Description:The following specification particularly describes the invention and the manner in which it is to be performed.
FIELD OF INVENTION:
[001] A paneer manufacturing plant, more preferably, a high-capacity fully automated paneer production plant is provided which is specially engineered for small to medium scale manufacturers, while also being suitable for large-scale production operations.
[002] BACKGROUND:
[003] Paneer manufacturers are required to produce paneer at varying volume and size to meet the customer demands. For example, in retail, the demand for paneer increases during the festive season and decreases on regular days. Accordingly, small scale manufacturing units must adjust their package sizes to match customer purchasing patterns. Apparatuses used by the small scale manufacturers focus on processing fixed quantities of milk, overlooking the importance of producing paneer blocks that match package sizes or customer demand. This mismatch results in wastage when large blocks are cut down to fit retail packaging.
[004] Most of the devices which are engineered for small scale manufacturers are semi-automatic and demands labor engagement at one or more stages of paneer manufacturing. For example, milk dosing, acid dosing, coagulant mixing, whey removal and molding. Paneer texture and taste are highly affected by differences in the physical strength and engagement of the workers at different stages. For example, to prepare paneer, a coagulant is added to milk that has been preheated to a temperature between 70°C and 90°C. This is followed by manual stirring to ensure effective curdling. The intensity of stirring often varies due to factors such as the high temperature of the milk and individual differences in the workers’ physical strength and engagement during the process. Non-uniform mixing of the coagulant and coagulum greatly affects the quality of the paneer.
[005] Thereafter, once coagulation process is completed, the hot coagulated mass is manually poured over a sieving medium, typically muslin cloth, and transferred onto multiple molds by workers. Due to the high temperature of the mixture, the efficiency of manual handling varies depending on each worker’s physical engagement and tolerance. Furthermore, most setups rely on fixed vats, which hinder complete drainage of the mixture. As a result, a portion of the curdled milk remains unrecovered, ultimately reducing the overall yield.
[006] Besides, no standardized procedures existed for assessment of the quality of milk intended for paneer production. Milk variety greatly affects the paneer production and quality of end products. For example, higher fat in milk results in a softer, smoother paneer, while lower fat results in firmer, drier paneer. Similarly, quality of coagulant solution affects the quality of paneer. None of the paneer manufacturing devices available in the art considers the variation in the quality of milk and/or coagulant to adjust the process parameter to prepare the finest quality of paneer.
[007] Various fully automatic paneer manufacturing systems are engineered while considering the need of large scale manufacturers. In most cases, such fully automated paneer manufacturing systems demand nearly ten times the amount of space and investment compared to traditional set-ups. These systems typically involve milk vats rotating across multiple conveyor sections spread over a wide area. This continuous movement causes frequent jerking and product spillage, which disrupts coagulum settling and adversely affects the final texture of the paneer. Moreover, despite their automation, the draining of milk vats is still performed manually. Due to their high operational costs and the need for skilled workers, such large-scale systems are not a practical solution for small-scale manufacturers.
[008] Furthermore, fully automatic paneer manufacturing systems at larger scale as well demands a ton of labors to perform milk dosing, coagulant dosing, agitation, coagulum pouring etc. The manual intervention adversely affects the quality and quantity of milk as discussed above.
[009] In conventional large-scale automated paneer production, coagulation is typically carried out in a single large vat. Post-coagulation, the curdled mass is manually transferred into multiple molds or containers. This manual pouring process lacks precision and uniformity, often resulting in inconsistent quantities of coagulant being dispensed into each mold.
[0010] Such variability leads to paneer blocks of unequal dimensions and mass after pressing. Consequently, during downstream packaging, especially where fixed-size retail packs are required, this inconsistency contributes to increased trimming waste and reduced yield efficiency. The lack of volumetric control during mold filling not only affects product uniformity but also escalates operational costs due to material loss and reprocessing. There is a growing need for a fully automated paneer manufacturing plant which is specifically engineered considering the need of small to medium scale manufacturers while the same can be used by large scale manufacturers as well. Such a solution should offer flexible yield capacity, minimize product wastage, and optimize both time and space efficiency. Crucially, it must be cost-effective and simple to operate, eliminating the barriers of high investment and skilled labor typically associated with large-scale systems.
 
SUMMARY OF THE INVENTION
[0012] In accordance with the first aspect of the present invention, a high-capacity fully automated paneer production plant is provided. A high-capacity fully automated paneer production plant comprising a continuous carousel frame comprises a continuous carousel frame, plurality of vats, servo motor along with a reduction gear box.
[0013] The continuous carousel frame comprising a central rotating shaft having a first plate mounted at its bottom end and a second plate mounted at its top end. Here, the second plate has a size which is smaller than size of the first plate. The continuous carousel frame comprises a plurality of first bars arranged radially and equidistantly on the first plate such that a first end of each of the first bar is affixed to the second plate while a second end is extending horizontally away from the first plate , and a plurality of second bars extending downward from the second rotary plate , where an opposite end of each of second bars is attached to the second end of first bars . The continuous carousel frame is comprising a plurality of U-Shaped flanges, where each of the plurality of U-shaped flange is mechanically fastened on the second end of first bars near second end of second bars. Here, the number of U-Shaped flanges, the number of first bars and the number of second bars is correspondent to each other. The U-shaped flange has a central tapered section which exhibits a V-shaped profile when viewed in horizontal cross-section, and a U-shaped slot formed at both lateral sides of the U-Shaped flange.
[0014] The plurality of vats is mounted at regular interval on continuous carousel frame (100). More specifically, the plurality of vats is mechanically fastened to the frame through opposite sides of a consecutive U-shaped flange. Here, the number of first bars and the number of second bars are correspondent to the number of vats.
[0015] The Servo motor along with a reduction gear box is operatively connected to the central rotating shaft to enable optimized torque transmission from the central rotating shaft to the plurality of vats.
[0016] In a preferred embodiment of the invention, the each of plurality of vat comprises an integrally formed single spout running on a wall thereof, a mechanical hinging system supported by lead bushes provided on the opposing lateral sides thereof, a pair of metal strips or prongs extending downward from a side bottom thereof and a horizontal rod configured to be received within central recess formed in the pair of metal strips or prongs.
[0017]
[0018] In the preferred embodiment of the present invention, a high-capacity fully automated paneer production plant is further comprising successively arranged a milk loading station, a coagulant dosing station, an agitation station, a holding station, a whey removal station and a vat unloading station through which the plurality of precisely aligned vats are successively rotated, and a central PLC/SCADA system to control the process parameters at each of the stations (S1 to S6).
[0019]
[0020] The plant A is further comprising a first pH controller sensor adapted to read pH of incoming milk and a second pH controller sensor adapted to read pH of the coagulant. The central PLC/SCADA system determines the required amount of coagulant to be added in the milk intended to form paneer using the pH data received from first pH controller sensor and second pH controller sensor.
[0021]
[0022] The coagulant dosing station comprising a first agitator and the agitation station is comprising a second agitator, where central PLC/SCADA system is adapted to control speed and direction of first agitator and second agitator to enable forward-reverse mixing of hot coagulated mass without causing shear damage therein.
[0023] The whey removal station comprises a customized microperforated dewheying funnel having a tapered cone shape with micro-sieves formed on all sides thereof. The customized microperforated dewheying funnel is designed to suck a major portion of whey from the hot coagulated mass while preventing entry of curd particles therein.
[0024]
[0025] The vat unloading station comprises a mechanical unloading arm adapted to hold the vat through horizontal rod followed by pushing the bottom of vat upward, causing pivoting of the vat around mechanical hinge leading to gradual and complete tilting of the vat.
[0026]
[0027] In accordance with a second aspect of the present invention, a method to produce paneer in a fully automatic paneer plant is provided. The method comprising steps of introducing, at the Milk loading station, a controlled quantity of milk into a vat using a Flow control Valve; adding, at the coagulant dosing station, a controlled quantity of coagulant into the vat, wherein the quantity of coagulant added into the vat is determined using real-time data from a first pH controller sensor and a second pH controller sensor, followed by a slow agitation to uniformly distribute the coagulant; Performing controlled agitation, at the agitation station, with forward-reverse motion to facilitate proper curd formation of a hot coagulated mass in the vat; holding, at the holding station, the vat for a predetermined period of time to allow proper settling of the hot coagulated mass therein; sucking, at the whey removal section, at least seventy percent of whey from the hot coagulated mass using a customized microperforated dewheying funnel, and tilting, at the vat unloading station, the vat to gradually transfers the remaining coagulated mass from the vat onto the paneer molds for further processing.
OBJECT OF THE INVENTION
[0028] To provide a high-capacity fully automatic paneer manufacturing plant which enables paneer manufacturers to flexibly design the paneer retail packages, i.e., weight, height, length, as per the customer purchasing pattern.
[0029] To provide a high-capacity fully automatic paneer manufacturing plant which enables paneer manufacturers to flexibly design the paneer retail packages, i.e. weight, height, length, with simple change of operational instructions.
[0030] To provide a high-capacity fully automatic paneer manufacturing plant which avoids adverse effects on quality and yield of paneer due to the ambiguity added by the manual handling at various stages of paneer processing.
[0031] To provide a high-capacity fully automatic paneer manufacturing plant which provides an increased yield and better quality of paneer by controlling the process parameters such as milk volume, coagulant quantity, agitation speed etc., considering one or more parameters selected from the group comprising quality of milk, quality of coagulant, size of mold and/or retail packages such that all processes are completed at a similar processing time at all stations.
[0032] In addition to these automated features, the system is designed with modularity in mind, allowing for quick reconfiguration based on production requirements. The integration of smart sensors and programmable logic controllers (PLCs) ensures real-time monitoring and adjustment of crucial parameters, thereby maintaining consistency and quality in every batch. Operators can select custom settings through a user-friendly interface, further reducing the learning curve and operational errors. By leveraging data-driven controls, the device adapts to fluctuations in input material, ensuring optimal paneer texture and minimizing resource consumption.
DEFINITION
[0033] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.
[0034] As used herein the term “Paneer” refers to a non-fermented, non-ripened, soft cheese product obtained by the coagulation of milk or standardize milk using food-grade acidulants such as citric acid, lactic acid, or lemon juice, followed by separation of whey and pressing of the resultant curd. Paneer is typically white to pale cream in color, bland to mildly acidic taste, with a firm, cohesive texture that retains shape upon cutting.
[0035] As used herein the term “milk” refers to both dairy and non-dairy sources that are functionally suitable for curd formation and paneer production. Dairy sources include, to any normal secretion obtained from the mammary gland of a mammal, such as cow, goat, horse or sheep milk. Non-dairy sources include, but not limited to soy, almond, oat, coconut, cashew, mung or other legumes, nuts, seeds, or grains, formulated to mimic the protein and fat profile of dairy milk and capable of undergoing coagulation. As used herein, the term “standardized milk” refers to milk whose fat content has been standardized to a desired level.
[0036] As used herein the term “coagulant” refers to any food-grade acidic agent or enzymatic substance capable of inducing coagulation of milk or milk-like emulsions to form curd suitable for paneer production. Some of the coagulant suitable for the present invention includes but not limited to, Citric acid, lactic acid, acetic acid, Lemon juice, vinegar, fermented whey, Rennet or plant-derived proteases etc.
[0037] As used herein, the term “small scale paneer manufacturers” or like refers to entities engaged in the production of paneer with limited processing capacity, typically operating at a local or regional level with daily production volume not exceeding 500 kilograms of paneer (or as defined by applicable regional food safety or industry standards)
[0038] As used herein, the term “medium scale paneer manufacturers” or like refers to entities engaged in the production of paneer with moderate processing capacity, and partial automation, with daily production volume ranging from 500 kilograms to 2,000 kilograms of paneer (or as defined by applicable regional food safety or industry standards).
[0039] As used herein, the term “medium scale paneer manufacturers” or like refers to industrial entities engaged in high-volume paneer production using fully automated or advanced semi-automated systems, with daily production volume exceeding 2,000 kilograms of paneer (or as defined by applicable regional food safety or industry standards).
[0040] As used herein, the term "PLC/SCADA" refers to a central Supervisory Control and Data Acquisition (SCADA) systems with programmable logic controllers (PLC). In general SCADA refers to an industrial control system and is usually a computer based system for monitoring and controlling a process or equipment or infrastructure. SCADA System can usually include the following subsystems: A Human-Machine Interface or HMI is the apparatus which presents process data to a human operator, and through this the human operator monitors and controls the process; A supervisory (computer) system, gathering (acquiring) data on the process and sending commands (control) to the process; Remote Terminal Units (RTUs) connecting to sensors in the process, converting sensor signals to digital data and sending digital data to the supervisory system. Host control functions are usually restricted to basic overriding or supervisory level intervention. For example, a PLC may control the flow of milk through part of an industrial process, but the SCADA system may allow operators to change the set points for the flow, and enable alarm conditions, such as loss of flow and high temperature, to be displayed and recorded. The feedback control loop passes through the RTU or PLC, while the SCADA system monitors the overall performance of the loop.
BRIEF DESCRIPTION OF DRAWINGS.
[0041] FIG. 1 shows a front view of a high-capacity fully automatic paneer manufacturing plant in accordance with a preferred embodiment of the invention
[0042] FIG. 2 shows an isoperspective top view of a part of high-capacity fully automatic paneer manufacturing plant A in accordance with a preferred embodiment of the invention.
[0043] FIG. 3 shows an isoperspective top view of a high-capacity fully automatic paneer manufacturing plant A in accordance with a preferred embodiment of the invention.
[0044] FIG. 4 shows an isoperspective side view of a high-capacity fully automatic paneer manufacturing plant A in accordance with a preferred embodiment of the invention.
[0045] FIG. 5 shows a front view of a high-capacity fully automatic paneer manufacturing plant A in accordance with a preferred embodiment of the invention.
[0046] FIG. 6 shows a top view of a high-capacity fully automatic paneer manufacturing plant A in accordance with a preferred embodiment of the invention.
[0047] FIG. 7 shows a schematic flow diagram of process for producing paneer in a high-capacity fully automatic paneer manufacturing plant A in accordance with a preferred embodiment of the invention.
DETAILED DESCRIPTION
[0048] Before explaining at least one embodiment of the invention in detail, it is to be understood that the present invention is not limited in its application to the details outlined in the following description or exemplified by the examples. The invention is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for description and should not be regarded as limiting.
[0049] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs. Besides, the descriptions, materials, methods, and examples are illustrative only and are not intended to be limiting. Methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention.
[0050] Further, the words "an" or "a" mean "at least one" and the word "plurality" means one or more unless otherwise mentioned. Furthermore, the terminology and phraseology used herein is solely used for descriptive purposes and should not be construed as limiting in scope. Language such as "including," "comprising," "having," "containing," or "involving," and variations thereof, is intended to be broad and encompass the subject matter listed thereafter, equivalents and any additional subject matter not recited, and is not supposed to exclude any other additives, components, integers or steps. Likewise, the term "comprising" is considered synonymous with the terms "including" or "containing" for applicable legal purposes. Any discussion of documents acts, materials, devices, articles, and the like are included in the specification solely to provide a context for the present invention.
[0051] The present invention is a high-capacity paneer manufacturing plant (referred to as “plant A” hereinafter for the purpose of brevity) which is specially engineered considering need of small to medium scale paneer manufacturers. Plant A is designed to standardize and streamline the paneer manufacturing process at a small to medium scale. This system automates the coagulation process, minimizes manual intervention, improves consistency, reduces losses due to process variability, and enhances product hygiene and efficiency.
[0052] Fig. 1 shows front view of a high-capacity fully automatic paneer manufacturing plant A in accordance with a preferred embodiment of the invention. The plant A is comprising of a continuous carousel frame 100 (referred to as “frame 100” hereinafter for the sole purpose of brevity), a plurality of vats 200 precisely mounted on the frame 100, a servo motor 300 with reduction box 400 mounted below frame 100. The plant comprises various processing stations, namely milk loading station S1, a coagulant dosing station S2, an agitation station S3, a holding station S4, a whey removal station S5 and a vat unloading station S6 arranged surrounding the frame 100. The stations are cumulatively abbreviated as S1-S6, hereinafter for brevity purposes. The plurality of vats is adapted to successively rotate through the station S1 to S6. All the processes at the stations S1 to S6 are controlled by Central PLC/SCADA system 500.
[0053] Fig. 2 shows a part view of frame 100 in accordance with a preferred embodiment of the present invention. Here, all other components of Plant A have been removed, except frame 100, for purpose of clarity and ease of understanding the structure of frame 100. Frame 100 comprises a central rotating shaft 101 having a first plate 101a and a second plate 101b mounted respectively at bottom and top end thereof, a plurality of first bars 102 arranged on first plate 101a and plurality of second bars 103 mounted on second plate 101b and a plurality of U-Shaped flanges 104 mounted on second bars 103.
[0054] The central rotating shaft 101 is a vertical upright shaft having first plate 101a mounted at bottom end thereof and a second plate 101b mounted top end thereof. The first plate 101a is a circular plate and is at least twice the size of the second plate 101b. The plurality of first bars 102 are arranged radially and equidistantly on the first plate 101a such that first end of each of first bar 102 is affixed to the second plate 101b while second end is extending horizontally away from the first plate 102.
[0055] Second plate 101b is a petal edged circular plate having a circular base with a scalloped or fluted rim that mimics flower petals. The plurality of second bars 103 extends downward from the scalloped edges of second plate 101b up to the second end of plurality of first bars 102. Here, second ends of plurality of first bars 102 and second end of plurality of second bars 103 are fixedly attached.
[0056] The plurality of U-Shaped flanges 104 are mechanically fastened on the second end of first bars 102. As can be seen from FIG.2, the number of U-Shaped flanges, the number of first bars 102 and the number of second bars 103 is correspondent to each other. U-shaped Flange 104 has a central tapered section 104a which exhibits a V-shaped profile when viewed in horizontal cross-section. This tapering is directed inward, forming a narrowing geometry that enhances rigidity while forming a round carousel structure for precise alignment of vats 200 thereon. On both lateral sides of the U-shaped Flange 104, there are U-shaped slots 104b. U-shaped slots act as connecting means for connecting the vat 200 with frame 100.
[0057] In a preferred embodiment of the present invention, the second plate 101b has a size which is smaller than size of the first plate 101a. In other words, the first plate 101a is bigger than the second plate 101b. In a preferred embodiment of the present invention, the first plate 101a is at least twice the size of the second plate 101b, however, the same is not limited herein.
[0058] In a preferred embodiment of the present invention, number of the first bar 102 is correspondent to the number of second bars 103. In a more preferred embodiment of the present invention, number of the first bar 102 is correspondent to the number of U-shaped flanges 104.
[0059] Fig. 3 shows a plurality of vat 200 mounted on frame 100 through U-shaped flange 104. More specifically, consecutive vat 200 is mounted on the frame 100 by lateral sides of consecutive U-Shaped flange. Precision alignment of paneer vats is ensured through a uniform circular rotary design. This enables rotation of vats without jerks avoiding splashing and hence, decreases the curd loss and increases the yield. Such an integrated structure eliminates the need for high-maintenance rail systems. Reduced number of moving mechanisms ensures durability and minimal service requirements.
[0060] Each vat 200 is a hollow vessel configured to receive and hold fluid, such as milk, at different temperature for carrying out various processing to make paneer. The vat may have cylindrical, rectangular, or any suitable geometric shape, that is not limited herein. Each vat further comprises a single spout 201 integrally formed in the vessel wall. The spout is elongated, extending outward from the container to facilitate controlled dispensing of the contents therein. The spout 201 may be tapered, curved, or angled as per the application.
[0061] Each vat 200 is equipped with a robust mechanical hinging system 202 supported by lead bushes, ensuring precise alignment, smooth motion, and reliable operation. The mechanical hinging system 203 positioned centrally on two opposing lateral sides of the vat. The hinging system 203 comprises metal hinges integrated with lead bushes. Specifically, metal hinges integrated with lead bushes are adapted to received in U-shaped slots 104b of U-shaped flange 104 when connecting vats to the frame 100. The metal hinges serve as rotational pivot points, enabling the vat 200 to tilt around a rotary axis defined by the pivot hinges.
[0062] In a preferred embodiment of the present invention, the each of vat 200 has capacity to hold at least 40 liters of fluid therein. In an alternative embodiment of the present invention. the each of vat 200 has capacity to hold upto 250 liters of fluid therein.
[0063] Each vat 200 is provided with a pair of metal strips or prongs 204 extending downward from a side bottom thereof. Each of metal strips 204 has a circular recess formed at one end thereof to receive a horizontal rod 203 therein. At Vat unloading station S6, the horizontal rod 203 carried by a pair of metal strip 202 is held by mechanical unloading arm 61 to tilt the vat 200. This tilting mechanism facilitates controlled unloading of the contents housed within the vat 200, enhancing operational efficiency and ergonomic handling. Tilting of vats enables complete drainage of all the content therein and increasing yield thereby.
[0064] The plant A comprises multiple vats 200. All vats are fully detachable, enabling thorough cleaning and hygiene maintenance. Flexible design allows easy scalability for higher capacity without major system modifications. Here, size, number, length, and filling volume of vat is adjustable considering the size and number of final retail packages needs to be produced. In a preferred embodiment of the invention, number of vats in plant A ranges from 6 to 12, preferably 6 to 9. One may increase or decrease the number as per the need. Fig. 2 shows mounting of six vats on frame 100. Here, at any one time, any one of vat is held at any one of six processing stations, S1 to S6. Rotation of frame 100 will lead to advancement of vat at next processing station. That is each vat is successively rotated through six processing stations S1 to S6 which results in higher yield.
[0065] In an alternative embodiment, on a Continuous Carousel frame 10, consecutive vat 200 is mounted on a centrally driven rotary frame 100 by a U-shaped flange 104 via a pivotable connector such that clevis pin connector. Other fasteners can also be used to connect multiple vats to frame 100, that is not limited herein.
[0066] In a preferred embodiment of the invention, each vat 200 has holding capacity ranging from 40 to 250 liters. One may increase or decrease the size of the vat as per the production demand. Here, plant A operates through a sequence of mechanical actions, beginning with the rotation of multiple vats across successive stations S1 to S6, and culminating in the discharge of vat contents into paneer hoops. The system operates entirely through mechanical means, with no reliance on electrical components or pneumatic means, thereby minimizing maintenance requirements and reducing operational costs.
[0067] FIG. 3 shows an isometric view of plant A in accordance with a preferred embodiment of the present invention. Fig. 3 explains the working of plant A with six vats mounted on frame 100. Stations S1 to S6 are successively arranged surrounding the frame 100. Essential components at each station are described for clarity purposes. Each station may have other components that are required for working thereof and are known to artisans, but are neglected here for sole purposes of brevity and ease of understanding the working of plant A.
[0068] Vats 200 are rotated through series of defined processing steps at six stations under control of PLC/SCADA 500. These stations are, namely, Milk loading station S1, Coagulant Dosing station S2, Agitation Station S3, Holding Station S4, Whey Removal Station S5, and Vat unloading station S6. Each vat performs one process step at a time, enabling simultaneous multi-batch processing and continuous operation.
[0069] Milk loading station S1 comprising a milk balance tank 11 for storing pasteurized milk, a milk dosing pipe 12 to introduce milk from milk balance tank 11 into the vat 200 under control of Flow control Valve 13. Flow control Valve 13 is an automatic flow control valve. Flow parameters are programmable based on the batch size. This ensures uniform batch input, reducing operator dependency.
[0070] Milk loading station S1 further comprises a first mechanical up–down dosing system 10 which is adapted to provide up and down motion to milk dosing pipe 12 in a controlled pattern which ensures uniform milk distribution and reduced foaming. This aids the consistent coagulation in later steps. The system operates without electrical drives, thereby lowering maintenance and increasing reliability.
[0071] Coagulant Dosing station S2 is comprising of a plurality of coagulant tank 21 and a coagulant dosing pipe 22 which provides coagulant from the coagulant tank 21 into the vat 200. coagulant dosing pipe is configured for providing synchronized up–down motion into vat 200 which ensures uniform distribution of coagulant with milk contained therein. In preferred embodiment of the present invention, coagulation tank 21 has storage capacity ranging between 200 to 500 liters.
[0072] Plant A further comprises a pair of pH controller sensor. The first pH controller sensor 71 (not shown) reads both pH of incoming milk and second pH controller sensor 72 (not shown) reads pH of coagulant solution and based on pre-set coagulation logic, the PLC/SCADA 500 system calculates and delivers the required amount of coagulant solutions (70-90 °C) into the preheated milk (70-90 °C). Here, real-time pH of Milk received from first pH controller sensor 71 and real-time pH of coagulant solution received from second pH controller sensor 72 is considered to determine the amount of coagulant solution required to be added in vat to produce better quality paneer. In contrast to pneumatic pump used in the prior devices, dosing is executed using a peristaltic or metering pump for precision controls to each paneer vat. Operator dependency to control the quantity of coagulant solutions to the milk is eliminated thereby.
[0073] As shown in FIG. 4, coagulant dosing station S2 further comprises a first agitator 23 comprising a pair of agitation blades 231 mounted on an agitation shaft 232. The first agitator 23 is adapted to gently mix the coagulant solution with milk for achieving better mixing without generating any shear forces.
[0074] Agitation Station S3 has a second agitator 31 comprising a pair of agitation blades 311 mounted on an agitation shaft 312. In a preferred embodiment of the present invention, both first agitator 23 and second agitator 31 are structurally similar to each other.
[0075] The second agitator 31 is adapted for providing controlled agitation in a programmable forward-reverse motion. The second agitator 31 features an automatically controlled and adjustable RPM, allowing for customizable mixing speeds and direction. The programmable forward and reverse motion of agitator ensure even mixing of the mass after coagulation without causing shear damage to the curd lumps formed therein. Agitation speed and direction can be also customized for different milk types or process condition. In any case, agitator blades and speed of agitation are specially designed to mimic the hand stirring. In a preferred embodiment of the present invention, agitators are operated at speed of 3 to 10 RPM. This provides uniform agitation of milk/curd mixture with minimal mechanical stress, which results in a better-quality paneer in terms of taste and yield.
[0076] Agitation is continued for a predetermined period of time which is sufficient to prepare curd lumps in the hot coagulated mass. The predetermined period of time is preset by PLC/SCADA depend upon one or more factors selected from the group comprising batch size and a quality of milk used to prepare paneer.
[0077] As shown in FIGs. 1 and 3, coagulant dosing system and agitation system is arranged inside a single housing 30 for ease of handling. The housing is mounted on a pair of linear up and down shaft 33 which enables simultaneous up and down motion of both system while the speed and direction of first agitator 23 and second agitator 31 is programmable independently by PLC/SCADA 500. As the up and down motion is imparted to complete housing enclosing coagulant dosing system and agitation system via linear up and down shaft 33, there is no chance of grease or like lubricant dripping inside vat 200 which is the problem in conventional devices.
[0078] After coagulation, it is important to retain as many solids as possible in the coagulum rather than in the whey. To ensure clear whey separation, during this stage, the hot coagulated mass in the vat is kept still, without performing any addition or agitation. This step allows the curd lumps to firm up and further separate from the whey. This resting period helps achieve a cleaner whey separation and hence, higher curd yield. Fig. 5 shows Vat 200 at holding station S4.
[0079] Whey Removal Station S5 comprises a customized microperforated dewheying funnel 51 and a whey suction up and down shaft 52. The customized microperforated dewheying funnel 51 has a tapered cone shape with micro-sieves formed on all sides thereof. The tapered design facilitates deeper penetration in hot coagulated mass in the vat while micro-sieves prevent any curd particles entering the whey collection line. The customized funnel is mechanically connected with a suction pump and a control valve to suck at least 70% of the whey from the settled coagulated mass. Once the excessive whey is collected, a whey suction up and down shaft 52 moves the customized microperforated dewheying funnel 51 upward away from the vat 200. Whey may be collected into a whey collection tank, which may be further sieved and transferred to a storage tank or in some cases, they use it for coagulation water.
[0080] In a preferred embodiment of the present invention, the customized microperforated dewheying funnel 51 has capacity to suck 10 to 50 liters of whey per minute.
[0081] As shown in FIG. 6, Vat unloading station S6 comprises a mechanically operated unloading arm 61 is designed to efficiently transfer the firm curd mass from the coagulation vat 200 to the next processing stage without disrupting the integrity of the curd lumps. Fig. 6 shows a clear view of mechanically operated unloading arm 61 in accordance with an embodiment of the present invention. The mechanically operated unloading arm 61 comprises a pair of metal strips having V-slots formed at one end thereof designed to receive the horizontal rod 203 of vat 200 therein. Once the vat is held through horizontal rod 203, the mechanically operated unloading arm 61 push the vat bottom in upward direction leading to pivoting of vat around lead bushes 202. This pivoting action causes the contents within the cylinder to shift and discharge progressively, allowing for controlled and gradual unloading. This step allows the curd to gently unloaded via spout 201, minimizing the mechanical stress and preserving curd texture. This tilting mechanism facilitates controlled unloading of the contents present within the vat 200, enhancing operational efficiency and ergonomic handling. The mechanism operates purely through mechanical force, without electrical components, ensuring minimal maintenance and high reliability in industrial or manual settings.
[0082] The unloading process can be synchronized with downstream equipment, such as cutting or pressing stations, to maintain continuous workflow and product consistency. As the curd is directly transferred to paneer hoops with mechanical actions, dependence on electrical actuators as well as labors is eliminated. This reduces downtime and simplifies troubleshooting, provides better process control and easy maintenance. Tilt mechanisms enable safe and gradual unloading of vat content preventing splashing. Further, tilting of vats enables complete drainage of all the content therein increasing yield thereby.
[0083] Fig. 7 shows the process for manufacturing paneer in a high-capacity fully automated paneer production plant A in accordance with a preferred embodiment of the present invention. In brief, Step 701, at milk loading station S1, a controlled quantity of milk is introduced from milk balance tank 11 within any one of a plurality of vat 200 at a time under control of Flow Control valve 13. Here, the batch size is calculated by PLC/SCADA systems based on total amount of paneer needs to produced, retail package size and quality of milk. For example, lower fat in milk results in low curd formation, while higher fat in milk results in higher yield of curd. Further, batch size i.e., milk volume in the vat is calculated considering the total quantity of paneer as well as number and size of retail package that needs to be produced, so that there is no waste or minimal paneer loss at time of packaging. The milk is heated at temperature of 70 to 90 DEG C before coagulation process starts.
[0084] Step 702, vat 200 is moved to location of coagulant dosing station S2, wherein a precisely controlled quantity of coagulant is added into vat 200 via peristaltic or metering pump. Here, precise quantity of coagulant is calculated by PLC/SCADA using data from first pH controller sensor and second pH controller sensor as described above. The same is not repeated herein. Addition of coagulant is followed by a gentle agitation of mixture using first agitator 23 to achieve uniform distribution of coagulant and effective mixing thereof results in consistent curd formation.
[0085] Step 703, vat 200 is moved below agitation station S3, where second agitator 31 is inserted inside the vat to impart gentle forward and reverse motion to hot coagulated mass to achieve effective curdling.
[0086] Step 704, vat 200 is moved to next holding station S4, where the vat is hold, i.e., kept still for a period of time to allow settling of curd formed at previous station. This results in a cleaner whey separation.
[0087] Step 705, vat is rotated to whey removal station S5, where a customized microperforated dewheying funnel 51 is penetrated inside the vat upto certain length of whey layer such that at least 70 to 80% of whey is sucked before moving the vat toward next station.
[0088] Step 706, at vat unloading station S6, a mechanical unloading arm 61 holds the horizontal rod 203 of vat 200 followed by pushing the rod upwards resulting in pivoting of vat 200 around mechanical hinges 202 supported by lead bushes, thereby resulting in gradual tilting of vat 200. The content from the tilted vat 200 can be directly collected in paneer molds for further processing. The placement of paneer molds or hoops may be manual or mechanized, depending on customer need and scale. In plant A can be synchronized with mechanized filling system as well.
[0089] Step 707, the emptied vat is now ready for next batch and is moved to milk loading station S1, where the vat enter into a new cycle of paneer making where all steps 601 to 606 are repeated.
[0090] Here, rotation of vat 200 through station S1 to S6 is achieved via rotation of carousel frame 100 which prevents splashing and jerking of vat 200 resulting in better quality and quantity of paneer production.
[0091] In a preferred embodiment of the present invention, PLC/SCADA regulate process parameters by assigning each coagulation vat (200) to any one of designated processing station (S1-S6) for a predetermined time interval. This time interval is preset within the control logic of the PLC/SCADA system to ensure that all requisite operations at the assigned station—such as milk filling, coagulation dosing, agitation, settling, or transfer etc.—are completed within the allocated duration without any manual intervention. The controlled timing mechanism ensures uniformity in processing across vats and stations, thereby maintaining consistent yield and quality of the final paneer product without interruption or deviation.
[0092] Plant A enables production of large quantity of paneer in smaller space at a high speed. In a preferred embodiment of the present invention, it takes 10 to 15 minutes to make one batch of paneer starting from milk loading to vat unloading steps. Plant A make it possible to produce paneer blocks at every two minutes from the consecutive vat 200 as multiple batches are processed simultaneously at different stage of paneer production.
[0093] Plant A is further comprising a servo motor 300 along with a reduction gear box 400 operatively connected with central rotating shaft 101 for optimized torque transmission from the servomotor 300 to plurality of vats 200. Frame 100 enables smooth rotation of precisely aligned vats without jerks which minimizes product spillage and provides better texture to coagulated mass.
[0094] All surfaces in contact with curd are preferably constructed from food-grade materials to prevent contamination and ease cleaning, supporting hygienic operations throughout the paneer production process.
[0095] Plant A completely eliminates the manual intervention at various stages of paneer making, namely coagulant dosage, coagulant mixing, whey removal and vat unloading. Avoidance of manual intervention at different stages removes the ambiguity added by differences in the engagement and strength of different labors leading to production of paneer with consistent quality throughout the batch processing. The plant A reduces the need of manpower to one third times while enabling 60 to 80 % capacity utilization.
[0096] Plant A is designed with high mechanical precision while remaining simple, robust, and cost effective. It eliminates dependency on complex electrical or pneumatic systems, making it easy to operate, even by unskilled labor. The design ensures reliability, hygiene, and scalability at a cost 2 to 3 times lower than fully automated electrical or pneumatic systems. Pneumatic systems often face accuracy and reliability issues due to air-pressure variations. Mechanical gear-driven systems offer superior precision, consistency, and long-term reliability with lower maintenance cost.
[0097] Precise control of coagulation and agitation parameters using a central PLC/SCADA gives uniform texture and quality.
[0098] In a preferred embodiment, the system is configured to determine the batch size such that the entire content of a coagulation vat is dimensioned to match the capacity of a single mold. This eliminates the need to divide the vat contents across multiple molds, thereby preventing inconsistencies in coagulant distribution. By ensuring that each batch corresponds precisely to one mold volume, the process avoids the formation of paneer blocks with uneven dimensions, which typically result from manual or imprecise multi-mold filling. This optimization enhances product uniformity, reduces trimming waste during packaging, and improves overall yield efficiency.
[0099] Plant A provides an increased yield by 15 to 30% by avoiding splashing of vat content during movement by eliminating used of large rails or conveyers, complete drainage of vats by the mechanical unloading arm 61 and reduced curd loss during whey separation. Plant A consumes 2 times less energy than any Automated Plant or even any traditional manufacturing plant of given capacity while requiring almost half space for same production capacity.
[00100] Production capacity of Plant A can be easily scaled up or scaled down as per the retail package size by changing the process parameters using the central PLC/SCADA. Preferably, all parameters are adjusted based on the batch size and the final package size to be produced within fractions of second. This reduces waste of paneer while cutting the paneer into desired retailed package size.
[00101] Plant A thus addresses the industry challenges of manual intervention, inconsistent quality, and hygiene issues in a fully automatic paneer manufacturing processes while considering needs of small to medium scale manufacturers.

Dated 1st Day of October, 2025
, Claims:We claim:
1. A high-capacity fully automated paneer production plant (A) comprising
1.1 a continuous carousel frame (100) comprising
a. a central rotating shaft (101) having a first plate (101a) mounted at a bottom end thereof and a second plate (101b) mounted at a top end thereof, wherein the second plate (101b) has a size which is smaller than size of the first plate (101a);
b. a plurality of first bars (102) arranged radially and equidistantly on the first plate (101a) such that a first end of each of the first bar (102) is affixed to the second plate (101b) while a second end thereof is extending horizontally away from the first plate (102),
c. a plurality of second bars (103) is extending downward from the second rotary plate (101b), wherein an opposite end of each of second bars (103) is attached to the second end of first bars (102), wherein the number of first bar (102) is correspondent to the number of second bars (103), and
d. a plurality of U-Shaped flanges (104), wherein each of the plurality of U-shaped flange is mechanically fastened on the second end of first bars (102) near second end of second bars (103), wherein the number of U-Shaped flanges, the number of first bars (102) and the number of second bars (103) is correspondent to each other, wherein
the U-shaped flange (104) has a central tapered section (104a) which exhibits a V-shaped profile when viewed in horizontal cross-section, and, a U-shaped slot (104b) formed at both lateral sides of the U-Shaped flange (104);
1.2 A plurality of vats (200) mounted at regular interval on continuous carousel frame (100), wherein the plurality of vat (200) is mechanically fastened to the frame (100) through opposite sides of a consecutive U-shaped flange (104), wherein the number of first bars (102) and the number of second bars (103) are correspondent to the number of vats (200), and
1.3 Servo motor (300) along with a reduction gear box (400) operatively connected to the central rotating shaft (101) to enable optimized torque transmission from the central rotating shaft (101) to the plurality of vats (200).
2. The plant as claimed in claim 1, wherein the each of plurality of vat (200) comprises an integrally formed single spout (201) running on a wall thereof, a mechanical hinging system (202) supported by lead bushes provided on the opposing lateral sides thereof, a pair of metal strips or prongs (204) extending downward from a side bottom thereof and a horizontal rod (203) configured to be received within central recess formed in the pair of metal strips or prongs (204).
3. The plant as claimed in claim 1, further comprising successively arranged a milk loading station (S1), a coagulant dosing station (S2), an agitation station (S3), a holding station (S4), a whey removal station (S5) and a vat unloading station (S6) through which the plurality of precisely aligned vats (200) are successively rotated, and a central PLC/SCADA system (500) to control the process parameters at each of the stations (S1 to S6).
4. The plant as claimed in claim 1, further comprises a first pH controller sensor (71) adapted to read pH of incoming milk (1) and a second pH controller
sensor (72) adapted to read pH of the coagulant, wherein the central PLC/SCADA system (500) determines the required amount of coagulant to be added in the milk intended to form paneer using the pH data received from first pH controller sensor (71) and second pH controller sensor (72).
5. The plant as claimed in claim 2, wherein the coagulant dosing station (S2) comprises a first agitator (23) and the agitation station (S3) comprises a second agitator (31), wherein central PLC/SCADA system (500) is adapted to control speed and direction of first agitator (23) and second agitator (31) to enable forward-reverse mixing of hot coagulated mass without causing shear damage therein.
6. The plant as claimed in claim 2, wherein the whey removal station (S5) comprises a customized microperforated dewheying funnel (51) having a tapered cone shape with micro-sieves formed on all sides thereof, wherein customized microperforated dewheying funnel (51) is designed to suck a major portion of whey from the hot coagulated mass while preventing entry of curd particles therein.
7. The set up as claimed in claim 2, wherein the vat unloading station (S6) comprises a mechanical unloading arm (61) adapted to hold the vat (200) through horizontal rod (203) followed by pushing the bottom of vat (200) upward, causing pivoting of the vat (200) around mechanical hinge (202) leading to gradual and complete tilting of the vat (200).
8. A method (B) to produce paneer in a fully automatic paneer plant (A) comprises
a) introducing (701), at the Milk loading station (S1), a controlled quantity of milk into a vat (200) using a Flow control Valve (13);
b) adding (702), at the coagulant dosing station (S2), a controlled quantity of coagulants into the vat (200), wherein the quantity of coagulant added into the vat (200) is determined using real-time data from a first pH controller
sensor (71) and a second pH controller sensor (72), followed by a slow agitation to uniformly distribute the coagulant;
c) Performing (703) controlled agitation, at the agitation station (S3), with forward-reverse motion to facilitate proper curd formation of a hot coagulated mass in the vat (200);
d) holding (704), at the holding station (S4), the vat (200) for a predetermined period of time to allow proper settling of the hot coagulated mass therein;
e) sucking (705), at the whey removal section (S5), at least seventy percent of whey from the hot coagulated mass using a customized microperforated dewheying funnel (51), and
f) tilting (706), at the vat unloading station (S6), the vat (200) to gradually transfers the remaining coagulated mass from the vat (200) onto the paneer molds for further processing.