New Full-Automatic Small Cheese Making Plant Production Processing Line for Dairy Factory
A cheese making plant is a facility designed for the production of various types of cheese, from the reception of raw materials through processing, aging, and packaging. The setup and operation of a cheese plant involve several stages, each critical to ensuring the quality, safety, and distinct flavors of the final product. Here's an overview of the key components and processes in a typical cheese making plant:
1. Reception and Storage• Milk Reception: Milk, usually from cows, goats, or sheep, arrives at the plant either in bulk tanks or tanker trucks. It's tested for quality parameters such as fat content, protein, pH, and bacterial counts.• Storage Tanks: The milk is transferred into refrigerated storage tanks to maintain freshness until it's ready for processing.
2. Preparation and Pasteurization• Standardization: Milk is often standardized to achieve a consistent fat-to-protein ratio for different cheese types.• Pasteurization: Milk is heated to a high temperature and then cooled rapidly to kill harmful bacteria. Two common methods are High Temperature Short Time (HTST) and Ultra-High Temperature (UHT).
3. Cheese Making Process• Coagulation: Depending on the cheese type, rennet or other coagulants are added to the milk to separate curds (solid part) from whey (liquid part).• Cutting and Cooking: Curds are cut to release more whey, then cooked (heated) to further expel moisture and develop texture.• Draining and Pressing: Curds are drained and sometimes pressed into molds to form the cheese shape and remove excess whey.
4. Salting and Ripening• Salting: Salt can be added directly to the curd or the surface of the formed cheese for flavor and preservation.• Ripening/Aging: Cheeses are aged in controlled environments with specific humidity and temperature conditions. The duration varies widely, from a few days for fresh cheeses to years for hard varieties.
5. Packaging and Storage• Packaging: Once the cheese has matured, it's packaged in materials that preserve its quality and extend shelf life.• Cold Storage: Packaged cheese is stored in cold rooms until distribution.
6. Quality Control and Testing Throughout the process, samples are taken for microbiological, chemical, and sensory analysis to ensure food safety and adherence to quality standards.
7. Waste Management Efficient management of whey and other byproducts is crucial. Whey can be processed for use in other food products, animal feed, or even as a sports supplement.
Equipment Involved
A cheese making plant includes a range of specialized equipment such as:• Milk reception and storage tanks• Pasteurizers• Cheese vats for coagulation and cutting• Curd handling and draining equipment• Cheese presses• Salting equipment• Aging rooms• Packaging machinery• Quality control laboratories
Setting up a cheese making plant requires careful planning, adherence to food safety regulations, and a deep understanding of cheesemaking techniques and technology. Expertise in dairy science and engineering is also crucial to ensure efficient operations and the production of high-quality cheese.
Plate pasteurizer(3 sections)
Technical parametre: 5
ºC→65
ºC(homogenization)
→85~95
ºC(15S)
→5
ºC
This unit can be connect with separator, homogenizer, flash evaporator & degasser ect. this unit is used as Pasteurizer (widely used in fresh milk, milk beverage, juice, tea, alcohol, ice cream ect.) ,and also pre-sterilize material when producing Pasteurized milk(long life milk).
This machine has features of high heat recovery, lower energy cost, strict design on the construction and easy operation, simple maintenance.
Control type:
Full-automatic control
(PLC with touch screen),
Semi automatic PID Control.
Standard attachments:
A. Plate heat exchanger;
B. Material-balance bucket;
C. Hot water-balance drum;
D. Hot water pump;
E. Product pump;
F. Steam & water mixer;
G. Electricity box;
H. Stainless steel pipes and valves etc.
I. PLC and color touch screen;
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Material
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SUS304/316L
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Capacity
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1-20TPH
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Power
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18-60KW
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External dimension(mm)
(L*W*H)
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|
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Weight
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800kg-1200kg
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Equipment name
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Cheese processing machinery
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Production capacity: 500L-20T/H
Condition: New
Brand name: Shanghai Beyond;
Type: whole processing Line/turnkey project/fruit and vegetables processing/dairy processing/beverage processing
Voltage: 220v/380v
Power(W): 100-200kw
Weight: Different size different weight/customized
Dimension(L*W*H): Different size different dimension/customized
Certification: CE&ISO
Warranty: 12 months/1 year
After-sales Service Provided: Engineers available to service machinery overseas
Main material: SUS304 or SUS316
Control type: automatic, semi-automatic
energy consumption: Low consumption with high efficiency
capacity: 500-10000L/H-customized
installation period: 1-3months
Period time: 30 days-120 days
Cups material: pouches, paper box, glass bottle, pet bottle, glass bottle
Product storage condition: room temperature; low temperature;
Related machinery of dairy(cheese, butter, milk, yoghurt,cream) processing line
Large outdoor storage tank, agitator tank, jacket tank, ferment growing tank, emulsification tank, milk weighing, milk receiving/collecting, extracting, pasteurizer yoghurt, UHT, HTST pasteurizer, plate pasteurizer, tubular UHT sterilizer, spraying type pasteurization, cooling tunnel, bottle tilting sterilization chain, CIP cleaning system, full-auto CIP, semi-auto CIP, evaporator, curd cutting, whey draining, cheese making, scalding/stretching/molding, cheese vat, mozzarella cheese, cheddar cheese, blending system, pre-pasteurization, cream separator system, powder melting, dissolving system, homogenizer system, turn-key project.
Installing and debugging a cheese processing line involves a series of meticulous steps to ensure that every component operates efficiently and safely, producing high-quality cheese products.
Below is a comprehensive guide to this process:
1. Site Preparation and Layout Planning• Area Selection: Identify a clean, well-ventilated area within the facility that accommodates the cheese processing line's spatial requirements and adheres to local hygiene regulations.• Infrastructure Assessment: Confirm that electrical, water supply, drainage, and waste disposal systems meet the equipment's specifications.• Layout Design: Plan the layout to optimize workflow, minimize cross-contamination risks, and allow for easy cleaning and maintenance.
2. Unpacking and Inspection• Equipment Arrival: Receive and carefully unpack all machinery and components, checking for any damages during transit.• Component Inspection: Thoroughly inspect each piece for defects, ensuring they match the order specifications and are compatible with the site layout.
3. Assembly and Installation• Assembly: Follow the manufacturer's instructions to assemble each machine or module. This may include installing frames, conveyors, mixers, vats, presses, and cutting equipment.• Pipeline and Electrical Connections: Connect all pipelines for milk supply, CIP (Clean-in-Place) systems, and drainage, ensuring leak-proof seals. Wire electrical systems per the electrical plan, including control panels and sensors.
4. Calibration and Settings• Instrument Calibration: Calibrate temperature gauges, flow meters, and other sensors to ensure accuracy.• Machine Settings: Configure each machine's operating parameters based on the intended cheese types and recipes.
5. Testing and Debugging• Individual Machine Testing: Power up each machine separately to check for any malfunctions, abnormal noise, or leaks.• System Integration Testing: With all machines connected, conduct a dry run simulation to test the integration between different units without actual cheese processing.• Water/CIP Testing: Perform a test run with water to simulate cleaning cycles, ensuring CIP systems function correctly.• Sanitization: After testing, thoroughly sanitize all equipment before introducing any ingredients.
6. Product Trial Run• Initial Batch Production: Under controlled conditions, produce a small batch of cheese to assess the line's performance, including temperature control, mixing, draining, pressing, salting, and forming.• Quality Control: Analyze the trial batch for taste, texture, and consistency, adjusting processes as needed.
7. Optimization and Fine-Tuning• Process Adjustments: Based on trial results, fine-tune process parameters like temperature, timing, and ingredient ratios to optimize cheese quality.• Training: Provide staff with comprehensive training on operating procedures, cleaning routines, and safety protocols.
8. Documentation and Compliance• Operating Manuals: Compile updated operation and maintenance manuals, including troubleshooting guides.• Regulatory Compliance: Ensure all installations comply with local health codes, food safety regulations, and environmental standards.
9. Final Acceptance• Performance Evaluation: Conduct a final assessment to confirm that the cheese processing line meets all performance specifications and quality standards.• Handover: Officially transfer the responsibility of the operational line to the facility team, with all necessary documentation and warranties in place.
Throughout the installation and debugging process, close collaboration with the equipment supplier's technical support team is crucial to address any issues promptly and ensure a successful installation.
The use of different types of cheese production and related equipment:
1. Mozzarella cheese production line
1.1 Case Background
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Customer: A traditional cheese producer in Italy
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Product: Mozzarella cheese
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Production capacity: 5 tons per day
1.2 Production Process
One
Raw milk receiving: Receive fresh raw milk from cooperative farms.
Two
Inspection: Conduct quality testing on raw milk to ensure compliance with standards.
Three
Standardization: Adjust the fat content to meet product standards.
Four
Heating: Heat the raw milk to the appropriate temperature.
Five
Solidification: Add rennet to solidify the cheese.
Six
Cutting: Cut the solidified cheese into small pieces.
Seven
Heating and stirring: Heat and stir the cut cheese pieces to form a filamentous structure.
Eight
Molding: Place the shredded cheese into a mold to shape it.
Nine
Cooling: Cool the formed cheese to a suitable temperature.
Ten
Packaging: Pack the cooled cheese.
Eleven
Storage and transportation: Store finished products in refrigerated warehouses and transport them to sales points.
1.3 Key equipment
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Heater: used to heat raw milk.
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Solidification tank: used for solidifying cheese.
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Cutting machine: used for cutting solidified cheese chunks.
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Heating mixer: used for heating and stirring cheese chunks.
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Molding machine: used to shape cheese.
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Cooler: Used for cooling cheese.
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Packaging machine: used for packaging cheese.
2. Cheddar cheese production line
2.1 Case Background
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Client: A large dairy company in the United States
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Product: Cheddar cheese
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Production capacity: 10 tons per day
2.2 Production Process
one
Raw milk receiving: Receive fresh raw milk from cooperative farms.
two
Inspection: Conduct quality testing on raw milk to ensure compliance with standards.
three
Standardization: Adjust the fat content to meet product standards.
four
Heating: Heat the raw milk to the appropriate temperature.
five
Solidification: Add rennet to solidify the cheese.
six
Cutting: Cut the solidified cheese into small pieces.
seven
Drainage: Drain the whey from the cut cheese pieces.
eight
Stacking: Stack the cheese blocks that have been whey free to promote further whey excretion.
nine
Slicing: Slice the stacked cheese pieces.
ten
Salting: Salting sliced cheese pieces.
eleven
Molding: Put the salted cheese chunks into a mold to mold.
twelve
Squeezing: Squeezing the formed cheese pieces to make them compact.
thirteen
Maturity: Place the pressed cheese into the maturation chamber for maturation.
fourteen
Packaging: Packaging mature cheese.
fifteen
Storage and transportation: Store finished products in refrigerated warehouses and transport them to sales points.
2.3 Key Equipment
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Heater: used to heat raw milk.
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Solidification tank: used for solidifying cheese.
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Cutting machine: used for cutting solidified cheese chunks.
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Drainage trough: used for draining whey.
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Stacker: used for stacking cheese chunks.
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Slicer: used for slicing cheese chunks.
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Salinization machine: used for salinization treatment.
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Molding machine: used to shape cheese.
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Squeezing machine: used for squeezing cheese chunks.
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Maturation Room: Used for cheese ripening.
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Packaging machine: used for packaging cheese.
3. Blue cheese production line
3.1 Case Background
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Customer: A high-end cheese producer in France
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Product: Blue striped cheese
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Production capacity: 2 tons per day
3.2 Production Process
one
Raw milk receiving: Receive fresh raw milk from cooperative farms.
two
Inspection: Conduct quality testing on raw milk to ensure compliance with standards.
three
Standardization: Adjust the fat content to meet product standards.
four
Heating: Heat the raw milk to the appropriate temperature.
five
Solidification: Add rennet to solidify the cheese.
six
Cutting: Cut the solidified cheese into small pieces.
seven
Drainage: Drain the whey from the cut cheese pieces.
eight
Molding: Place the cheese chunks that have been whey free into a mold to mold.
nine
Piercing: Piercing holes in formed cheese pieces to facilitate mold growth.
ten
Mold inoculation: Spray mold spores onto the surface of cheese.
eleven
Maturity: Place the inoculated cheese in the maturation chamber for maturation.
twelve
Packaging: Packaging mature cheese.
thirteen
Storage and transportation: Store finished products in refrigerated warehouses and transport them to sales points.
3.3 Key Equipment
•
Heater: used to heat raw milk.
•
Solidification tank: used for solidifying cheese.
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Cutting machine: used for cutting solidified cheese chunks.
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Drainage trough: used for draining whey.
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Molding machine: used to shape cheese.
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Piercing machine: used to pierce holes on cheese chunks.
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Mold inoculation machine: used for spraying mold spores.
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Maturation Room: Used for cheese ripening.
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Packaging machine: used for packaging cheese.
4. Soft cheese production line
4.1 Case Background
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Customer: A small boutique cheese producer in Denmark
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Product: Soft cheese (such as Brie cheese)
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Production capacity: 1 ton per day
4.2 Production Process
one
Raw milk receiving: Receive fresh raw milk from cooperative farms.
two
Inspection: Conduct quality testing on raw milk to ensure compliance with standards.
three
Standardization: Adjust the fat content to meet product standards.
four
Heating: Heat the raw milk to the appropriate temperature.
five
Solidification: Add rennet to solidify the cheese.
six
Cutting: Cut the solidified cheese into small pieces.
seven
Drainage: Drain the whey from the cut cheese pieces.
eight
Molding: Place the cheese chunks that have been whey free into a mold to mold.
nine
Salting: Salting the formed cheese pieces.
ten
Maturity: Place the salted cheese in the maturation chamber for maturation.
eleven
Packaging: Packaging mature cheese.
twelve
Storage and transportation: Store finished products in refrigerated warehouses and transport them to sales points.
4.3 Key equipment
•
Heater: used to heat raw milk.
•
Solidification tank: used for solidifying cheese.
•
Cutting machine: used for cutting solidified cheese chunks.
•
Drainage trough: used for draining whey.
•
Molding machine: used to shape cheese.
•
Salinization machine: used for salinization treatment.
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Maturation Room: Used for cheese ripening.
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Packaging machine: used for packaging cheese.
Success factors
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Equipment selection: Choose high-quality equipment that meets production needs.
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Process optimization: Continuously optimizing the production process to improve production efficiency and product quality.
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Quality control: A strict quality control system ensures product quality at every stage.
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Environmental protection: Take measures to reduce wastewater and exhaust emissions and protect the environment.
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Employee training: Regularly train employees to improve their operational skills and safety awareness.
A typical Small Cheese Making Plant equipment customization solution includes a full chain equipment configuration from raw material receiving, pretreatment, standardization, pasteurization, fermentation, coagulation and cutting, whey discharge and shaping, salting and aging to packaging. The selection and layout of each type of equipment need to be carefully planned based on actual production needs and space conditions to ensure smooth and efficient production processes and compliance with food safety standards.
To help you further refine the plan, we suggest the following steps:
•
Clarify production scale and product type: Determine the type of cheese you want to produce and the expected output, which will directly affect equipment selection and production line design.
•
Evaluate existing space and budget: Consider your factory area, height, and investment budget, which can limit the size and complexity of equipment.
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Consulting professionals: Contact cheese production equipment suppliers or hire industry consultants who can provide professional customization advice and optimize design solutions based on your specific situation.
•
Consider future development: Reserve expansion interfaces in the initial design to facilitate future production capacity increase or product line expansion.
Pre sales services
After-sale service
1. Equipment warranty period: We provide a one-year free warranty service for mechanical equipment. If any non-human caused problems occur during the warranty period, we will provide free repair or replacement services.
2. Maintenance and upkeep services: We provide regular or irregular equipment maintenance and upkeep services to ensure the normal operation of the equipment. We will provide 24-hour online technical support services.
3. Accessory supply: We guarantee to provide original factory accessories in a timely manner in case of equipment damage or replacement of parts.
4. Training services: In order to enable customers to effectively operate and maintain equipment, we will provide equipment operation and maintenance training.
5. Installation and debugging: We will provide equipment installation and debugging services to ensure that the equipment is installed correctly and can operate normally.
Company Profile
Our Service
Trade shows
Certificate
FAQ
1 ) Q: How can we visit your factory?
A: If you come from abroad, air to shanghai airport, then we can pick you up at airport.
2) Q: How do you ensure the quality of your products?
A: Our Company is a state owned enterprise with more than 16 years experience , strict operation policy is performed, advanced processing machines guarangtee the precision of all components, workers with operation license, parts get multiprocessing, transmission& electrical parts are of international famous brand. Series of test and inspection are done in the whole producing state.
3) Q: What payment methods your company accept?
A: We accept most of the payment methods , but mainly accept T/T, L/C at sight .
4) Q: How long is the warranty time for your products?
A: Our officially promised warranty time is 12 months after commissioning .
5) Q: I am new in this field,can you supply us turnkey services?
A: YES.We can supply all the system including Market Analysis/Product Analysis/Location Choice/Processing Flow Design/Equipment Layout Design/Building Design direction/Equipment mode selection/Equipment Manufacturing/Equipment Mounting/Equipment Debugging/Worker Training.
6) Q: What ' s the shipment terms and delivery time of your company?
A: Well, the delivery time depend on the quantity of your order. Usually is 20 days . For some customized machine 30 days is necessary.
7) Q: Can you supply OEM services?
A: Yes,we have our R&D team,and we have more than 400 workers with workshop area 75000 square meters.
8) Q: Do you give any Discount?
A: I will surely try my best to help you get those by the best price and good service at the same time.
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