Tribhuvan University

Institute of Engineering
Western Regional Campus
Department Of Electrical Engineering

A Report
On
Instrumentation II Case Study

Visit Undertaken At
Marshyangdi Hydropower,Tanahun Nepal
Hetauda Dairy Industries, Hetauda Nepal
Kulekhani Hydropower plant, Makwanpur Nepal
Hetauda Diesel power Plant, Hetauda Nepal
Bharatpur Grid, Chitwan Nepal
ABC Noodle Factory, Chitwan Nepal
NEEK Transformer Factory, Hetauda Nepal

Submitted by
Bibash Adhikari(PAS-073BEL209)
Dilli Neupane(PAS-073-BEL-)
Surakshya Pudasaini(PAS-073-BEL-)
Bipin Silwal (PAS-073-BEL-)
Shishir Karki(PAS-073-BEL-)

Submitted to:
"DEPARTMENT OF ELECTRONICS AND COMMUNICATION ENGINEERING"
PASCHIMANCHAL CAMPUS
Lamachaur , Pokhara Nepal
MAGH 2075

Table of content

Preface ............................................................................................................................... i
Acknowledgement ............................................................................................................ ii

• Introduction/Organizations Backgrounds........ ........ ............................................

• Objectives of the Case Study ...................................................................................
• Description Of The Plants And Production ........ .................................................
Hetauda Dairy Industries, Hetauda Nepal
• Problems ................................................................................................................
• Conclusion And Recommendations........................................................................

Preface
As a part of the engineering curriculum and in order to gain practical of knowledge in the field
of Engineering and its applications, we are required to make this case study report on our field
visit to different industries and production areas of Nepal. The basic objective behind doing this
report is to gain knowledge of existing technology, methods, current situation and associated
challenges in these industries. Doing this report helped us to enhance our knowledge regarding
the process of dairy products production, Noodles production, making process of transformers
and power generation using diesel plants and we found that it is better and efficient to produce
the above mentioned products as Nepal is an agricultural country which is best suited for dairy
industries and noodle production as well as diesel plant power production can meet the
demand of electricity in the peak time. But we found that the technology used is somehow
outdated and more scientific, recent and advance technologies could be used so that the cost
of the productions also reduces as well as we get a good quality production.
Acknowledgement

The field programs provide an opportunity to apply previous knowledge, view real examples set
in a worldly framework, and opportunity to be involved, physically, with real situations in the
field. All of this promotes a deeper understanding of the subject being studied and an improved
ability to recall the information and experiences, later, as needed.
It is understood that personal experiences gained by working with "real" world activities and in
"real" settings enhance and improve learning, increasing understanding and knowledge. Since
activities in the field are never limited to one discipline or aspect, they will always broaden
awareness and emphasize connections between ideas and practical realities. Practical
experiences are invaluable and the fact that Western Regional College of Engineering has
always been an outstanding educational leader in higher education is largely due to its long
standing commitment to providing real, hands-on, learning opportunities for its students.
We would like to express our gratitude to the "Department of Electrical Engineering" to provide
the opportunity to go the field and observe the practicality of Electrical/Electronic instruments
and uses of different types of Software in the industry.
Also we would like to thank our HOD Er. Shahabuddin Khan and vice-HOD Er.Menuka Karki for
guiding and co-operating us in various obstacles of ours with attention and care. Also we would
like to thank them for providing the directions without which preparation of this report would
have been a nightmare.

HETAUDA DAIRY INDUSTRIES

Introduction
Dairy products have always been one of the most needed products for consumption all
over the world .In Nepal also the product demands are increasing day by day. The per capita
consumption of milk and dairy products has increased from 53 litres three years ago to 57 litres
in the current fiscal year.But there must be a healthy supply to meet the increasing demand.
Among Nepal’s leading dairy products companies, HDI has the vision to establish a modern
dairy center with capacities to produce pure, healthy and hygienic products for distribution
across the country. From the date of its establishment HDI has been providing safe and healthy
dairy products .The Industry is situated in Hetauda . The factory daily possesses and prepares
20,000 liters of milk products like sweetened condensed milk, pasteurized butter, milk fat
(ghee), flavored milk, curd and other dairy products. HDI is a preferred supplier to other dairy
product manufacturers also.
HDI’s state-of-the-art plant was set up in 2006 close to the highway at Newarpani, Hetauda
(Makawanpur). It was establish under BLC Conglomerate in order to provide best quality dairy
products to the consumers. BLC (Bhuramal Lunkarandas Conglomerate) represents a legacy of
socially-conscious business which has carved out a special position for it in Nepal. Currently,
over a dozen BLC companies are operating successfully in sectors like agro-business, nutrition,
healthcare, specialty manufacturing, education and community development. HDI is one of
them.

Objectives of the Case Study

The main objectives of doing case study is to get acquainted with the use of
instrumentation in real field. So, we research about the design of different designs of
electronics. We were guided to find any problem in existing plant and propose a
design to solve the problem. So, in our case study we propose a design to solve the
problems related to processing of dairy milk.

The objectives of the research are listed below:

1. To gain creative, descriptive, analytical and explanatory understanding of dairy and
noodles production and the technology used.
2. To understand the application of instrumentation system in real field and to observe
application of different types of electrical and electronics instruments in an industry.
3. To find whether there are any problems in the plant.
4. To explore the possibilities of exploiting renewable energy sources in agro based food
processing industries

DESCRIPTION OF THE PLANTS AND PRODUCTION

The Plant can be divided into several production sectors. Each division produces wastewater of a
characteristic composition, depending on the kind of product that is produced (milk, cheese, butter,
milkpowder, condensate). Figure below presents a schematic flow sheet of the main dairy products.
Figure 1: Block Diagram of processing Dairy milk.

PROCESS DESCRIPTION OF EXISTING SYSTEM

First of all, milk is received at the reception from the supplier (farmer) who brings
milk from villages in their can, then it is sent to the weighing scale to weight the
quantity of milk. A small test is done there to check the purity of milk whether it has
contained water or not. It is done with the help of lactometer. Here sample of milk is
taken in a glass filled completely and lactometer is immersed in it, after doing so if
the lactometer shows reading between 27-29, it is confirmed its milk of cow, and if it
shows reading between 29-31 it is buffalo’s milk. Otherwise the milk has impurity if
water in it.
The milk is then sent to a unit called milk chilling unit. Here milk is chilled or cooled
up to 40C. The chilled milk is then standardized with suitable condition. The
standardized milk is now ready to change in any format like making curd, cheese,
cream(ice-cream), paneer, packing of milk by doing some more processes. The
process of making those things from the standardized milk are described below.

1. Milk receiving
In this sector the milk from different sources are collected and stored in large Milk storage tanks.

2. Liquid milk products

In this sector boiling but also fermenting may be used as a means to preserve milk in the absence of
refrigeration facilities. Usually, as a sanitizing method, the vessels for the storage of milk are smoked.
Fermented milk may be used in fermented form but often it is churned so as to produce butter and
buttermilk.

3. Cheese/Whey/Curd
There are about 500 varieties of cheese produced throughout the world. These are classified in nine
major cheese families. These varieties come about as a result of different types of production processes.
The composition of the wastewater of each specific production process varies from variety to variety.
For the purpose of discussing the environmental impact, the production of cheese will be related to the
production of whey. For hard cheeses (Cheddar cheese, Dutch cheese, etc.), the quantity of whey
produced is high and equals more or less the amount of milk used. During the production of other types
of cheeses, such as soft types, the whey production is much lower or there is no production of whey at
all.

4. Butter/Ghee
The technology in use for the making of butter and ghee is closely related to the technology to make
fermented milk. Traditional butter is made from fully soured whole milk that is churned.

5. Milk powder
Milkpowder is made from raw milk, skimmilk or sweet buttermilk. After pasteurization, decreaming etc.
the water from the milk is removed through evaporation.

6. Condensate/Cream/Khoa
For condensed milk and cream, a portion of the water is removed by evaporation. Khoa is produced by
thermal evaporation of milk to 65-70% solid state and serves as base material for a variety of Indian
sweets.
Milk equipments, process and operation in dairy plants:

1. Automation: It is the process or solution to control dairy respective operations,

equipments and lines.

2. Pasteurization: The pasteurizers equipments are used to pasteurization process for heat
treatment of products to kill bacteria and reduce enzymatic activity.

3. Mixing: Mixing is a high complex operation for emulsifying, dispersing, dissolving the
powder and liquid ingredients into a liquid medium.

4. Milk separators: The milk separators are very useful in milk processing plants to ensure
the texture and excellent quality of products and elevated performance of skimming milk by
preventing intake of destructive air.

5. Standardization: The standardization is the main process in milk production whereby the
protein, total solids, fat and solids non-fat have previously separated from a product.

6. Homogenization: The homogenizers is used to perform this operation for achieving a variety of
different results, for improving the taste, texture and viscosity of cream or juice-based drinks, for
preventing a cream line and sedimentation in milk products, for preventing the separation of the whey
in yogurt.

7. Sugar Treatments: It is the process to make low-grade sugar suitable for use in food.
There is various type of sugar treatment performed by milk equipments.

8. Milk tanks: The milk tanks are the main part of the dairy plants used for storing or
receiving raw milk, skimmed milk and cream.

Moreover, these milk processing equipments are helpful to make good quality cheese by
performing various operations like block forming, draining, mellowing, mold filling, liquid filled
cheese, whey handling and pasteurization. Similar to ice cream production, the milk processing
machines are helpful to perform various operations like mix preparation, extrusion, filling,
freezing, handling, hardening, inclusion and at the last packaging. These all advanced hi-tech
machines play the main role for farmers to get leads and success in dairy business.

DESCRIPTION
The new proposed system consists of following major components.

1. Measuring unit
It is the first unit of proposed system. Here the milk from the reception is weighted
using the weighing machine which is controlled by the weight sensor. It works till
there is input(milk) and automatically controlled or cutoff if there is no any input.

2. Lactometer
The weighted milk is then tested whether it has impurity of water or not. Also,
lactometer tests the quality of milk by measuring lactic acid present in the milk. It can
also be digitalized so that everyone can know the purity of milk and the supplier does
not add water to it.

3. Chilling unit
The tested milk thus obtained is now sent to chilling unit, where it is chilled up to
40°C which is suitable temperature for the further processing. Here also we need not to
check temperature time to time because of the use of temperature sensor. If the
temperature tries to fall down below the specified temperature the sensor senses and
inform the microcontroller then microcontroller sends signal to relay to cut out. This
way the sensor and microcontroller work in this unit and no more workers required.

4.Pasteurizer

Pasteurization is a process applied to milk to destroy all the pathogens in each particle
of the milk. It involves a heating of each and every particle of milk to a certain specified
temperature so that all the germs are killed. Some of the pasteurization temperatures are
listed below:
1. 630°C vet pasteurization (30 mins)
2. 720°C high temperature short time pasteurization (15 sec)
3. 890°C high heat shorter time (1.0 sec)
4. 900°C high heat shorter time (0.5 sec)
Here also we have used sensor so that we can get the desired result in specified time
and we can control automatically using the sensor and microcontroller.

5.Cream separator
The pasteurized milk is then send to the cream separator unit where the cream is
separated to give the skimmed milk. Skimmed milk is further used to make flavored
milk, curd, ice-cream etc.

6.Heating unit
The skimmed milk is then sent to heating unit where the milk is further heated to
ensure that there are no germs and finally reached a temperature where the flavor is
added to milk to make it flavoured in one hand and in other hand it is made suitable
for curd making. This all steps are done using the microcontroller and sensor. Here
we use temperature sensor to sense the temperature whether we have reached
optimum temperature or not if it is then automation starts and cutoff step occurs.
These all process can be seen in a signal by using the microcontroller. The cream
obtained from the cream separator is then subjected to heating unit to separate out the
butter and ghee separately. They are then finally packed in packing unit which is
described in further section.

7.Acid adder
Acid adder is a process of adding acid to the hot milk after certain cooling. Here
mainly we are using lactic acid bacteria which reacts with casein contained in milk to
give a ppt. the process involve is fermentation process. The amount of acid required
and the suitable temperature is given by the sensor used and automatically it is
happened.

8.Printing and sealing

This unit is used to print the logos and level of bags used to pack the product. The
appropriate size required is monitored by the length sensor and the bags are printed
and sealed at the interval.

9.Cutting unit
The packed product after finding out the length and filled product and is sealed it is
cut or separated from the adjacent packet. The collector(worker) then collect the
packet to mark the manufactured date and expiry date. After that the product is ready
for selling.
10.Weight sensor

While the product is obtained from the processing and during the packing the
weight sensor works to give the exact amount of the product to be packed. It is also
controlled by the microcontroller. The microcontroller gives information to the sensor
to give the exact quantity of the product.

11.Microcontroller
The microcontroller used for the new proposed scheme is the 8255A. the
sensors at the various check points senses the signal and fed the signal to the signal
conditioner, the conditioned signals are then converted to the digital equivalent to
process in the microcontroller. The microcontroller then generates an appropriate
signal to govern the controller via Relays.

POSSIBLE IMPROVEMENTS:
1. The milk has to be carried upstairs to feed the chilling unit. An
automatic system can be made to carry the milk to the top.
2. An ac motor can be replaced by a dc motor to obtain the smooth and precise speed
control.
3. Precipitated products after boiling milk can also be utilized to make some other
secondary products.
4. Conventional technique may also be applied for acid adder (quality improvement).
5. Lactometer can be kept within the measuring container.

COST BENEFIT:
➢Using sensors, ADC, timer, relay, microcontroller, computer and other equipments
with professional supervision it is estimated about 2,00,000 rupees will cost to
implement all these automated systems.
Reduced operating cost after modification:
1. Modification in carrying milk will reduce at least 2 people with automated control
mechanism.
So, cost reduction per month = salary of a person * 2
= Rs 5,000*2=Rs 10,000/-

2. Reduction of lactometer spacing will save cost of pipes.

3. Due to inaccuracy in rpm of ac motor, the curd may not be stirred properly. But with
the use of dc motor, the stirring can be done perfectly which saves time and effort.
Therefore, total cost saved per day=Rs 50/-
And the total cost saved per month= Rs 50*30= Rs 1500/-

4. When the bacteria of the prepared curd are reused instead of acids, the cost for acid
can be eliminated.
Cost saved per day = Rs 1,000/-
So, cost saved per month = 1,000*30 = Rs 30,000/-

5. We can get Profit by selling the precipitated products although new components are
required for packaging it.
Profit per month = per month selling – packaging cost
=1,00,000 – 50,000
=50,000/-
Now, Cost saved per month=Rs. (10,000+1500+30,000)
=Rs. 41,500/-
Profit per month from precipitated products=50,000
So, total saving per month= Rs. (41,500+50,000)
=Rs. 91,500/-
Since our Implementation cost is Rs. 2,00,000/- it will be returned back within about
two to three months.

Feasibility analysis:
For implementing the modification in the plant, following feasibility analysis were
Done:
1. Economical feasibility:
The following two methodologies are used in the economic evaluation of the system:

a. Technical feasibility:
The equipments that we have proposed in this new system are easily available in the
local shops. These equipments can be easily implemented and they also robust enough
to be used in the plant.

b. Operational feasibility:
Use of the modern equipments like microcontroller, ADC, sensors, timers, etc. very
friendly to use and makes the system more efficient and effective.

Other benefits:
Our new proposed system has following benefits:
➢The machine can be used more easily and efficiently.
➢After automation only 2-3 person can control the whole plant.
➢New products also can be made.
➢The uniformity in production can be obtained by the use of our automation system.
➢Production of the factory can be increased since the machine operates automatically.

Drawbacks of our system:

There are some drawbacks of our proposal system. They are as follows:
➢There is the need of trained manpower as our proposed system is based on modern
instruments.
➢There is the need of modern and expensive instruments which may increase the cost.
➢It takes quite longer time to pasteurize the milk using conventional techniques.
➢Repair and maintainance has to be done by trained persons.
➢The instruments like sensors, ADCs, microcontroller, etc. need to be done by trained
person.

CONCLUSION:
In Nepal, classical methods are being implemented in the manufacturing sectors.
Replacing those methods by new and modernized techniques is necessary for the
efficient production. The use of modern instruments like ADCs, sensors,
microcontroller, etc. can improve the production rate and quality too. Moreover, it too
reduces the human effort and saves time due to its easing controls.
In our visit we encountered many primitive methods for the operations and we have
noted some useless techniques too. They also haven’t modernized some parts with the
new computer technology. As a result, large numbers of manpower are applied which
increases the operating or manufacturing cost. Also, there were some parts of the
plant which are left unused either due to their improper functioning or lack of trained
manpower. The precipitated milk products are also thrown out which can be used
better in the utilization of other products. So as a technical student we proposed the
new system which will ultimately change the production rate, cost and efficient
operation. Hence our proposed theory can be feasibly applied by the plant.
From this visit we got a lot of information on the manufacturing processes of
industries. Also, we got a chance to be familiar with many technical characteristics of
the industries and their products. This helped us to extend our knowledge and
information on the automation sectors and somehow make us liable for proposing the
better system which applied our theoretical knowledge practically.