Dairy Factory Research Articles

Моніторинг проблем та тенденцій розвитку галузі козівництва в Україні

The development of the goat industry in Ukraine has not moved for last years. There is attention from the government and business. The industry is developing very slowly and agricultural companies do not have sufficient economic motivation for its progress. Goat products are not very popular in the country. These products are expensive and most of its buyers are well-off people. But even among them it is difficult to sell these goods. The most popular is goat's milk, the sellers of other products need to constantly advertise their goods, and spend a lot of money for it. Demand have only big agricultural companies, which can do large batches of milk all year. Small farms release products with seasonal fluctuation and they are not interesting in processing enterprises and connected with they trade networks. As a result, they are experiencing economic losses and even in a season they cannot sell their products, or they sell them too cheap. Ukrainian processing enterprises cannot expand assortment because of small batches of milk and they produce only pasteurized milk, saying no to other products. Most dairy factories do not have special equipment for the processing of goat milk. Even more problems with the processing of goat meat. There are large farms in the country, it is impossible to buy meat for processing. Assortment of goat meat products has not developed for nowadays. There is demand for products from the population. No one ready to invest money in the industry. The situation is similar with the processing of goat fluff, wool, leather and other. All exported abroad in the form of raw materials. The problem is the lack and obsolescence of the normative-technical and technological documentation. That we have, it does not agree the requirements of international standards. The problem of goat industry in Ukraine is the lack of a sufficient number of goats. It is not possible to buy the necessary number of high-performance pedigree animals. The country is not working to create and distribute its own domestic breeds of different directions of productivity. Some farms on the aboriginal animals use absorbing crossing, but to buy a high-quality, checked male goat abroad is not so easy, because really valuable breeding animals cost a lot and they almost do not sell. Quite often there is a question where to put unclaimed animals. Goat meat is not in demand in the country. There are many questions that goat farm owners try to find an answer by themselves: how many animals are optimal to keep, what technology to use in the industry is better, what kind of feed to use as a basis for the diet, what complex of veterinary and sanitary events to use on the farm, how to escape the hard stress during transporting the animals, where to buy equipment for goat industry and others. All these questions will have to be decided by Ukraine. Effective development of goat industry needs an integrated approach based on the usage of rational technologies in animal keeping and industry, together with the choice of optimal marketing strategy for product pricing and sales.

Efficiency of Water Resources in Small and Medium-sized Dairy Factories in Egypt

Efficiency of Water Resources in Small and Medium-sized Dairy Factories in Egypt

A study on the aflatoxin M1 rate and seasonal variation in pasteurized cow milk from northwestern Iran.

Present study aims to assess aflatoxin M1 (AFM1) contamination in 100 samples of pasteurized milk which were conventionally gathered during spring, summer, autumn, and winter from supermarkets located in Maragheh city of northwestern Iran. Samples were evaluated for AFM1 with a high-performance liquid chromatography (HPLC) method and with fluorimetric detection. The results showed that approximately 44% (11.25) of samples in winter, 32% (8.25) of samples in spring, 24% (6.25) of samples in summer, and 20% (5.25) of samples in autumn had AFM1 concentrations that exceeded the limit (0.05μg/l) set by the European, Codex Alimentarius Commission and Iran standards. According to the statistical analysis of the data, there was no significant variation between the mean content of AFM1 during different seasons (P = 0.076). The results of our study suggest a high level of contamination of AFM1 in pasteurized milk in all seasons which may be due to the fact that milk supply for dairy factories is provided from dairy farms that are low in livestock feed quality. In Iran, pasteurized milk is consumed more than other milk products by all age groups. The total daily aflatoxin intake from contaminated milk and possibly other food products will be a significant risk to public health.

Aluminum in Effluents and Sludges from the Preliminary Coagulation in Dairy Factory Aerated Balancing Tanks: An Analytical and Sorption Study

The coagulation process is used as the first step for the chemical treatment of liquid waste. Resulting wet sludge is treated with coagulants or polyelectrolytes to improve dewatering characteristics of its so-called conditioning. The coagulants such as aluminum sulphate or polyaluminum chloride (Al2Cln(OH)6−n) are widely used for dairy wastewater treatment systems. The pretreatment dairy sludge can be applied in agriculture as fertilizer containing valuable nutrients. Hence, a simple, cost effective, and rapid method for the determination of aluminum content in the sludge is essential for calculation of the appropriate coagulant dose at the sludge pretreatment process. In this paper either colorimetric or atomic absorption spectrometric methods as applied for the determination of aluminum concentration in the dairy wastewater are compared. For colorimetric method, the optimum experimental conditions such as pH, reaction time, and concentration of other ions in the sample were determined. The sorption isotherms of aluminum on the activated sludge were determined for diverse aluminum species.

The Effect of Outside Air Temperature on Transportation Temperatures and Processing Quality of Cow's Milk

The objective of this study was to assess the effect of outside air temperature on the transportation temperature and processing quality of cow’s milk. The data used in the analyses (208 bulk samples) were collected on four farms over a period of 52 consecutive weeks. The samples were grouped into four outside air temperature‑based groups, namely: below 1.0 °C; from 1.1 to 8.0 °C; from 8.1 to 15.0 °C; above 15.1 °C. Mean values of the observed characteristics were as follows: average outside air temperature 7.40 °C, milk temperature on dairy farms 5.19 °C (at collection) and milk temperature on arrival at the dairy factory 5.60 °C. The average duration of transport was 211 minutes, milk volume in the tanker 12,885 l, fat content 4.13 %, protein content 3.40 %, lactose content 4.89 %, casein content 2.97 %, titratable acidity 6.31 SH, active acidity 6.75 (pH), rennet coagulation time (RCT) 201 sec., curd class 1.11 (on five‑point scale) and 1.49 (on ten‑point scale). Increasing outside air temperature was closely correlated (p < 0.01) with an increase in milk temperature at the dairy factory (at delivery). A significant (p < 0.01) increased difference between the temperatures on the farm (at collection) and at delivery in the dairy factory was also recorded. The titratable acidity decreased and so did the curd class on the ten‑point scale. Milk temperature on the farm (at point of entering transportation tank) also increased significantly (p < 0.01) with outside air temperature. Other differences were not significant (p > 0.05). Findings of this study suggest that outside air temperature influences the properties and processing quality of the transported milk, even though the temperature differences of the milk itself ranged within the acceptable limits. It therefore stands to reason that, when the temperature of milk on load is close to the recommended temperature limits it can exceed this limit during transportation to the dairy factory and cause significant damage to the processing quality of the transported milk.

Gate-to-gate environmental impacts of dairy processing products in Thiruvananthapuram, India

Environmental impacts associated with a dairy processing industry are directly related to consumption of water and energy, as well as the generation of waste and wastewater. The objective of this research is to suggest improvements for increasing the environmental efficiency of a dairy factory using Environmental audit and Life Cycle Assessment (LCA) for the first time in south India. A gate-to-gate approach was conducted based on environmental audit data. LCA calculations of 10 dairy products was performed according to ISO 14040 and ISO 14044 to identify and quantify the impacts within the system boundary using the LCA software SimaPro® 8.1.1.16. Calculations were based on IMPACT 2002+ impact assessment method consisting of 15 midpoint categories and four endpoint categories. The results clearly indicate that the frozen products such as ice cream candy, ice cream, and sip-up attributed more environmental burden to endpoint categories. The global warming potential related to the products ghee and butter (0.0039 kg CO2 eq.) is high. Relative contributions revealed sodium hydroxide, nitric acid and wastewater were the major impact contributing factors to endpoint categories. Among them, sodium hydroxide contributed more impact to the endpoint categories: human health (99.4%), eco-system quality (96.4%), climate change (97.1%) and resource usage (97.9%). Based on the findings a new eco-design proposal has been proposed for improving the environmental efficiency of the industry. Also, suitable alternatives were proposed to minimise the environmental impacts.

Effectiveness of air disinfection by ozonation or hydrogen peroxide aerosolization in dairy environments

Indoor air of dairy industry acts as a source or vehicle of microbial contamination affecting both food safety and product shelf life. This research focused on both the monitoring of the air microbial load in selected areas of a dairy factory and in evaluating the effect of air disinfection through ozonation or chemical aerosolization by hydrogen peroxide. The air microbial load was weekly monitored in the autumn/winter season after the routinely applied sanitation procedures. Air samplings, through impaction method, were carried out in 3 critical areas (cheese making, storage and packaging). Total bacteria, moulds and yeasts resulted in mean counts of 161 (±154) MPN m−3, 228 (±234) MPN m−3, and 137 (±439) MPN m−3, respectively. The dairy location exhibiting the lowest contamination was the storage cell. A large variability of microbial loads characterized the packaging area. Mycobiota pattern consisted in 11 species of moulds isolated and identified through mycological and molecular techniques. The isolates observed in the indoor air mainly consisted of Cladosporium spp., Alternaria spp., and Penicillium spp.. The yeast community was mainly represented by Cryptococcus spp., Debaryomyces spp., Bulleromyces spp., and Sporobolomyces spp.. Both ozonation and hydrogen peroxide aerosolization were effective techniques in the inactivation of airborne microorganisms. After air treatment only residual fungi were identified. We verified that their occurrence was promoted by environmental recontamination.

Development and testing of the Product Environmental Footprint Milk Tool: A comprehensive LCA tool for dairy products

The paper describes the general structure of the PMT_01 tool developed to assess the environmental impacts of different dairy products as Protected Designation of Origin (PDO) cheeses of Lombardy Region (Po Valley - Northern Italy) and High Quality fresh pasteurized milk in a cradle-to-distribution center gate approach.Based on the PEF Product Environmental Footprint (PEF) methodology, the authors aim to provide a useful instrument for technicians and researchers in the evaluation of the environmental load of dairy products, allowing the process-hotspots identification through 16 different impact categories. The tool requires a modest amount of data that can be easily collected at the farms and at the dairies.In order to test the tool's performance, the environmental impact of 10 g dry matter of Grana Padano PDO cheese was evaluated starting from the data of three different dairy farms used as “reference farming systems” and one dairy factory. A scenario and a sensitive analysis were also included in the study.The main contribution to most of the environmental impact categories was related to the raw milk production while the dairy factory process affected significantly only a few impact categories.The scenario analysis suggested that the anaerobic digestion could have a strong potential in the mitigation of the GHG emissions while the sensitive analysis confirmed that the choice of the allocation method at the dairy factory level is a key point in the methodological choices.Despite the test of the tool was done only on three farms and one dairy factory, the results were consistent with those of recent studies. Even if some improvements in the tool functionalities are needed, we believe that in the future it could be easily applied on a wider sample of farms and dairies, and used to guide the stakeholders through a responsible environmental strategy.

Effect of microbial sanitizers for reducing biofilm formation of Staphylococcus aureus and Pseudomonas aeruginosa on stainless steel by cultivation with UHT milk.

Biofilm is a serious issue in the dairy factory due to it increases the opportunity for microbial contamination. Staphylococcus aureus and Pseudomonas aeruginosa are the bacteria capable to construct the biofilm on materials and equipments. Therefore, the bacterial growth and efficiency of sanitizing agents to solve the problems were evaluated. These bacteria grew well in UHT milk when they were cultivated at 37°C, especially S. aureus. The exponential growth phase and biofilm on stainless steel were discovered by short contact time at 2h. The mature stage of biofilm cycle was found at 4h during bacteria growth and it was continuously constructed until 48h. The 10, 24, and 48h-old biofilm adhering on stainless steel were established with oxisan and chlorine used as microbial sanitizers. The 4% of sanitizing agents was the efficiency concentration to reduce biofilm on stainless steel up to 82% when these bacteria grew in UHT milk.

Industrial Heat Pump Integration in Non-Continuous Processes Using Thermal Energy Storages as Utility – A Graphical Approach

The aim of this paper is to demonstrate a practical methodology for heat pump (HP) integration in non-continuous processes which is not expensive in terms of computation time and resources. Therefore, a methodology is developed based on graphical Pinch Analysis techniques and further on the developed COP Curves. The methodology is applied to an AMMIX butter production of a large dairy factory. It is shown, that by integrating a HP and using thermal energy storages (TESs) to compensate for the non-continuous behavior, the capital cost for the system is approximately reduced by the factor of 2.2. Further, greenhouse gas (GHG) emissions can be reduced with a slight decrease in total annual cost (TAC). However, by considering future natural gas and electricity prices, it is shown that the TAC can be reduced further.

Environmental and Agronomical Aspects of Sludge Produced from Tannin-Based Coagulants in Dairy Industry Wastewater Treatment

A study was carried out of the environmental and agronomic features of the sludge generated by a dissolved air flotation process applying a tannin-based coagulant in a dairy factory. First, the chemical and physical characteristics of the sludge were examined. Subsequently, a solubilization test was performed to evaluate the potential of groundwater contamination after the application of sludge on soil. The data obtained were compared to the United States Environmental Protection Agency (US-EPA) criteria for evaluation and classification of solid residues for land application. The results show that the studied sludge is a non-hazardous waste, and all evaluated parameters are lower than the maximum reference values according to international criteria. Based on the set of parameters which were evaluated, no organic pollutants were found. Additionally, the agronomic characterization shows good potential for agricultural purposes. However, in the solubilization test, chemicals such as phenols, cyanide, nitrate and fluoride were solubilized from the studied residue. As a result, the water showed concentrations above the limits required by the international criteria for drinking water established by US-EPA and World Health Organization. In conclusion, although tannin-based coagulants produce sludge with the potential for agronomic applications, some limits have to be considered to avoid environmental impacts.

Cost price/quality relationship of a strategic product and self-sufficiency challenge in the Algerian dairy sector: The case study of a local dairy industry

Since independence, Algeria has continued to spend massive sums on importing milk powder to satisfy local demand. In recent years, the state has improved several development programs to overcome this situation. Thus, this work aims at studying the cost price/quality relationship of a strategic product for wide consumption (Milk and dairy products) and describing the state subsidy policy regarding the safety of milk. To achieve these objectives, we proceeded on the one hand, to carry out a hygienic quality analysis of 50 samples of packaged pasteurized milk, calculating their cost price at the private dairy factory of Adrar (Algeria) and, on the other hand, to analyze recently published official statistics and the various programs adopted by the Algerian state when defining this policy. According to the results obtained it appears that the state subsidy contributes toward covering the demand of the national market but with a high dependence on the importation of raw material (about 30%). The results of the bacteriological analysis were in the range of thresholds set by the national standard. The analysis of spending data given by the tcr showed that for this factory, the cost price of one liter of pasteurized milk is estimated at 27.79 dzd/l compared a quay-factory fixed selling price at 23.20 dzd/l, revealing a deficit of -3.79 dzd/l (-13.64%), while, produced fermented milk (sour milk) showed a profit of +10.65 dzd/l representing a margin of distribution equivalent to (+37.56%) of the cost price that estimated at 28.35 dzd/l. Nevertheless, it is essential that the state contributes to the training and support of farmers, collectors and the dairy factory, which appear disconnected from the local production sector that supplies it with fresh raw milk; besides, it must focus on typical farms, which seem to be more productive than family small-sized farms. These must come together and form cooperative, not only so as to be in the official circuit but also to be under a hygienic control system in order to avoid any kind of peril to consumer’s health.

Application of methodology for the adequacy of the electrical motor's power sizing: permanent and transient analysis

Abstract The suitability of the motive force contributes to the efficient use of electrical energy. On the other hand, the inadequate size of electric motors is directly connected to increased investment and running costs. This article presents the theory and mainly the application of a methodology for the adequacy of the motive power. The research was conducted at the Federal University of Vicosa dairy factory. This methodology consists in measuring motor rotation, acquiring technical information from the manufacturer's manual, and identifying the type of motor load. In addition, it uses the linearization method to estimate the resistance torque in steady state. This step is achieved without the need for using additional equipment or sending the motor to a laboratory for measuring the torque. In this sense, the studies can be made during the production process. Thus, this relevant methodology has the advantage of allowing the studies to be carried out at the agro-industry facilities. After getting all the information described above, it was possible to determine whether each motor at the factory was oversized. Then, the suitable motor was selected according to the load type. The application of the methodology described herein could provide around 50.6% savings in the monthly electricity costs at the dairy factory, and an attractive internal return rate.

Применение статистических методов контроля для оценки стабильности производства молочной продукции

The article presents the results of an estimation of defectiveness level of sour-milk production (on an example kefir), developed on one of dairy factories of region. To assess the level of defect, statistical methods of control are used - a checklist for the registration of defective products, a control p-chart and Ishikava diagram. The initial data were obtained at the stage of quality control of finished product and entered in the developed form of the control sheet for product defects. The most common defect in the production is established - the leakage of the package, which can be assessed visually, and not with the help of measuring instruments. For evaluation and subsequent analysis of the reasons for the appearance of the established defect, a control p-chart was used on an alternative basis, which makes it possible to control the quality of manufactured products by the number of defective products. As a result of the analysis of the obtained data, it was established that the technological process, from the point of view of statistical forecasting, is acceptable, but this does not mean a high production stability and does not exclude the appearance of defective products. The analysis of the main reasons for the emergence of unsealed packaging products, among them the qualification of personnel, the quality of the used materials and the conditions for their storage, the production environment, compliance with production technology, and others. A subsequent study of the impact of each of these factors will prevent the appearance of defective products and ensure the production of consistently high quality products.

Fundamental characterisation of caseins harvested by dissolved air flotation from dairy wastewater and comparison with skim milk powder

Disposal of milk protein-containing wastewater from the milk industry is of considerable environmental concern. Solid material, including caseins, can be harvested in large quantities from dairy factory wastewater using dissolved air flotation (DAF). DAF-casein is an under-utilised waste product that has potential for added-value products. In this study, the fundamental properties of DAF-casein were compared with skim milk and skim milk powder. The gel electrophoresis protein migration pattern of DAF-casein had a casein profile similar to that of skim milk powder. DAF-caseins differed from skim milk powder in their hydrophobic properties when analysed by reversed phase-high performance liquid chromatography and partitioning in chloroform-methanol. Casein prepared from skim milk by acid coagulation exhibited hydrophobic properties similar to those of DAF-casein, but differed in rheological properties. This indicates that dairy industry cleaning-in-place procedures, combined with DAF processing of the wastewater to generate DAF-casein, cause changes in protein composition and hydrophobic properties.

Environmental Awareness of University Students on White Cheese Waste Water

Universal environmental contamination is a real situation that deteriorates our world step by step. The dairy factory out flowing is the second greatest source of contamination in water streams. The environmental impact of these factories can be very high, especially due to the discharge of wastewater with high content of organic matter and nutrients. These problems can be analyzed only after performing factual study of various physicochemical characteristics. In the presented study, physicochemical parameters like, temperature, pH, COD, TDS, TS and SS were taken into account. Another purpose of this study is to ascertain university student’s awareness and consciousness against general and dairy products related environments. These levels were evaluated by the survey method. The data obtained from the questionnaire were analyzed using SPSS 20.0. Results showed that the public and company owners/ employees in particular should be informed about the seasonal and cheese variety dependent patterns in environmental pollution.

Water quality and resource management in the dairy industry

Food industry is one of the most important and fastest growing sectors of economy in Poland. This sector is also characterized by high demand for the resources, particularly for water. Polish food industrial plants consumed 793 hm3 of water in 2014. Dairy branch had a combined 35% share of the above consumption. As shown by the data obtained from the Polish Central Statistical Office, the majority of dairy plants use its own source of water, so this branch is also important water producer in Poland. Water used for dairy industry should meet the requirements of at least drinking water quality, so the factories need to treat the water. This paper analyses the correlations between selected technical process, equipment profiles and water quality, and consumption in two types of dairy factories (DF). The first one DF-1 processes approx. 50,000 L of milk, and the second, DF-2 processes approx. 330,000 L of milk per day. The water taken from the wells needs to be pre-treated because of iron and manganese concentration and due to specific requirements in various industrial processes. As a result of this work, we have managed to propose technological solutions in the context of water consumption rationalization. The proposed solutions aim at improving water and wastewater management by reducing the amount of consumed water by industry.

Applications of spectroscopic techniques for fat and fatty acids analysis of dairy foods

Fat and fatty acids (FAs) are important quality parameters of dairy foods, characterizing their nutritional value. Efficient routine analyses of their contents are of critical importance for dairy farms and factories. Conventional methods for determining fat and FAs contents of dairy foods are time-consuming, laborious, destructive to samples and often requiring use of hazard solvents, which make it impossible for real-time and on-line measurements. Spectroscopic techniques based on near-infrared spectroscopy (NIRS), Raman spectroscopy (RS), nuclear magnetic resonance (NMR) have been studied extensively for fat and FAs analyses of dairy foods, and promising results have been shown. In this context, this paper summarized the current research progress in application of the three important techniques in predicting fat content and FAs composition of dairy products such as milk, milk powder and cheese. First, the working principles and features of these techniques were described, and then the research advances of each technique for fat and FAs analyses of the dairy foods are presented in detail and the factors influencing their modeling results are discussed. Perspectives on their current situation, future trends and challenges are also discussed.

Energy and Carbon Impact of Precision Livestock Farming Technologies Implementation in the Milk Chain: From Dairy Farm to Cheese Factory

Precision Livestock Farming (PLF) is being developed in livestock farms to relieve the human workload and to help farmers to optimize production and management procedure. The objectives of this study were to evaluate the consequences in energy intensity and the related carbon impact, from dairy farm to cheese factory, due to the implementation of a real-time milk analysis and separation (AfiMilk MCS) in milking parlors. The research carried out involved three conventional dairy farms, the collection and delivery of milk from dairy farms to cheese factory and the processing line of a traditional soft cheese into a dairy factory. The AfiMilk MCS system installed in the milking parlors allowed to obtain a large number of information related to the quantity and quality of milk from each individual cow and to separate milk with two different composition (one with high coagulation properties and the other one with low coagulation properties), with different percentage of separation. Due to the presence of an additional milkline and the AfiMilk MCS components, the energy requirements and the related environmental impact at farm level were slightly higher, among 1.1% and 4.4%. The logistic of milk collection was also significantly reorganized in view of the collection of two separate type of milk, hence, it leads an increment of 44% of the energy requirements. The logistic of milk collection and delivery represents the process which the highest incidence in energy consumption occurred after the installation of the PLF technology. Thanks to the availability of milk with high coagulation properties, the dairy plant, produced traditional soft cheese avoiding the standardization of the formula, as a result, the energy uses decreased about 44%, while considering the whole chain, the emissions of carbon dioxide was reduced by 69%. In this study, the application of advance technologies in milking parlors modified not only the on-farm management but mainly the procedure carried out in cheese making plant. This aspect makes precision livestock farming implementation unimportant technology that may provide important benefits throughout the overall milk chain, avoiding about 2.65 MJ of primary energy every 100 kg of processed milk.

TECNOLOGIAS EMPREGADAS NO TRATAMENTO DE EFLUENTES DE LATICÍNIOS DO VALE DO RIO BRAÇO DO NORTE - SC

Associada à atividade produtiva de laticínios está o grande montante de efluentes gerados no processo de beneficiamento do leite. Pela complexidade de composição, variação nas taxas de produção e variação na própria composição do efluente gerado nesta atividade, a escolha de um sistema eficaz na remoção dos contaminantes ali presentes pode ser bastante complexa. Desta forma, com o presente estudo buscou-se apresentar as técnicas utilizadas em escala global para essa finalidade, e paralelamente traçar um perfil das tecnologias aplicadas pelas empresas de laticínios na região do Vale do rio Braço do Norte, sul de Santa Catarina, bem como demais aspectos relacionados à gestão ambiental dessas empresas. Após levantamento de dados, por meio de pesquisa de campo via questionário e avaliação documental, observou-se que as empresas dessa região aplicam predominantemente sistemas anaeróbios para remoção de matéria orgânica biodegradável, atingindo níveis de remoção dentro da legislação. Contudo, demais parâmetros analisados, como óleos e graxas, pH e sólidos sedimentáveis apresentaram alguns valores fora do preconizado pelos órgãos ambientais. A gestão ambiental das empresas é realizada predominantemente por pessoal terceirizado, deixando evidente a falta de pessoal interno, tecnicamente capacitado para atuar nas empresas.