About SARAS DAIRY

Towards fulfillment of the national objective of making India self-sufficient in milk

production, a small step was taken in March 1975 and Jaipur Zila Dugdh Utpadak
Sahakari Sangh Ltd., Jaipur (popularly known as Jaipur Dairy) was registered under
Cooperative Act 1965 to work in then Jaipur District. Initially this union did not have the
processing facilities. It started with a modest beginning of procuring 250 liters of milk
per day.

The initial handling capacity of the dairy plant was 1.5 Lakh Lt. per day with a powder
plant of 10 MT per day capacity, which was commissioned in the year 1981 under
Operation Flood Program 1 by National Dairy Development Board for service of
thousands of rural farmers families of Jaipur.

Over the years, there has not been looking back for Jaipur Dairy and the significant
growth has been made in all fields i.e. procurement, processing and production of
various milk and milk products and marketing thereof under the brand name of
SARAS. The plant is managed and operated by well-qualified, competent and
experienced managerial cadre and highly motivated work force to provide highest
quality of products and best of the services to our esteemed customers.

To further improve the efficiency and effectiveness of the plant performance, Jaipur
Dairy (Jaipur Zila Dugdh Utpadak Sahakari Sangh Ltd., Jaipur) had earlier obtained
the Quality Management Systems Certification as per ISO 9002:1994 in combination
with IS: 15000 (HACCP) in the year 2000. Now the dairy has upgraded the system in
accordance with ISO: 9001: 2000 in combination with (HACCP) as per IS: 15000:
1998.

The various products produced by Jaipur Dairy are different toned milk,
curd,butter,ghee,lassi,chach,paneer,powder milk etc.
Process:
The sequence of milk production right from input of raw milk to delivery of final product
is as follows-

Mixing

Pasteurization

Homogenation

Packing

Cooling

Delivery

Mixing: In mixing the milk from different collection centres are put in silos and mixed
thoroughly in mixing chamber.

Pasteurization:Pasteurization is the process of heating milk up and then quickly

cooling it down to eliminate certain bacteria. For effective pasteurization, milk can be
heated up to 145 degrees Fahrenheit for 30 minutes, but this method isn't very
common. More common is heating milk up to at least 161.6 degrees Fahrenheit for 15
seconds, which is known as High-temperature Short-Time (HTST) pasteurization, or
flash pasteurization. This method will keep milk fresh for two to three weeks.

Homogenization: is an entirely separate process that occurs after pasteurization in

most cases. The purpose of homogenization is to break down fat molecules in milk so
that they resist separation. Without homogenization, fat molecules in milk will rise to
the top and form a layer of cream. Homogenizing milk prevents this separation from
occurring by breaking the molecules down to such a small size that they remain
suspended evenly throughout the milk instead of rising to the top.
Packing:Packaging is a technique of using the most appropriate containers and
components to protect, carry, identify and merchandise any product. It constitutes an
important link between the manufacturer and ultimate consumer for the safe delivery of
the product through different stages of production, storage, transport, distribution and
marketing. Milk is packed in different capacity packets (0.5litr, 1litre) in
differentvarieties like full cream, single toned, double toned, and skimmed.

Cooling:Milk cooling affects milk quality. The quicker the milk is cooled after milking,
the better the quality when it is collected from the farm.

Cooling milk immediately after milking keeps bacteria from multiplying rapidly. Holding
milk at temperatures below 40°F (4°C) and above freezing maintains its excellent
quality until it is processed for fluid milk or manufactured into dairy products. Each
degree in temperature above 40°F (4°C) elevates bacteria counts and decreases the
shelf life of finished products.

Delivery:The cooled milk is then delivered to different distribution centers (dairy

shops, parlors) on trucks, vans, etc.

OBJECTIVES OF PROJECT

Process mapping:Develop a detailed process map for the different plants in order
to construct a hierarchical structure that will help in understanding the production flow
processes that exist. The map will highlight the flow from the area where milk is
received in its unprocessed form to where it is used in production in the different plants
and end in the packaging area of the different plants.

PROBLEM STATEMENT:To study and analyse different process times and to

develop an improved model to reduce overall production time. In the current process,
the packed milk is manually put on tray and moved towards cold storage. This action
increases the process time. Despite the manual action we have improvised the
process to be completed automatically that is the packed milk will be directly
transported to cold storage without any manual interference.

Simulation modelling:
Simulation is one of the most powerful analysis tools available to those responsible for
the design and operation of complex processes or systems. In an increasingly
competitive world, simulation has become a very powerful tool for the planning, design,
and control of systems. Simulation modelling is a common paradigm for analyzing
complex systems. In a nutshell, this paradigm creates a simplified representation of a
system under study. The paradigm then proceeds to experiment with the system,
guided by a prescribed set of goals, such as improved system design, cost–benefit
analysis, sensitivity to design parameters, and so on.

MODELLING SOFTWARE USED (ARENA 3.0)

IN ARENA3.0 environment, the word "entity" is a generic term used to denote any
person, object, or thing- whose movement through the system causes change in the
state of the system. Every entity possesses some unique characteristics referred to
as attributes. For example in a factory a job may have attributes specifying the part
number, due date, and priority of the job. The term variables, refers to the set of
changeable values characterizing the components of the system as a whole. Example
of a variable is TNOW. It specifies the current value of the simulated time.

In the ARENA3.0 modelling framework, there is a fundamental distinction between

the Model and the Experiment. The model is a functional description of the system’s
components and their interactions. The experiment defines the experimental conditions
under which the model is exercised to generate specific output data. An ARENA3.0
simulation program generates both a model and corresponding experiments.

Processes are modelled in SIMAN by using a block diagram. A block diagram is a flow
graph depicting the process through which the entities in the system move. The block
diagram is constructed as a sequence of blocks, the shapes and names of which
indicate their general function. The experimental section of the program consists of
elements which, are specified interactively in the Arena modellingenvironment.

Analysis and utilization

For a model to give results that are correct or more representative of the real life
system. One would have to input data that is correct because as it is in computer
programming garbage in equals‟ garbage out (GIGO) which means even the results
that we will get will not be representative of the system. The two subheadings will
discuss how one could input information more accurately and how output could be
checked for relevance according to (Altiok & Melamed, 2002).

Input Analysis

Input analysis can be divided to stages that relate to the modelling process which will
be mentioned below:

Stage 1.Data Collection- the model analyst should make sure that the data they
collect is correct and relevant by exercising caution and patience throughout their
collection process
The data collected should also be of a sample size large enough to be representative
of the realmodel.

Stage 2.Data analysis- after enough information has been collected then the
analyst should makes computation of statistics related to moments (mean, standard
deviation), distributions and temporal dependence (auto relations, cross relations).

Stage 3.Time series data modelling-the data that is collected is fitted to empirical
time series where the time is paired with corresponding observations for what was
observed in data collection. They could be modelled as Poisson or
Markovianprocesses.

Output Analysis

Output analysis looks at analysis of simulations outputs statistics/results and the

following are looked at:

Replication design-a good design of a simulation allows the analyst to run the
model and obtain statistical information at the least computational cost, thus if you
construct a model and it runs for very long periods of time one would have to be
more alert and check their models inputs and build to see if the is no need
fordebugging.

Estimation of performance- when replication statistics can be used to compute

point estimates and confidence intervals for system parameters then the models
outputs could be taken as valid for that systems operation.

System analysis and experimentation-statistical outputs are used to understand

system behavior and performance prediction under varying input parameters and
operations.

Our visit to the plant was coordinated by visit manager of the plant. We first came to
understand the layout of the plant. The layout of the plant is as follows:
Area of the plant chosen for study is from homogenization to delivery of final product.
Here we collected our data taking flow of 170 liters of milk as our reference. The
corresponding time was noted for flow of different varieties of milk. Different time was
recorded for milk homogenization, milk packing, tray assembly and cold storage. It
was then fed to input analyzer of arena software. From there we obtained different
expressions for all the respective processes. After feeding all these expressions and
parameters into the software we obtained the processing time and waiting time for all
the individual processes.

FULL COLD
PMM1 TRAY 1 DELIVER 1
STORAGE 1
CREAM

SINGLE COLD
PMM2 TRAY 2 STORAGE 2
DELIVER 2
TONNED

DOUBLE COLD
PMM3 TRAY 3 DELIVER 3
STORAGE 3
TONNED

COLD
SKIMMED PMM 4 TRAY 4 STORAGE 4
DELIVER 4

After plant visit, we collected the data and fed it into the arena software. We studied all
the processes in the plant .After feeding the expressions for all the processes we could
find the time of processing for all the processes listed above. The arena layout for case
study is as shown below. After we analyzed our processes we tried to improvise the
processing time.
Arena layout of the case study

Data collection
Curve fitting of collected data

Step 1:- Insert the data in .txt file

Step 2:- Open ARENA software and go to Tools > Input Analyzer

Step 3 :- In input analyzer go to “USE EXISTING DATA FILE” and select

the required file
Step 4 :- After a curve is generated select “FIT ALL”.
Step 5:- Note down the expression

By following the above steps the following expressions are generated

Creating arena model

Step 1:- Make the layout as shown

Step 2:- Feed the expression for create, assign and other processes
Step 3:- Go to RUN>SETUP

Step 4:- Run the model

Report

Improved Model
Improved Report

Comparison

CONCLUSION:
The arena software that we have used to study and analyze the
processes at Saras Jaipur dairy is very effective and user friendly. With the help of the
software we can alter the resource capacities and study the corresponding change in
output of different processes without actually changing the parameters.We eliminated
the tray assembly by managing the packing and cold storage process. In our improved
model the processing time was reduced.