Milk processing and
cheese production

Main | Milk processing and
cheese production

Milk processing and
cheese production

DONI®Therm TCH is a tubular heat exchanger "pipe-in-pipe" type. It is designed to cool the curd-whey mixture in the manufacturing of soft non-maturing cheese and coagulated yogurt products. The heat exchanger is also used to heat and cool other liquid ingredients like washing water, cleaning solutions etc. The module comes as a set with an adjustable frame, indication sensors and a control panel.

The maximum temperature difference between the cooling and heating processes is 30°С.

It is designed for CIP cleaning.

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DONI®Therm UHT is an automated module for ultra high temperature treatment of milk. It comes with a tube heat exchangers, a homogenizer and a de-aerator. It is designed for the sterilization and cooling of milk to the desired manufacturing/processing temperatures. DONI®Therm UHT has four operating programs:
- unit sterilization cycle;
- milk starting cycle;
- sterilization;
- final CIP cleaning or local cleaning;
DONI®Therm UHT operates in the following cycle:
- inlet 5°С;
- homogenization 75°С;
- sterilization 138 to 140°С with 4s hold;
- outlet 20 to 25°С;
DONI®Therm UHT includes safety systems that guarantee the pasteurization cycle and the outlet temperature.

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DONI®Therm CH is a plate heat exchanger designed for manufactiring processes where a change in temperature of the processed product is involved:
- Milk cooling for storage
- Cooling of yogurt products
- Heating of liquids when necessary etc.
The module is supplied with a temperature control system and a system for slow heating, if required. It is designed for CIP cleaning.

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DONI®Therm is an automated module for heat treatment and it comes together with a plate heat exchanger. It is designed for the pasteurization and cooling of milk to the desired processing temperatures. DONI®Therm has five operating programs:
- unit sterilization regime
- standby regime
- pasteurization
- intermediate CIP cleaning
- pasteurization
- final CIP cleaning
When used correctly and with good quality milk DONI®Therm can work continuously for 10 hours to the intermediate CIP cleaning cycle and then 4 more hours following this. DONI®Therm covers all temperature cycles for the heat treatment of milk:
- thermization at 65°С and cooling at 4°С for storage;
- pasteurization at 72° to 76° C and cooling to 32° to 34° C for production of cheese
- pasteurization at 95° to 96° C and cooling to 22° to 45° C for production of yoghurt
- pasteurization at 85° to 95° C and cooling to 4° C for drinking milk
- outlet for separation and clarification at 45° to 65° C
- outlet for homogenization at 65° C
- outlet for de-aeration at 68° C
DONI®Therm is designed with a high regeneration level that can reach up to 94 % in some temperature cycles. DONI®Therm is designed with safety systems that guarantee the pasteurization cycle and the outlet temperature.

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DONI®Aseptank is designed for the storage of sterilized products and it is a buffer module between DONI®Therm UHT and the packaging machines. DONI®Aseptank should be used when:
- there is a difference in the production output of DONI®Therm UHT and the packaging machines;
- Any of the packaging machines suddenly stop.
- there are products which cannot re-circulated;
Before use DONI®Aseptank should be sterilized with steam and cooled with water. Pressure is maintained with sterile air in the void.
It is designed for CIP cleaning.

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DONI®Tank L are buffer tanks for temporary holding of raw or pasteurised milk and other liquid ingredients. They are also used for certain manufacturing processes. They are installed indoors and in a vertical position. The tanks have different components depending on the manufacturing process.
- with insulation or without insulation;
- with or without a stirring mechanism;
- with a manhole on the top or on the side;
- with sensors for low, high and current levels;
- spray balls for CIP cleaning.
The manufacturing lines are designed according to the manufacturing process and the specific working environment.

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DONI®Tank is designed for the storage of raw or pasteurized milk and other liquid components. It can be installed indoors or outdoors, horizontaly or vertically.
Milk is filled into DONI®Tank from the base to avoid foam forming. When the tank is filled to the top level, the agitator switches on. It homogenizes the milk, to prevent it from dividing into different fractions. During stirring the milk moves uniformly within the whole of the tank which guaranties equal temperature and prevents the separation of fat. The working regime of the agitator can be controlled according to the specific requirements of each product. DONI®Tank is insulated with a stainless steel cover. It is equipped with spray balls for CIP, an air vent and a control panel. During filling the current levels of filling are indicated and during discharge the lowest filling level is controlled. In rare cases the tanks can be equipped with cooling elements for temperature control during longer storage periods.

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The module is designed to dissolve salt and to dose brine into DONI®Plastformer or DONI®Tank L A perforated basket is loaded with salt and the salt is dissolved through internal circulation. The built in conductivity sensor, that controls concentration, signals for ready brine to be fed in doses into DONI®Plastformer or DONI®Tank L .

The module requires CIP-cleaning.

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The module is designed to dissolve salt and to dose brine into DONI®Plastformer or DONI®Tank L A perforated basket is loaded with salt and the salt is dissolved through internal circulation. The built in conductivity sensor, that controls concentration, signals for ready brine to be fed in doses into DONI®Plastformer or DONI®Tank L .

The module requires CIP-cleaning.

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The module is designed for the brining of curd in the manufacturing of cheese with grainy structure. Inhibiting action on the development of the microflora is not observed during the preliminary brining (salt content of 0.5% to 0.7%). Meanwhile the time spent in the brine baths is significantly reduced, which accelerates the brining process and reduces the quantity and the volume in the brine baths.
Thanks to DONI®Drain/Brine the practice of partial brining in the cheese vat which generates up to 60% of salty whey is avoided. The process of whey desalting is very complex. DONI®Drain/Brine consists of two draining drums, connected with a U-tube where the curd stays in brine to absorb the necessary quantity of salt. The whey is drained in the first drum and the brine is drained in the second one.
The salt concentration in the brine is maintained automatically. Before the beginning of the process it is pasteurised and cooled down to 40°С.

The module is designed for CIP cleaning.

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DONI®Hotmix Topup is designed for the production of different types of processed cheese with higher viscosity. The main ingredient (crumbled cheese) and additives are added through the upper lid. The finished product is discharged through a valve at the elliptical bottom. The mixture is heated indirectly. The unit has a double wall filled with water, where steam is injected at a pressure of 0,3 MPa. The maximum steam pressure of the unit is 0,3 MPa which is regulated by a safety valve. The working temperature is regulated automatically and can reach a maximum temperature of 95°С max . As an option there is a possibility to feed clean steam of 0,2 MPa directly into the unit in order to speed up the process and to control the water content. The maximum steam pressure of the unit 0,2 MPa, which is regulated by a safety valve.
Homogenisation of the mixture is carried out by a single or double knife installed in the centre at the bottom of the unit. Processing time is 10 to 20 min, depending on the heating method. The rotation frequency is slowly regulated at between 1 500 and 3 000 min ⁻¹.
A mixer for additional intensive homogenization of the product is installed on the top lid. It also cleans the inner walls during operation. The rotation frequency is slowly regulated at between 10 and 40 min⁻¹. DONI®Hotmix is equipped with a control panel which allows the programming of different recipes and controls all of the manufacturing parameters during processing.
A vacuum system may be supplied as an option.
DONI®Hotmix Topup is designed for CIP cleaning.

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DONI®Hotmix is designed for the production of different types of processed cheese. The main ingredient (crumbled cheese) and additives are added through the upper lid. The finished product is discharged through a valve at the elliptical bottom. It is possible to incline the unit for better discharge. The mixture is heated indirectly. The unit has a double wall filled with water, where steam is injected at a pressure of 0,3 MPa.
The maximum steam pressure of the unit is 0,3 MPa which is regulated by a safety valve. The working temperature is regulated automatically and can reach a maximum temperature of 95°С max . As an option there is a possibility to inject clean steam of 0,2 MPa directly into the unit in order to speed up the process and to control the water content. The maximum steam pressure in the main unit should be 0,2 MPa, which is regulated by a safety valve.
Homogenisation of the mixture is carried out by a single or double knife installed in the centre at the bottom of the unit. The processing time is 10 to 20 min, depending on the heating method. The rotation frequency is slowly regulated at between 1 500 and 3 000 min ⁻¹.
There is a rotating paddle with rotation frequency of 22 min⁻which is installed on the top lid to clean the inner walls during operation. DONI®Hotmix is equipped with a control panel which allows the programming of different recipes and controls all of the manufacturing parameters during processing. A vacuum system may be supplied as an option.
DONI®Hotmix is designed for CIP cleaning.

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The module is designed for final pressing, maximum separation of whey and moulding of the cheese block.
DONI®Pressmatic is fully closed and designed for CIP cleaning. The full moulds are transported on step conveyor belts which ensure correct positioning under the pneumatic cylinders. The pressing follows a set program and the pressure increases gradually until it reaches the maximum value for the product.
DONI®Pressmatic is designed and completed individually for each client depending on:
- the volume and number of cheese vats;
- type of cheese;
- size of moulds.

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The module is designed for final pressing, maximum separation of whe and moulding of the cheese block.
DONI®Press consists of a trolley where the moulds are placed and a stainless steel frame with pneumatic cylinders. Each cylinder presses one mould. The module is individually designed and its size is based on the largest moulds that are going to be used.
The number of modules depends on the volume of the cheese vat and the capacity of the moulds. The maximum length of Doni Press should not exceed
4 000mm and its maximum width should not exceed
1 800mm. This is to allow for the underpress trolley to be serviced. The module is supplied with a control panel.

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The module is designed for preliminary pressing of curd immersed in whey in the manufacturing of cheese with dense structure. The maximum pressure that can be achieved is 60 g/cm² and it is determined by the cheese type. The curd whey mixture is fed through the pipes of the spray balls. During operation the spray balls are uninstalled. A draining belt is installed at the bottom and after pressing the whey drains through here. At the end of the process the curd is transported out. A pneumatic guillotine for cross cutting and knives for lengthwise cutting are installed at the front. The cycles of pressing and removing of the curd and CIP washing are fully automated.
Теchnical specifications:

Volume /l/ 5 000÷8 000 8 000÷15 000
Power
supply /kW/
10 12
Air consumption
6 atm /l/min/
600 600
Consumption during CIP-cleaning /l/h/ 15 000 25 000

Layer size after pressing:

Volume /l/ 5000 6000 8000
Width /mm/ 1150 1150 1400
Length /mm/ 3900 4600 5060

 

Volume /l/ 10000 12000 15000
Width /mm/ 1400 1600 1850
Length /mm/ 6210 6670 7130

These dimensions are for a layer with a height of 125 to 130 mm. If a client requires a layer with different height then the length needs to be changed.
The volume of DONI®Pressvat usually corresponds to the cheese vat volume. A change in the curd block height can be achieved when a cheese vat with non corresponding volume is used.
 

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