The continuous Paneer and channa-making machine has been developed to handle cow and buffalo milk (Figure-1). The machine is an integrated unit involving various unit operations in a synchronized manner (1 to 5 of Figure-1). The prototype has demonstrated the sequencing of operations in a manner, which would eliminate the prevalent batch type manufacturing system.
The existing technological approach for production of such coagulum is based on the traditional manufacturing technique of coagulating milk by acid and heat in a steam-jacketed vat. In the existing process coagulation starts before the entire mixing process is complete, which leads to lesser solids recovery and a lower yield. Due to shear force generated by intense agitation, the already formed coagulum starts disintegrating and this affects final product texture. As traditional process is purely batch type there is variation in quality from one batch to another. Being batch process it involves extensive manual labour and also makes the process unhygienic. In the present invention complete mixing and reaction occurs prior to the start of coagulation, which leads to greater product recovery and better textural quality. Being a continuous process, product obtained is of uniform quality. Application of Present invention gives a hygienic product as mixing of acidulant and milk takes place in line at T-junction in a transverse jet mixer-reactor (TJM-R), leaving no exposure to contamination.
The invention 'continuous Paneer/Channa making machine' is the first prototype designed and developed to handle cow and buffalo milk. The designed system consist of:
1) Supply of preconditioned milk (1)
2) Supply of coagulant (2)
3) Curd dewatering and matting system (5)
The milk conditioning and supply unit consists of a plate heat exchanger with provision of heat regeneration, heating of milk from 25°C to 90±2°C holding for two minutes and cooling it from 90±2°C to 70±2°C. This heat treatment was incorporated to denature whey protein for maximum product recovery. Other accessories in this unit are of appropriate

sizes/capacities such as balance tank, pump, flow meter, temperature indicator and auto thermal control unit etc.
Coagulant supply unit consists of stainless steel tank with agitator. Steam is used for indirect heating of acidulant.
Both the above units are connected through a TJM-R (3) wherein effective mixing of milk and acidulant takes place; subsequently coagulum is fed in to the dewatering unit.
The continuous dewatering and matting unit (Figure-2) consists of twin apron conveyer to carry out primary and secondary filtration in the same machine. The lower conveyor is flanged type while the upper one is unflanged type. The flanged unit has perforations for drainage. The additional fine filter of appropriate size is placed over the conveyor to prevent the solids loss. The linear filter size corresponding to applied pressure was selected. The linear speed of conveyor is designed so that it gives the residence time required for the dewatering. Flexibility in the motion is incorporated through a variable speed drive, giving 5-8 min of residence time. As per design Paneer/Channa could be obtained in a continuous manner. The complete unit is, made of stainless steel. All the three units operate in integrated manner. A functional prototype is available at NDRI, Karnal.
3.2 OPERATIONAL PROCEDURE
1. Clean all the components, which require assembling and where milk comes in contact.
2. Preparation for Milk Conditioning and supply unit:

a) Switch-on the power supply from the main control panel.
b) Turn-on steam and tap water supply from main service line.
c) Fill hot water battery with water and turn-on the steam and observe rise in the
temperature.
d) Fill-up balance tank with water and switch-on the milk pump and hot water pump to
stabilize unit with water.
e) Set the flow rate of water into the system with the help of flow meter and control
valve.
f) Adjust the outlet temperature of water in the range of 70-75°C by regulating tap water
supply in the cooling section of PHE.
3. Acidulant conditioning and supply unit:
a) Fill-up the acidulant tank with measured quantity of water.
b) Turn on the steam supply to raise and maintain the temperature to 80°C.
c) Add measured quantity of acidulant to maintain solution strength as recommended.
d) Switch-on the agitator of acidulant supply tank.
e) Establish and calibrate the flow through TJM-R by measuring desired flow rate and
check for blockage if any.
4. Preparation for Dewatering and matting section:
I) For Paneer making:
a) Ensure proper fixing of Nylon filter of recommended mesh size on the lower endless belt
conveyor.
b) Switch-on dyno-drive control for lowest speed of the conveyor.
c) Fill dewatering unit up to the conveyor level for rinsing.
d) Warm-up the dewatering units to 70°C by opening steam valve.
e) Now the unit is ready to take-up the curdled milk for dewatering and matting operation.

5. When the outgoing temperature is established turn-on milk supply to balance tank to replace
water.
6. Switch-on the acid dosing pump and set the flow of acidulant at desired level.
7. Check pH of whey entering in to the dewatering section and regulate it by adjusting flow rate
of acidulant, for paneer manufacturing.
8. Observe product coming out of the dewatering section in the form of continuous cake, if not,
change the conveyor speed to avoid clogging of curdled mass at the entrance of dewatering
section.
9. Cake of required size is removed manually from the end of dewatering section and dipped
into the chilled water.
II) For Channa making:
Since no pressing is required for channa, the conveyor speed is to be kept high with low feed rates. The cake thickness should be low enough to avoid pressing by top conveyor. The acidulant strength is also modified accordingly.
10. Cleaning operation:
a) At the end of the operation replace milk with tap water in the balance tank.
b) When clear water starts coming out in the dewatering section turn flow diversion valve
for caustic cleaning.
c) Prepare caustic solution in the balance tank at recommended strength and circulate for
15 min and drain the solution carefully.
d) Rinse out the caustic solution by water at 75°C for 10 min.
e) Cleaning of dewatering section is done same as above, using wet scrubbing through
nozzle.

11. After cleaning Switch off all the pumps and the drive units.
12. Switch-off main control panel.

4. STATEMENT OF CLAIMS We claim:
4.1 that the continuous paneer and channa making machine as stated in section- 3, is a
unique system and first of its kind for making paneer and channa in continuous manner from raw standardized buffalo milk (6% Fat and 9% SNF) and whole cow milk respectively.
4.2 that the system consists of an integrated milk preconditioning and supply unit,
a coagulant supply unit and a curd dewatering/ matting unit working in a
synchronized manner.
4.3 that the milk preconditioning and supply unit comprises of a plate heat
exchanger (PHE) with provision of heat-regeneration, heating the milk from
25°C to 90+2°C and holding it in a tubular holder designed to give two
minutes holding timeand then supply milk at 70+2°C through a flow controller
into a coagulant mixing unit named as transverse jet mixer-reactor (TJM-R).
4.4 that the transverse jet mixer reactor receives the preconditioned coagulant
(citric acid) of 1.5-5% concentration injected through a hole 1-3 mm
diameter(d) into milk stream diameter(D) maintaining d/D ratio of 0.125 to
give velocity above 10,000 Reynolds number into milk stream to maintain pH
5.2 to 5.3 for instant curdling of milk.
4.5 that the curdled hot mass passes on to the curd dewatering unit comprising of
twin-apron conveyors with primary and secondary filtration sections operating
under laminar flow conditions to avoid damage to the curd particle and
maintaining the mix stream temperature of 70+2°C for effective matting.
4.6 that the primary filtration section retains the curd and drains out 90% whey
through 1 mm screen ,on a moving conveyor, maintaining a constant liquid
level to keep curdled mass floating and movable with help of a slow moving
star wheel for uniform feeding over the apron conveyor.
4.7 that the secondary filtration unit comprises of long aprons, the lower one
flanged and perforated with 3mm holds ,with additional food grade filter fine
Nylon of std Tyler gauge-100 (85 + 3 holes/inch) in size placed over the
perforated slates forming an endless membrane sewed on a slate and dragged
in a manner to fully cover lower conveyor moving at a linear velocity 10-40
cm/minute and the 1.5 to 2.5 meter conveyor length giving matting/ filtration
duration of 5-10 minutes . The lower conveyor is flanged slate type forming a

channel, while the other moving in unison to it is unflanged and imperforated and acts as a cover to press the retained mass, duly supported in a manner to give an applied pressure of 80-100 KPa
4.8 that the secondary filtration zone also collects the residual whey rich in total
solids separately and is provided with spray nozzles for pressurized on-line
cleaning of moving conveyor housed in an appropriate enclosure.
4.9 that the frame and enclosures are made of stainless steel, with hygienic design
and holds all instruments and control systems.
4.10 that the optimum pH regulation is done through a pH control unit having a pH
sensor and regulating the coagulant supply unit.
4.11 that the optimum matting pressure is regulated through a pressure sensing and
control device fitted over the apron conveyors.
4.12 that the paneer layer of 10-30 cm wide and 3-5 cm thick is removed, cut into
pieces and dipped in saline water, whereas during processing of channa the
upper conveyor is disengaged to release pressure over the curdled mass, and
the later is collected and cooled.