Project Location: Gokul Dairy, Kolhapur, Maharashtra
SHMECH executed a complete butter processing and automation project at Gokul Dairy, Kolhapur, covering continuous butter production, butter storage, automatic bulk packing and integration with the dairy’s existing cream storage system.
The project was developed to bring the butter production and packing section under a coordinated automation system while retaining integration with the existing plant infrastructure.
The scope included a 2 MT/hr Continuous Butter Making Machine (CBMM) suitable for both salted and unsalted butter, a 2 MT Butter Silo, automatic bulk butter packing, cream silo integration and a centralized PLC-SCADA control system.
Continuous Butter Production – 2 MT/hr
The main production equipment supplied for the project was a 2 MT/hr Continuous Butter Making Machine.
The CBMM is designed for continuous butter production with controlled processing conditions and hygienic product handling. The machine can be operated for production of both unsalted and salted butter, giving the dairy flexibility to manufacture different butter products using the same production system.
Continuous processing also provides a steady product flow towards the downstream Butter Silo and packing section, making it suitable for integration with an automated dairy plant.
2 MT Butter Silo
A 2 MT Butter Silo was installed as an intermediate storage and buffering unit between the CBMM and the packing system.
The silo helps accommodate variations between butter production and packing rates and provides a controlled supply of butter to the downstream bulk packing system.
The arrangement also helps minimize manual handling of butter and maintains a more organized product flow through the section.
Automatic Bulk Butter Packing System
The project included an Automatic Bulk Butter Packing System for packing the finished butter into bulk packs.
By integrating the packing system with the CBMM, Butter Silo and PLC-based control architecture, the overall section can operate as a coordinated production and packing line.
Automation of the bulk packing operation also reduces dependence on manual product handling and provides better control over the movement of butter from production to final packing.
Integration of Existing Cream Silos
A key engineering requirement was the automation and synchronization of five existing cream silos.
Rather than creating an independent control system for the new butter section, the project involved integrating the existing cream storage system into the overall automation architecture.
This allowed information and operating conditions from the five cream silos to be incorporated into the butter production sequence.
Such integration is important in a dairy plant because butter production depends directly on the availability and controlled supply of cream. Connecting the upstream cream storage section with the new processing equipment provides better coordination of the complete process.
MCC & PLC Control System
SHMECH supplied the MCC and PLC panel for centralized electrical and process control.
The PLC manages the operating sequences and interlocks of the connected equipment, while the MCC provides the required motor control and electrical distribution for the system.
The control architecture was developed to bring the new equipment and existing cream silos together into a common automation platform.
Three SCADA Stations
The project also included three dedicated SCADA PC stations:
Operator Station – for day-to-day monitoring and operation of the process.
Engineering Station – for engineering access, diagnostics and system management.
MIS Station – for production-related monitoring and management information requirements.
With multiple SCADA stations, different plant functions can access the automation system according to their operational requirements without depending on a single workstation.
An Integrated Butter Processing Solution
The overall system at Gokul Dairy can be summarized as:
Existing Cream Silos – 5 Nos.
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Continuous Butter Making Machine – 2 MT/hr
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Butter Silo – 2 MT
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Automatic Bulk Butter Packing System
The PLC, MCC and SCADA system provide the automation layer connecting these sections and coordinating their operation.
Project Scope
| Equipment / System | Scope |
|---|---|
| Continuous Butter Making Machine | 2 MT/hr, salted & unsalted butter |
| Butter Silo | 2 MT |
| Bulk Butter Packing | Automatic |
| Cream Silo Integration | 5 existing silos |
| MCC & PLC Panel | Supplied by SHMECH |
| SCADA PC | 3 stations – Operator, Engineering & MIS |
This project reflects SHMECH’s capability to combine new dairy processing equipment with existing plant systems, while providing a unified automation and control platform.
From continuous butter production and intermediate storage to automatic bulk packing and SCADA-based supervision, the complete system was designed around the operating requirements of Gokul Dairy, Kolhapur.
SHMECH – Dairy Processing Equipment, Butter Systems & Plant Automation
