensures long trouble and maintenance free life of critical components.

Lubrication pressure is monitored and the machine is stopped with an indication if oil pressure falls below preset value with oil pressure safety switch.

A remote oil level indicator is provided on the front cover for easy visibility.

Lubricating oil is externally cooled outside the crank case to avoid contamination and emulsification of oil with any possible water leakage that can lead to a major failure. A plate heat exchanger is used for oil cooling where oil pressure is set at a higher value than that of water pressure to avoid any possible contamination. Oil is filtered just before the point of use.

Pulsation Dampeners: SS pulsation dampeners shall be provided on the inlet and outlet of the machine to smoothen the pulsating effect of the homogenization pumps.

Inlet and Outlet Connections: Standard SMS unions shall be provided at the inlet/outlet connections. Inlet and outlet are on the front left side of the machine.

Main Motor: Three phase four pole squirrel cage induction motor in TEFC enclosure, IP 55 Protection, class “F” insulation of ABB make shall be provided.

Operator Panel: An operator panel is mounted on the machine for operation of the machine. The panel has Start, Stop buttons, push buttons for both 1st and 2nd stage pressure On/Off with homogenization pressure control knobs. Any tripping of machine because of electrical, water/air, oil or product failure is indicated by lamps.

Drive System: Imported unicase gear box is used along with a single long life Multi-Pull Poly-V belt for flap free zero slippage silent and efficient power transmission.

Structural: Machine is supported on heavy design structure. The machine is covered with AISI 304 covers with the original hairline mill finish. Heavy duty stainless steel articulated feet with anti-vibration pad are used for leveling and vibration dampening. A sturdy centrifugal silent blower is used to remove hot air inside the cabinet. The machine has small foot print and operator panel is located at a convenient level.

Electrical Panel: Powder coated duly wired electrical panel having starters, controls and incoming switch is supplied with the machine. The panel is to be installed near the near the Homogeniser and interconnecting wiring are to be carried out. Three phase power supply 415 V ± 10%, 50 Hz ± 5% with earthing is to be provided to the panel.

Tools & Spares: 1 set of special tools and spares for commissioning are provided with the machine.

26




Machine Manual: 2 numbers of operation and maintenance manual shall be provided at the time of machine supply.

Efficiency Test:

i) Bidder has to give homogenizations efficiency guarantees more than 90 % or creaming index less than 10.

ii) Sample shall be drawn at outlet of the Homogeniser. iii) Homogeniser efficiency shall be established by standard Feral Index or by NDDB creaming

index method. iv) Test shall be conducted at the outlet of the homogenizer.

27




Annex -III

TECHNICAL SPECIFICATION OF LASSI PASTURISER MODULE

CAPACITY: 2000 LPH

Make: Modules should be IDMC/Tetra Pak/APV only.

FUNCTIONAL REQUIREMENT

Type : Plate Heat Exchanger

Capacity : 2000 LPH MOC of plates : SS 316 Temp Program : 25-65-70-4 Deg. C Sections : Regeneration, Heating I & Heating II Holding Time : 20 Sec in Tube Gasket : Glue free (Nitrile) Homogenization Outlet : 65 deg C Pasteurisation Temp : 70 Deg C

Utilities Required

Hot Water @ 93 deg C (4000 LPH) for heating Generated by Steam at 2.0 Bar Dry saturated steam @ 2 bars pressure

Basis of operation:

Lassi shall be pasteurized at a temperature of 70 deg C. After pasteurization lassi shall be cooled to 4 deg C and left at the outlet of Pasteurizer for onward use.

Technical specifications and scope of supply

1.0 Plate Heat Exchanger - Lassi Pasteurizer (HTST)

Plates: The plates shall be made from stainless steel (SS 316) in sanitary design. All the product contact and exterior surfaces shall be easily accessible or readily removable for cleaning and inspection.

Gaskets: The sealing gaskets must ensure complete sealing and prevent any cross - leakage between product and service liquids. Gaskets shall be of sanitary type and shall be continuously bonded to the heat transfer surface. The gasket material shall be food grade, non-toxic, fat resistant, non-absorbent and shall have smooth surface. The material shall withstand a water sterilization temp. of 100 Deg. C. and 2% caustic solution at 80 Degree Centigrade.

Supporting Frame: The supporting frame for the plate pack shall be of a self supporting design made of stainless steel (AISI 304) clad mild steel with a manually operated stainless steel (AISI 304) tightening device. The tightening device shall be able to exert uniform pressure on all the parts of heat transfer plates to prevent any leakages from Pasteurizer. The frame and tightening device shall prevent the plates from deflecting under pressure differential of minimum 4 kg/sq.cm.

Accessories

Inlets/Outlet: The inlets and outlets in each section of the heat exchanger for products as well as services shall be provided with complete stainless steel (AISI 304) unions.

28




Thermo-wells: SS (AISI 304) pockets for thermometer on required ports for Product and service inlet and outlet connections. Suitable nos. of pockets are included. However thermometers are excluded from our scope of supply.

Ball Feet: The frame shall be provided with adjustable SS ball feet with provision for height adjustment of 50 mm.

2.0 Holding: It shall be designed for continuous holding of the product for at least the minimum specified holding time of 20 Sec at the Pasteurization temperature of 80 deg C.

3.0 Float Balance Tank: The float balance tank of 200 L capacity shall be fabricated from 2 mm thick SS sheet conforming to AISI 304. The tank shall be provided with cover, sanitary type SS (AISI 304) float valve with the Product inlet, cup type outlet, return Product inlet, inlet for water, over flow and adjustable SS ball feet. The float valve shall be designed to give the rated flow rate and withstand an inlet pressure of 1.5 kg/sq.cm.

4.0 Feed Pump & Booster Pump (IDMC Make): The Pasteurizer stainless steel feed pump & Booster Pump shall be of sanitary steel shroud with louvers for air-cooling and suitable design as per dairy standard. Its capacity shall be adequate to facilitate efficient CIP. The TEFC drive motor shall be fitted with stainless arrangement for cable connection.

The feed pump & booster pump shall be of suitable capacity to withstand the flow rates required during product run & CIP.

5.0 Flow Controller (Mechanical Type): Flow Controller for Product: Stainless steel flow control device shall be supplied to maintain the required flow rate. The flow controller shall be of a sanitary design.

6.0 SS Duplex Filter: with accessories shall be provided for pre-filtration of Lassi.

7.0 Heating Device: – PHE Based

Hot water system shall be PHE based and shall have an expansion chamber and other safety devices to take care of the volume of expansion and increased pressure ensuring the complete operational safety. It will be designed as per duty parameters required for pasteurization. It shall consist of PHE (with SS 316 plates and MS painted frame with SS 304 cladding). The system shall be supplied with steam control valve with bye pass assembly, expansion chamber, safety valve.

Safety Device: A safety device shall be provided in the hot water side of heating section to avoid damage to the heat exchanger caused by excessive pressure. It shall be of sanitary design.

Hot water Pump: One number of Hot water pump of suitable capacity will be supplied which will be used for hot water circulation for heating of milk up to 80 deg C.

One no of PID Temperature control arrangement for control of pasteurization temperature together with Steam Regulating and control valve is included.

8.0 Instrumentation and control panel:

Automatic controls shall be provided to ensure pasteurization temperature of product. If the required temperature of product is not reached, the flow of product shall be automatically diverted to the float balance tank with an audible alarm.

The instrumentation and control panel shall be made in standard execution built to dust and vermin proof design. The control panel shall be leg supported and house the following components all pre-wired to terminal strip:

8.1 PID Controller for temperature of pasteurized Product with display of set temperature and actual Product temperature. The controller has a facility to automatically tune to the requirement of set temperature.

29




8.2 Six point Strip chart recorder with digital display of temperatures of pasteurized product. The temperature recorder has microprocessor based with functional key facility for zero and span calibration.

8.3 Audio alarm with hooter and acknowledge and reset push button.

8.3 Auto manual selection switch and forced forward flow provision

8.4 I/P Convertor for steam control valve operation and electrically operated solenoid valve for air supply to flow diversion valve.

8.5 Air pressure regulator cum moisture separator with isolating valve to ensure proper air supply to the I/P Convertor and solenoid valves.

8.6 Incoming on/off switch for control supply.

One set of `ON’ and `OFF’ push buttons with indicating lamps and suitable inscriptions shall be provided for operation of motors of various module. (Two numbers spare push buttons are included)

8.7 Indication lamp for showing the position of flow diversion valve (forward/diverted mode)

9.0 Pipes and Fittings (SS 304): All inter connecting pipes with necessary fittings for product as

well as service shall be supplied within the specified battery limits and exclusions.

9.1 Product: The supply shall include all the necessary SS 304 pipes and fittings from the outlet of balance tank to the finished Pasteurized Product outlet as required interconnecting the above equipment. However the Piping To & Fro from the Homogenizer is excluded from the scope of Supply.

9.2 Hot Water: The supply shall also include necessary SS 304 pipes and fittings for pumping hot water to the heating section of the Pasteurizer and return to the hot water set.

10.0 The module shall be mounted on SS 304 Skid as per compact layout. However the Pasteuriser plate pack & holding coil shall be floor mounted.