Dairy Manufacturing

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Dairy Manufacturing

• Presented By
• Mathieu Angers-Goulet
• Kurt Colling
• Jim Jackson

2
Agenda

• General overview
• Economics
• Equipment and technology
• Quality control
• Products and processes
• Case study
• Conclusion

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When and where it all started?

• History
• - Between 9000 and 8000 BC
• First used as human food (Middle East)
• - Around 7000 BC
• Cattle being herded (Turkey)
• - 1878
• Milk bottles are first delivered (Milk Day)

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Dairy product categories

• -Natural products
• Cream
• Butter
• Yogurt
• Ice cream
• Cheese
• -Industrial products
• Casein
• Whey protein
• Condensed milk
• Powdered milk

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Sources of milk

• Cow
• Goat
• Sheep
• Yaks
• Water buffalo
• Horse
• Camel
• Zebra
• Moose
• Humans

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Dairy cows

• Types of cattle
• Holstein (90 in USA, 80 in Great Britain)
• Ayrshire
• Brown Swiss
• Jersey
• Milking Shorthorn

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World consumption

• -Consumption (USA)
• 83.9 litres of liquid milk
• 16.0 kg of cheese
• 2.1 kg of butter

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Economics

• Statistics (USA)
• Produces 80,150,000 metric tons
• Market value is 21.315 billions
• 65,000 dairy farmers which represents the second
  largest agricultural commodity industry in the
  United States by value.
• The average yearly salary for a dairy director
  is 58,550 (depending on the size and products).

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World production
-United states is the leader for cow milk.
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Dairy farm profile (Massachusetts)
Farmers Days cows are milked 365 days per year
Average operator hours worked 90 per week
Average work day 13.8 hours Number of days
worked 6.5 per week Hourly wage rate 3.65 per
hour Farms Family owned dairy farms 262 Average
herd size 67 cows Milk Production Total annual
production 38 million gallons Consumers served
by an average dairy farm 6,000
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Market

• Price Increasing
• Competition biofuel production vs. feedstocks.
• Price above the estimated prices of the
  financial analysts.
• Demand Increasing
• General increased in worldwide prosperity.
• The continuously increase in China dairy product
  consumption.

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Economic concerns

• Transportation costs due to the increase of oil
  prices.
• Alternative products to milk
• Soy milk
• Rice milk
• Almond milk
• Coconut milk
• - Labor liability and availibility

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Dairy Video

• http//www.youtube.com/watch?vkIbVwE5zb1Y

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Original Hand Milking Processes

• Until the late 1800s, the milking of the cow was
  done by hand
• Milking took place indoors in a barn with the
  cattle tied by the neck with ropes or held in
  place by stanchions.
• With the availability of electric power and
  suction milking machines, the production levels
  that were possible increased but the scale of the
  operations continued to be limited by the labor
  intensive nature of the milking process.

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Modern Milking Parlor Operations

• Milking machines held in place by vacuum. The
  vacuum is also used to lift milk vertically into
  the receiving can
• Milk is extracted from the cow's udder by
  flexible rubber sheaths. The vacuum inside the
  inflation causes the inflation to collapse around
  the cow's teat, squeezing the milk out in a
  similar fashion as a baby calf's mouth
• It takes the average cow three to five minutes to
  give her milk. Slow-milking cows may take up to
  fifteen minutes to exhaust themselves of milk.
  The milker can only process a group of cows at
  the speed of the slowest-milking cow
• The extracted milk passes through a strainer and
  plate heat exchangers before entering the tank,
  where it can be stored safely for a few days at
  approximately 42F

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Milking Shed Layout

• Bail-style sheds About 50 cows an hour can be
  milked in a shed with 8 bales by one person.
• Herringbone Milking ParlorsLarge herringbone
  sheds can milk up to 600 cows efficiently with
  two people.
• Swingover Milking ParlorsThe advantage of this
  system is that it is less costly to equip,
  however it operates at slightly better than
  half-speed and one would not normally try to milk
  more than about 100 cows with one person.
• Rotary Milking shedsThe rotary system is capable
  of milking very large herdsover a thousand cows.
• Automatic Milking shedsCurrent automatic milking
  sheds use the voluntary milking (VM) method. The
  entire process is computer controlled.

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Surge Bucket Milker

• Invented in 1922
• Large roasting pan would hang under the cow
• Natural surging action as the milker moved back
  and forward while milking
• Tug-and-pull movement was similar to the tugging
  and pulling of a calf
• Easy to clean and sanitize
• Increased income by harvesting more milk

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Modern Milking Machine

• The machine includes
• Teat cups that contact the cows teats and
  remove the milk
• Claw where milk pools as it is removed from the
  four teats
• Vacuum tubes that provide vacuum to the teat cups
• Milk tube that removes milk away from the claw
• Vacuum for the machine
• Pulsator that regulates the on-off cycle of the
  vacuum
• Automatic take-off (ATO or detacher) device
  removes machine from cow when milking is
  completed
• Computer system regulates machine and generates
  data about the cow and its milk

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Lely Astronaut A3 robotic milking system

• Robust robot arm controlling entire milking
  process
• 4 Effect pulsation unit for tailor-made milking
• On-line somatic cell count measuring system
• Advanced dairy farm management program
• Maximum cow comfort in spacious robot box

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Advantages

• Elimination of labor - The farmer is freed from
  the milking process
• Increased milking frequency - Milking frequency
  may increase to three times per day. Higher
  frequency milking increases milk yield per cow
• Perceived lower stress environment - Elective
  milking schedules reduce cow stress
• Herd Management - The use of computer control
  allows greater scope for data collection. Farmer
  can improve management through analysis of trends
  in the herd

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Disadvantages

• High initial cost - VMS systems cost
  approximately 120,000 per milking unit
• Low return on investment - A VMS takes longer to
  pay for itself than a conventional parlor
• Increased complexity - Increased complexity of
  the VMS milking unit over conventional systems
  reduces the ability of the farmer to perform
  repairs, increasing reliance on manufacturer
  maintenance services and possibly increasing
  operating costs
• Difficult to apply in pasture systems - VM works
  best in zero-grazing systems, in which the cow is
  housed indoors for most of the lactation period
• Lower milk quality - A high somatic cell count
  (SCC) indicates reduced udder health and implies
  lower milk quality. A high plate loop count (PLC)
  indicates bacterial contamination, usually
  through poor sanitation or cooling and similarly
  implies low milk quality
• Possible increase in stress for some cows - Cows
  are social animals, and it has been found that
  due to dominance of some cows, others will be
  forced to milk only at night
• Decreased contact between farmer and herd -
  Illness may go unnoticed for longer periods and
  both milk quality and cow welfare suffer
• Environmental concerns - Concentration of animals
  in zero-grazing VM systems increases the
  accumulation of excrement that must be collected
  and treated by the farm

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Quality Control

• Inspection and grading activities are carried out
  through four major programs which help to improve
  the quality, manufacture, and distribution of
  dairy products
• 1) Plant Inspections and Equipment Reviews
• 2) Inspection and Grading
• 3) Dairy Product Grades and Quality Control
• 4) Resident Grading and Quality Control

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Plant Inspection

• Inspection and grading services assure the
  quality of dairy products and are offered to the
  dairy industry on a voluntary basis.
• Official approval of a manufacturing plant is a
  prerequisite for grading.
• Only after an inspection shows that a plant has
  substantially met the requirements can the plant
  qualify for the other services of grading,
  sampling, testing, and certification of its
  product.

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Inspection Grading

• Grades are based on nationally uniform standards
  developed by Dairy Programs' experts in
  cooperation with industry representatives.
• Sellers can request grading services to assure
  that products meet specific grade or contract
  requirements and have good keeping quality
  properties.
• Buyers can request grading services to assure
  that products have uniform high quality.

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Dairy Product Grades

• Almost all dairy products can be graded, but the
  service is used most widely for butter, Cheddar
  cheese, instant nonfat dry milk, and regular
  nonfat dry milk.
• For cottage cheese, or any other dairy product
  for which no U.S. grade standards have been
  established, there is a USDA program for official
  quality approval.
• Such products may earn the "Quality Approved"
  rating, which is based on a USDA inspection of
  the product and the plant where the product was
  made.

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Resident Grading

• Resident grading and quality control service is
  available to approved plants.
• This service is a combination of the plant
  inspection, laboratory programs, and inspection
  and grading.
• It provides for quality checks on sanitation,
  grading, and certification of the finished
  product by an inspector stationed at the plant on
  a full-time basis.

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Butter

• Butter is made by churning pasteurized cream.
  Federal law requires that it contain at least 80
  percent milkfat.
• There are three grades for butter U.S. Grades
  AA, A, and B. The ratings are assigned on the
  basis of flavor, body, and color.
• U.S. Grade AA Butter has a delicate sweet
  flavor, with a fine, highly pleasing aroma, is
  made from fresh sweet cream, andhas a smooth,
  creamy texture with good spreadability

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Cheddar Cheese

• Cheesemaking consists of separating most of the
  milk solids from the milk by coagulating with
  safe bacterial cultures and rennet or a microbial
  enzyme. The curd is then separated from the whey
  by heating, stirring, and pressing.
• There are four grades for Cheddar cheese U.S.
  Grades AA, A, B, and C. As with butter, all
  grades may be used in the wholesale trade, but
  only the top grade is used at the retail level.
• U.S. Grade AA cheese has fine, highly pleasing
  Cheddar flavor smooth, compact texture uniform
  color and attractive appearance.

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Milk

• Milk available in stores today is usually
  pasteur-ized and homogenized. Very little raw
  milk is sold today.
• In pasteurizing, milk is heated briefly to kill
  pathogens and harmful bacteria. Then, it is
  rapidly chilled.
• Homogenized milk has been processed to reduce the
  size of the milkfat globules so the cream does
  not separate and the product stays uniform
  throughout.
• The Grade A rating designates wholesomeness or
  safety rather than a level of quality.

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Dairy Facts

• Of all milk products, milk, yogurt, and cheese
  are the best sources of calcium.
• Some milk products contain added sugars.
• Some are high in sodium or fat, especially
  saturated fat, while others are low.
• Although butter is made from cream, nutritionally
  it is a fat and is not in the milk group of the
  Food Guide Pyramid.

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Dairy Facts(continued)

• The Food Guide Pyramid suggests 2 to 3 servings
  each day of food from the milk, yogurt, and
  cheese group.
• Choose a diet low in fat, saturated fat, and
  cholesterol to help reduce the risk of getting
  certain diseases and to help maintain a healthy
  weight.

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Questions?