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Design and Development of a Cream Separator (2018-19)

M S Miah
Farm Machinery & Postharvest Process Engineering Division, BARI, Joydebpur, Gazipur, Bangladesh

M Z Hossain
Farm Machinery & Postharvest Process Engineering Division, BARI, Joydebpur, Gazipur, Bangladesh

M N Amin
Farm Machinery & Postharvest Process Engineering Division, BARI, Joydebpur, Gazipur, Bangladesh

M A Hossain
Farm Machinery & Postharvest Process Engineering Division, BARI, Joydebpur, Gazipur, Bangladesh

Abstract/ Executive Summary:

A prototype of cream separator machine was designed and fabricated at Farm Machinery and Postharvest Process Engineering (FMPE) Division, BARI, Gazipur during 2017–2018. The machine was made of a motor, SS rod, SS sheet, and SS bar, etc. Two types of milk sample named control (fresh milk) and treated (fermented) was prepared for churning in the machine for testing. The control milk (cow milk) sample produced ghee of 0.08 kg (1.6% of total milk) from 0.26 kg (5.2%) cream which was derived from 5 kg milk sample after 15 minutes of churning. The treated sample yielded 0.140 kg ghee from 0.160 kg butter which was also derived from 5 kg of milk sample. The fresh milk fat was determined at 3.30% while the amount down to 1.57% when churned in the machine and the separation the efficiency found 52%. However, for the treated milk sample the separation efficiency was 85%, while the fat down from 3.25% to 0.47%. This control sample need 58 kg milk to prepare 1 kg ghee while the treated milk need only 36 kg. This year another type of cream separator was developed, because capacity of previous machine was low compared with the current one. Current cream separator capacity was to produce 10.25 kg cream (Ghee 6.2kg/h) from 180 kg fresh milk per hour. About 3.36% of Ghee can be obtained from fresh milk. The average machine capacity was 180 kg/h. Therefore, the experiment will be continued in the next year.

Keywords: Fabricated cream seperator, Seperation efficiency, Cream

Location: (FMPE) Division, BARI, Gazipur

Start Date: 01-07-2017

End Date: 30-06-2018

Program Area: Farm Mechanization

Commodity: Cream separator

Objectives:

To design and fabricate a cream separator
To study the performance of the cream separator

Methodology:

A cream separator was designed and fabricated in the workshop of FMPE Division in the year of 2017–18. The design was done based on the farmer's practice, literature study in Bangladesh. A field visit was done at Chuadanga in April, 2016–17 to observe ongoing practice for collecting cream. The drawing of the machine was done in SolidWorks 2016 followed by Tut et al. (2010) for machine design and drawing. Machine fabrication: The main components of the machine are motor, blade, power transmission shaft, milk pot and handle. The motor (0.25 hp, single phase, 50 Hz, 2900 rpm) act as the prime mover of the machine. It helps in rotating the blade through the shaft. The shaft is made of Stainless Steel (SS). It is 270 mm long from the clump joined with motor shaft. To maintain the alignment of the shaft a SS flat bar structure of rectangle shape is adjusted and the top of the shaft is inserted to the bore hole at the bottom. The shaft is threaded so that blade can be adjusted at any desired places by nut and hold tight. The blades (2 no.) are also made of SS, 40^otilted from the base, over a linear length of 50 mm. Each blade contains two wing and position as opposite. The blades are enclosed between top and bottom SS flat bar having a gap of 100 mm. The height and diameter of milk pot is 340 mm and 230 mm respectively. The bottom clearance of the blade from the top is 35 mm. New machine fabrication: During 2018-19, we developed another type of cream separator. It has 25 number of rotating disc and made of SS material. It has several kinds of spiral gear to transfer power from the handle to the rotating disc. The cream separator can be operated by manually or motor, which one is preferred by the customer. Activities of different parts of the cream separator were recorded. Milk sample: Two types of replication were done namely treated and control for churning of cow milk sample. The treated samples are prepared by the formation of bacteria in the milk. This was done by simple technique people use for making sour yogurts. This technique is termed as aging, where the milk is subjected to give the fat the required crystalline structure. As a rule, aging takes 12–24 hours. The optimum souring temperature of aging was between 42 ^oC and 44 ^oC. In this case the p^H goes down to 4.5 and the Lactobacilli grow to give a crystalline structure (Routray and Mishra, 2011). In the churning process the milk was violently agitated to break down the fat globules, causing the fat to coagulate into butter grains, while the fat content of the remaining liquid, the buttermilk, decreases. During operation, fat removed from globular to free fat. Water droplets decreased in size during working and should not be visible in properly worked butter. After churning one liter of normal water was added to the sample so that fat become semisolid and easily separable from skim milk. (Fox and McSweeney, 2009; Clark et al., 2009; Walstra et al., 2006) This year we collected 30 kg of milk from a local farmer. The milk was totally fresh, we did not add anything with it. At first, milk need to feed in the bucket of the machine, start to rotate the handle and when RPM of the handle would be 50-60 then open the bucket tap that means allow the milk to come in a rotating disc. Due to high pressure in rotating disc, non-fat milk and cream were separated and come out through two different channels. After separating the cream and non-fat milk, cream need to be cooked until Ghee appeared in the fry span. Determination of TSS: The total soluble solids (TSS) were determined as per method described by Mazumdar and Majumder (2003) using Digital-Bench Refractometer. Before use, the instrument was cleaned and adjusted to zero at 20°C using distilled water. An appropriate quantity of sample of each product prepared was placed on the prism-plate of the refractometer with the help of a glass rod and folding back the cover. For each sample, the instrument was calibrated using distilled water. The reading appeared on the screen was directly recorded as total soluble solids as brix. Determination of p^H: For determination of p^H (hydrogen ion concentration) in the products, a method of AACC (2000) was adopted and digital pH meter was used. Sample solution was taken in the beaker and directly inserted the electrode into the solution. When the first reading was completed, the electrode was wiped with distilled water and dried-up with tissue paper. Similarly, as a continue series, all other samples were determined accordingly. Determination of Fat: The Soxtec™ 2045 extraction unit is a fully automated system for fast and safe determinations of milk fat. For total fat analysis, the Hydrocap filter was transferred from the hydrolysis unit to the extraction unit which then performs the four extraction steps boiling, rinsing, solvent recovery and auto shut down, fully unattended. Determination of protein: The nitrogen present in the sample is converted to ammonium sulphate by digestion at flask with sulphuric acid in presence of a catalyst, potassium sulphate and mercuric oxide. Acid liberated by distilling the digest with sodium hydroxide solution was absorbed by boric acid titrated for quantitative estimation. Separation efficiency (Es): Separation efficiency depends on initial milk fat content and residual fat in the skim. Cream or butter separation efficiency was determined.

Source of Information: Annual Research Report 2018-2019, BARI, Gazipur, Bangladesh

Article Link (Online Journal):

Funding Source:

1.

Budget:

Total Budget (Tk.) :

Achievement/Findings:

A prototype of a cream separated machine was designed, fabricated and installed in Farm Machinery and Postharvest Process Engineering (FMPE) Division, BARI, Gazipur
The control milk sample produced ghee of 0.08 kg (1.6% of total milk) from 0.26 kg (5.2%) cream from 5 kg milk sample after 15 minutes of churning
This year we developed another type of prototype during 2018-19. It capacity higher than previous one. About 3.36 percentage of Ghee was obtained from of fresh milk by using this machine. The machine capacity was 180 kg/h.

Knowledge Management: Report/Proceedings