DPTC Pilot Plant Equipment and Photos
Raw Milk SilosGeneral Description: Refrigerated storage tanks for raw milk.
Specifications: DCI two (2) refrigerated 2000-gallon capacity
Cold Milk SeparatorGeneral Description: Separate cream from raw milk with a skim milk fat content of .10 %
Specifications: Alfa-Laval 10-gallon rated fluid capacity per minute.
Tri-BlenderGeneral Description: Disperse dry ingredients at high shear rate into liquid flow stream.
Specifications: Tri-clover
HTST (High Temperature Short Time) PasteurizerGeneral Description: Pasteurize milk and ice cream mixes with homogenization unit. (HTST is a legally sealed unit by the State of California and PMO)
Specifications: APV 300/600-gallon per hour capacity. Additional 21/2 minutes extended holding tubes available. H.T.S.T is legally sealed, and inspected by the State of California.
Cream Processing VatGeneral Description: Pasteurization of cream and fluid milk products.
Specifications: DCI 200-gallon tank capacity with heating and cooling capabilities. Low and high speed agitator.
Batch TankGeneral Description: Fluid milk fortification/additions with dry or liquid ingredients. Ice cream mixes, chocolate milk.
Specifications: DCI 400-gallon capacity tank positioned on load cells to assure accurate weights of ingredient additions. Attached to plate heat exchanger for additional fluid heat treatment.
Nimco Carton FillerGeneral Description: Gable top carton filler
Specifications: Capable of filling 1/2 gallon, quart, 1/3 quart, and pint containers.
Process Holding TanksGeneral Description: Non-jacketed holding tanks
Specifications: DCI two 500-gallon, one 1000-gallon.
Hoyer Frigus SF 600 N Continuous Ice Cream Freezer General Description: equipped with a self-contained freon refrigeration unit and a vertical freezing cylinder. A piston pump meters ice cream mix and air intake. The frozen ice cream is discharged from the cylinder by means of a constant pressure valve.
Specifications: produces from 53-158 gallons/hour at 100 % overrun.
Hoyer Addus FF 2000 C Ingredient Feeder
For continuous and accurate injection of free fl owing granulates or highly viscous ingredients with inclusions. It is manually controlled, the operator selects the speed of the dosing screw for constant fl ow of ingredients into the lamella pump.
Ice Cream Cup FillerGeneral Description: Piston feed, rotary table.
Specifications: Sawvel 3.5 oz. or 1 pint cup capability.
Emery Thompson Batch Ice Cream FreezerGeneral Description: For batch ice cream manufacturing. Specifications: 44-quart capacity.
Ice Cream Process Mix Tank
General Description: Ice cream mix process/holding tank with two additional flavor vats. Specifications: Crepaco 300-gallon capacity with heating and cooling capabilities. Two 50-gallon flavor vats.
Blast Hardening and Traditional Freezer StorageGeneral Description: Storage of frozen products
Specifications: Blast hardening room @ -25F Traditional freezer @ -15
Cheese VatsGeneral Description: Open cheese vats with traveling agitation paddles.
Specifications: (1) 1000-gallon, (1) 500-gallon, (2) 150-gallon, (2) stirred-curd draining tables, (3) potable 50-gallon cheese vats.
Salt Brine TankGeneral Description: Submersion of cheese blocks into a salt brine solution.
Specifications: 150-gallon salt brine solution tank with pneumatic host and racks.
Universal Pilot Plant
General Description: Small scale High Temperature Short Time (H.T.S.T) with two 15-gallon process tanks with heating and cooling capability, 2-stage homogenizer, swept surface agitations and high shear agitators. Manual temperature control for variable product heat treatments. Continuous ice cream freezer attached to unit.
Specifications: H.T.S.T. rated at 33 liters per hour. Continuous ice cream freezer rated at 100 liters mix per hour.
Marriot Walker Rising Film EvaporatorGeneral Description: Single effect evaporator, for removal of water and solids concentration of fluid milk products.
Specifications: 20-gallon tube chest capacity. Water removal rate 150 lbs. at 130F @ 29 hg vacuum.
Blentech Process Cheese Cooker General Description: Steam jacketed, variable speed, counter rotating twin screw augers.
Specifications: 60 lb. capacity
Suprema Pasta Filata System General Description: Cheese curd, cooker stretcher and molder. Temperature controlled wash water. Dual screw augers in contained temperature controlled housing.
Koch Vacuum Packaging SystemGeneral Description: Vacuumed sealed plastic wrap packages.
Specifications: 1-40 lb block
4- Groen Process Steam Kettles
General Description: Steam jacketed mixing tanks with swept surface and high speed lighting mixers.
Specifications: 40-60 gal
2- APV Conical Bottom Swept-surface Processors General Description: Jacketed process tank with swept surface agitators. Cooling and heating capability.
Specifications: 100 gal
R-12 Universal Membrane System
General Description: A membrane system containing one or two commercial size spiral-wound membranes. The system can be configured for RO, NF, UF or MF depending on the type of membranes and pumps employed. Membranes are in parallel when two elements are used.
Specifications: The system, as used for either RO, NF, UF or MF contains one commercial size spiral-wound membrane. Also included in the systems is a centrifugal stuffing pump, a positive displacement pump, appropriate temperature and pressure gauges, retentate and permeate flow meters and a retentate flow control valve. The membranes are placed in parallel when two elements are used. The system components are similar to those used for RO/NF with the exception of the positive displacement pump that is not required for UF/MF. Membranes routinely available include: Thin film composite RO membrane with an operational pH range of 3 - 10 and a maximum operating temperature of 120o F. The RO membrane has a typical NaCl rejection of 99.5%. Polyethersulfone UF membrane with a 10,000 MWCO, a maximum operating temperatures of 120F and pH range of 2 - 12. Each UF membrane has approximately 60 ft2 of membrane area. This type of membrane is designed to concentrate sweet/acid whey, WPC (35 - 90% protein) or skim milk to 32% total solids and whole milk to 45% total solids. System is also capable of ceramic membrane processes.
Niro Filterlab Spray DryerGeneral Description: A gas fired spray dryer with nozzle core and orifice. The system has co- current, countercurrent and two fluid drying capabilities. The spray dryer can remove approximately 150 lbs water/hr.
Specifications: The dryer consists of a high pressure feed pump, gas fired burner, spray nozzle, drying chamber, filter mat, cyclone and gauges.
Final product is collected in the cyclone collection container or directly from the filter mat.
A number of variables can be controlled on this system thereby permitting the drying of a wide range of products. The temperature of the drying air can be varied continuously over a wide range. Liquid pressure to the nozzle orifice can be changed to alter the powder characteristics.
Egli Continuous Butter ChurnGeneral Description: Continuous butter churn with attached crystallization tank with heating and cooling capabilities for cream tempering. Variable speed motor controls for beater blade, buttermilk removal cylinder, first stage working, and second stage working cylinders. Programmable heating and cooling profile for cream tempering.
Specifications: Rated capacity 1.5-2.25 lb. per minute. Butterfat range 36 % -50 %.
Ceramic Micro Filtration UnitGeneral Description: A filtration system using ceramic elements for UF/MF. The system uses one element with 2.2 ft2 of filtration area. The unit can tolerate operating temperatures up to 150 F and meets sanitary design standards.
Specifications: The ceramic system consists of one ceramic element, feed pump, heat exchanger, feed tank and appropriate valves and gauges. The Tami ceramic elements have2.2 ft2 of filtration area.
A list of other elements on hand is available by contact.
Fluid Milk Storage (34 to 38 degrees F)
Cheese Room Storage (48 to 52degrees F)
Controlled temperature storage - approx. 3,000 sq ft 
Sermia cheese/buttermilk fines separator
DDS Ultra Filtration System (single membrane housing)
Micro Thermics UHT/HTST Direct and Indirect Processing System with an Inline Homogenizer and Clean-Fill Hood with Sterile Product OutletIncludes Direct/Indirect Heat Exchange, Vacuum flash cooler, Clean Fill Hood, Fluke Data Acquisition System and Recorder, sterilizable, variable speed homogenizer (.8 L – 3.3 L/min), extra holding tube from 30 – 60 sec., s It is capable of processing pudding, cheese sauces, juices, broths, purees, dairy fluids.
Silverson High Shear MixerUsed for pilot batching and reconstitution of ingredients. This piece of equipment handles liquids with varying viscosities and rapidly produces a homogenous product while minimizing aeration. It's unique design makes it ideal for dissolving powders and stabilizers as well as mix, emulsify, and homogenize liquids in one single operation. It is mounted on a floor stand making it flexible in various applications in the pilot plant.
Contact Phil Tong for use of facilities or special projectsptong@calpoly.edu or call (805)756-6102.
