Tender For Supply, Installation & Commissioning Of Various Equipment for Dairy Plant Of Khyber Agro Farms Pvt. Ltd, Srinagar (J&K) PART: B (TENDER FOR SUPPLY, INSTALLATION & COMMISSIONING OF EQUIPMENT FOR EXPANSION OF CAPACITIES OF EXISTING CURD & PANEER SECTIONS) Tender Ref. NIT: KHYBER AGRO FARMS/DAIRY/01 Date 15/11/2017. PRE-BID MEETING 04.12.2017 AT 01:00 PM
TABLE OF CONTENTS SECTION DESCRIPTION PAGE NO. SECTION - 1 SECTION - 2 SECTION - 3 SECTION - 4 SECTION - 5 Invitation for Bids Instruction to bidders /Supplier Introduction Technical Specifications Financial Bid Form & Schedule
TENDER FOR SUPPLY, INSTALLATION & COMMISSIONING OF EQUIPMENT FOR EXPANSION OF CAPACITIES OF EXISTING CURD & PANEER SECTIONS PART - B Tender Form issue date and time: Last date for sale of Tender: 17-11-2017 Time 11:00AM 16:00 HOURS 11-12-2017 Time up to 14:00 HOURS Last date of submission of Tender: 12-12-2017 Time up to 14:00HOURS Time & Date of opening of Bids: 13-12-2017 Time 12:00HOURS Pre-Bid meeting: 04-12-2017 Time 13:00 HOURS Address of office & Place of opening of Bids: Khyber Agro Farms Pvt. Ltd. First Floor, SDPS Building, Goni Khan, Hazuri Bagh Road Srinagar-190 009 (J & K) Contact Person: Mr Parvez Ahmed Mobile: +91 94195 12792 NOTE: 1. Tender document can be purchased from the office of Khyber Agro Farms Pvt. Ltd., First Floor SDPS Building, Goni Khan, Hazuri Bagh at Srinagar. after depositing Tender Document Fees either cash or DD in favour of Khyber Agro Farms Pvt. Ltd. Payable at Srinagar, 2. Against receipt of request, tender documents shall also be sent thru courier or post at an additional cost Rs. 500/- for each part. 3. Tenders documents can also be downloaded from website of the Khyber Agro Farms, www.khybermilk.com for reading purpose.
(A) KHYBER AGRO FARMS PVT. LIMITED Tender shall be submitted in two parts in separate sealed covers as described below:- Part-1- Technical Bid containing Technical Offer and terms - conditions. Technical offer for main equipments shall contain a) Technical specification if not detailed in tender papers otherwise confirmation of the one given with tender with filed in details as desired. b) Scope of supply & bill of materials c) Catalogues, literature & drawings as required to give details of items. d) P & I diagrams showing sizes of pipes & fittings and inter connection details of main equipments if applicable. e) Optional items. f) Recommended list of spares for three years of operation. g) Schedule of completion of erection and commissioning job. h) Guarantees offered for equipments. i) Listing of deviations. j) Listing of exceptions & assumptions. k) Delivery schedule. l) Validity of offer. m) Services & materials to be provided by the purchaser. n) Schedule of stage/final inspections at suppliers works if required. o) A confirmation whether earnest money is given with the part II i.e. price Bid or not with name of bank and draft No. p) Any other details/ document desired in tender documents. Technical offer shall contain a) Agreed terms & conditions (copy of those with tender paper to be returned duly signed in token of acceptance.) b) General terms & conditions & deviations if any.
Part-II PRICE BID / FINANCIAL OFFER It will contain. a) The best offer with firm prices in the price schedule format indicating basis of price, Packing & Forwarding charges, Excise duty, GST, Freight, Octroi, insurance, unloading etc, ex site basis. b) Erection and commissioning lump sum charges/unit wise charges for main equipments & other items. The tenderer shall provide commissioning spares & consumables at no additional cost unless stated otherwise in tender documents. c) Earnest money as per requirement of tender documents Note 1) Any corrections/amendments shall be properly and fully authenticated. if not done so, the offer is liables for rejection. Firstly only part (1) containing TECHNICAL OFFER shall be opened and shall be technically & commercially evaluated. In case it is necessary to ask for technical commercial clarifications/ confirmation from the tender-er to bring the offer in line with the requirement of specifications, fresh/ revised price bid shall be submitted, only if requested by the purchaser, in separate sealed cover super scribed as revised price bid (Part II), revision No.. Unsolicited fresh/ revised bids shall not be entertained. After getting necessary clarifications if required, Part II containing final revised price bid, otherwise the original price bid shall be opened for which the date and time shall be intimated to the technically & commercially acceptable tenderer only, in case of public opening. Note (2) KHYBER AGRO FARM reserves the right to open the price bid, if any, of any bidder, if required.
B) Pre-qualification terms to make the tenderers eligible for participation in the bid. 1) Bidders annual turnover in the same name and style in each of the last three years shall not be less than the total tender value Rs.- 500 Lakhs. (certified supporting documents to be attached in proof) 2) Bidders must have successfully completed during any one of the last 5 years similar works and the value as follows:- Two similar jobs each costing not less than the amount equal to 50% of the estimated cost (certificates of completion from clients in co-operative/ Private Reputed companies should be attached in proof besides P.O. copies, Experience of Foreign projects will be an added qualification ). For Bidders quoting on behalf of their principals, the purchase orders on their principals may be considered. 3) Bidder should furnish certified copy of latest Annual report along with their GST/PAN/TAN Nos. The above three conditions are essentially required. Note: - Without compromising with the experience and above eligibility criteria, the Bidders registered with the sale tax/ GST department and completed at least one similar type of project in Jammu & Kashmir state will be preferred. Besides the bidders should also furnish. a) List of manpower with qualification and experience to access their technical competence to under-take supplies as well as erection jobs. b) List of plant and machinery at their works.
(C) CHECK LIST 1) Has the Bid security (Earnest money) as per terms Yes/ No. in tender notice been submitted in technical bid. 2) Has the price/financial bid in terms of clause of Yes/No Instructions to bidder been quoted. 3) Has the delivery period been mentioned correctly and Yes/ No. precisely indicating separately the time for dispatch from your works, anticipated transit time and the time for erection and commissioning. 4) Has the offer been kept valid for 120 days. Yes/No 5) Has the income tax clearance certificate been furnished Yes/No if no, state reasons. 6) Has the registration certificate of sales tax/gst as applicable Yes/No been attached.. Has the statement of deviations been furnished. Yes/No 7) Do you specifically agree to the Yes/No clauses As per tender terms. 8) Do you agree to start the work within Yes/No two months from the date issuance of purchase order. 9) Have you attached Yes/No A. Performance/Experience certificate(certified). B. Yearly Turn over CHART (Certified). C. Eligibility Criteria. D. Balance Sheet (Certified) E. Duly signed tender documents. F. Site Inspection report/ views (Signature with seal of bidder)
1. INTRODUCTION Khyber Agro Farms Pvt Ltd is one of the largest milk plant in the private sector in the state of J & K having its installed capacity of 60,000 litres of Milk per day with a provision to handle up to 1,20,000 litres per day. The process for establishment of milk plant by Khyber Agro Farms Pvt. Ltd. was initiated in the year 1997 and the project was completed and commissioned by June 1998. Plant is located at Lethpora, in Tehsil Pampore of Pulwama district. The plant is equipped with most modular technology to produce Homogenised & Pasteurised Liquid milk of different variants like Toned Milk, Double Toned Milk, Standardized Milk and Full Cream Milk as well as products inclusive of Probiotic Dahi, Cream, Paneer and Ghee. The plant is provided with precision quality control equipment to maintain composition and hygiene of the products. Khyber Agro Farms is now in the process of a major expansion of its capacities for production of Paneer as well as Curd. Expansion project shall use the existing available equipment, add new equipment for enhancing manufacturing & packing capacity as well as modify certain existing equipment/ realign them with new installation. 2. EXPANSION PROJECT BRIEF 2.1 CURD CAPACITY EXPANSION At present Khyber Agro has a capacity to manufacture approx 8,000 Kgs of set curd in plastic cups of 200 & 400 grams. It is envisaged to expand the curd production capacity to 15,000 kgs per day which shall also include stirred curd (Lassi) and chacch. Stirred curd (Sweet Lassi) is to be packed in plastic glasses and chacch in pouches. Thus in addition to existing two number cup filing machine of 2500 cups/hr, one more cup filler for stirred curd and one number pouch filling machine for chacch packing are to be added. Besides capacity expansion, upgradton of existing equipment is also to be done for improving the quality. For example, homogenizer is to be added, holding time of pasteurization process is to be increased, incubation and blast chilling rooms are to be stream lined. Expansion project is also for improving material handling by adding conveyors. AHU for packing room and gowning system aimed at better quality management.
2.2 PANEER CAPACITY EXPANSION It is planned not only to expand Paneer manufacturing facility from existing one ton per day to 5 ton per day but also to aim upon improving the shelf life of Paneer to 15-21 days (under refrigeration). Expansion plan not only involve supplementing the existing capacities by adding better heating system but also aim at energy conservation. Better housekeeping, monitoring & controlling CCP areas and Paneer under vacuum intended to increase shelf life of Paneer. packing of It is intended to have Milk heating for Paneer using plate heat exchanger with provision for heat recovery from hot whey of previous batch. Before disposal, whey cream shall be recovered. Manufacturing capacity is to be enhance by adding additional Vats for milk coagulation, Pneumatic Paneer press, additional hoops, Paneer cooling system, machine for Paneer Slice cutting and packing under vacuum sealing/ nitrogen flushing. 3. TENDERERS/ SUPPLIERS/ MANUFACTURERS RESPONSIBILITIES The Supplier's/Manufacturer s responsibilities are as follows: Preparation & submission of GA drawing. Manufacture/Fabrication of equipment as per approved GA drawings Inspection/Testing/Certification / FAT Delivery to Site Provide P&ID /G.A drawing/ BOQ with specs Separately for each equipment Installation & Commissioning, if applicable and trial runs. All equipments shall be provided with CIP system/spray balls/provision for CIP (as applicable). The Supplier shall be solely responsible for the supply of materials that meet the performance requirements set out. Grouting of insert plates and foundation bolts etc. 4. BUYERS' (KHYBER AGRO) RESPONSIBILITY Obtaining all government approvals, sanctions and licenses related to civil/ building, labour & factory acts, Electricity, Steam Generation, Weights & Measures, Pollution clearances any other applicable statutory permissions. All types of civil works including buildings, foundations etc. Electrical panel shall be provided by Buyer at the Power Controlling Centre (PCC) - LT Panel. Providing raw material, consumables, detergents, etc required for trials. All the utilities required during installation as well as for operation. Modification of PUF panels in curd cold store and blast chilling room as well as PUF panelling in gowning room.
5. EQUIPMENT/MATERIAL TO BE PROVIDED BY SUPPLIER The Supplier's scope of supply shall include the following materials: 5.1 CURD MANUFACTURING Tag-No. Description Quantity CR 01 Standardized Milk storage tanks, 5000 Liters 01 No. CR 02 Holding Tube/ Thermoniser, for 3000 LPH HTST pasteurizer (Additional) 01 No. CR 03 Curd Cup Filling Machines, 6000 Cups/Hr 01 No. CR 04 Two stage Milk Homogenizer, 3000 LPH, APV 01 No. make CR 05 Culture Inoculation tanks, capacity 1000 Liters 02 No. CR 06 AHU for curd/ Dahi, Lassi, Chacch packing room 01 set CR 07 Gowning Room - (PUF panels not in scope) 01 set CR 08 SS Working Platform 01 No. CR 09 Crate Conveyor -I (packing to incubation rooms) 01 No. CR 10 Crate Conveyor-II (incubation rooms to blast 01 No. chiller) CR 11 Revamping curd cold store & Blast Chiller 01 set CR 12 Sugar syrup preparation tank, 500 Liters 01 No. CR 13 HTST Pasteurizer, 1000 LPH 01 No. CR 14 Lassi & Chacch Preparation Tanks, 2000 Liters 02 No. CR 15 Cooling Tower, 15 TR 01 set CR 16 SS Centrifugal Pumps, as required 04 No. CR 17 FFS Machine, single head, 2500 PPH for Chacch 01 No. CR 18 SS Pipes & Fittings (as per P & I drawing) 01 set 5.2 PANEER MANUFACTURING Tag-No. Description Quantity PR 01 PHE, Double section With Holding, 5000 LPH 01 No. PR 02 Paneer Vat, 2500 LITERS 02 No. PR 03 Whey Pump with strainer, 5000 LPH 01 No. PR 04 Hot Whey Storage Tank, 2500 Liters 01 No. PR 05 Whey separator 2000 LPH 01 No. PR 06 Paneer Press 4 heads 01 No. PR 07 Paneer Hoops 12 kg 16 No. PR 08 Paneer Cooling Vat, 2000 Liters 01 No. PR 09 Paneer Slice Cutting machine 01 No. PR 10 Double Chamber Vacuum Sealer 01 N0.
6. EQUIPMENT DESCRIPTIONS & SPECIFICATIONS FOR CURD SECTION - FOR MANUFACTURING CURD, LASSI & CHACCH: 6.1 MILK STORAGE TANK Tag CR 01 Type Application Standardized Milk Storage Tank, 5000 Quantity Liters Vertical, Insulated with Agitator mounted on Capacity top Storage of standardized milk for Curd (Dahi) MOC: production AISI-304 Vertical double walled insulated and welded construction of sanitary design. All internal and external including accessories - in stainless steel conforming to AISI-304 except stiffeners - in MS/ painted with red oxide primer. Inner Shell, conical top and flat sloping bottom 2 mm thick. Outer cladding- 2 mm thick Slope of minimum 1:15 towards outlet for free and complete drainage of liquid. All metal to metal contact between the inner and outer shells shall be at the place where fittings for tank are provided. Insulated pad plates fixed between inner stainless steel shell and stiffeners. All welding joints ground smoothly. All stainless steel surfaces should be polished to 150 grits. 02 5000 Liters INSULATION 80 mm PUF Or 100 mm thermocole over 15 mm PUF sheet Accessories i. Inlet:51 mm dia no-foam inlet at top ending in SMS union - 1 No ii. Outlet: 51mm cup type outlet with two way flanged plug with SMS union at other end. Height of outlet 450 mm from the finished floor level - 1 No. iii. Air vent: Dust & vermin proof, with wire mesh, 100 mm dia, 1 no. iv. Manway: Open able round man way of 450 dia with airtight cover, at the top of the tank. The gasket should be of neoprene or nitrite rubber of food quality - 1 no. v. Sight & Light Glass Assemblies: With toughened glass of 100 dia x 6 mm thick, flanged, with easy to open wing nuts, gasket food quality rubber, on top of the tank, at such orientation facilitate easy reading of level from lowest to highest point. Light glass with 24 V/ 100 W light bulb/ brass holder. - 1 set each.
vi. Agitator: Complete with geared motor of adequate capacity and should be able to uniformly agitate and mix milk in the tank within 10 minutes. The agitator shaft can be scheduled 40 pipe tripod supported (tripod with Teflon bush). Shaft entry in the tank should ensure no oil spillage in the tank in case of leakage from gear box-1 set vii. Lifting Lugs: Stainless Steel conforming to AISI 304 lifting lugs should be provided at top with suitable pad plates - 2 no. viii. Spray Ball: Rotary type, removable with SMS union, 38 mm size. 1 no. ix. Sampling Cock: Sanitary design, provided on the outlet pipe nozzle - 1 no. x. Legs: Conical mild steel legs, cladded with Stainless Steel conforming to AISI 304 sheet cladding, ending with +/- 50 mm height adjustable ball feet in stainless steel. - 4 No. xi. Temperature Gauge: Digital thermometer with RTD probe for monitoring temperature of milk. xii. Level Switches: for High & Low level i. All weld joints DP testing ii. Water fill testing for the inner before insulation. iii. Volume to be checked by calculation as well as by measurement. iv. Insulation test - not more than 1 deg C rise in temp in 24 hours/ when filled with milk at 4 deg C & temperature gradient of 35 deg C 6.2 HOLDING TUBE Tag CR 02 Holding Tube (Thermoniser) Quantity 1 set Type Coil, insulated, covered/ cladded Capacity 3000 LPH/ 10 minutes holding Application Holding milk at pasteurization for whey MOC AISI-304 protein denaturation Modification of existing holding time. Existing pasteurizer of 3000 LPH capacity with 6 minutes holding. Holding time to be increased by 4 minutes such that milk is held at pasteurization temperature (90 deg C) for 10 minutes Coil from 51 mm pipe, insulated and enclosed. End connections with SMS unions. Sanitary design & CIP compatible. Coil hydraulically tested at 3 bar Validation of holding time.
6.3 CUP FILLING MACHINE Tag CR 03 Cup Filling Machine Quantity 1 set Type Rotary type, fully automatic, PLC based Capacity 6000 Cups/Hr Application Filling of Curd Milk in plastic cups, size 200& 400 ml, with top lid sealing and printing of batch codes etc. Filling : Up to 500 ml - Adjustable Container : Heat sealable plastic cup Output : 6000 cups / hr. MOC Accuracy : Plus/Minus 1.5 grams. Function includes: Cup release, Filling, Lid placing, Heat sealing Ejecting & cup push, Batch coding/ printing Structure : Stainless Steel conforming to AISI - 304 Contact parts AISI-304 : SS 30 Stainless Steel conforming to AISI - 304 or food grade material Safety features: Necessary safety devices shall be provided for interlock of cup release/ Ejecting cylinder/ heat sealing to avoid accident. No milk, no cup release If No cup, no filling operation In case of No cup, no lid release If No lid, no sealing operation Low level in balance tank, no filling/ lid placing/ heat sealing Performance Validation during operation
6.4 MILK HOMOGENIZER Tag CR04 Milk Homogenizer (Two Stage) Quantity 1 set Type Two stage, high pressure, Make APV Capacity 3000 LPH Application Accessories Homogenizing & uniform distribution of milk fat globules. MOC AISI-304 Product Milk Operating Pressure Maximum - 200 Bar Suction Pressure - 1 to 1.5 Bar Homogenizing Head Two stage, manually operated Homogenizing Valve & Valve Seat Stellite-material Suction Discharge Valve & Valve Seat Stellite- material (Removable type) Lubrication Splash Plungers Three, special Alloy Steel Contact Parts AISI-304 Mounting M.S. Frame with SS Enclosures Body Spheroid, Cast Iron Drive Arrangement Pulley drive Inlet / Outlet Connection 38 mm Installed Power as required - Vendor to specify, TEFC Electric motor of Crompton/reputed make Rating Power TEFC Electric Motor, 415 V, 3 Ph, 50 c/s Pressure Gauge Digital Type, 0 400 Bar, stainless steel body, glycerine filled, diaphragm type, 1 no. Dampener Suction & Discharge - 1 set Spares For Commissioning, - 1 set O & M Manual - 1 set Tool Kit - 1 set Homogenizing efficiency minimum 90%
6.5 CULTURE INOCULATION TANK Tag CR05 Culture Inoculation Tank Quantity 2 No. Type SS vertical insulated tanks, with agitator. Capacity 1000 Liters Application Addition of culture to the pasteurized milk MOC AISI-304 and thorough but gentle mixing. Rated capacity to be measured 100 mm below the weld line of shell and top cone Vertical & cylindrical with conical top and reverse conical bottom. Sufficient slope towards the outlet for complete drainage. CIP compatible, with rotary CIP spray ball. Slow speed propeller type agitator. No foam inlet at top with SMS union. Outlet, cup type with flanged butterfly valve. Temperature monitoring with digital thermometer Low & high level switches. Airtight manhole with easy to open cover, with food grade gasket. Air vent with Hepa Filter All welding joints ground smoothly and all stainless steel surfaces polished to 150 grits. Radii of all welded and permanent attachment joints shall be at least 6 mm. Where the conical top and reverse conical bottom join the cylindrical shell the radii shall not be less than 25mm. Hot insulation & cladding with AISI-304 Sheet thickness - VTS Visual inspection. Water fill test. Capacity validation Smoke test for air tightness of manhole
6.6 AIR HANDLING UNIT (AHU) Tag CR 06 Air Handling Unit Quantity 2 units Type Fin Tube Type, Horizontal. Wall mounted. Capacity 3 TR each Horizontal Free Return. Compact unit. Application For cooling of dahi packing room and MOC maintain positive (+5mwc) pressure with filtered air. Air flow rate 2000 CMH / 35 mm WG Air Temp Ambient 40 C. Expected room temperature :- 22 C. Room Size :- 11000 L x 11000 W x 5000 H. ed for quiet and efficient operation Removable fan assembly. Filter Section complete with Integral filter rack designed to remove particles down to 10 Microns. air grilles.rear or bottom return. One inch pleated filters (throwaway )Integral and Tight fitting to prevent air bypass. Filters easily removable from the unit.. Four point hanger mounting brackets. Cooling - 2 to 6 row chilled water. Single wall galvanized casings or optionally stainless AXIAL FLOW FAN heavy duty of suitable Dia Fan made out of GSS Casing having cast aluminium alloy impeller with high efficiency Aero-foil section blade directly driven by TEFC squirrel cage induction motor suitable for 3 phase AC Supply 2 HP/4 Pole Class-H, Motor shall be suitable for 415 Volts, 50 Cycles,3 Phase AC Power Galvanised Coil with aluminium fins for multi row chilled water available at 5 deg. C. High efficiency aluminium fin. Optimal pressure drop. Standard drain pans in stainless steel. Double sloped to drain Discharge air temperature sensor Crompton/Equivalent make TEFC squirrel cage induction motor suitable for operation on AC 3 Phase, 415 volts, 50 c/s. Electrical enclosure powder coat Panel. Remote mounted Performance validation during operation
6.7 GOWNING ROOM Tag CR 07 Gowning Room Quantity 1 set Type PUF panel enclosure, two number interlocked doors, changeover and sanitizing room. Capacity Size 2.0 m x 3.0 m Application Restriction of entry into CCP area of Dahi packing Gowning room essentially is to restrict entry into Dahi packing area which is CCP area. And ensuring sanitization for those entering the room. Thus person entering Dahi packing room has to cover his personnel clothing with a sterilize gown, cover his mouth as well as head. Shoes are removed and replaced with sterilize foot wear. Gowning room shall have the following : A. Hand Wash & Dry Station: for washing hands before and after donning gloves. Flush Wall-mount and free-standing Foot valve for hands free operation. Made of 304 stainless steel B. Mirrored Gowning Room Garment Rack: Wall-Mount OR Freestanding with sliding or fixed hangers for garments - before entry Dahi packing room. Double doors with self-closing hinges allow easy access Full Length mirror industrial-grade and copper-free glass. Approximate size 1321 x 631 x 2014 high. 152 mm stand with levelling feet. Garment rack (Good for 10 garments) Right side shelves and Left side Hanger. Left-hand door mirror. PVC Front door, transparent panels, mounted in reinforced doors C. Gowning Room Bench: Person to sit for shoe change & Cross over Free-standing, floor-mounted. Made of 304 stainless steel, : Non-Conductive ESD Material : Stainless Steel. Top Seat 2.5mm thick mirror polished. Overall Length.: 36". Overall Height : 18" Overall Width : 16". Resting support legs Teflon padded. D. Gowning Room Floor Trap Mat: Chemical-resistant polyester floor, blue color, covering traps foot wear contaminants and inhibits bacterial growth ed to remove foot-borne contamination simply and effectively, without carry-over or damage to shoe covers. Cleans with a detergent solution and sponge squeegee Withstand 40kg/sq. cm traffic loads, non-toxic and resistant to chemical corrosion. Heat Resistance at least to 55 C Resistance to earth of 10 10 ohms/square and 10 8 ohms/square for static dissipative. Operational validation
6.8 WORKING PLATFORM Tag CR 08 Stainless Steel Working Platform Quantity 1 set Type Structural platform, self supported on columns with anchored foot plates Capacity Suitable size Application Mounting of 4 number inoculation tanks MOC AISI-304 Fabricated from RHS With railing and toe plates Above the cup filling machines With access ladder, steps with anti skid chequered plate Chequered plate on top Supported with anchor bolts Without any sharp edges or dead pockets. Load bearing capacity certified by structural engineer Vibration free No stagnation of water on top 6.9 CRATE CONVEYOR - I Tag MR 09 Crate Conveyor -I Quantity 1 set Type Chain conveyor, motorized, horizontal Capacity 300 crates per hour Application To carry curd milk filled cups crates from MOC Stainless steel filling machines to incubation rooms. Horizontal conveyor. Frame work from RHS/ angles, self supported. UHWMPE wear strip for SS chain. Linear speed 3-4 meters per minute, variable with VFD Width of conveyor approx 500 mm x approx 15 meters long Loading manually. SS table at the delivery end Geared motor (IP 55) of suitable rating, complete with sprockets, idlers etc. An SS protection cover shall be provided for the drive, chain etc. VTS all the make Drive and driven roller suitably mounted on bearings, fabricated from stainless steel and machined. Complete with remote panel Operation of the conveyor
6.10 CRATE CONVEYOR-II Tag MR 10 Crate Conveyor -II Quantity 1 set Type Chain conveyor, motorized, horizontal Capacity 300 crates per hour Application To carry set curd filled cups crates from MOC Stainless steel incubation rooms to blast cooling room. Horizontal conveyor. Frame work from RHS/ angles, self supported. UHWMPE wear strip for SS chain. Linear speed 3-4 meters per minute, variable with VFD Width of conveyor approx 500 mm x approx 10 meters long Loading manually. SS table at the delivery end Geared motor (IP 55) of suitable rating, complete with sprockets, idlers etc. An SS protection cover shall be provided for the drive, chain etc. Drive and driven roller suitably mounted on bearings, fabricated from stainless steel and machined. Complete with remote panel Operation of the conveyor 6.11 REFERIGERATION UNIT FOR BLAST CHILLING ROOM REVAMPING OF CURD COLD STORE & BLAST CHILLER Tag CR 11 Refrigeration Unit for Blast Chiller Quantity 1 set Type Freon based Stand alone refrigeration unit with diffuser Capacity 3 x 10 TR Application Revamping of existing blast and cold store room - installation of standalone diffuser/ condensing units in Blast Chilling Room PUF panels modification to be done by Khyber Agro/ his contractor - by partitioning of cold store in to blast and cold store as per revised requirements. Existing blast room has chilled water based diffuser - to be replaced with Freon based independent condensing unit of 10 TR. capacity x 3 No. Requirement is to rapidly chill set curd from 45 deg C to less than 10 deg C @ 3000 LPH Operation of the unit
6.12 SUGAR SYRUP PREPARATION TANK Tag CR 12 Sugar Syrup Preparation Tank Quantity 1 No Type Vertical, Triple walled, insulated and welded Capacity 500 Lit construction of sanitary design. Application Preparation of sugar syrup, cooling and MOC AISI-304 storage. Jacketed vat having a torospherical dish bottom. Top open type with removable covers. Central bridge for mounting geared motor, CIP spray ball and two number inlet nozzles. Sugar charging hopper on top. Heating by hot water circulation in jacket during sugar dissolving and syrup preparation. Cooling to ambient temperature by cooling tower water circulation in jacket. Jacket suitable for 3 bar. Inner shell: 5 mm thick Stainless Steel conforming to AISI 304 sheet. Intermediate shell: 4 mm thick AISI 304 Outer cladding : 2 mm thick Stainless Steel conforming to AISI 304 sheet.- Spiral stiffeners between inner & intermediate shell from stainless steel. Stiffeners between Intermediate Shell and Outer Shell from Mild Steel of commercial grade. All the Mild Steel stiffeners used painted with two coats of Epoxy Primer after through de-rusting. Insulation with mineral wool Scope of supply: i. Inlet:38 mm dia inlet nozzles at top ending in stainless steel complete union - 2 No. ii. Bottom Outlet: 40 NB mm outlet with SS ball valve. - 1 No iii. Agitator: Anchor type, with geared motor of adequate capacity, with bearing and tripod supported at bottom with teflon bush. Solid rod shaft of suitable diameter. iv. Pipe Legs: Self supported on stainless steel pipe legs, ending with adjustable ball feet. v. Water Inlet Nozzle: 40 NB with gate valve for hot and cold water- 2 No. vi. Water Outlet Nozzle: 40 NB with NRV for hot & cold water - 2 No. vii. Safety Valve assembly: With safety valve, pressure gauge and air vent viii. Temperature monitoring: For the product with a digital thermometer, provided with RTD probe. i. Visual inspection and dimensions as per GA drawing. ii. Hydraulic testing of jacket at 4.5 bar iii. Operation of agitator.
6.13 HTST PASTEURIZER Tag CR 12 HTST Pasteurizer Quantity 1 No Type Skid mounted with regeneration, heating cooling and chilling sections. Capacity 1000 LPH Application Pasteurization and cooling/chilling of Sugar syrup, Lassi and Butter Milk MOC AISI-304 Parameters Sugar Syrup (50%) Temp of sugar syrup: 50 deg C Pasteurization temperature: 75 deg C Holding Time: 15 sec Outlet temperature of Sugar syrup: Ambient ( Cooling by cooling tower water) Lassi/Chacch Temp of Feed: 45 deg C Pasteurization temperature: 55 deg C (Maxm) Holding Time: 15 sec Outlet temperature of Lassi/Chacch: 8 deg C ( Cooling as well as chilling) Pasteurizer consist of a standard PHE of Tetrapak or equivalent make. PHE plates shall be in SS-316 with snap on neoprene gaskets. Frame of PHE should be self supporting, floor mounting with adjustable ball feet. PHE shall have four sections: i. Regeneration ii. Heating iii. Cooling ( using cooling tower water at inlet of 25 deg C) iv. Chilling ( chilled water at inlet temp of 2 deg C) Accessories shall include: a. SS float Balance tank, 100 liters b. SS Centrifugal feed pump, 1000 lph at 30 MWC c. Flow regulating (micro valve) d. External holding time : 15 secs e. Steam heated Hot water battery/ PHE/Tubular heater with hot water circulation pump and piping f. Flow diversion valve (manual) g. Steam Control Valve. h. Interconnecting SS piping i. Control panel in SS enclosure. All the above shall be mounted on the skid fabricated from SS -304 sections. Operational validation of capacity & parameters
Tag CR 14 6.14 LASSI/ CHACH PREPARATION TANK LASSI/ CHACH Preparation Tank Quantity 2 Type Stainless steel, vertical, cylindrical tanks with conical top & bottoms Capacity 2000 Liters Application Preparation & storage of Lassi or Chacch MOC AISI-304 Fabricated in stainless steel conforming to AISI-304 Vertical tank, self supported on pipe legs ending with adjustable ball feet for height adjustment of +/- 50 mm. High speed mixing agitator for breaking the curd and homogeneously mixing with water/ seasoning/ sugar syrup as per recipe. Nozzles: i. Man Way - 450 dia on top with airtight cover - 1 No. ii. Inlet Nozzle - 38 mm, with SMS unions, on top - 2 No. iii. Outlet nozzle - 38 mm with butterfly valve, at bottom - 1 No. iv. CIP Nozzle - 38 mm, with rotory spray ball, removable type - 1 No v. Agitator - with geared motor, suitable rating, for homogenizing the product - 1 set vi. Light & sight glass assemblies - with toughened glass vii. Temperature monitoring with digital thermometer/ RTD probe viii. Low & High level probes Nozzles: Testing: DP test of weld joints & water fill test. Visual Inspection Dimensions & orientation check as per GA drawing.
6.15 COOLING TOWER Tag CR 15 Cooling Tower Quantity 1 No. Type Induced Draught Counter Flow Capacity 15 TR Application Dissipation of heat from water to air MOC FRP Water Flow Capacity : 7000 LPH Temperature Gradient : 7 deg C Wet Bulb Temperature : 28 C Casing Material : FRP Basin Material : FRP Fan / Aluminium Material : ALUMINIUM Mechanical Equipment Supports : MSHDG Hardware : Electroplated Eliminator Material : PVC Fill Material : PVC Water Distribution : PVC Drift Eliminator made from FRP / PVC Fan with Electrical Motor Performance validation during operation 6.16 CENTRIFUGAL PUMPS Tag CR16 Centrifugal Pump Quantity 4 Type Centrifugal pumps, sanitary design, with SMS fittings Capacity As required Application Transfer of curd, chacch, Lassi and sugar syrup as per process requirements. MOC AISI-304 Centrifugal pump, sanitary design and mono block construction. All contact parts fabricated from stainless steel conforming to AISI 304. Coupled with flanged motor & provided with mechanical seal Squirrel cage TEFC motor with IP55 protection and class F insulation suitable for 415 V 50 Hz AC supply. Inlet/Outlet: Stainless steel (AISI 304) inlet and outlet complete with SMS unions. The inlet shall be 230 mm above the finished floor level. Motor Shroud: Easy to remove protective shroud for the motor. It shall have provisions for air circulation and entry of electric cable. Legs: Supported on legs with SS ball feet. The ball feet shall have provision for height adjustment of 50mm. Performance validation during operation
6.17 POUCH PACKING MACHINE FOR CHACH Tag CR 17 Pouch Packing Machine Quantity 1 set Type Form - fill -seal type, single head, mechanical Capacity 2500 pouches/hour Application Packing of chacch in poly pouches MOC AISI-304 Scope of Supply The machine shall consist of SS body built on a treated Aluminium chassis. All sub assemblies are to be mounted on this chassis. All tapped holes on chassis to have helical steel inserts. Feeding System shall be by gravity and Dosage shall be up to 1000 mm with an accuracy of (-) zero (+) < 0.5% on 500ml to 1000ml under normal working condition. Packing material shall be of Virgin Food Grade Film of thickness 50 to 55 micron for 100ml, 200ml and 500ml. Spool bearer Assembly & Film guide: For mounting film roll up to, at the rear bottom of the machine, assembly to be sliding type to facilitate easy changeover of the film roll. Vertical seal: Overlapping, sealing to form sealed tube by vertical electrode. The jaw shall be mechanical cam operated and is to be water cooled. Downward feed: Down ward movement of film tube shall be controlled by a set of rubber nip roller driven by a motor through a reduction gear unit and electromagnetic clutch brake system. Horizontal seal: The horizontal sealing and cutting shall take place at the same time by horizontal electrode mounted on fixed horizontal jaw -water cooled & mechanical cam operated. Injection system: A constant level tank with mechanical float. Filling quantity of product in each pouch controlled by adjustment of opening distance of the gate valve at the lower end of the injection tube. The flow of the continuous. Machine operation: Using Cam timer switches, mechanical cam operated. Electrical control: The electrical switches, control relays, solid state varies, panel pouch counters are mounted in this panel fixed on left or right side of the machine. Auto operation facility shall stop the machine and audio visual alarm shall be given to operator if film roll is exhausted. Emergency switch to stop the machine is to be provided on front side of machine. Static electricity eliminator. Photo mark scanner: The machine shall be provided with photocell on each head with all mounting arrangement to control the length of pouch. Machine should stop if front or back door is opened. Pouch filling machine is supplied with CIP hoses with adaptors for CIP of the machine. Tools: Essential special tools shall be provided with the machine. To meet legal requirement in filling/ weight variation
6.18 STAINLESS STEEL PIPES & FITTINGS Tag CR18 Stainless Steel Pipes & Fittings Quantity 1 No. Type ERW pipes, with crushed beads and Capacity As required polished, with SMS fittings Application Process flow as per P & I drawing: Transfer of pasteurized milk to inoculation tanks Transfer of inoculated milk to cup filling machines. Transfer of stirred curd to Lassi/ Chacch tanks. Transfer of sugar syrup from manufacturing Transfer from Lassi/Chacch tanks to FFS or cup filling machine. MOC AISI-304 Stainless Steel pipes &fittings confirming to AISI -304 as per ASTM A- 312 standard. Outside polished and inside pickled as per dairy standard. Pipe fittings in welded execution conforming to sanitary design. Pipe supports in Stainless Steel RHS sections with suitable size pipe clamps and nipples. All floor mounting supports with SS floor plates of standard design. All Stainless Fittings conforming to AISI - 304of SMS Standard. All gaskets in contact with product shall be of food grade rubber. Hydraulic testing of pipelines.
7. EQUIPMENT DESCRIPTIONS & SPECIFICATIONS PANEER SECTION - EXPANSION OF PANEER MANUFACTURING CAPACITY 7.1 PLATE HEAT EXCHANGER Tag PR 01 Plate Heat Exchanger Quantity 01 Type Two Section Capacity 5000 LPH Application To Heat chilled milk from 4 to 90 deg C and hold for 30 secs. MOC AISI-304 Skid mounted Plate Heat Exchanger complete with all the accessories, hot water system, PID control with safety measures and field instruments for monitoring & controlling. First section of PHE shall be used for heating the milk by recovering heat from the previous batch's hot whey (maxm temp of 70 deg C), if available. Second section should have sufficient heat transfer area to heat milk from 4 to 90 deg C in case hot whey is not available. Accessories 1 No. Float Balance Tank, 100 Liters 1 No Feed Pump, 5000 LPH at 30 mwc 1 set Interconnecting piping for process as well as for CIP of the system. 1 set holding tube for 30 secs 1 set PHE for water heating using steam with auto steam control valve 1 set hot water pump & piping 1 No. Control Panel Performance validation during operation
7.2 PANEER VAT Tag PR 02 Paneer Vat Quantity 2 No Type Rectangular, insulated with removable agitators Capacity 2500 Lit Application Acid coagulation of hot milk for Paneer production MOC AISI-304 Horizontal, insulated, double walled, rectangular with semi-circular ends, and welded construction of sanitary design. Volume of the vat should be such that after filling up to the rated capacity the level should be 150 mm below the line from the top. Bottom with sufficient slope towards outlet for complete drainage. Inner vat/ cladding from 2 mm thick stainless steel conforming to AISI- 304. Stiffeners between Inner vat and cladding from Mild Steel of commercial grade. All the Mild Steel stiffeners painted with two coats of Epoxy Primer after thorough de-rusting. The Paneer Vat shall be complete with the following fittings / accessories. - Agitator: Twin agitator of removable type with a common drive to facilitate proper mixing of coagulant and subsequently coagulated mass. - Central Girder for mounting drive, supported on the outside of Vat with pinion shaft and bevel gears for two agitator's shaft/ on thrust bearings, easy to remove propeller blades - Complete with Outlet Valve for whey drainage, Legs with Ball feet, Digital Temperature monitoring, No-Foam type Inlet, Sliding type strainer made from perforated sheet over the outlet. Following test should be conducted by the manufacturer at their workshop. - Dye Penetration Test of weld joints. - Water Fill up of Inner Vessel for Water Tightness. Visual inspection and dimensional check, Agitator working Complete Drainage of whey.
7.3 WHEY PUMP WITH STRAINER Tag PR 03 Whey Pump With Strainer Quantity 1 set Type Mobile, trolley mounted on common skid for strainer and pump. Capacity 5000 LPH at 25 mwc Application Removal of fine curd and transfer of whey to storage. MOC AISI-304 SS strainer (tank) of suitable capacity to retain fine paneer curd and permit drainage of whey, provided with butterfly valve. SS Centrifugal Pump of 5000 LPH/ 25 mwc, connected to SS tank with flexible hose connections on discharge end. Tank and pump mounted on trolley with wheel. Trolley to be movable between three vats (1 existing + 2 New), with remote starter mounted on trolley and flexible electric cable provided. Performance test during operation. 7.4 WHEY STORAGE TANK Tag PR04 Whey Storage Tank Quantity 1 No. Type Vertical, Cylindrical, Insulated Capacity 2500 Lit Application Storage of hot whey MOC AISI-304 Vertical Double Walled insulated and welded construction of sanitary design. Inner Shell, Conical Top and flat sloping bottom 2 mm thick. Outer cladding- 2 mm thick Slope of minimum 1:15 towards outlet for free and complete drainage of liquid. All metal to metal contact between the inner and outer shells shall be at the place where fittings for tank are provided. Insulated pad plates fixed between inner stainless steel shell and stiffeners. All welding joints ground smoothly and polished to 150 grit finish
Accessories i. Inlet: 38 mm dia at top ending in SMS union - 1 No. ii. Outlet: 38 mm cup type outlet with two way flanged plug with SMS union at other end. Height of outlet 450 mm from the finished floor level. - 1 No. iii. Air vent: Dust & vermin proof, with wire mesh, 100 mm dia. - 1 No iv. Manway: Open able round man way of 450 dia with airtight cover, at the top of the tank. The gasket should be of neoprene or nitrite rubber of food quality. - 1 no. v. Sight & Light Glass assemblies: With toughened glass of 100 dia x 6 mm thick, flanged, with easy to open wing nuts, gasket food quality rubber, on top of the tank, at such orientation facilitate easy reading of level from lowest to highest point. Light glass with 24 V/ 100 W light bulb/ brass holder. - 1 set each. vi. Agitator: Complete with Geared Motor Shaft entry in the tank should ensure no oil spillage in the tank in case of leakage from Gear Box - 1 set vii. Lifting Lugs: Stainless Steel conforming to AISI 304 lifting lugs should be provided at top. - 2 no. viii. Spray Ball: Rotary type, removable spray ball with SMS union, 38 mm 1 no. ix. Legs: Conical mild steel legs, cladded with Stainless Steel conforming to AISI 304 sheet cladding, ending with +/- 50 mm height adjustable ball feet in stainless steel. - 4 No. x. Temperature Gauge: Digital thermometer with RTD probe for monitoring temperature of milk. xi. Level Switches for High & Low level xii. Tests: DP testing of joints and water fill test of inner tank. Visual & Dimensional Checks.
7.5 WHEY SEPARATOR Tag No. PR 05 Whey Separator Quantity 1 No. Type Centrifugal, solid bowl Capacity 2000 LPH Application Separation of fat from whey to get whey cream. MOC (Contact parts) Stainless Steel conforming to AISI 304 The centrifuge should be of solid bowl type. The bowl hood, disc, distributor and other contact parts made of Stainless Steel conforming to AISI 304. The lower drive part of the centrifuge made of cast iron casting and machined. Centrifuge base frame with shock absorbing pads with proper grouting arrangement.. Drive: The drive for the centrifuge shall be mounted just under the centrifuge and integrated together. The motor shall drive the bowl spindle by a worm wheel mechanism connected to the motor shaft. Drive motor provided with stainless steel protective shroud. Lubrication system: Splash Lubrication system complete in all respect. Tachometer: For stabilising RPM of the disc assembly while in operation. Gaskets: All the gaskets should be of food grade rubber, non-toxic, fat resistant and non-absorbent. Tools: Essential special tools to be supplied with the machine. Separation efficiency shall be 99% 7.6 PNEUMATIC PANEER PRESS Tag PR 06 Paneer Press Quantity 1 No. Type Pneumatic, 4-head, vertical press Capacity 400 kg Application Expulsion of whey from Paneer curd mass filled in hoops. MOC AISI-304 Frame of press in heavy duty RHS pipe sections. Pressure plate, MS and SS clad. Pneumatic cylinders mounted vertically, provided with connector and pneumatic flexible piping. Panel with solenoid valves and push buttons - one set for each cylinder, for downwards and upwards movement. SS tray at the bottom to collect expelled whey. Tray with sloping bottom and butterfly valve for whey drainage. Frame self supported, pipe legs and with floor plates for grouting. Visual and dimensional check as per GA drawing. Operational validation.
7.7 PANEER HOOPS Tag PR 07 Paneer Hoops Quantity 16 Type Rectangular, with perforation Capacity 12 Kgs Application Whey removal/ Body & texture formation MOC AISI-304 Rectangular shape - three piece design - bottom trough, central separator and top lid. Trough with perforation on all four sides. Bottom of trough and lid also with perforations. Perforations of 6 dia hole at square pitch of 40-60 mm. Holding needles for separator, for pulling and providing pressing margin once placed under press. Visual & dimensional check Capacity - weight of formed block s.t tolerances. 7.8 COOLING VAT Tag PR 08 Cooling Vat Quantity 1 set Type Rectangular & plain Vat Capacity 2000 Liters Application Dip cooling of formed Paneer block Stainless steel vat, rectangular shape with sloping bottom. Sufficient slope to completely drain, when required. Water inlet and overflow nozzles for replacing the water as required. All weld joints ground smooth, no sharp edges or corners, top lip double bent and provided with removable cover in two parts. Following test to be conducted during fabrication: i. Dye Penetration Test for all weld joints ii. Water Fill test. Visual and dimensional check as per GA drawing.
7.9 PANEER BLOCK CUTTING MACHINE Tag PR 09 Paneer Block Cutting Machine Quantity 1 No. Type PLC based, pneumatic with horizontal & vertical cutting Capacity 500 Kgs/ Hr Application Cutting paneer block in to slices of 100 grams to 1000 grams MOC AISI-304 Consisting of one horizontal blades frame and guided by UHMW bushes and connected to pneumatic cylinder for up and down operation. Another horizontal Servo Cylinder attached with UHMW Pusher to index Paneer Accurately. All blades and structural frame are of S.S.304 Acrylic doors are provided for visibility of cutting material. Validation during operation Repeatability and accuracy in weight of slices. 7.10 VACUUM SEALING MACHINE Tag PR 10 Paneer Block Cutting Machine Quantity 1 No. Type Double chamber with nitrogen flushing Capacity Up to 1000 grams size Application Sealing of pouches after air evacuation and MOC AISI-304 nitrogen flushing. Double chamber vacuum packing. To seal paneer packed in pre formed pouches. Depth of chamber minimum 100 mm. Sealing length up to 600 mm in each chamber. Provision for attaching Nitrogen gas. Sealing speed up to 4 packs per min. Performance validation during operation.
8. INSTALLATION & COMMISSIONING Vendor is required to complete the mechanical and electrical installation of the equipment. For electrical installation, battery limit shall from the buyer PCC. Mechanical installation has to take into consideration existing equipment and link exiting as well as new equipment as per expansion & modernization plan. All the utilities to be drawn from the existing headers, Vendor shall submit his P & I drawing for approval of the buyer. Work shall be complete in line with the approved drawing. Buyer shall provide all the raw materials/ consumables for conducting the trials. Plants shall be considered commissioned after five successful trials. 9. SURVEILLANCE The Supplier will be expected to operate an accredited Quality Management System. Stage inspections (i.e., during manufacture) and Final Inspection (FAT - factory acceptance test at Buyers' discretion) will be conducted by the Purchaser and/or his representative. 10. DOCUMENTATION The Supplier shall provide documentation like Material test certificates, manufacturer test certificates for bought out and inspection reports as applicable. Sufficient information shall also be given to permit the following to be achieved: 11. DELIVERY SCHEDULE Integration of the materials into the Purchaser s design Installation and commissioning Operation, maintenance and cleaning The Supplier shall adhere to the delivery schedule as agreed at the time of order placement. 12. GUARANTY /WARRANTY 15 Months from delivery or 12 Months from the date of commissioning whichever is earlier for the entire supply including bought out equipment/components, software and hardware.
13. BIDDING BY VENDOR 13.1 TECHNICAL BID Vendor to submit his technical bid complete with: i. Technical specifications of the equipment offered for Curd expansion and Paneer expansion projects ii. Submit technical capabilities/ his past experience for setting up similar projects. iii. In case of any deviations in the technical specifications, vendor has to clearly specify. 13.2 COMMERCIAL/ FINANCIAL BID Commercial bid shall specify the following: i. Price bid should mention basic price, packing charges (if any), applicable taxes/ GST as applicable, freight, insurance. ii. Quoted price to be on turnkey basis including supply, installation & commissioning. iii. Bid should be valid for minimum 60days. iv. Payment terms shall be specified by the bidder. Our standard payment terms are: 30% advance, 50% upon supply, 10% upon installation and final 10% payment within 30 days of commissioning. v. Separate price bid to be submitted for Curd project and Paneer Project. vi. Delivery: Vendor to specify
Financial BID CURD MANUFACTURING Description Standardized Milk storage tanks, 5000 Liters Holding Tube/ Thermoniser, for 3000 LPH HTST pasteurizer (Additional) Curd Cup Filling Machines, 6000 Cups/Hr Two stage Milk Homogenizer, 3000 LPH, APV make Culture Inoculation tanks, capacity 1000 Liters AHU for curd/ Dahi, Lassi, Chacch packing room Gowning Room - (PUF panels not in scope) SS Working Platform Crate Conveyor -I (packing to incubation rooms) Crate Conveyor-II (incubation rooms to blast chiller) Revamping curd cold store & Blast Chiller Sugar syrup preparation tank, 500 Liters HTST Pasteurizer, 1000 LPH Lassi & Chacch Preparation Tanks, 2000 Liters Cooling Tower, 15 TR SS Centrifugal Pumps, as required FFS Machine, single head, 2500 PPH for Chacch SS Pipes & Fittings (as per P & I drawing) TOTAL PRICE FOR CURD PLANT PART - B Quantity 01 No. 01 No. 01 No. 01 No. 02 No. 01 set 01 set 01 No. 01 No. 01 No. 01 set 01 No. 01 No. 02 No. 01 set 04 No. 01 No. 01 set Basic Price P& F GST FOR Price Place/Date Bidders Signature & Seal with address