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Seminar onDairy Plant Maintenance

Name:- Shamim HossainRoll:- DT-18/12Course:- DT-4712Submitted to:- PROF. S.K.GANGOPADHYAY

West Bengal University of Animal and Fishery Sciences1

Introduction: The determination of plant efficiency at all essential points of the process is the first step in creating a maintenance system which is fundamental to achieving optimal performance in any milk plant. Maintenance section is a very important section in any dairy plant mainly high capacity plant. Maintenance schedule should be designed and maintained to optimize the overall plant performance.

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Types of Maintenance:M

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Preventive Maintenance

Periodic Maintenance

Predictive MaintenanceCorrective

Maintenance

Breakdown Maintenance

Maintenance Prevention 3

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Preventive maintenance:

It is a daily maintenance (cleaning, inspection, oiling and retightening), design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis, to measure deterioration. It is further divided into --1. Periodic maintenance2. Predictive maintenance

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1. Periodic maintenance (Time based maintenance-TBM) which consists of periodically inspecting, servicing and cleaning equipment and replacing parts to prevent sudden failure and process problems.

2. Predictive maintenance is a method in which the service life of important part is predicted based on inspection or diagnosis, in order to use the parts to the limit of their service life. It manages trend values, by measuring and analyzing data about deterioration and employs a surveillance system, designed to monitor conditions through an online system.

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Objectives of Preventive Maintenance1. Increase the efficiency and improve the performance of all

processing and auxiliary equipment.2. Increase the overall productivity of the entire plant by

achieving coordinated and continuous operation of all plant equipment.

3. Increase the certainty of meeting daily production schedule.4. Reduce unscheduled downtime.5. Reduce costs of maintenance and repair.6. Reduce overall processing costs.7. Reduce utility usage.8. Reduce Bio-chemical Oxygen Demand (BOD) of sewage.9. Minimize property and personal hazards.10. Conserve raw materials.11. Conserve fuel.

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Element of Preventive maintenance1. Planning and scheduling2. Proper installation3. Periodic inspection4. Planned lubrication5. Adjustment of machines and instruments6. Replacement of worn and damaged parts7. Recording and reporting observations, adjustments, repairs, and

replacements8. Periodically reviewing records on inspection, lubrication, repairs and

performance of equipment9. Keeping an adequate supply of spare parts10. Determining maintenance costs11. Cleaning and painting equipment and buildings12. Inspection and maintenance of all emergency, personnel and plant

protective equipment13. Maintaining full serviceability of all utilities

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Advantages of Preventive Maintenance1. Less production interruptions2. Fewer large-scale repairs3. Less raw material and product spoilage4. Increased life expectancy of equipment5. Less standby equipment needed6. Identification of items with high maintenance costs

leading to investigation and correction of causes, such as misapplications, operator abuse or obsolescence

7. Better spare parts control, greater work safety and lower manufacturing cost.

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Preventive maintenance programme (PMP)

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• The first comprises collecting and recording all basic information on machines and installations: the equipment records of the plant.

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• The second comprises identification of inspection objectives, frequency and location, and is known as the Inspection Schedule.

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• The third part of the PMP procedure is the action which starts with the analysis of the records and is followed by decisions on what must be done, by whom, when and by what means.

4• The last component of the action part of the PMP is the

maintenance cost estimate.9

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Corrective maintenance

It improves equipment and its components so that preventive maintenance can be carried out reliably. Equipment with design weakness must be redesigned to improve reliability or improving maintainability.

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Breakdown maintenance

It means that people wait until equipment fails and repair it. Such a thing could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost.

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Maintenance prevention It indicates the design of new equipment. Weakness of current machines is sufficiently studied and is incorporated before commissioning new equipment.

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Lubrication System Lack of lubrication is one of the principal causes of equipment breakdown. The best solution is to have a regular lubrication schedule, and perhaps a lubrication chart for each machine, setting the frequency of lubrication, type of lubrication needed, and places to be lubricated. Modern equipment calls for certain types of lubricants for certain types of bearings e.g. light, high speed bearing will require a light oil, whereas a heavy duty, low speed bearing will require heavier oil

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Benefits of Lubrication

1. Less production downtime (because fewer breakdowns) with all its related in-plant savings and customers' benefits.

2. Fewer major overhauls, hence less costly repair bills.3. Fewer repetitive repairs.4. Less spoilage and product waste, hence a factor in better

quality control.5. Postponement or elimination of cash outlays for premature

replacement of physical plant and/or equipment/ because of better conservation of assets and increased life expectancy.

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6. Requirement of less standby equipment thus reducing capital investment.

7. Shift from inefficient “breakdown” maintenance to less costly scheduled maintenance/ hence better work control and saving due to

8. Less plant outage and reduced maintenance costs.9. Better spare parts control, leading to minimum inventory yet

having appropriate spares at hand when needed.10. Greater safety for workers and improved protection for

plant.11. Reduced utility and fuel costs.12. Lower unit costs of manufacture.13. Greater certainty in meeting production schedules.

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