VISIT REPORT
NANDAN DAIRY, MALEGAON(BK)
(On 21st September 2013)
DEPARTMENT OF MECHANICAL ENGINEERING,
VPCOE, BARAMATI
2013-14
As per instructions and permission given from the honorable Principal of
VPCOE Baramati, Department of Mechanical Engineering had organized one day visit
at “Nandan Dairy” to study the use of boiler in the dairy and different processes related
to milk. Around 76 students of SE mechanical including two staff members visited
“Nandan Dairy” Malegaon(BK), Baramati on 21st September 2013. "BARAMATI
TALUKA SAHAKARI DOODH UTPADAK SANGH MARYADIT", BARAMATI,
well-known for its popular brand ‘NANDAN’ is a cooperative dairy project
established on 1st December 1977 and since then it has achieved many landmarks in
Milk Procurement, Extension, Animal Health, Breeding, Milk Processing, Product
Making and Marketing. At present “NANDAN” has modern 1.5 Lakh Liters/day
capacity dairy plant with modern Packing Unit at Malegaon(BK), Tal. Baramati.
Students had left the college for visit on 21st September2013 at 8.00 am and
reached “Nandan Dairy” plant at 9:15 am. Teachers divided these students into two
batches for the visit. Mr. Bhagavan Dadas was our instructor. Before entering into the
plant he gave an overview of the plant. At 10 am students entered the boiler room. The
total area of the dairy is 35 acres. The dairy produces 43000 packets of milk daily. The
instructor gave us the detailed information about each and every aspect of the boiler,
boiler mounting, accessories and detailed processes on milk from collection to
packing.
Two types of boilers were used there: one is the wood fired fire tube boiler and
another one is oil fired fire tube boiler. The Oil Fire boiler is manufactured in 1985 and
wood fired boiler is manufactured in 2009.
SPECIFICATION OF OIL FIRED FIRE TUBE BOILER
Boiler Manufacturer: - Revotherm
Boiler No. :-MR 11368
Boiler Type:-Fire tube boiler
Boiler fuel: - oil (1000 lit. /day)
Boiler installed:-1985
Working Pressure=10.55 kg/cm2
Two safety valves
Two oil tanks: capacity of each is 1000 liters
Time of operation 14-15 hours per day
Oil temperature: 90-100°C
Efficiency: 70-80%
Photo: Oil Fired Fire Tube Boiler Used in Nandan Dairy Plant.
SPECIFICATION OF WOOD FIRED FIRE TUBE BOILER
Boiler Manufacturer:- Forbe’s Marshall Boiler
Boiler No. :-MR 14820
Boiler Type:-Fire tube boiler
Boiler capacity:- 1.5 ton
Boiler fuel:- Wood(2 ton/day)
Boiler installed:-2009
Working Pressure=10.55 kg/cm2
Two safety valves
Steam temperature=184°C
Boiler runs for 14-15 hours per day
Wood Used: Babhul, neem, 2 tons per day.
Boiler Efficiency:70-80%
Photo: Wood Fired Fire Tube Boiler Used in Nandan Dairy Plant.
Photo: Boilers Used in Nandan Dairy Plant (Front View).
Boiler uses water which is softened by using softener, which reduces its PPM
from 90 to 10 PPM. Both boilers are used to generate steam of temperature 450 K,
maximum Pressure 10 kg/cm2 which is directly used for various processes like
Pasteurization and cleaning of cans. The requirement of steam as a working substance
is either for power generation or for process and space heating in industrial application.
Steam generator or boiler as per Indian boiler act 1923 is a closed pressure used
generation of steam under pressure. A boiler is usually made of steel in which the
chemical energy of fuel is converting by combustion into heat and this heat energy of
product of combustion is transferred to water to produce steam. In case if steam is used
for power generation, it is generated at high pressure and in large quantity due to high
efficiency requirement. The design of such boiler is quiet intricate and it depends upon
the type of fuel use and its capacity.
All students understood the details about operation and the use of boiler and
boiler mountings like water level indicator, feed check valve, safety valve, pressure
gauge, Blow off Cock, accessories and how the steam is used for different purposes.
Students also understood the role of different workers and management in the plant.
Pressure gauge:
A pressure gauge is used to measure the pressure of the steam inside the boiler.
It consists of an elastic metallic type of elliptical cross-section and is bent in the form
of circular arc. One end of the tube is fixed and connected to the steam space of the
boiler and other end is connected to a sector wheel through a link. The sector remains
in mesh with a pinion fixed on a spindle. A pointer is attached to the spindle to read the
pressure on a dial gauge. When high pressure steam enters the elliptical tube, the tube
section tries to become circular which causes the other end of the tube to move
outward. The movement of the closed end of the tube is transmitted and magnified by
link and sector. The magnitude of the movement is indicated by the pointer on the dial.
Photo: Pressure Gauge, Water Level Indicator.
Water level indicator:
It is an important fitting which indicates water level inside the boiler to the
observer. Usually two water level indicators are fit in front of the boiler. The water
indicator shows the level or water in the boiler drum and warns the operator if by any
chance the water level goes below a fixed mark, so that corrective action may be taken
in time to avoid any accident. A water level indicator is used in low pressure boiler. It
consists of three cocks and a glass tube. The steam cock-1 keeps the glass tube in
connection with the steam space and cock-2 puts the glass tube in connection with the
water space in the boiler. The drain cock-3 is used to drain out the water from the glass
tube at intervals to ascertain that the steam and water cocks are clear in operation. The
glass tube is generally protected with a shield. For the observation of the water level in
the boiler, the steam and water cocks are opened and drain cock is closed. In this case,
the handles are placed in vertical positions as shown in photo. The steam enters from
the upper end of the glass tube and water enters from the lower end of the tube. So the
water level inside the boiler will be same as seen in the glass. The rectangular passage
at the ends of the glass tube contains two balls. In case the glass tube is broken, the
balls are carried along its passage to the ends of glass tube and steam out of the boiler
is prevented.
Photo: Safety Valve, Blow off Cock.
Fusible plug:
The main object of the fusible plug is to put off the fire in the furnace of the
boiler when the water level in the boiler falls below the unsafe level and thus avoid the
explosion which may take place due to overheating of the tubes and shell. This plug is
generally fit over the combustion chamber. A fusible plug which is commonly used is
hollow gun metal body screwed into the crown of the boiler grate. Under normal water
level condition in the boiler, this plug covers water which keeps the temperature of the
fusible metal below its melting point. But when the water level in the boiler falls low
enough to uncover the plug, the fusible metal between the plug quickly melts and plug
drops out. The opening is made in such a way which allows the steam to rush water
into the furnace and extinguish the fire. The steam rushing out puts out the fire and
gives warning that the crown of the furnace is in danger of being overheated.
Feed check valve:
The function of the feed check valve is to allow the supply of water to the boiler
at high pressure continuously and to prevent the back flow of water from the boiler
when the pump pressure is less than boiler pressure or when pump fails. A commonly
used feed check valve is fit to the shell slightly below the normal water level of the
boiler. The lift of the non-return valve is regulated by the end position of the spindle
which is attached to the hand wheel. The spindle can be moved upward or downward
with the help of hand wheel as the upper portion of the spindle is screwed to a nut. In
normal working conditions, the non-return valve is lifted due to the pressure of water
from the pump and water is fed to boiler. But when the pump pressure falls below
boiler pressure or if the pump stops, non-return valve is closed automatically due to
pressure of the water from the boiler and prevents the escape of water from the boiler.
Blow-off cock:
The blow off cock is used for dual functions:
1. To empty the boiler when necessary for cleaning, repairs and inspection.
2. To discharge mud and sediments carried with the feed water and accumulated at the
bottom of the boiler.
After visiting the boiler section students observed milk processes section there.
Mr Anil Pimple, inspector of milk process plant gave detailed information about
different types of milk processes carried in “Nandan Dairy”.
Photo: Milk Collection and Filtering.
Pasteurization:
Raw milk has a lot of bacteria, which spoils milk. Some bacteria are harmful to
human beings. Pasteurization kills the pathogens and some of the spoilage organisms.
Ultra high temperature is designed to kill essentially all of the bacteria from the milk.
In processes of Pasteurization; milk is initially boiled and then hold at above 70 0C and
then it is made cold.
After Pasteurization processes milk is transferred to storage tank which is also at
low temperature and then milk is packed on packing machine. Different volumes of
packet like half litre, one litre are packed on automated machine. Collected Packets are
transferred to market.
Photo: Pasteurization of Milk; Control panel and Storage Tank.
Photo: Crate Washer, Packing Machine.
Nandan Dairy is also famous in the production of different types of milk
products with brand “Nandan”.
Photo: Product of Nandan Dairy Plant.
Contact of staff from “Nandan Dairy Plant”
Name of Staff
Post
Contact No.
Mr. Bhagavan Dadas
Boiler Attendant,
9921087249
Mr. Anil Pimple
Dairy plant Inspector
9766749577
List of SE-Mechanical Students for Educational Visit
Batch-A
Sr.
No.
1
Roll
No.
1324001
2
Batch-C
AGLAVE PRAVIN NANDKISHOR
Sr.
No.
38
Roll
No
1324041
MEKALKI SUYASH SUHAS
1324002
ANIKET ARUN SABALE
39
1324042
MOHITE SAGAR VISHWAS
3
1324003
ANKIT MAKDE
40
1324043
MULLA IMRAN VINAYTULLA
4
1324004
BABARE ASHISH BAPU
41
1324045
PAWAR ANMOL HANUMAN
5
1324005
BAGADE YASH PRAMOD
42
1324046
PAWAR HEMANT MAHADEV
6
1324007
BANSODE SAGAR POPAT
43
1324047
PAWAR SWARUP MAHADEV
7
1324008
BHAPKAR NIKHIL SATISH
44
1324048
PUROHIT AMEY AJAY
8
1324009
BHINGARE SADHANA H.
45
1324049
RAJESHIRKE SHUBHAM N.
9
1324010
46
1324050
RAUT MAYUR ARUNRAO
10
1324011
47
1324051
ROKADE AMIT ANIL
11
1324012
BIRADAR SANAND BASWARAJ
DAMALE NITINKUMAR
BHAUSAHEB
DONE ROHIT RAJENDRA
48
1324052
ROKADE NIKHILKUMAR S.
12
1324013
GHARGE RAJKIRAN DILIPKUMAR
49
1324053
SAWANT SURAJ DILIP
13
1324014
GHEWARI PRIYANK PRAKASH
50
1324054
SHEDGE SUSHANT M.
14
1324015
GHODKE BALAJI SUBHASH
51
1324055
SHEJAWAL SHWETA SANJAY
15
1324016
GODGE ASHWINI AUDUMBAR
52
1324056
SHELAR AJIT RAJENDRA
16
1324017
GOLANDE SHIVANI PRAKASH
53
1324058
SHINDE RUTUJA SANJAY
17
1324019
INAMKE SNEHA NITIN
54
1324060
SHINDE SHIVAJI BUVASAHEB
18
1324020
JADHAV GAURAV ANIL
55
1324061
SHINDE SHRUTI SUHAS
56
1324062
SHINDE SNEHAL ANIL
57
1324063
SHINDE SWAPNIL SUNIL
Student Name
Batch-B
Student Name
Batch-D
19
1324021
JADHAV JAGDISH VAIJANATH
58
1324064
SHIRKE RAHUL MACHINDRA
20
1324022
59
1324065
SHITOLE AKASH SHIVAJI
21
1324023
60
1324066
SONAWANE ABHISHEK B.
22
1324024
JAGALPURE RAJAT D.
JAGTAP AKSHAY
CHANDRASHEKHAR
JAGTAP PRATHAMESH RAMESH
61
1324067
TANDALE BALAJI S.
23
1324025
62
1324069
WAGH AKASH RAVINDRA
24
1324026
63
1324070
WAGHOLE CHAITANYA B.
25
1324027
64
1324071
WALA MAYUR HEMANT
26
1324028
KALE PRASAD VIJAY
KALKHAIRE SACHIN
PANDHARINATH
KAMBALE PAURNIMA
BHAGAVAN
KAMBLE RAJESH PANDIT
65
1324072
CHEVALE SUMIT C.
27
1324029
KAZI MOIN ANIS
66
1324073
GADHAVE AJINKYA SHIVDAS
28
1324030
67
1324074
KALAPAHAD RAM ASHOK
29
1324031
68
1324075
KARANDE KIRAN HANMANT
30
1324032
KHATAL ADITYA SHASHIKANT
KULKARNI PURUSHOTTAM
DEEPAK
KULKARNI SWAPNIL SAMARTH
69
1324076
KOLHEWAD PRALHAD BALAJI
31
1324033
LABHSHETWAR GOVIND G.
70
1324077
MHASE SACHIN BAPUSAHEB
32
1324034
LIMBORE SAYALI SANJAY
71
1324078
PATIL ABHISHEK N.
33
1324035
LOKHANDE MAYUR BALASO
72
1324079
POMANE AMIT SURYAKANT
34
1324036
LONDHE PANCHASHILA ANIL
73
1324080
SASTE PRIYANKA B.
35
1324037
MADANE ANANDA MUKUND
74
1324081
SONAR ANURADHA D.
36
1324039
MARKANDE RISHIKESH SATISH
75
1324082
TAPKIRE VIKAS RAMESH
37
1324040
MASKE DIPAK SANDIPAN
76
1324083
WALE GAURI DHARMDAS
List of Staff Members for Educational Visit
Sr.
No.
Name of Staff
Designation
Department
1
Prof. K.M. JADHAV
Assistant Professor
Mechanical Engineering
2
Mr. S. B. MARKAD
Lab. Technician
Mechanical Engineering
Photo: Group of Students, Department staff and two staff from dairy plant at Nandan Dairy
Plant Malegaon(BK), Baramati.
Students Feedback
We, the Students of SE-Mechanical Engineering are extremely thankful to
Honorable Principal of VPCoE, Baramati, Dr S B Deosarkar, Head of Mechanical
Engineering Department Prof. P V Gogte, and staff coordinators of the visit Prof. K.
M. Jadhav and Mr. S. B. Markad for arranging such a visit.
We hope that this visit will help us in our future practical life and bring a
positive change in our thinking and practical behavior regarding engineering
education. Educational visit to Nandan Dairy, Malegaon, Baramati, was very
informative. The guidance of the staff and industrial members was very helpful for all
the students during the entire visit. We request our college to organize such type of
visit in future also to enhance and explore students’ technical skills.
PREPAIRED BY
Mr. P. N. Aglave, Mr. A. A. Purohit,
Prof. K. M. Jadhav
(Staff Coordinator)
Mr. P. R. Jagtap and Mr. S. B. Mhase
(SE-Mechanical Students)