Dairy Processing Plant Consultancy

1. Process Design & Engineering

• Development of detailed Process Flow Diagrams (PFDs) and mass & energy balance

• Technology selection for cream ripening, butter melting, ghee boiling, clarification, and filtration

• Capacity planning for multiple SKUs: 250 g, 500 g, 1 kg, 15 kg

• Hygienic process zoning and material flow planning to prevent cross-contamination

2. Equipment Engineering, BOQ & Technical Specifications

• Preparation of detailed BOQ and comprehensive equipment lists covering:

  • Processing

  • Utilities

  • Packaging

  • Cold storage

  • Effluent Treatment Plant (ETP)

• Technical specifications and datasheets for major equipment:

  • Ghee boilers

  • Clarifiers

  • Ripening tanks

  • Plate Heat Exchangers (PHE)

  • Packaging lines

• Utility sizing:

  • Steam boiler

  • Electrical load

  • Compressed air

  • Water heating systems

  • DG set and solar integration

3. Plant Layout & Infrastructure Planning

• Equipment layout and plant arrangement drawings as per plot dimensions and statutory setbacks

• Hygienic architectural zoning:

  • Raw material receiving

  • Processing areas

  • Packaging clean rooms

  • Cold storage

  • Utilities and ETP

• Support for PEB + RCC building concepts suitable for food-grade operations

4. Procurement & Vendor Technical Support

• Assistance in vendor finalization and techno-commercial evaluations

• Review and approval of vendor GA drawings, technical compliance, and performance guarantees

• Support during Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT)

5. Installation, Commissioning & Trial Runs

• Technical support during erection, installation, and commissioning of process and utility equipment

• Process validation, performance trials, and production stabilization

• Support to achieve rated throughput and consistent product quality

6. Product Development & Standardization

• Formulation and standardization of Desi Ghee variants:

  • Special grade

  • General grade

  • Export quality

• SOPs for authentic flavor development:

  • Cream ripening

  • Controlled fermentation

  • Heating and clarification profiles

• Yield optimization and quality consistency protocols

7. Regulatory, Statutory & Export Compliance

• Support for:

  • FSSAI licensing

  • Agmark certification

  • MPCB Consents (CTE / CTO)

• Implementation guidance for:

  • HACCP

  • ISO 22000

  • FSSC 22000

• Consultancy for US-FDA, FSMA, EU regulations, and APEDA export compliance

• Clean room and hygienic design compliance as per global food safety standards

8. Packaging, Labeling & Market Compliance

• Development of nutritional labeling and statutory declarations

• Packaging line selection for:

  • Retail packs

  • Bulk packs

  • Export-ready formats

• FIFO-based packaging material storage and handling planning

9. Sustainability & Utility Optimization

• ETP design review and water recycling strategies (up to 70% reuse)

• Energy optimization:

  • Boiler efficiency improvement

  • Solar energy integration

• Waste utilization strategies:

  • Ghee residue to animal feed

  • Fat recovery and by-product management

10. Training, SOPs & Operational Readiness

• Development of:

  • SOPs

  • GMP manuals

  • HACCP documentation

• Training of plant personnel on:

  • Hygiene practices

  • Process control

  • Food safety systems

• Pre-operational readiness audits before commercial production

11. Dairy Consultancy & Financial Closure Support

• Technical and commercial consultancy for dairy processing projects

• Preparation of Detailed Project Reports (DPR)

• Support for bank loan sanction and financial closure

• Coordination with financial institutions and government agencies