"Confirmed"
Director of «Shurtan Gas Chemical Complex » LLC
_________ O.Temirov
«____» _________ 2016
THE REQUIREMENTS SPECIFICATION
for delivery of complete set of the equipment for
dairy plant of
«Shurtan Gas Chemical Complex » LLC
Shurtan – 2016
1. General
1.1. The present Requirements specification (RS) is developed for the purpose of reception from
potential suppliers technical and commercial offers for delivery of complete set of the equipment for
Dairy plant of «Shurtan Gas Chemical Complex » LLC
1.2.
The Dairy plant is intended for receiving, cleaning and processing of 7500 kg of raw milk
per day with production, packing and storage of following dairy products:
1.2.1. Milk pasteurized;
1.2.2. Kefir;
1.2.3. Cream;
1.2.4. Cottage cheese (curds);
1.2.5. Whey;
1.3.
Raw material for production is cow’s milk, receiving from an existing Cattle-breeding
complex of «Shurtan Gas Chemical Complex» LLC
1.4.
Distance from Dairy plant to Milking parlor of the Cattle-breeding complex is approximately
80 meters.
1.5.
Customer - «Shurtan Gas Chemical Complex» LLC (address: 180300, SGCC, Shurtan
settlement, Guzar district, Kashkadarya region, Uzbekistan);
2.
2.1.
2.2.
Product volume and assortment
In dairy plant it is planned to produce following finished products from 7500 kg of raw
(unboiled) milk with fat content of 3.5 %:
Fat content
%
2,5
2,5
Raw milk,
kg
4000
2000
Finished
product, kg
3950
2000
Cream
22
500
450
Cottage cheese
Whey
10
1000
250
750
№
Product name
1
2
Milk pasteurized
Kefir
3
4
5
Plastic bottles, 0.5-1.0 liter
Plastic bottles, 0.5 liter
Plastic glasses,
200-250 gram
Weight, friable
Supplier of the equipment can offer, as an alternative variant, its decision of kinds and
volume of products.
3.
3.1.
Packing
Scope of supply
Delivery of the complete set of the process equipment according to requirements of the
Customer specified in point 5 and according to modern requirements to the similar
equipment;
3.2.
Scope of supply should include all necessary equipment for a complete process cycle, that is
should be enough for receiving, cleanings and processing of 7500 kg of milk per day, and for
production, packing and storage of the dairy products specified in point 2.1. above as well as;
3.3.
Delivery set should consist, but not limited to, of following process equipments:
№
Pieces
1
1
2
1
3
1
4
1
5
1
Name
Specifications
THE EQUIPMENT FOR THE MILK RECEPTION BLOCK
For milk transportation to distance not less than 100 m (from the
Pump
Milking parlor to Dairy plant)
For mechanical cleaning of milk with replaceable washed out
Filter
cartridges
Milk flowmeter
For measurement of quantity of receiving milk in a stream
Destination: Automatic cooling of milk to 4 0С and its storage;
In the complete set:
1.
Stainless steel isothermal Tank ready assembled:
• Α basic frame with adjustable legs
• Α ladder
• Α double casing (cooling/heating)
• Manhole and a sampling point
• Α mixer with function of adjustment of rotation speed
Milk cooler, V = not less
• Washing heads
than 8000 liter
• Valve
• Measuring device (ruler)
• Gauges for temperature, level, etc.
2.
The Compressor-condenser block (the refrigerating unit
with cold carrier);
3.
Pump;
4.
Independent system of automatic washing;
5.
Control panel
Pump
For milk pump out to pasteurization and cooling unit
THE EQUIPMENT FOR THE TANK BLOCK
It is intended for instant heating (to 900С) and the subsequent
6
1
Pasteurization and cooling
unit, capacity is not less
than 2000 l/hour
cooling (to 4-60С) of milk in the counterflow plate-type heat
exchanger.
Characteristics:
1. It should be preliminary assembled, tested and mounted on
a frame of stainless steel with adjustable legs;
2. Automatic control of temperature and holing time;
3. The Design should correspond to CIP washing
requirements
4. The pasteurization System should be adapted for work with
separation and homogenization systems.
5. Fast heating and fast cooling of milk.
In the complete set:
1. Equalizing tank for reception of raw milk with adjustment
of level (gauges);
2.
Sanitary-technical centrifugal pumps (for milk and
washing-up liquids, for heat-carriers);
3.
Plate-type heat exchanger;
4.
Flowmeter;
5.
Filter;
6.
Complete set of gauges (temperature, pressure, a
flowmeter);
7.
Pasteurization and cooling process automatic control and
management system (control panel);
7
1
8
1
9
1
10
1
11
1
8.
Regulating and gate valves system;
9.
Milk holding section;
10. Pipeline system;
11. CIP washing system
Characteristics:
1. The Hermetic separator with function of normalization and
automatic unloading of a deposit
2. The Design should correspond to CIP washing
requirements
3. The separation system should be connected to
pasteurization and homogenization systems and should
Milk separator, capacity is
work and controlled as a one block
not less than 2000 liter/
In the complete set:
hour
1. Casing and covering;
2. Drum;
3. Driven mechanism (centrifugal pump, electric motor);
4. Intake and discharge device;
5. Pressure regulating valves;
6. Bypass pipe and valves.
Characteristics:
1. The homogenization System should be connected to
pasteurisation and separation systems and should work and
cope as the uniform block
2. The Design should correspond to requirements CIP of
washing
Homogenizer, capacity is
In the complete set:
not less than 2000 liter/hour
1. The Chamber;
2. Pumps;
3. The Electric motor;
4. Valves for pressure adjustment;
5. Gauges (temperature, pressure, level);
6. The Control panel.
Stainless steel isothermal tank for storage of separated cream.
In the complete set:
• Α basic frame with adjustable legs
• Α double casing (cooling/heating)
Production tank for the
• Manhole and sampling point
separated cream, V = not
• Α mixer with function of adjustment of rotation speed
less than 500 liter
• Washing heads
• Valves
• Measuring device (ruler)
• Gauges of temperature, level, etc.
THE EQUIPMENT FOR PRODUCTION OF SOUR-MILK PRODUCTS
Stainless steel isothermal tank for storage, cooling and mixing
of the pasteurized milk.
In the complete set:
•
Α basic frame with adjustable legs
Production tank for the
•
Α double casing (cooling/heating)
pasteurized milk, V = not
•
Manhole and sampling point
less than 5000 liter
•
Α mixer with function of adjustment of rotation speed
•
Washing heads
•
Valves
•
Measuring device (ruler)
•
Gauges of temperature, level, etc.
Production tank for kefir,
Stainless steel isothermal tank for production of kefir.
V= not less than 3000 liter
In the complete set:
•
•
•
•
•
•
•
•
12
1
13
1
14
1
15
1
16
1
17
2
Α basic frame with adjustable legs
Α double casing (cooling/heating)
Manhole and sampling point
Α mixer with function of adjustment of rotation speed
Washing heads
Valves
Measuring device (ruler)
Gauges of temperature, level, etc.
Stainless steel isothermal tank for production of cream.
In the complete set:
•
Α basic frame with adjustable legs
Production tank for cream
•
Α double casing (cooling/heating)
(holding pasteurization
•
Manhole and sampling point
tank) V=500 liter
•
Α mixer with function of adjustment of rotation speed
•
Washing heads
•
Valves
•
Measuring device (ruler)
•
Gauges of temperature, level, etc.
THE EQUIPMENT FOR PRODUCTION OF COTTAGE CHEESE
Stainless steel isothermal tank for production of cottage cheese.
In the complete set:
•
Α basic frame with adjustable legs
•
Α double casing (cooling/heating)
•
Manhole and sampling point
Production tank for cottage
•
Cutting and kneading device
cheese (bath)
•
Washing heads
V= not less than 1000 Liter
•
Valves
•
Measuring device (ruler)
•
Gauges of temperature, level, etc.
•
Nozzles (Branch pipes) for whey drain and cheese grain
withdrawal
Stainless steel drum for cottage cheese pressing and cooling in
sacks.
In the complete set:
• Α frame on which the tubular drum with a loading window
is mounted
• Α demountable bath
Cottage cheese pressing
• Driven station for shaft rotation
and cooling unit
• Reversing-type magnetic starter for drum rotation direction
change
• Valves
• Sacks
• Α filtering insert
• Branch pipes for whey drain
Pump
For pumping-over of whey to storage tank
Stainless steel tank for whey accumulation
In the complete set:
• Pump
Production tank for whey,
• Α washing head
V= not less than 2000 liter
• Branch pipes for whey drain
• Gauges of temperature, level, etc.
• Valves
THE EQUIPMENT FOR THE POURING AND PACKING BLOCK
Pump
For pumping-over of viscous and high viscous products (kefir,
18
1
19
1
20
1
21
1
22
1
23
1
24
1
25
1
26
1
cream, etc.)
For pumping-over of the pasteurized milk
Characteristics:
1. Possibility of pouring and packing viscous and high viscous
products (kefir, cream, etc.)
An automatic machine for
2. Possibility of adjustment of speed and the size of packing
pouring and packing in
(from 0,4 to 2,0 liter)
plastic bottles,
3. The Design should correspond to requirements of CIP
Capacity is not less than
washing
1000 liter/hour
In the complete set:
1. Controller;
2. Bottles rinsing and disinfection system;
3. Filling System;
4. Cap installation and screwing up system;
Characteristics:
1. Possibility of pouring and packing viscous and high viscous
products (kefir, cream, etc.)
2. Possibility of adjustment of speed and the size of packing
An automatic machine of
(from 100 to 500 gram)
pouring and packing in
3. The Design should correspond to requirements of CIP
plastic glasses,
washing
Capacity is not less than
In the complete set:
500 liter/hour
1. Controller;
2. Glasses rinsing and disinfection system;
3. Filling System;
4. Cap installation system;
ADDITIONAL EQUIPMENT
Air compressor with a receiver and a refrigerator dehumidifier
Compressor
for the packing equipment and for a drive of pneumatic valves.
A generator for reception of ice water and reservation of energy
of a cold. Capacity of the unit should be enough for providing
dairy plant with ice water.
In the complete set:
•
Metal frame
•
Isothermal tank of steel
Generator of ice water
•
Compressor
(chiller)
•
Evaporator
•
Air condenser
•
Pump group for a glycol contour
•
Pump group for ice water loop
•
Gauges (temperature, pressure, level, etc.)
•
Control system
For keeping of refrigerating room temperature (a room for
Refrigerating unit
storage of finished products) at +4 0С. Capacity of the unit
should be defined on the basis of the room size (about 30м3).
It is intended for producing of saturated water steam at 150°С at
Steam generator (boiler)
the expense of the heat produced by burning of natural gas.
Productivity: 150-200 kg/h.
For definition:
1. Fat mass fraction;
Equipment for control of
2. Protein mass fraction;
quality of milk and milk
3. Mass fraction of the added water;
products (milk analyzer)
4. Dry fat-free milk residue;
5. Density;
6. рН (acidity)
Equipment for automatic
Characteristics:
washing (CIP unit)
1. For washing and disinfection of pipelines, tanks, devices of
Pump
27
Valves
28
Instrumentations
29
The equipment for binding
30
Spare parts and components
for two years operation
31
1
32
1
The control panel
pouring and packing, heat exchangers and other parts of a
technological line, including milkline from the milking
parlor to dairy plant without their dismantling.
2. Economical consumption of water and washing-up liquids.
In the complete set:
•
4 stainless steel isothermal tanks of 500 l each (2 for
washing-up liquids with heating, 1 for cold water, 1 for hot
water)
•
Stainless steel pump for washing-up liquids feed (an
option: pump for return line);
•
Pumps for acid and alkali feed;
•
Counterflow dismountable plate-type heat exchanger for
heating of acid, alkali, water;
•
Washing solutions automatic dosing system
•
Valves with a pneumo-drive for regulation of washing-up
liquids flow
•
Conductometric gauges for regulation of acidity level after
washing;
•
Frame of stainless steel;
•
Control panel;
•
Piping;
•
Automatic level control in buffer tank;
•
Control by means of PLC via touch screen control panel;
•
Built in standard programs:
Gate valve, protective valves, regulating valves
Devices for measurement of pressure, temperatures, density,
level an etc.
Corrosion-proof pipes, dairy hoses, connections, electric
accessories, materials and accessories for a binding and
installation of equipment, assembly-fixing materials
The integrated system of indication and management for
visualization of technological processes
Distribution box
Set of ferments, enzymes
and other necessary
solutions for the period of
33
carrying out of starting-up
and adjustment works
OPTION: Supplier can offer following equipment in exchange for THE EQUIPMENT FOR THE
MILK RECEPTION BLOCK
For reception, filtration and accounting of milk.
Passing product flow, 3 m3/h
Leaving product temperature, 4 0С
Ice water flow, 8 m3/h
In the complete set:
1. Corrosion-proof frame.
2. Centrifugal pump.
1
1
Station of milk accounting
3. Reception tank for 50 liters.
4. Flowmeter
5. Control box
6. Temperature gauge.
7. Return valve.
8. Sight glass.
9. Sampler.
10. The filter for rough cleaning.
11. The filter for fine cleaning.
12. The complete set of pipeline valves.
13. Plate cooler.
2
1
Tank for milk storage,
V = not less than 8000 liters
For maintenance of milk low temperature (4 0С) and its storage;
In the complete set:
• Stainless steel isothermal Tank ready assembled:
• Washing head
• Casing for cooling
• Manhole and sampling point
• Mixer with a drive
• Necessary branch pipes and Valve for filling and drain
• Gauges of temperature, level, etc.
• Α basic frame with adjustable legs
• Washing system;
3.4.
The set of equipment given above is subject to clarification with participants of the tender
(suppliers) before they form their final version of tender offers. If it is well-founded the
supplier can offer its decision for quantity, volume and capacity of the equipment on the
basis of product assortment and volume.
3.5.
The Supplier can offer its decision on transportation of milk from the Milk parlor to Dairy
plant and the necessary equipment for this purpose;
3.6.
The Place of delivery of the goods - Shurtan Gas Chemical Complex;
3.7.
The Supplier carries out:
3.7.1.
Equipment delivery, assembly and supervision works;
3.7.2.
Starting-up and adjustment at Customer site;
3.7.3.
Test of the equipment and trial start-up at the guaranteed capacity on all parameters;
3.7.4.
Training of the customer personnel:
− Technical training: full engineering and technical training, training to work with
all machines existing at dairy plant, operation and maintenance service of
separate kinds of the equipment, equipment washing and cleaning order, etc.
− Technological training: full technological and laboratory training (technological
process of production, production recipes, laboratory analyses of raw milk and
dairy products), necessary systems of sanitary and factory hygiene, system of
milk preparation, processing, packing, storage, etc.
− After sale technical and technological support by phone, e-mail, fax and periodic
visits to the plant.
3.8.
The Supplier should give a guarantee for the equipment with indication of hours or days of
operation;
3.9.
The Supplier should give assembly (mounting) drawings of piping with instrumentations.
3.10. Packing should provide safety of the equipment during transportation, cargo handling works.
4.
Dairy plant designing and construction general requirements
4.1.
The Supplier, on the basis of a full cycle of production (from reception of raw materials to
finished goods and storage) gives design drawings of arrangement of a technological line
(equipment) with indication of connection point of utilities according to which the customer
carries out construction of a dairy plant building.
4.2.
The Customer at its account carries out construction of a dairy plant building. The building
will be provided by necessary systems of utilities (heating, ventilation, water, electricity, airconditioning).
5. General requirements to equipment
5.1.
The equipment offered to delivery should give the chance to accept, keep, process 7500 kg of
raw milk per day and receive the qualitative dairy products specified in point 2 above;
5.2.
The equipment should be made no earlier than 2016, meet requirements of the international
standard and to be certificated;
5.3.
Operating mode - 24 hours a day, 8760 hours per year;
5.4.
Designed service life of the equipment - not less than 15 years;
5.5.
Automatic control system of operating modes with operation possibility in a manual and
semi-automatic mode;
5.6.
All basic production operations should be carried out and documented automatically;
pasteurizer, separator, homogenizer and pouring and packing machines should be integrated
into the general automatic control system;
5.7.
Execution of control panels should allow the operator to receive in due time the full
information, such as parameters and schemes of technological process, the graphic and
tabular information, data recording;
5.8.
Each equipment or each unit of all technological process should be equipped by necessary
instrumentations (temperature gauge, pressure gauge, level gauge, density measuring
instrument, рН, valves, flowmeter, etc.) for normal control of each process of production;
5.9.
Range of regulation of productivity - from 20 to 100 %;
5.10. Simplicity of operation, maintainability of technological blocks, personnel safety, proof to
the external influences, convenient for maintenance service and repair;
5.11. All delivered equipment should be new in the manufacturer packing, not used, and not
restored after repair, not exhibition copies;
5.12. All the equipment should be delivered by the complete sets ready to installation on site;
5.13. The equipment offered to delivery should be provided by the complete set of documentation
in Russian and English, including maintenance instructions and other documentation
delivered by manufacturer, including guarantee certificates and the information on presence
of the service centers, addresses and ways of communication;
5.14. The equipment should be made of a high-quality material, mainly from stainless steel grade
of AISI 304 (DIN 1.4301) or AISI 316 (DIN1.4401), allowed for contact to foodstuff and
designed to work in the conditions of the raised humidity;
5.15. The Supplier should give a mechanical and technological guarantee to the equipment
according to certain requirements;
6. Documentation
6.1.
Supplier in its technical offer for the tender provides following documentation for definition
of equipment specifications:
6.1.1. General engineering documentation, technical characteristics (specification) of the
equipment, with indication of parameters and requirements for utilities, base
completeness, etc.;
6.1.2. Information on producers (brief information on producers, which equipment is
offered by the supplier);
6.1.3. Power of attorney of the equipment producer, confirming that the producer (name)
trusts the supplier (name) or its representative (name) to participate in the tender, to
carry on negotiations, to sign a contract for delivery (goods), made by (producer);
6.1.4. Certificates of conformity for each equipment;
6.1.5. Referents-sheet of the realized projects for last 3 years (with indication of deliveries
to Uzbekistan - if any);
6.2.
Supplier together with the equipment provides paper and electronic copies of documentation
according to the following list, but not limited to, in Russian and English:
6.2.1. Erection manual (installation guide)
6.2.2. Operation manual (complete description of technological process, the recipe) and a
service technique
6.2.3. Description of malfunctions with indication of the reasons and elimination methods
6.2.4. General engineering specifications, information on the equipment with indication of
parameters and utility requirements;
6.2.5. Technical characteristics and the description of units of the equipment, other
technical information.
6.2.6. Quality Certificates, the sanitary-and-epidemiologic certificates, certificates of
conformity, origin certificates, certificates for materials, equipment passports.