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Teagasc/IMQCS Recommendations for the installation and testing of

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1. 37 8 92 Rekorder fagi ironia 37 Attachments to The milking tics tirita 37 long milk TUDOS ac coc cite roe emule rear an 37 9 Gleaningus ees lina 38 9 1 Additional IMOCS requirements for milk pumps and milk filters 39 10 Vacuum system Mechanical tests ISO 6690 10 1 General requirements and preparation IN Generalista 10 12 Preparation before testi GERA 10 2 Vacuum regulatoria 10 2 1 Test of vacuum regulation 10 2 2 Regulation SenslitiVIty ie ci 123 Regala ton isso iii 10 2 4 Tests of regulation characteristics 10 2 5 Effective reserve Tor milking ann ee 10 32 Vacuum pumps ein ital 10 3 1 Vacuum pump unie nenne 10 3 2 Vacuum pump exaust back pressure 10 4 Vacuum regulator leakage mnes 10 5 Vacuum gauge 10 6 Vacuum drop in airline 10 7 Leakage in vacuum system 11 Pulsation SySterm 46 11 1 Pulsation rate pulsator ratio pulsation vacuum phases and vacuum drop in pulsator 47 12 SY SOM oia 12 1 Slope of milkline 12 2 Milk system leakage 13 Milking Unit een rennen 50 13 1 Teatcup or cluster fall off air inlet 13 2 Leaka
2. 8 6 Vacuum shut off It shall be possible to shut off vacuum to the liner when not milking 8 7 Air vent and leakage a Total air admission per cluster shall be at least 4 l min and shall not exceed 12 l min for cows at the nominal working vacuum b Air vent s shall be made of a rigid material c Where there is a risk of slugs in the short milk tube at designed milkflow means shall be applied to avoid them d The above quantitative requirements do not apply to quarter milking or clusters with deliberate cyclic air admission or other specific designs In such cases the total air admission per cluster or teat cup shall be stated in the User s Manual e Air vents necessary for proper operation of milk meters automatic teatcup valves or other devices may add air admission This air use and location shall be stated in the User s Manual f Leakage into each cluster assembly with the liners and air vent s plugged and the vacuum shut off valve opened shall not exceed 2 l min Air vents should be positioned to avoid unnecessary turbulence in the milk 8 8 Vacuum in the milking unit a User s Manual shall state for specified milkflows i The desired average liner vacuum and or the desired average liner vacuum during phase b and phase d of the pulsation chamber vacuum record ii The corresponding nominal vacuum in the milkline based on the average vacuum drop Note Both research and field experience indicate that a mean li
3. 1 The vacuum pump s shall have adequate capacity to meet the performance requirement for milking and cleaning This includes air used by all ancillary equipment operating during milking and cleaning whether continuously or intermittently 2 Calculate the airflow used for all equipment continuously running or using airflow during milking and during cleaning such as pulsators air inlets and vacuum operated milk pumps The milking units and the pulsators shall be regarded as continuously running Check the airflow for equipment that uses air for a short time 3 Addthe effective reserve fromTables 1 4 to the airflow use during milking from 2 above 4 Add the airflow use for cleaning from Table A4 to the airflow use during milking from 2 above 5 Take the higher of the values calculated in 3 and 4 6 Add 10l min plus 2 l min for each milking unit for leakage into the milk system and add airflow admitted deliberately into the milk system Add leakages in the airlines Add the regulation loss The derived values for airflow and vacuum are the basis for choosing the vacuum pump ooN Example of prediction of a vacuum pump capacity Data a A herringbone milking parlour with 12 milking units direct to line automatic cluster removers and automatic shut off valves at claw situated lt 300m above sea level b One milker c Working vacuum 50 kPa d Milkline diameter 73 mm e Airflow use for each pulsator 35 l min f Airf
4. 11pm to 8am in wintertime and 12 midnight to 9am in summertime The cost of Units on the normal Rural Domestic rate is 15 97 cent unit This is 1 09 cent unit cheaper than the day rate on the new Domestic Rural Nightsaver 89 sas puaddy Bulk Tank Sizing To calculate the capacity of the bulk tank you require you need to know how many milkings you need to store at peak It is 5 milkings for E2D collection and 7 for E3D collection Other factors are the number of cows now and in say b years time and the yield per cow e g 30 litres day at peak 6 5 gals day Example Herd Size 50 Bulk tank capacity for E2D 50 x 30 x 2 5 3750 litres 825 gals Bulk tank capacity for E3D 50 x 30 x 3 5 5250 litres 1155 gals The size of the dairy may decide the type or make of tank you buy i e differences in dimensions between manufacturers and between types of tank e g DX may fit in where IB would not Allow at least 600mm around the tank for cleaning Extra space may of course be required for other equipment e g wash trough work space at the wash trough etc Allow sufficient headroom above tank for sampling inspection service etc headroom of 2m above standing platform is recommended Get detailed written quotation stating model of tank rated capacity make model and HP of condensing unit s details of automatic washer details of new pre cooling system or modifications to existing system rough sketch of where tank and an
5. b c d e f 9 h saddle type nipples shall have a protrusion into the milk transfer lines to prevent poor alignment with the hole in the milk transfer line due to rotation of the saddle This protrusion shall not protrude more than 0 8 mm past the inner surface of the milk transfer line Rubber joints or bends may not be used in milk transfer lines plastic or stainless steel unionized cone seal connections are acceptable All bends in milk transfer lines should be stainless steel with a centreline radius not less than 1 5 times the diameter All milk transfer lines shall have a stainless steel end entry nipple or a side entry nipple no more than 30 from the blank capped end In either case the end of the milk transfer line should be capable of being inspected i e a removable end piece on the milk transfer line This does not preclude the use of valving systems at the end of milk transfer lines to facilitate washing The stainless steel shall be cut at 90 at all milk transfer line joints this necessitates using mechanical cutting equipment Stainless steel of 0 9mm gauge 20 wall thickness or greater and quality Standard 304 Dairy Tubing shall be used in milk transfer lines Provision shall be made for the inspection of the inside of milk transfer lines The milk transfer line should not be higher than two thirds of the height of the recording jar when it is intended to milk though the jars Milk transfer l
6. i It is necessary that the pulsators can be stopped or disconnected to measure leakage into the vacuum system and of air used to produce pulsation Requirements 11 SAFETY AND HYGIENE 2 SAFETY AND HYGIENE a Installations shall comply with the relevant safety requirements given in ISO 12100 1 and ISO 12100 2 The electrical components shall comply with the relevant safety requirements given in IEC 60335 2 70 b Installations shall comply with the hygiene requirements given in ISO 14159 c The equipment has to be effective easy and safe to use and test 13 Ty lt 3 lt ee 1 MATERIALS 3 a b c d f 9 MATERIALS All components that are subjected to a vacuum shall be designed and constructed to withstand a minimum vacuum of 90 kPa without permanent distortion Materials that may involve danger if damaged such as glass shall be designed using a safety factor of 5 against external pressure i e 5 x 90 kPa All materials in contact with milk or cleaning solutions whether used for rigid components for example pipelines or recording jars or flexible components for example joint rings teatcup liners shall be constructed to withstand the maximum temperature used in the plant as specified in the instructions In addition such materials when used in accordance with the manufacturer s recommendations shall not impart taint to the milk All m
7. 53 3 ExXhaust is 5 3 4 Prevention of reverse flow through vacuum 20 93 5 o OO 20 5 3 6 Additional IMOCS requirements for vacuum pumps 21 5 3 7 Additional IMOCS requirements for exhausts Vacuum regulator or uoi erroe nhe t Hr Ihrer us 5 4 1 Regulator leakage 542 Vacuum regulator cnet tarte cita citan 5 4 3 Examples of location of sensing points for vacuum 21 544 Additional IMOCS requirements for vacuum regulators 22 5 5 Vacuum en 22 551 Vacuum erre 22 5 5 2 22 PENDIENTE POLLO DILLO PES 22 5 6 1 Airlines general rennen ennt ntt 22 5 7 5 8 5 9 5 10 6 1 6 2 6 3 6 4 7 1 Te 73 7 4 75 7 6 77 78 78 710 711 12 7 13 8 1 8 2 8 3 8 4 8 5 8 7 8 8 8 9 8 10 8 11 5 6 2 Airlines internal diameter and 22 5 6 3 Additional IMOCS requirements for airlines 22 iii iia 23 Sanitary ia a ace 23 Leakage into the vacuum 5 23 Additional IMOCS requirements for sanitary 23 Pulsatton system ic ia 24 Design data that shall be included in the user s manual
8. Note This section describes tests for measuring vacuum in the milking unit Normally these tests are carried out by equipment manufacturers for the design of milking units and are generally not conducted on farms These tests should be performed by specially trained personnel C 1 Suitable measuring equipment C 1 1 Vacuum meter C 1 2 Data acquisition equipment that can simultaneously record the vacuum in the liner in the pulsation chamber and in the milkline C 1 3 Artificial teats for example in accordance with Figure C 1 andTable C 1 The outlet holes are intended to be closed by the liner To achieve effective shut off it is important to position the teat such that the closed liner will cover the holes in the teat It is recommended to have the teatcups fixed and the teats flexibly connected to the liquid source in order to avoid leakage between teat and mouthpiece If the combination of teatcup and artificial teat being tested does not stop liquid flow during Phase d shut off valves for the liquid may be used Such shut off valves for the liquid shall be directly upstream of the artificial teat 76 Suitable means shall be used to ensure that the liquid pressure supplying the teats remains constant at about 3kPa to 5 kPa C 1 4 Water flow meters with a minimum accuracy as specified in C 4 C 1 5 An airflow meter with an accuracy at least equal to that specified in C 4 to measure the air vent in the cluster Table C
9. 25 Fulsator 25 Pulsation rate pulsator ratio and pulsation chamber vaciiummpDI dSBS i iiti iioi SEHR abo 25 Additional IMOCS requirements for pulsation systems 26 Milk System tinet ne 28 29 Design OF MINS ae 29 Additional IMOCS requirements for milklines 29 Additional IMOCS requirements for washlines milkline plants 30 Additional IMOCS requirements for milk transfer lines recording Jar plantines 31 Additional IMOCS requirements for milking vacuum Awash lines recording jar plants eere 31 Additional IMOCS requirements for milk recording equipment 32 Air leakdqgg aue A REN Rr RE 32 PAA Gets ic ii ida aa das 32 Mike cec e 32 Diversion Of milk a 32 RECAE ras 32 E ead TENNIS 33 PARASITES 33 713 2 Control of releaser milk Pumps onore ono vcn 33 714 Delivery line sg Cri t een Teatre Additional IMOCS requirements for milking clusters Teatcup auae ais p P Eo Ht Fra ze Tealcup A A Vacuum Ut ii a Sur vent and Bi sessi A 36 Vacuum IN the milking Unit 36 Milk recording Sqguipment ae 37 Sl casas sas OOo oO
10. Regulation undershoot 3 2 Regulation overshoot 4 5 Average vacuum in the milk system Minimum vacuum during air inlet Average vacuum during air inlet Maximum vacuum during stop of air inlet Average vacuum after stop of air inlet Fall off vacuum drop 9 11 Regulation undershoot 11 10 Regulation overshoot 12 13 During the operation as in during attaching delete what does not apply gt Air inlet in teatcup for quarter milking in cluster with claw delete what does not apply 61 sas puaddy Table A2 Installation vacuum regulation sensitivity and vacuum drop Parameter Milking Airflow Connection Vacuum kPa unit 1 point Measure Limit s Vacuum on plant vacuum gauge Vacuum near plant vacuum gauge Vacuum gauge accuracy 1 2 Vacuum in the milking system Working vacuum for the milking machine Regulation Sensitivity 4 5 Vacuum regulation deviation nominal vacuums 5 Regulator working vacuum Working vacuum for the vacuum pump Vacuum pump exhaust Yes back pressure Vacuum in the milk system Yes at effective reserve Working vacuum at regulator Yes at effective reserve Vacuum drop receiver regulator 12 11 Working vacuum at vacuum pump at effective reserve Vacuum drop receiver vacuum pump 14 11 Lowest value of maximum pulsation chamber vacuum
11. close claw air admission l min Milking system leakage 3 4 l min Open air admission at claws l min Claw air admission 4 5 l min Add ancillary equipment connected to milkline l min Milking system ancillary equipment usage 5 6 l min Add pulsators all units milking l min Pulsation usage 6 7 l min Add ancillary equipment connected to airline l min Airline ancillary equipment usage 7 8 l min Manual Reserve receiver Drop vacuum 2kPa all units milking regulator plugged l min Effective Reserve receiver Add regulator drop vacuum 2kPa all units milking l min Required reserve l min Regulator sensitivity with and without milking units operating Regulator sensitivity 11 1 Exhaust backpressure positive pressure Vacuum drop one unit open Pulsation Tests Regulator leakage 9 10 l min Minimum Pulsation Graphs Attached yes no LIMPING lt 5 69 sas puaddy Faults and recommendations Faults Recommendations Inspection service check list Check Belt guard fitted and in good condition Rectified Yes No Is there adequate oil in the pump on arrival Height of oil in reservoir adequate Pump receiving adequate lubrication Is recommended mi
12. 3 1 1 measure and record the exhaust back pressure at the connection point Pe 10 4 Vacuum regulator leakage 10 4 1 With the milking machine operating in accordance with 10 1 2 connect the airflow meter with a full bore connection to connection point A1 with no airflow through it A vacuum meter shall be connected to connection point Vr 10 4 2 Record the vacuum as the regulator working vacuum 10 4 3 Decrease the vacuum by 2 kPa by opening the airflow meter and record the airflow 10 4 4 Stop the airflow through regulator s 10 4 5 Open the airflow meter and decrease the vacuum to the same as in 10 4 3 and record the airflow 10 4 6 Calculate the regulator leakage as the difference between the airflow recorded in 10 4 5 and that in 10 4 3 10 5 Vacuum gauge error 10 5 1 With the milking machine and vacuum regulator operating but with 44 10 5 2 no milking unit operating and the test vacuum meter connected to connection point Vr record the values on the vacuum gauge of the plant and the test vacuum meter Record the difference between these two values as the error of the gauge 10 6 Vacuum drop in airline 10 6 1 10 6 2 10 6 3 10 6 4 10 6 5 10 6 6 With the milking machine operating in accordance with 10 1 2 connect the airflow meter with a full bore connection to point A1 with no airflow through it A vacuum meter shall be connected to point Vm Record the vacuum as the working vacuum for the milking m
13. Vacuum drop receiver maximum pulsation chamber vacuum 5 16 62 Table A3 Measurement and calculation of airflow Parameter Vacuum Milking Connection point Airflowl min regulator units Vacuum Airflow Measure Limit s Effective reserve A1 Airflow with regulator A1 Manual reserve A1 Regulation Loss 1 3 Airflow without regulator Regulator leakage 2 5 Vacuum pump capacity Vacuum Vacuum at bOkPa pump pump Vacuum pump capacity Vacuum at working vacuum pump Airflow with vacuum system A2 Leakage into vacuum gt system 8 9 Airflow with milk system Leakage into milk system 9 11 Airflow in the installation Addition of airflow for accessories operated during milking but not in test Equipment Airflow l min Gate Cylinder Cluster remover Milk meter Releaser Other 63 sas puaddy Airflow use and vacuum for cleaning Milklines and milk transfer lines are usually cleaned by a cleaning solution transported and agitated by the vacuum difference to achieve effective cleaning Slug speeds of 7 m s to 10 m s optimize this cleaning action To achieve these slug speeds it might be necessary to use a higher vacuum pump capacity than that necessary for milking Other washing systems may not need increased vacuum pump capacity Table A4 gives the air capacity for some milkline dimensions and working va
14. always during cleaning Therefore during milking the pump capacity will exceed milkflow and drain the receiver jar This leads to a stop start milk pumping pattern and continue pumping is used for cleaning The use of variable speed controllers on milk pumps allows the pump to match the milkflow into the receiver as it varies over the course of the milking Variable Speed Milk Pumps Various control strategies for milk pumps can be selected from simple on off step changes to continuously variable speeds Peak flow rates through the milk pump during milking are reduced roughly by half by the use of variable speed with an optimum control strategy Furthermore there is a threefold increase in the time the milk pump is pumping which slows down the milkflow rate through the plate cooler thereby reducing cooling time This 84 strongly favours the use of these types of variable speed centrifugal pumps for large throughput milking machines Plate coolers used to pre cool the milk before entering the bulk tank are selected according to milkflow rate Variable speed pumping match plate cooler expected flow rate much more closely It has been shown that that the maximum flow rate is up to 80 higher than the average flow rate used to size the plate cooler This applies to the continuously variable speed controls strategies If the peak flow rate of milk through the plate cooler is reduced the peak flow rate of water needed to maintain cooling efficiency
15. and milk filters is not easy More often than not it is based on practical experience It can either be planned on the basis of the milk collected over an hour which can be linked to theTables D3 and D4 which also show their capacities in litres per hour An alternative approach more in keeping with the ISO standards and the cyclic nature of the milkflow over the course of the milking is to base it on a peak milkflow of 5 litres per minute per unit This should cope with all situations but may be fine tuned to particular installations if lower flow rates are found workable in practice Milk Filtering An inline milk filter should be fitted in all milking installations Where a plate cooler is fitted the filter should be fitted between the milk pump and the plate cooler Generally milk filters should be mounted vertically with the drain cap at the base The filter should be plumbed so that sediment is collected on the outside of the filter sock Mount the filter high enough so that an operator is not forced to bend down when changing a filter sock For effective filtering and trouble free operation it is essential to match filter sock sizes to milk pump sizes types and flow rates Table D4 outlines a range of filter sock sizes for different milkflow rates The weight of material that manufactures use in in line filter socks varies from 60 155 g m The most common one used is 75 g m The 75 g material will filter particles as small as 70 micron
16. can also be reduced To improve efficiency further a solenoid valve may be fitted in the water line to the cooler This solenoid valve is wired to the liquid level controller on the milk pump and ensures that water flows only when the milk pump operates and thus helps to conserve water The solenoid should have a time delay of no longer than 20 30 seconds which will allow the water to continue to flow for a short time after the milk pump has stopped This will improve the performance of the plate cooler It is not good practice to insert a restrictor between the milk pump and the filter A restrictor will reduce the flow rate through the filter and plate cooler but it may also cause milk fat damage and possibly froth in the milk Diaphragm Milk Pumps Diaphragm milk pumps are used in many milking installations throughout the country From the point of view of milk pre cooling a pipeline milking system without recording jars with an intermittently operating diaphragm milk pump is a good arrangement Typical output of diaphragm milk pumps under full flow is 1300 1800 l h 290 400 gal h for a single diaphragm milk pumps and 2600 3600 l h 580 800 gal h for a double diaphragm milk pumps Within these ranges the flow rate of diaphragm pumps can be set by using different combinations of pulley sizes Where froth is a problem diaphragm pumps can clear froth from the milk receiver jar but to do this the pump must be switched over to continuous p
17. mounted in a readily accessible location and be protected from moisture from the milking machine and installed in a place and manner in which it does not take in excessive dust The regulator should be installed in a place and manner so as to minimize noise for the operator s 5 4 3 Examples of location of sensing point for vacuum regulator a In pipeline and automatic milking machines either between the interceptor and the sanitary trap or on the sanitary trap or in the receiver 21 b In recorder milking machines either between the interceptor and the sanitary trap or on the sanitary trap or in the milking vacuum line 5 5 Vacuum gauge 5 5 1 Vacuum Gauge General a Shall indicate intervals of 2 kPa or less from 20 kPa to 80 kPa b Gauge error shall not exceed 1 kPa at the working vacuum 5 5 2 Mounting a Gauge is readable by the operator milker while milking b More than one vacuum gauge may be needed 5 6 Airlines 5 6 1 Airlines general a Airlines shall be sloped to a readily accessible drain valve b Airlines shall be self draining when the vacuum is shut off c Airlines shall have provision for cleaning and inspection 5 6 2 Airlines internal diameter and airflow a Airlines shall be large enough so vacuum drop does not seriously affect milking machine function b Vacuum drop between Vm and Vr shall therefore not exceed 1 kPa c When Vp Vm the higher vacuum at Vp increases power consumption and
18. pumped initially through the plate cooler and later through water jackets in the tank to maintain the storage temperature The ice builder should ideally be able to cope with two milkings to make the best use of night rate electricity A properly installed setup can pre cool the milk to within 1 3 C of the recommended storage temperature An ice builder can also be used in conjunction with a direct expansion tank This arrangement can be used with a smaller condenser on the direct expansion tank which will keep the milk at the correct temperature between milkings and save the built up ice for after milking Well water is more suitable than water from the public supply because it is generally much cooler and is usually cheaper where water charges are per unit volume The extra investment needed to allow more effective pre cooling e g to install a water chiller a two stage plate cooler etc should follow a careful cost benefit analysis Centrifugal Milk Pumps There are many options to choose from when it comes to deciding on a milk pump At present centrifugal milk pumps are preferred because of their higher flow rates Higher flow rates are needed for circulation cleaning of modern milking machines Centrifugal pumps are cheaper than diaphragm pumps and are arguably more hygienic and more straight forward to install however increase the noise levels in the milker s pit Milk pumps must be sized according to the maximum flow conditions This is
19. slope of each branch between the receiver and the most distant milk inlet from the receiver The minimum slope shall be given for a 5 m section of each branch Find the average slope over a series of 5m distances along the milkline and choose the lowest value to present the minimum slope ofthe branch Slope shall be given in mm m with a positive value meaning falling towards the receiver With the milking machine operating in accordance with 10 1 2 connect the airflow meter with a full bore connection to connection point A2 with no airflow through it Connect vacuum meter to connection point Vr or Vp Record the vacuum as the regulator or vacuum pump working vacuum Stop the airflow through the vacuum regulator Stop or isolate the pulsators and all vacuum operated equipment Plug all air admissions Adjust the airflow meter until the vacuum is the same as the vacuum recorded in 12 2 2 Record the airflow Isolate the milk system Open the airflow meter until the vacuum becomes the same as recorded in 12 2 2 Calculate the milk system leakage as the difference between the airflows 12 2 6 and 12 2 4 49 MILKING UNIT 13 MILKING UNIT 13 1 Teatcup or cluster fall off air inlet 13 1 1 With the milking machine operating without the vacuum regulator and airflow meter connected to point A1 with a full bore connection and a vacuum meter connected to point Vm adjust the airflow meter until the vacuum is 50 kPa 13 1 2 Open one
20. to the upper half of a pipeline There shall be provisions to ensure that withheld abnormal or undesirable milk cannot be mixed with normal milk Receiver shall have sufficient volume to accommodate slugs of liquid which may be formed during milking and cleaning and the volume shall be stated in the installation instructions Inlet s should be shaped to limit formation of foam during milking 32 7 13 Releaser 7 13 1 General a b c d Releaser shall be adequate to deal with the maximum flow at which milk cleaning and disinfecting fluids flow through the system The releaser milk pump s discharge flow at 50 kPa working vacuum and typical discharge pressures shall be stated in the instructions for installation There shall be no air leaks in the releaser or between the receiver and the releaser Back flow of milk from the releaser shall be prevented 713 2 Control of releaser milk pumps a Milk pump operation shall be controlled by the quantity of milk in the receiver so that flooding of the receiver or mixing of air and milk is avoided 7 14 Delivery line a b c d e Means shall be provided at every low point to permit drainage of the delivery line filters and any in line cooling equipment If compressed air is used to purge milk this air shall be free from contaminants The method of air injection should prevent unnecessary formation of free fatty acids Means preferably automatic shal
21. 0 litres cooled With 25 night rate for DX and 70 With 50 night rate for DX and night rate for IB and 5096 pre cooling 100 night rate for IB and 5096 pre cooling 5 36 4 65 Looking at all the tables with all the costs may be confusing but each shows the costs calculated for a possible cooling scenario It is interesting to note that the costs reduce depending on the use made of Nightsaver rate and pre cooling Table D10 shows that for that scenario with the correct use of Nightsaver rate and pre cooling there is little to choose from between the DX and IB in terms of running costs If we take an average for Table D10 Pre cooled milk of say 5 to cool 1000 gallons the annual cost of cooling milk for a farmer supplying 50 000 gallons would only amount to about 250 The costs outlined in the tables are based on modern efficient refrigeration units in good condition and well maintained The costs are likely to be considerably higher with older type compressors where maintenance is neglected or where condensers are damaged Night Rate Electricity Most dairy farmers are on the ESB Domestic Rural Nightsaver rate There is an extra standing charge in addition to the normal Domestic Rural scheme of 6 20 every two months The charge for Units kWh on Nightsaver is now as follows Day Units 1706 c Unit kWh Night Units 8 44 c Unit KWh Domestic Rural Nightsaver is available from 11 00pm to 8 00am GMT i e
22. 1 Artificial Teat Dimensions Diameter A mm Outlet hole diameter B mm Number of outlets holes Dimensions in millimetres y 4 7 Key 1 measuring channel 2 liquid channel A diameter of artificial teat B outlet hole diameter of artificial teat Figure C 1 Artificial Teat C 2 Test conditions Vacuum levels and vacuum variations shall be measured while drawing water through artificial teats The milking unit shall work normally C 3 Description of the connection to the plant The connection to the plant shall be described by a the length and internal diameter of the long milk tube b the shape of the long milk tube see Figure C 2 determined by e the vertical distance between the teat base and the milkline axis h1 the vertical distance between the teat base and the lowest point of the long milk tube h2 the vertical distance between the teat base and the highest point of the long milk tube h3 77 sas puaddy the vertical distance between the claw and the lowest point of the long milk tube h4 the vertical distance between the top of the short milk tube at the teacup and the lowest point of the long milk tube h5 the horizontal distance between the centre of the udder and the milkline axis l adescription of any device fitted in the milking unit between the cluster and the milkline c the description of the milk inlet valve d the descriptio
23. 78 380 10 48 5 1155 678 440 10 60 1290 678 500 10 60 1426 1004 520 10 60 1899 1004 540 20 60 2029 1004 560 20 60 2160 1004 580 20 2291 1004 600 20 h US 2422 1004 620 20 73 2553 1004 640 20 73 2683 1809 660 20 73 3662 1809 680 20 73 3793 1809 700 20 98 3924 1809 20 98 4055 1809 20 98 4185 1809 20 98 4316 1809 20 98 4447 1809 20 98 4578 The pump capacity is an informative value only and incorporates a large safety factor the adequacy of a vacuum pump should be determined by verifying the system meets the effective reserve requirements Note The above table shows reserves for milking and cleaning The cleaning reserve or air demand for cleaning may be reduced where cleaning by air injection is not used or where the air cleaning system does not use the assumed demand In the ISO standards and IMOCS recommendations it is only necessary for the machine to either meet the reserve requirement during milking or pass the attachment and fall off tests If energy saving technologies are used which can reduce the effective reserve e g variable speed vacuum pumps then the plant should pass the attachment and fall off tests For number of units x10 effective reserve 20 30 For number of units gt 10 effective reserve 50 10 N 10 Number of units 54 Table 2 Midi level recording jar plants with 2 stalls unit Milkline Effective Effecti
24. Have the claw kits been changed at recommended intervals Are all claw bowls free from cracks Are auto shutoffs fitted Liners Have the liners been changed at recommended intervals 2000 cow milkings Are liners fitted approved by the manufacturer No holes in liners or short milk tubes Are the liners and short milk tubes free from cracks Are the anti twist indicators aligned correctly Liner manufacturer and type marked Are liners approved original or copies Shell manufacturer and type marked Long Milk Tubes Is bore 13mm or greater Are tubes free from excessive loops 73 sas puaddy Check Correct Rectified Yes No Yes No Milkline Milkline inlets into the top or top third of milkline and aligned correctly Is there an adequate continuous fall in the milkline and in the correct direction towards the receiver Each milkline has a separate entry into receiver milkline not restricted at receiver entry point Has the milkline remained rigidly supported Is the end of the milkline blank Highest points of milk lift less than 2 1m above cow standing Drainage tap present at every low point filter inline cooling If compressed air is used to purge milkline is filtered air used Recorder Jars Is the recording jar unit free from leaks Are the hand controls functioning correctly Are other rubber parts in good condition Jar vac
25. Teagasc IMOCS Recommendations for the installation and testing of milking machines Table of Contents Recommendations for the installation and testing of milking machines 1 1 1 1 2 3 1 4 1 4 2 4 3 5 1 5 2 5 3 5 4 5 6 Performance requirements 8 Tests for 9 Access Tor Measurement ne 9 1217 aia 9 1 2 2 Airflow measuring connections se 9 1 2 3 Vacuum measuring 10 12 4 A Additional IMOCS requirements for test points and iSolatonValV8S iocum Sess Safety and hygierie cette ritiene 12 Materials asesina ei 14 Additional IMOCS requirements for materials User s manual General tuis NS ae dut A iue Installation dert 17 A IE 17 General Vacuum regulation 52 1 Vacuum dev ION 19 5 2 2 Regulation Sensitivity Lada neo pant oreet nao Ep 19 5 2 3 Regulation 1955 di 19 5 2 4 Regulation characteristics and effective reserve Vacuum PUIN PSs sauna 5 3 1 Vacuum Pumps general 5 3 2 Influence of altitude
26. achine Open the airflow meter until the vacuum at Vm decreases by 2kPa and record the working vacuum Move the vacuum meter to regulator connection point Vr and record the working vacuum Calculate the vacuum drop between Vm and Vr as the difference between the vacuum recorded in 10 6 2 at Vm and that recorded in 10 6 3 at Vr with the same airflow in both cases Move the vacuum meter to vacuum pump connection point Vp and record the working vacuum Calculate the vacuum drop between Vm and Vp as the difference between the vacuum recorded in 10 6 2 at Vm and that recorded in 10 6 5 at Vp with the same airflow in both cases 10 7 Leakage in vacuum system 10 7 1 10 7 2 10 7 3 10 7 4 10 7 5 10 7 6 With the milking machine operating in accordance with 10 1 2 with all units plugged connect the airflow meter with a full bore connection to point A2 with no airflow through it Connect a vacuum meter to point Vr or Vp Record the vacuum as the regulator or vacuum pump working vacuum Isolate the vacuum system from the milk system Stop the airflow through the vacuum regulator Adjust the airflow meter until the vacuum is the same as that recorded in 10 7 2 Record the working vacuum at the vacuum pump connection point Vp Isolate the vacuum pump from the rest of the vacuum system Connect the airflow meter directly to vacuum pump with a full bore connection Open the airflow meter until the working vacuum at the vacuum p
27. al spoilage and to extend storage on the farm so as to minimise milk transport costs Good hygiene in all aspects of milk production is essential to the production of quality milk and the growth of bacteria during the storage interval must also be curtailed Bacteria in milk increases very quickly at body temperature and even milk with a low initial count will sour rapidly When cooled by well water to between 15 C and 20 the growth rate is restricted and milk produced under hygienic conditions will retain good quality for a period of up to 15 to 20 hours However when the storage period exceeds this limit further cooling by refrigeration is necessary The storage temperature and also the time to reach the storage temperature which is normally 4 are both important Hence refrigerated bulk milk coolers must be designed and selected to cool the milk to 4 within a specified time This cooling period should not extend beyond the normal milking time by more than one hour at peak The general recommendation is to cool to 6 C for everyday collection ED 4 C for every second day collection E2D and 3 C for every third day collection E3D 80 Bacterial Growth Rate in milk The effects of time and temperature on bacterial growth in farm milk are outlined in Table D1 The starting Total Bacterial Count TBC is 5000 The dilution effects of milking additions may be offset by blend temperature increases during milking Table D1 The e
28. al teat end The measurement should preferably be made by means of a built in transducer in the artificial teat A transducer connected to the measuring point by a tube may be acceptable if it is proved that the measurement can be made with sufficient frequency response C 7 Measuring period A measuring period shall be chosen as a full number of pulsation cycles and shall be at least 5 pulsation cycles The number of cycles shall be recorded C 8 Results C 8 1 General Based on the measured values one or more of the following parameters shall be calculated and presented as results The maximum error in those calculated values for vacuum variations shall be 10 of this value or kPa whichever is the greatest C 8 2 Average liner vacuum The average vacuum during the measuring period shall be calculated as defined in ISO 3918 C 8 3 Average liner vacuum during Phase b The average vacuum during Phase b of the pulsation waveform is the average of the average registered values during phase b of the pulsation waveform in each measured pulsation cycle during the measuring period C 8 4 Average liner vacuum during Phase d The average vacuum during Phase d of the pulsation waveform is the average of the average registered values during Phase d of the pulsation waveform in each measured pulsation cycle during the measuring period 79 sas puaddy Appendix D Milk Cooling Cooling milk on the farm has two main aims to inhibit bacteri
29. all not protrude more than 0 8 mm past the inner surface of the washline c Rubber joints or bends may not be used in washlines plastic or stainless steel unionised cone seal connections are acceptable All bends in washlines should be stainless steel with a centreline radius not less than 1 5 times the diameter d All washlines shall have a stainless steel end entry nipple or a side entry nipple no more than 30 mm from the blank capped end In either case the end of the washline should be capable of being inspected i e a removable end piece on the washline This does not preclude the use of valving systems at the end of washlines to facilitate washing e The stainless steel shall be cut at 90 at all washline joints this necessitates using mechanical cutting equipment f Washline entries shall be into the top or top third of the pipeline g Stainless steel of 0 9mm gauge 20 wall thickness or greater and quality Standard 304 Dairy tubing shall be used in washlines This does not preclude the use of inspection windows in washlines h When closed circulation is required for plants with diaphragm pumps a method for the safe connection of the suck up tube to the return tubes shall be provided i A suitable mechanism should be installed for the safe uptake and return of detergent solutions to avoid accidental splashing of chemicals 30 75 Additional IMOCS recommendations for milk transfer lines in recording jar plants a
30. ct a vacuum meter to the connection point Vm Record the vacuum as the working vacuum for the milking machine Shut off all milking units and record the vacuum The milking machine shall then be in the same state as during milking but with no milking unit in operation Calculate the regulation sensitivity as the difference between the vacuum measured with no milking units in operation 10 2 2 3 and that with all units operating 10 2 2 2 10 2 3 Regulation loss 10 2 3 1 10 2 3 2 10 2 3 3 10 2 3 4 10 2 3 5 10 2 3 6 With the milking machine operating in accordance with 10 1 2 with liners plugged connect the airflow meter with a full bore connection to connection point A1 with the airflow meter closed Connect a vacuum meter to the connection point Vm Record the vacuum as the working vacuum for the milking machine Open the airflow meter until the vacuum decreases by 2kPa and record the airflow Stop any airflow through regulators that admit air Decrease the vacuum by opening the airflow meter to drop the vacuum 2 kPa Calculate the regulation loss as the difference between the airflows recorded in 10 2 3 5 and 10 2 3 3 42 Figure 2 Regulation undershoot vacuum drop and regulation overshoot for rapid changes in air admission Key A undershoot 1 Phase 1 no teatcup open B vacuum drop 2 Phase 2 teatcup s are open C overshoot 3 Phase 3 teatcup s open 4 Phase 4 teatcup s are closed 10 2 4 Tests of r
31. cumulating in the plate cooler Water filter s may be necessary if foreign matter or minerals are present in the water supply The water flow rate should be adjusted to about double the measured milkflow rate for optimum efficiency in milk cooling thereby reducing the milk temperature to within 3 5 C of the inlet cooling water Table D2 At a higher water flow rate only a marginal reduction in milk outlet temperature is achieved At a lower water flow rate a reduction of milk temperature to within 5 109 of the inlet water temperature could be expected Table D2 also shows the effect of water inlet temperature on plate cooler performance 82 Table D2 Plate cooler milk and water outlet temperature as affected by water inlet temperature and water to milkflow ratio Milk inlet temperature 359C Water Water milk 1 1 Water milk 2 1 Water milk 3 1 Inlet C Milk C Water C Milk C Water C Milk C Water C 10 20 27 14 7 15 22 28 18 21 20 25 30 22 25 Source M G Fleming and J O Keeffe Teagasc Moorepark Research Centre Plate Cooler Size As well as water temperature and water to milkflow rate the size of the plate cooler is also important Under sizing the plate cooler will result in reduced cooling efficiency The plate cooler should be sized according to the milkflow rate For a single stage plate cooler the number of plates generally required is given in Table D3 Oversizing the plate cooler where cont
32. cuums at an atmospheric pressure of 100 kPA Table A4 Airflow for cleaning at a speed of 8 m s and under atmospheric pressure of 100 kPa Internal Airflow admission l min to produce milkline slug flow for cleaning at a Diameter vacuum of 45 kPa 240 269 299 332 401 477 518 746 903 1104 1990 Ancillary equipment Ancillary equipment can be divided into three groups a Equipment running continuously during milking b Equipment that uses a quantity of air for a short time during milking c Equipment only operating before or after the milking session For equipment of typed defined in a the minimum airflow use shall be added when calculating the pump capacity and effective reserve For equipment of type defined in b the ancillary equipment simultaneously uses the same vacuum supply as that for milk extraction In many cases it is not necessary to take their air use into account as ancillary equipment used 64 during milking consumes only small quantities of air over a short time Such equipment includes cluster removers and gate cylinders However this equipment may use a high instantaneous airflow that shall be considered when sizing the airlines For equipment of type defined in c there is no need to take its capacity into account when calculating the vacuum pump capacity for milking Calculations of vacuum pump capacity based on effective reserve requirements
33. decreases the vacuum pump capacity Vp should preferably not exceed Vm by more than 3 kPa 5 7 Interceptor a b c d e f g Shall be fitted near the vacuum pump between the vacuum pump and the regulator There shall not be any intermediate connections into the airline between the interceptor and the vacuum pump except as required for test purposes or for the connection of a safety valve A safety valve may be fitted to protect the pump from effects of high vacuum caused by the activation of any vacuum shut off valve in the interceptor Means shall be provided to prevent liquids trapped in the interceptor from entering the vacuum pump Interceptor s shall have automatic drainage facilities It shall be possible to inspect and clean the inside of the interceptor s The effective volume of the interceptor s shall be given in the user s manual and should be adequate to facilitate washing of the airlines as determined by airline sizes 5 8 Sanitary trap a b c d e f g A sanitary trap shall be fitted between the milk system and the vacuum system in pipeline and recorder milking machines The sanitary trap shall be located between the receiver vessel and the vacuum system except where the vacuum and pulsation systems form part of the routine circulation cleaning and disinfection system The sanitary trap shall have provision for drainage and means to minimize liquid entry into the vacuu
34. e contribution of Margie Egan Teagasc Moorepark in compiling this booklet PERFORMANCE REQUIREMENTS 1 PERFORMANCE REQUIREMENTS ISO 5707 Milking machine Installations Construction and Performance specifies minimum performance and information requirements and certain dimensional requirements for satisfactory functioning of milking machines for milking and cleaning 11 Tests for compliance The methods for performance testing referred to in this manual are specified in ISO 6690 1 2 Access for measurements 1 2 1 General a Connection points for measuring airflow and vacuum shall be provided b Dismantling is acceptable to access connection points c All connection points and their location shall be described in the user s manual 1 2 2 Airflow measuring connections Figure 1 A1 to enable measurement of effective reserve manual reserve and regulator leakage a For bucket or direct to can milking machines connection to be between the regulator sensing point and the first vacuum tap b For pipeline milking machines connection to be at or near the receiver s upstream of the sanitary trap s c For recorder milking machines connection to be at or near the sanitary trap s on the milking vacuum line s A2 to enable measurement of leakage into the vacuum and milk systems a Connection to be between the vacuum pump s and the sanitary trap s or the first vacuum tap Note When not in use tes
35. e g variable speed vacuum pumps then the plant should pass the attachment and fall off tests 56 Table 4 Double up midi level milkline plants with 1 stall unit Milkline Effective Effective Sanitary Wash Main Estimated Bore Reserve Reserve Trap E Line Airline Pump mm for for Volume Bore Bore Capacity Washing Milking I mm mm l min l min l min Minimum 443 440 10 48 5 1042 678 520 10 60 1557 678 560 10 60 1818 678 600 20 60 2080 1004 640 20 73 2683 1004 680 20 73 2945 1004 720 20 73 3206 1004 760 20 US 3468 1004 800 20 TE 3729 1004 840 20 98 3991 1004 880 20 98 4252 1809 920 20 98 5362 1809 960 20 98 5624 1809 1000 20 A 98 5885 1809 1040 20 98 6147 1809 1080 20 98 6408 1809 1120 20 98 6670 1809 1160 20 98 6981 1809 1200 20 98 yos The pump capacity is an informative value only and incorporates a large safety factor the adequacy of a vacuum pump should be determined by verifying the system meets the effective reserve requirements Note The above table shows reserves for milking and cleaning The cleaning reserve or air demand for cleaning may be reduced where cleaning by air injection is not used or where the air cleaning system does not use the assumed demand In the ISO standards and IMOCS recommendations it is only necessary for the machine to either meet the reserve requirement during milking or pass the attachme
36. egulation characteristics 10 2 4 1 10 2 4 2 10 2 4 3 10 2 4 4 10 2 4 5 10 2 4 6 10 2 4 7 10 2 4 8 10 2 4 9 10 2 4 10 10 2 4 11 The regulation characteristics are preferably tested in the fall off and attachment tests Milking unit with automatic shut off valve a Use one cluster with shut off valve enabled fall off test b Use one teatcup with the shut off valve in attachment position attachment test c Figure 2 Regulation undershoot vacuum drop and regulation overshoot for rapid changes in air admission With the milking machine operating with liners plugged connect a vacuum recorder to measuring point Vm Record the vacuum for 5 s to 15 s Phase 1 of Figure 2 While recording open one teatcup or one cluster and record for 5 s to 15 s after the vacuum has stabilized Phases 2 and 3 of Figure 2 If there are 32 or more clusters or teatcups for quarter milking are connected open one cluster or teatcup per every 32 clusters While recording close the teatcup or cluster and record for 5 s to 15 s after the vacuum has stabilised Phase 4 of Figure 2 Calculate the average vacuum during 5 s of Phase 1 Find the minimum vacuum of Phase 2 Calculate the average vacuum during 5 s of the stable part of Phase 3 Find the maximum vacuum of Phase 4 Calculate the average vacuum during 5 s of the stable part of Phase 4 Calculate the fall off vacuum drop or the attachment vacuum drop B in Figure 2 as the ave
37. en prepared by the lrish Milk Ouality Co Operative Society IMOCS IMOCS has its registered office at 84 Merrion Square Dublin 2 The organization was incorporated in 1989 with the aim to improve milk quality standards in Ireland to ensure that Irish milking machine installation and testing standards exceed the best international standards This manual combines lrish Milk Quality Co operative Society IMOCS Guidelines and ISO standards International Standards Organisation ISO 5707 2007 ISO 6690 2007 and ISO 3918 2007 into a reference guide for all milking machine installers and advisers in the Republic of Ireland The manual also contains information on some equipment and topics related to milking machines which are outside the scope of the ISO standards The IMOCS guidelines and ISO standards have been developed to ensure best practice in the installation and testing of milking machines and are not a legal requirement The basis of the manual is compliance with existing standards directives and legislation and agreed installation practices for the fitting of new milkline and recorder parlour plants for bovines The manual applies only to the main milking facility which is usually a parlour and does not apply to new bucket plants Where possible and practicable the recommendations shall be applied to existing installations The IMOCS has informed each person who is listed in its Register of Certified Milking Machine Testers and In
38. ffect of time and temperature on bacterial growth in farm milk Milk Storage Expected TBC after storage for Temperature C 2 days 3 days 4 days 5 000 15 000 50 000 10 000 30 000 100 000 1 000 000 cooling to 2 is technically difficult Recommendations for extended storage e Fast cooling rate i e avoid high blend temperatures e Accurate temperature control during storage 4 C Excellent hygiene from teat to tank Milk Cooling Options 1 Direct Expansion DX 2 IB with either in tank ice builder or external ice builder 3 DX or IB plus single stage plate cooler with water from either deep well shallow well or mains 4 DX or IB plus single stage plate cooler with chilled water from either the tank or chiller unit 5 DX or IB plus double stage plate cooler with water from either deep well shallow well or mains and chilled water Pre cooling Effective pre cooling of milk can lead to energy savings and enhance the keeping quality of the milk Pre cooling of milk in line by well or mains water before it enters the tank has a number of advantages These include 1 Economy cooling costs can be reduced by up to 5096 depending on the temperature and supply of water and the operational efficiency of the cooler e g water to milkflow ratio 2 Milk quality pre cooling ensures a lower milk blend temperature which helps to curtail growth of bacteria 3 The tepid water fro
39. from accessories attached in the long milk tube 13 5 1 The effect of milk meters or accessories inserted in the long milk tube shall be registered by measuring the average liner vacuum in a specified milking unit both with and without the accessories connected and by comparing the results Details of the measurement procedure are given in Appendix C 51 13 6 Airflow at the end of the long milk tube 13 6 1 13 6 2 13 6 3 13 6 4 13 6 5 13 6 6 Check the length and internal diameter of the long milk tube With the milking machine operating with all units plugged connect a vacuum meter to the connection point Vm Record the vacuum as the working vacuum for the milking machine Connect the airflow meter and a vacuum meter to the end of the long milk tube instead of the claw or teatcup Record the vacuum at the end of the long milk tube with the airflow meter closed and with an air inlet of 10 l min Open the airflow meter until the vacuum at the end of the long milk tube is 5 kPa lower than the vacuum measured above Record the reading of the airflow meter as the airflow at the end of the long milk tube 52 TABLES Table 1 Midi level milkline plants with 2 stalls unit Milkline Effective Effective Sanitary Wash Main Estimated Bore Reserve Reserve Trap E Line Airline Pump mm for for Volume Bore Bore Capacity Washing Milking 1 mm mm l min l min l min Minimum 443 320 10 38 48 5 771 6
40. g vacuum wash line may come from the sanitary trap receiver or receiver airlines The milking vacuum wash line shall slope towards the 3 way valve or equivalent for drainage purposes 77 Additional IMOCS recommendations for milk recording equipment a b c d e f 9 h i The highest point of the long milk tube should ideally not be greater than 2 1m above the cow standing and preferably 1 7m or less Recording jars shall be rigidly fixed in a vertical position consistent with accurate measurement of milk volume Recording jars shall be graduated to allow milk recording in units of 0 5 kg from 2 kg upwards Recording jars shall be fitted with a spreader device to distribute the wash over the jar surface without excessively restricting airflow The milking vacuum wash line nipple on the recording jar shall have a minimum bore of 16mm The milking vacuum wash tube connected to recording jars shall have a minimum bore of 15mm A facility shall be provided for agitating the milk removing a sample and draining the recording jar contents The exit nipple bore at the base of the recording jar and the transfer tubes bore shall be at least 18mm All milk meters shall be International Committee for Animal Recording ICAR approved Air leakage shall not exceed 10 l min plus 2 l min for each milking unit Provisions shall be made for complete drainage of all parts of the milk system a a Shall be fitted
41. ge through shut off valves of milking units 51 13 3 Air vent and leakage into teatcup or 5 51 13 4 Measuring the vacuum in the cluster eene 51 13 5 Measurement of the vacuum drop from accessories attached in the long Milk tub messes nano ea 51 13 6 Airflow at the end of the long milk 52 Tables 53 Table 1 Midi level milkline plants with two stalls unit 54 Table 2 Midi level recording jar plants with two stalls unit 55 Table Double up low level milkline plants with one stall unit 56 Table 4 Double up midi level milkline plants with one stall unit 57 Table 5 Double up midi level recording jar plants with one stall unit 58 Table 6 Recommended sizes of diversion 59 Appendices Appendix A Measurements and 61 Appendix B Test report and inspection service check list 67 Appendix C Laboratory and parlour tests of vacuum in the milking unit 76 Appendix D Milk Cool 80 RECOMMENDATIONS FORTHE INSTALLATION AND TESTING OF MILKING MACHINES Recommendations for the installation and testing of milking machines Introduction This manual has be
42. ilk contact surfaces shall be free from engraving or embossing All metal milk contact surfaces except for welded seams shall have a surface roughness less than or equal to 2 when tested in accordance with IS EN ISO 4288 Surface roughness Ra on welded seams shall not exceed 16um Copper or copper alloys shall not be used in any part of the installation that may come in contact with milk or cleaning and disinfecting fluids other than water Materials that come into contact with milk shall be resistant to both milk fat and cleaning and disinfecting solutions 15 USER S MANUAL 4 USER S MANUAL 4 1 General a The User s Manual written in at least one of the country s official languages shall specify a system of measures that ensure that the function safety and hygiene of the milking machine are maintained during its intended lifetime This includes instructions for routine servicing and replacement of individual parts An indication shall be given as to whether particular actions should be performed by the user or if other suitably qualified personnel are needed 4 2 Installation details At least the following installation details shall be provided a b c d e f g Mounting dimensions space requirements and critical building dimensions Recommended ambient conditions for the different parts of the milking machine Minimum electrical power supply and earthing grounding requirements Mini
43. in towards the sanitary trap s Pulsation line Is the automatic drain valve functioning correctly Is the pulsation line clean internally Is there an adequate continuous fall in the pulsation line and in the correct direction Tap at end of the line for washing purposes Is pulsation line rigidly fixed Airflow test point fitted to the end of the pulsation line Pulsation line fitted with flush taps and removable plugs caps Pulsation Are pulsators relays clean Have the pulsation relay kits been changed at recommended service intervals Is there a filtered air supply fitted Are filters on air supply to relays clean and free from unnecessary restrictions Is the clean airline free from debris Are pulsators and relay tubes in good condition and without leaks 72 Check Rectified Yes No Rubber Tubing Condition Are long milk tubes satisfactory Are long pulse tubes satisfactory and correctly sized Are short pulse tubes satisfactory Are long and short jetter tubes satisfactory Tubes to cluster removers satisfactory Are milk transfer tubes from recorder jars satisfactory Is other rubberware satisfactory Long Pulse Tube Bores Alternate at least 7 mm Simultaneous at least 9 5 mm Claws Are claws clean Are the air admission holes fully opened Are claw bowls gaskets nipples and shut off valves satisfactory
44. ine slopes shall be 196 or greater 7 6 Additional IMOCS recommendations for milking vacuum wash lines in recording jar plants a b c d e saddle type nipples shall have a protrusion into the milking vacuum wash lines to prevent poor alignment with the hole in the milking vacuum wash line due to rotation of the saddle This protrusion shall not protrude more than 0 8 mm past the inner surface of milking vacuum wash line Rubber joints or bends may not be used in milking vacuum wash lines plastic or stainless steel unionised cone seal connections are acceptable All bends in milking vacuum wash lines should be stainless steel with a centreline radius not less than 1 5 times the diameter All milking vacuum wash lines shall have a stainless steel end entry nipple or a side entry nipple no more than 30 mm from the blank capped end In either case the end of the milking vacuum wash line should be capable of being inspected e a removable end piece on the milking vacuum wash line This does not preclude the use of valving systems at the end of milking vacuum wash lines to facilitate washing Where nipples are welded on to a milk transfer line the inside of the weld shall be flared and suitably dressed Three way valves shall be full bore stainless steel or other suitable food grade material 31 f 9 h Three way or equivalent valves shall be easily accessible The vacuum supply to the milkin
45. inuously operating diaphragm pumps are used should be avoided because air from the diaphragm pump passing through the residual milk in the cooler can cause milkfat damage and cleaning difficulties This may occur with older plants but present day milking machine standards insist that all types of milk pumps are operated intermittently Centrifugal pumps have always had to be operated intermittently to prevent them from dry running and damaging seals Table D3 Number of plates required in a single bank model M plate cooler each plate is 120 mm x 632 mm Plate cooler capacity milkflow rate No of plates Gal hr Litres hr 18 200 900 20 250 1 140 24 300 1 360 30 400 1 820 36 500 2 270 42 600 2 730 48 700 3 180 54 800 3 640 Source M G Fleming and J O Keeffe Teagasc Moorepark Research Centre 83 sas puaddy Plate Cooler Installation Plate coolers should be mounted so as not to pose a bang hazard for the operator Pick a location that will be convenient for use by the operator Ensure that the plumbing work is well planned and installed The pipe sizes should be sized to cope with the flow rates intended Two Stage Plate Coolers The best pre cooling performance is got using a two stage plate cooler with water from either a deep well shallow well or mains and chilled water The chilled water can be produced from either an in tank or external ice builder With ice bank tanks the chilled water is generally
46. itude 5 3 3 Exhaust a The exhaust shall not obstruct the passage of the exhaust air by sharp bends T pieces or unsuitably designed silencers b Means shall be provided to minimize oil discharge from oil lubricated vacuum pumps into the environment for example with an oil separator collection or recirculation system fitted in the exhaust pipe c Moisture from the exhaust shall be prevented from entering the vacuum pump for example by fitting a moisture trap or having the exhaust pipe with a continuous slope away from the vacuum pump d The exhaust should not discharge into a closed room where foodstuffs are stored or processed or where persons or animals are present 5 3 4 Prevention of reverse flow through vacuum pump a Automatic means shall be provided to prevent reverse flow of air from the exhaust which may contaminate the milk system 5 3 5 Location a The vacuum pump shall be located so that airline vacuum drop recommendation 5 6 2 shall be achieved using airlines with reasonable diameter b The vacuum pump shall be installed so that its capacity vacuum and 20 where applicable speed can be easily measured c The vacuum pump s should be placed in a well ventilated and non freezing area isolated from the milking parlour and milk room 5 4 Vacuum regulator 5 4 1 Regulator leakage shall not exceed 35 l min of free air or 5 96 of the manual reserve whichever is greater 5 4 2 Vacuum regulator shall be
47. l be provided to stop flow of coolant in in line cooling equipment during the wash cycle If a restriction needs to be fitted in the delivery line to reduce milkflow to that suitable for an in line cooler or where an in line cooler restricts flow below that needed for cleaning and disinfection means shall be provided to open or bypass the restriction during the washing cycle 33 E MILKING Milk contact surfaces shall be accessible for convenient visual inspection a Shell and liner shall be marked to identify manufacturer and type b Liner and shell combination shall be provided with a means of indicating if the liner is twisted or a means of preventing the liner from twisting in the shell c The internal dimensions of the shell shall not restrict the operation of the liner d User s Manual shall include air use caused by a teatcup fall off or cluster fall off and sufficient data to be able to choose the liner for a herd 8 3 Additional IMOCS recommendations for milking clusters a The effective volume of each claw shall not be less than 150 ml b Where an air admission hole is present in the claw it shall allow a constant 6 12 l min air admission and the air bleed shall be located above the normal level of milk in the claw c Claw entry nipples shall be designed to allow short milk tubes to be sealed during cluster attachment d Claw milk exit nipples shall be at least 12 5 mm in bore e Cla
48. le 3 Double up low level milkline plants with 1 stall unit Milkline Effective Effective Sanitary Wash Main Estimated Bore Reserve Reserve Trap E Line Airline Pump mm for for Volume Bore Bore Capacity Washing Milking I mm mm l min l min l min Minimum 532 440 10 48 5 1136 814 520 10 60 1699 814 560 10 60 1960 814 600 20 60 2222 1205 640 20 US 2895 1205 680 20 7 3156 1205 720 20 73 3418 1205 760 20 7 5 3679 1205 800 20 98 3941 1205 840 20 98 4202 1205 880 20 98 4464 2171 920 20 5 98 5743 2171 960 20 98 6005 2171 1000 20 d 98 6266 2171 1040 20 98 6528 2171 1080 20 98 6789 2171 1120 20 98 7051 2171 1160 20 98 7 318 2171 1200 20 98 7574 The pump capacity is an informative value only and incorporates a large safety factor the adequacy of a vacuum pump should be determined by verifying the system meets the effective reserve requirements Note The above table shows reserves for milking and cleaning The cleaning reserve or air demand for cleaning may be reduced where cleaning by air injection is not used or where the air cleaning system does not use the assumed demand In the ISO standards and IMOCS recommendations it is only necessary for the machine to either meet the reserve requirement during milking or pass the attachment and fall off tests If energy saving technologies are used which can reduce the effective reserve
49. litate washing Where nipples are welded on to a milkline the inside of the weld shall be flared and suitably dressed 29 h The stainless steel shall be cut at 90 at all milking joints this necessitates using mechanical cutting equipment i For mid level parlours curved swan neck entries are preferred to straight entries for milklines when swing over arms milk meters and or ACRs are not used Stainless steel of 0 9mm gauge 20 wall thickness or greater and quality Standard 304 Dairy Tubing shall be used in milklines k Provision shall be made for the inspection of the inside of milklines l The vertically dropping section into the receiver of the milkline shall be less than 300 mm m Air injection or other appropriate washing systems shall be used with milkline greater than 48 5 mm in bore n The highest point of each long milk tube at each unit before entering milklines and milk diversion lines shall be equal except where valving systems are used to control the flow of wash solution between the lines o Milk entries shall be in the top third of the milk pipeline in pipeline milking plants 74 Additional IMOCS recommendations for washlines in milkline plants a Washlines shall be of adequate bore as shown in Tables 1 5 as appropriate b All saddle type nipples shall have a protrusion into the washline to prevent poor alignment with the hole in the washline due to rotation of the saddle This protrusion sh
50. lking machine oil being used incorrect oil will shorten pump life Is there a tee piece and ball valve for airflow meter Vac pump capacity test point and isolation valve fitted Backpressure measurement tap fitted on the exhaust line near the vacuum pump outlet Exhaust as large in bore as the pump outlet Are the oiler wicks in good condition and the pump is receiving adequate lubrication Are the pulleys in good condition Are the pulleys tight Are the belts in good condition Are the belts tight About 12mm play in belts with thumb pressure Is there a safety switch fitted functionally No excess vacuum pump noise vibration 70 Interceptor Fitted Correct Rectified Yes No Yes No Is gasket on lid satisfactory Is automatic drain valve functioning correctly Does the interceptor appear to be clean Automatic cut off fitted Is the shut off float functioning correctly Automatic drain valve fitted Drain valve NOT discharging on other equipment Internal diameter for the inlet and outlet NOT less than that of the airlines Vacuum line No restriction in the main airline at the Interceptor No restriction at sanitary trap Is the automatic drain valve functioning correctly Is the airline vacuum line clean internally Is there an adequate fall in the airline and in the correct direction towa
51. low inlet in the clusters 12 l min g Airflow for ancillary equipment per cluster 12 l min h Wash slug speed 8 m s i Peak milkflow 5 kg min Milkline slope 1 5 65 sas puaddy Calculations The effective reserve capacity for milking will be 500 12 10 x 10 520 l min The airflow use for cleaning at 50 kPa should be 1004 l mm for a milkline with a diameter of 73 mm Table A4 Airflow use for the milking units claw air inlets pulsators will be 12 x 12 35 l min 564 l min The milking units will consume about the same amount of airflow during milking and cleaning Total airflow use during milking will be 520 l min 564 l min 21084 l min Total airflow use during cleaning will be 1004 l min 564 l min 21568 l min In this example the capacity for cleaning is the larger and therefore will be the first basis of calculating the pump capacity Leakage into the milk system 10 l min 2 x 12 l min 234 l min Losses due to ancillary equipment 12x12 144 l min Total 1568 l min 34 l min 144 l min 1746 l min Regulation loss is 1096 of the manual reserve The effective reserve was 520 l min and is smaller than the manual reserve Consequently Manual reserve 520 l min x 100 100 10 578 l min Regulation loss 578 l min x 10 100 58 l min Total 1746 l min 58 l min 1804 l min Leakages into the airlines are equal to 596 of the pump capacity that is Vacuum system leakage 1804 l min
52. m system Effective volume of the sanitary trap shall be stated in the User s Manual It shall be possible for the operator to detect the presence of milk and or cleaning solutions in the sanitary trap when the machine is running It is an advantage if the sanitary trap is visible to the operator during milking Where there is no provision for circulation cleaning of the sanitary trap s the receiver s and the receiver airline this line shall be designed to drain towards the sanitary trap 5 9 Leakage into the vacuum system Leakage into the vacuum system shall not exceed 5 of the vacuum pump capacity at the working vacuum and for capacity controlled vacuum pumps at the pump s maximum capacity a 15 6 PULSATION SYSTEMS b c d d e The pulsation rate and pulsator ratio at a nominal vacuum and specified temperature The temperature range over which the pulsation rate will stay within 596 of the nominal pulsation rate The temperature range over which the pulsators can be operated and the variation of pulsation rate within this range Typical pulsation chamber vacuum records for a defined milking unit Total air use with a defined milking unit connected under specified operating conditions Deliberate variations in pulsation rate and pulsator ratio e g in conjunction with stimulation and changes in milkflow a a b c Vacuum drop between working vacuum Vm and maximum pulsa
53. m the pre cooler can be used for udder washing yard washing and for stock drinking water 4 Condensing unit size can be reduced provided pre cooling to less than 18 can be consistently achieved This is advantageous where power supply is limited and 5 Backup cooling a pre cooling system provides a useful auxiliary system in the event of condensing unit failure 81 sas puaddy 6 Pre cooling milk will reduce cooling times when comparing equivalent systems Some of the benefits of pre cooling will be undone if the bulk tank cooling unit is not installed and maintained properly It is important to ensure a good airflow to and from the condensing unit radiator Anything that restricts the supply of fresh air and or causes the recirculation of warm air will increase running costs increase cooling times and reduce compressor life It is very common to see condensing units on farms that are damaged and partially blocked and recirculating warm air Plate Coolers A plate cooler fitted to the discharge side of the milk pump is the most popular pre cooling system mainly due to its high efficiency and compactness The plate cooler consists of a sandwiched arrangement of stainless steel plates with the milk and cooling water flowing in opposite directions through spaces between alternate plates The spaces between the plates are small so the milk filter must be located before the plate cooler to prevent debris from entering and ac
54. mum water supply and drainage requirements Nominal working pressure and capacity of a compressed air system Amount of airflow and vacuum for cleaning The minimum required airflow use of vacuum driven ancillary equipment 4 3 Instructions for use At least the following instructions shall be provided a b c d e f 9 h Start up operating and shut down procedures The effective reserve as calculated and as measured Recommended cleaning and disinfecting procedures including temperatures and chemicals and components requiring manual cleaning The maximum temperature at which the installation can be cleaned and disinfected Definition of any manual intervention such as manual actuation of valves or replacement of single use items such as filters along with the appropriate time intervals Procedures necessary to avoid contamination of the milk from cleaning solutions and from withheld abnormal and undesirable milk The maximum number of units or maximum milkflow per slope of the milkline Procedures for introducing animals new to milking installations 17 VACUUM SYSTEM 5 VACUUM SYSTEM 5 1 General a The ultimate goal is to maintain vacuum at teat end within the intended range The machine shall be capable of adequate vacuum control and operators shall use the machine with reasonable care and in accordance with the user s manual 5 2 Vacuum regulation 5 2 1 Vacuum deviation The working vac
55. n of the vacuum tap When comparing milking units the length of the long milk tube shall be so matched that the distance h1 and will be the same for all units To be able to compare measuring results the dimension h1 should preferably be 1300 mm for high line and 700 mm for low line plants a High line plant bj Low line plant vertical distance between the teat base and the milkline axis vertical distance between the teat base the highest point of the long milk tube vertical distance between the teat base the highest point of the long milk tube vertical distance between the centre of the udder and the milkline axis vertical distance between the top of the short milk tube at the teatcup and the lowest point of the long milk tube horizontal distance between the claw and the milkline axis NOTE Additional measurements may be recorded to fully describe the test configuration Figure C2 Representative shape of the long milk tube C 4 Liquid and airflow The water flow shall be specified and measured with an error of less than 0 1 kg min The water temperature shall be between 15 and 22 The airflow through the air vent shall be measured The air admission shall be 8 0 5 l min for cows C 5 Vacuum in milkline The vacuum in the milkline shall be constant during the test within 1 kPa measured close to the milk inlet at the upper side of the tube 78 C 6 Measuring point The measuring point shall be at the artifici
56. ner vacuum within the range 32 kPa 42 kPa during the peak flow period of milking for cows ensures that most cows will be milked quickly gently and completely b The effect on the milking vacuum conditions shall be stated in the User s Manual For non standard devices not originally fitted to a milking unit between the cluster and the milkline or milking vacuum line 36 8 9 Milk recording equipment 8 9 1 General Milk recording equipment shall comply with the requirements given in 8 10 The requirements for official yield recording are stated by the International Committee for Animal Recording ICAR 8 9 2 Recorder jars shall comply with the following requirements a b c d Effective volume shall be stated in the User s Manual Internal diameter of the outlet shall be not less than 18 mm for cows Connections should be placed to minimize the risk of carry over of milk or froth into the vacuum system Recorder jars should have means of ensuring even distribution of cleaning and disinfecting fluids over the internal surface during washing without adversely affecting the vacuum in the recorder jar during milking 8 10 Attachments to the milking unit a Devices including additional necessary connecting tubes fitted between the cluster or teatcup and the milkline or milking vacuum line shall not cause any additional vacuum drop greater than 5 kPa at a milkflow of 5 kg min for cows compared with the same milking unit
57. nt and fall off tests If energy saving technologies are used which can reduce the effective reserve e g variable speed vacuum pumps then the plant should pass the attachment and fall off tests 57 Table 5 Double up midi level recording jar plants with 1 stall unit Milkline Effective Effective Sanitary Wash Main Estimated Bore Reserve Reserve Trap E Line Airline Pump mm for for Volume Bore Bore Capacity Washing Milking I mm mm l min l min l min Minimum 272 440 10 48 5 1039 272 520 10 60 0 1389 272 560 20 60 0 1693 272 600 20 60 0 1996 443 640 20 73 0 2300 443 680 20 73 0 2604 443 720 20 73 0 2907 443 760 20 73 0 3211 443 800 20 73 0 3515 443 840 20 3818 443 880 20 4122 920 20 4425 678 960 20 4729 678 1000 20 5033 1040 20 5336 1080 20 5640 1120 20 5944 1160 20 6247 1200 20 6551 The pump capacity is an informative value only and incorporates a large safety factor the adequacy of a vacuum pump should be determined by verifying the system meets the effective reserve requirements Note The above table shows reserves for milking and cleaning The cleaning reserve or air demand for cleaning may be reduced where cleaning by air injection is not used or where the air cleaning system does not use the assumed demand In the ISO standards and IMOCS recommendations it is only necessary for the machine to ei
58. obstruction or a reduction in vacuum milkflow or drainage such as enlargements restrictions or filters shall not be used Minimum centre line radius for bends shall be 1 5 times the diameter Milklines should be installed to minimize the milk lift and preferably no more than 2 m above the animal standing level 73 Additional IMOCS recommendations for milklines a b c d e f g Milklines and milk diversion lines shall have a slope towards the receiver vessel of 1 or greater The highest point of the long milk tube should ideally not be greater than 2 1m above the cow standing and preferably 1 7m or less saddle type nipples shall have a protrusion into the milkline to prevent poor alignment with the hole in the milkline due to rotation of the saddle This protrusion shall not protrude more than 0 8 mm past the inner surface of the milkline Rubber joints or bends may not be used in milklines plastic or stainless steel unionized cone seal connections are acceptable All bends in milkines shall be stainless steel with a centreline radius not less than 1 5 times the diameter All milklines shall have a stainless steel end entry nipple or a side entry nipple no more than 30 mm from the blank capped end In either case the end of the milkline should be capable of being inspected i e a removable end piece on the milkline This does not preclude this use of valving systems at the end of milklines to faci
59. or cleanliness consistent with the proper function and good hygiene standards should be carried out at all routine tests j The visual observation of safety features within the parlour and dairy is important but advice and comments shall always be within the tester s experience and qualifications refer to a suitably competent person when in doubt Health and Safety Requirement Ear protection shall be used where noise levels exceed 85d A e g measuring vacuum pump capacity Rotating parts may pose a health hazard eg measuring vacuum pump speed Calibration A calibration service for airflow meters electronic pulsation analysers and vacuum meters is available at Teagasc Moorepark Dairy Production Research Centre Fermoy Co Cork A laboratory milkflow simulator is also available at Teagasc Moorepark Dairy Production Research Centre for establishing vacuum losses in milking systems The flow simulation data provides design guidelines for optimum design of milking systems 67 sas puaddy Test Report Airflow and Vacuum Regulator Tests 1 Operating vacuum AFM at test point near receiver Farm gauge vacuum level kPa Operating vacuum level recommended Pump capacity AFM direct to pump l min l min l min l min AFM at test point near regulator teatcup plugs inserted air pipeline added only regulator plugged l min Airline leakage 2 3 l min Add milking system
60. rage vacuum Phase 1 minus the average vacuum in 10 2 4 8 Phase 3 43 10 2 4 12 Calculate the regulation undershoot A in Figure 2 as the average in 10 2 4 8 Phase 3 minus the minimum vacuum in 10 2 4 7 Phase 2 10 2 4 13 Calculate the regulation overshoot C in Figure 2 as the maximum in 10 2 4 9 Phase 4 minus the average vacuum in 10 2 4 10 Phase 4 10 2 5 Effective reserve for milking 10 2 5 1 With the milking machine operating in accordance with 10 1 2 connect the airflow meter with a full bore connection to connection point A1 with the airflow meter closed Connect a vacuum meter to the connection point Vm 10 2 5 2 Record the vacuum as the working vacuum for the milking machine 10 2 5 3 Open the airflow meter until the vacuum decreases by 2kPa from the value in 10 2 5 2 10 2 5 4 Record the airflow through the airflow meter 10 3 Vacuum pumps 10 3 1 Vacuum pump capacity 10 3 1 1 With the machine operating in accordance with 10 1 2 record the vacuum at the vacuum pump measuring connection Vp as the working vacuum from the pump 10 3 1 2 Isolate the vacuum pump from all other parts of the installation Connect the airflow meter directly to the vacuum with a full bore connection 10 3 1 3 Record the airflow meter reading at the same vacuum as recorded in 10 3 1 1as the pump capacity at the working vacuum 10 3 2 Vacuum pump exhaust back pressure 10 3 2 1 With the vacuum pump operating in accordance with 10
61. rds a drain Is vacuum line rigidly fixed Vacuum line fitted with flush taps and removable plugs caps Vacuum Regulator Is air intake clean Is valve clean Is valve seating clean Are the diaphragms in good condition Located between interceptor and sanitary trap Test point and isolation valve fitted near receiver upstream of sanitary trap or on interceptor Sensor if fitted nearer cow than vacuum pump Is the sensor positioned correctly top of line away from bends Is the regulator rigid and upright Is the regulator joined by a full bore connection to the main airline or interceptor Regulator sensor tube is not less than 450mm from a tee or bend Was a service kit fitted Vacuum gauge installed between regulator and the first unit Vacuum gauge visible during milking 71 sas puaddy Check Sanitary Trap Fitted Rectified Yes No 15 gasket on lid satisfactory 15 drain valve wash tube functioning correctly Does the sanitary trap appear to be clean Automatic cut off fitted Is the shut off float functioning correctly Isolation valve fitted Can the sanitary trap be shut off during milking Automatic drain valve or CIP Drain valve NOT discharging on other equipment Is the sanitary trap being CIP washed If no do receiver s and receiver airlines dra
62. ricity is used for cooling The IB tank is costed using 100 Nightsaver rate and the DX tank using 50 Table D8 Cost of cooling 4500 litres 1000 gals with Nightsaver electricity Cost per 4500 litres cooled Cooled to 4 C Cooled to 3 C DX 765 8 44 760 8 44 100 IB and 50 DX on Nightsaver rate and no pre cooling Table D9 outlines the savings that can be made by pre cooling with a plate cooler where 5096 of the cooling is done by the plate cooler with a 2 1 water to milk ratio 4500 litres is the amount of milk cooled standard Domestic Rural electrical rate is used mains water is charged at 4 per 4500 litres and 1 25 units of electricity are used to pump each 4500 litres of water with a deep well submersible pump Table D9 shows the costs cooling to 3 C only Table D9 Savings using a plate cooler No plate Shallow Deep well Deep well cooling well submersible surface pump 11 29 6 07 6 07 713 1706 8 96 8 96 10 58 100 IB and 50 DX on Nightsaver rate and no pre cooling 88 Table D10 shows the cost of cooling 4500 litres 1000 gals with direct expansion DX and ice bank IB tanks cooling to 3 C where different proportions of night rate electricity and 50 pre cooling with well water are used Table D10 Cost of cooling 4500 litres 1000 gals to 3 C with different combinations of Nightsaver rate electricity and 50 pre cooling Cost per 450
63. rlour If clean air is sourced inside the milking parlour a filter shall be fitted to the manufacturer s specification If clean air is sourced outside the milking parlour the breather airline shall have end pieces angled downwards and meshed The fitting of breather airlines shall not alter the pulsation performance The pulsation air consumption should typically be within the range of 25 35 litres per minute per unit and shall not exceed 45 litres per minute per unit The pulsation a phase shall be less than 2296 26 MILK SYSTEM b a b d e f 9 It shall be possible to inspect the inside of the milk system for cleanliness Any air that is deliberately admitted into the milk system shall be stated in installation instructions Vacuum drop between the receiver and any point in the milkline shall not exceed 2 kPa with all units operating at the designed milkflow and airflow Diameter and slope shown in Table 1 for a mid level plant are based on milkflow per cow of 5kg min 100 l min transient airflow per slope and 1 596 slope If installed in a loop each end shall have a separate full bore connection to the receiver If several loops two ends may be grouped together directly in front of the receiver to form a single line with adequate cross sectional area for the combined designed milkflow and airflow Milklines shall have a continuous fall towards the receiver for drainage Equipment that can cause an
64. s one fourteenth of a millimetre Apart from the size there is no information on the packaging indicating the quality of filter socks The flow rate of each filter will vary depending on the fat content of the milk e pumping pressure of the milk pump e weight of material per square metre used in the sock e temperature of the milk As an example of the resistance in the filter material a 25mm 1 diameter round disc of 75 gram material with a 3m head of pressure 4 3 psi or 0 7 bar using water has a flow rate of only 28 litres per minute 8 5 gallons per minute Table D4 shows filter sock sizes for different milkflow rates 86 Table D4 Filter sock sizes for different milkflow rates Filter Sock Size Flow rate up to 430mm x 75mm sock 1500 litres hour ES 330 gals hour 600mm x 75mm sock 3000 litres hour 24 x 3 660 gals hour 600mm x 100mm sock 4500 litres hour 24 x 4 990 gals hour 650mm x 150mm 6500 litres hour 1430 gals hour 2 x 600mm x 100mm socks positioned 9000 litres hour in parallel 1980 gals hour 2 x 24 x 4 Milk Cooling Costs Table D5 shows litres of milk which can be cooled with one unit kWh of electricity with direct expansion DX and ice bank IB tanks cooling to 4 C and 3 C One kWh is one unit of electricity It follows from the cooling rates shown in Table D5 that in order to cool 4500 litres 1000 gallons of milk to 4 C 60 units of electricity would be
65. stallers of the importance of complying with these recommendations IMQCS is not in a position to police adherence to these recommendations and cannot accept any responsibility for any loss or damage of any nature which might be incurred by non compliance with these recommendations The use of shall indicates that a clause is mandatory for compliance with these recommendations whereas should clauses are recommended on the grounds of good practice The term manufacturer is used in these recommendations to refer to the original equipment manufacturer OEM and installer is the actual installer This is in contrast to CE documentation in which the installer is defined as the manufacturer In a situation where a main contractor provides a complete milking installation consisting of components from more than one manufacturer he has responsibility to all CE and ISO standards requirements for the complete installation and therefore deemed to be the manufacturer of the complete installation If a main contractor provides an individual component e g pulsation system in an existing installation he shall be responsible only for the CE and ISO requirements of that component This manual has been prepared by Mr Seamus Goggin IMOCS Dr Edmond Harty IMOCS Mr George Kearns Secretary 5 Dr Eddie O Callaghan Editor Teagasc Mr Alan Pearson IMOCS Mr Sean Reid IMOCS Tom Ryan Teagasc The committee wishes to acknowledge th
66. t connections shall not form a trap for liquids Connections shall have the same internal diameter as the airline or 48 522 mm whichever is smaller a zi 79 E El D Figure 1 Location of test points in ISO standards ISO 3918 tees isolation valves IV 1 2 3 Vacuum and airflow measuring connections Figure 1 The following measuring points shall be provided for a vacuum or an airflow meter V at or upstream of the measuring point 1 b V near each regulator sensing point c V near each vacuum pump inlet d P Connection for measurement of exhaust backpressure of the vacuum pump outlet e Ina pipeline milking machine Vm can be any point in the milking system or upstream of the receiver In a recorder jar milking machine Vm can be in the milking vacuum line or in the nearest convenient recorder jar In a bucket milking machine Vm Vr and can be combined with the nearest convenient vacuum tap f All test connections shall be at least five pipe diameters from any bends air inlet points or other fittings creating air turbulence g Ifthe regulator sensing point is on a branch there shall be two measuring points Vr one to measure the vacuum drop in the airline upstream of this branch and the other one to determine the regulator leakage near the regulator sensing point h Means shall be provided to isolate vacuum pump s to measure vacuum pump capacity
67. teatcup or one cluster with the shut off valve open and adjust the airflow meter until the vacuum is the same as 13 1 1 13 1 3 The cluster or teatcup consumption is the difference in airflow 13 2 Leakage through shut off valves of milking units 13 2 1 Connect a flowmeter between the long milk tube and the cluster or teatcup under test 13 2 2 With the shut off valve in take off position measure the airflow and record this value as the leakage through the shut off valve 13 3 Air vent and leakage into teatcup or cluster 13 8 1 Connect a flowmeter between the long milk tube and the claw or teatcup under test 13 3 2 Connect the flowmeter to the vacuum system milkline or airline and record the working vacuum for the milking machine 13 3 3 Plug the teatcup s and open any cluster shut off valve 13 3 4 Record the airflow through the flowmeter as the total air admission 13 3 5 Close the air vent and record the airflow through the flowmeter as the air leakage 13 3 6 Calculate the difference between the airflows as the air vent admission 13 4 Measuring the vacuum in the cluster Appendix C 13 4 1 Record the vacuum in the milkline at the teat end and in the pulsation chamber with the specified liquid flows equally divided between all teatcups of the cluster 13 4 2 Calculate the working vacuum in the milkline the average teat end vacuum and during Phases b and d the average teat end vacuum 13 5 Measurement of the vacuum drop
68. ther meet the reserve requirement during milking or pass the attachment and fall off tests If energy saving technologies are used which can reduce the effective reserve e g variable speed vacuum pumps then the plant should pass the attachment and fall off tests 58 Table 6 Recommended sizes of diversion line Peak flow 4kg min Slope Internal diameter mm 1 0 15 2 0 35 1 1 1 48 5 4 6 60 9 12 16 73 21 25 91 98 60 unlimited unlimited Peak flow 5kg min Slope Internal diameter mm 1 0 15 2 0 48 5 4 5 60 7 10 12 73 16 25 unlimited 98 43 unlimited unlimited Note The tables above show the number of cows with an average peak milkflow of both 4kg min and 5 kg min It is recommended that all main milklines are sized at 5kg min as the average peak flow rate for new milking installations It is preferable that diversion lines should be sized using the same criteria 59 APPENDICES Appendices Appendix A Measurement and Calculations Table A1 Regulation characteristics Parameter Air inlet in Automatic shut off valve Vacuum kPa in operation Teatcup Cluster Measure Limit s kPa Average vacuum in the No No milk system Minimum vacuum during No Yes No air inlet Average vacuum during Yes No air inlet Maximum vacuum during stop of air inlet Average vacuum after stop of air inlet Attachment vacuum drop 1 3
69. tion chamber vacuum shall be no more than 2 kPa The pulsation rate shall not deviate more than x 5 from intended values given in the User s Manual Note Pulsation rate is typically between 50 cycles min and 65 cycles min for cows The pulsator ratio shall not differ more than x 5 units of percentage from the values given in the User s Manual The pulsator ratios shall not vary from each other by more than 5 units of percentage 25 d e Limping shall not be more than 5 units of percentage except where the milking unit is designed to provide different ratios between the fore and hindquarters Phase b shall be not less than 30 96 of a pulsation cycle and phase d shall be not less than 150ms Vacuum drop during Phase b shall not be more than 4 kPa below maximum pulsation chamber vacuum Vacuum during Phase d shall not be more than 4 kPa 6 4 Additional IMOCS recommendations for pulsation systems a b c d e f 9 Simultaneous or alternate pulsation patterns are acceptable Pulsation relays shall be de synchronized to reduce the amplitude of vacuum fluctuations within the pulsation airlines Long pulse tubes shall have a minimum bore of 9 5 mm for simultaneous pulsation or 7 mm for alternate pulsation Pulsation relays and pulsators should be capable of being washed through the long pulse tubes A breather airline shall be fitted Clean air may be sourced inside or outside the milking pa
70. ts ii Leave surfaces free from undesirable residues of cleaning and disinfecting chemicals iii Reduce the count of viable bacteria to an acceptable level on milk contact surfaces 39 VACUUM SYSTEM MILKING MACHINE INSTALLATIONS MECHANICAL TESTS ISO 6690 10 VACUUM SYSTEM MILKING MACHINE INSTALLATIONS MECHANICAL TESTS ISO 6690 5 o N lt n E 10 1 General requirements and preparation 10 1 1 General a To keep the plant in good condition periodic checking is recommended If the effective reserve has not changed it is not necessary to carry out further tests on the vacuum regulator or pump capacity tests 10 1 2 Preparation before testing a Start the vacuum pump and put the milking machine into the milking position with all milking units connected Teatcup plugs shall be in the milking position All vacuum operated equipment associated with the installation shall be connected including those not operating during milking Allow the vacuum pump to run for at least 15 minutes before taking any measurements 10 2 Vacuum regulation 10 2 1 Test of vacuum regulation deviation With the milking machine running in accordance with 10 1 2 record the working vacuum at the receiver and compare it with the nominal vacuum 10 2 2 Regulation sensitivity 10 2 2 1 10 2 2 2 10 2 2 3 10 2 2 4 With the milking machine operating in accordance with 10 1 2 with liners plugged conne
71. ump becomes the same as recorded in 10 74 Calculate the vacuum system leakage as the difference between the airflow recorded with the vacuum system disconnected 10 76 and the airflow with the vacuum system connected 10 74 45 PULSATION SYSTEM 11 Pulsation system 11 1 11 1 1 11 1 2 11 1 3 Pulsation rate pulsator ratio pulsation vacuum phases and vacuum drop in pulsator airline With the milking machine operating in accordance with 10 1 2 let the pulsator s run for at least 3 minutes and measure working vacuum at Vm Connect the pulsation analyzer to the pulse tube Record five pulsation chamber cycles and analyze the results to determine the maximum pulsation chamber vacuum the average pulsation rate the average pulsator ratio and the average duration of phases a b c and d These values shall be obtained for every pulsator and the average limping shall be calculated Phase b shall be checked to ensure that the vacuum is not less than the maximum pulsation chamber vacuum minus 4 kPa Phase d shall be checked to ensure that the vacuum never exceeds 4 kPa Calculate vacuum drop in the pulsator airline as the difference between the vacuum recorded in 11 1 1 and the lowest value of maximum pulsation chamber vacuum as derived in 11 1 2 47 79 a 2 N lt a E 3 MILKING SYSTEM 12 1 1 12 2 1 12 2 2 12 2 3 12 2 4 12 2 5 12 2 6 12 2 7 Calculate the minimum
72. umping at least until the froth is gone Diaphragm milk pumps intermittingly controlled will not pump away froth because the froth floats on top of the milk Where a milk diversion line is installed a good arrangement is to install a diaphragm pump for the milkline and an ordinary centrifugal for the diversion line Both pumps are switched to continuous pumping during washing In a situation of up grading extending or even building a new parlour effective use can be made of an existing single or double diaphragm pump in conjunction with a centrifugal for circulation cleaning with or without a diversion line If an existing diaphragm pump output is inadequate for the increased milkflow rate of the extra units say when cows are at peak the centrifugal pump is installed in parallel with the diaphragm pump There are two sets of probes in the receiver jar The set nearer the bottom of the receiver controls the diaphragm pump and the set near the top controls the centrifugal pump The diaphragm pump pumps milk for most of the time but if the milk level in the receiver reaches the upper probes the centrifugal pump cuts in to lower the level quickly When the level drops below the upper probes the centrifugal pump cuts out again Both pumps are run continuously during washing Installing a diversion line with this arrangement requires an additional centrifugal milk pump 85 sas puaddy Matching up the Components Matching milk pumps plate coolers
73. used with a DX tank and 90 units with an IB tank without taking pre cooling into account Night rate electricity and pre cooling must be taken into account to get a true picture of running costs Table D5 Litres cooled per kWh unit of electricity Litres cooled per kWh gals Cooled to 4 C Cooled to 3 C 75 16 5 68 15 50 11 45 10 Table D6 outlines the cost of cooling 4500 litres 1000 gals with direct expansion DX and ice bank IB tanks cooling to 4 C and 3 C Table D6 Cost of cooling 4500 litres 1000 gals on normal Domestic Rural electricity rate Cost per 4500 litres Cooled to 4 C Cooled to 3 C 10 24 1229 15 35 1706 87 sas puaddy Table D7 shows the present cost of cooling 4500 litres 1000 gals with direct expansion DX and ice bank IB tanks cooling to 4 C and 3 C where proportion of Nightsaver rate electricity is used for cooling The IB tank is costed using 70 night rate and the DX tank using 2596 Table D7 Cost of cooling 4500 litres 1000 gals with Nightsaver electricity Cost per 4500 litres cooled Cooled to 4 C Cooled to 3 C DX 8 94 9 86 IB 9 92 11 03 70 IB and 25 DX on Nightsaver rate and no pre cooling Table D8 shows the cost of cooling 4500 litres 1000 gals with direct expansion DX and ice bank IB tanks cooling to 4 C and 3 C where a proportion of Nightsaver rate elect
74. uum Vm after a defined start up period shall be within 2 kPa of the nominal 5 2 2 Regulation sensitivity Shall not to exceed 1 kPa 5 2 3 Regulation loss shall not exceed 35 l min of free air or 10 96 of the manual reserve whichever is the greater 5 2 4 Regulation characteristics and effective reserve a Regulation overshoot shall be less than 2 kPa b One of the following requirements shall be fulfilled 1 Vacuum drop and undershoot during cluster fall off test shall be less than 2 kPa This requirement is more appropriate for large milking systems and where the operators are less careful during attachment 2 The minimum effective reserve given inTable s 1 4 is more appropriate for small milking systems 8 units c In large milking systems the effective reserve should be sufficient to maintain working vacuum Vm within x 2 kPa during the course of normal milking including teatcup attachment and removal liner slip or teatcup cluster fall for at least 99 96 of the milking time 5 3 Vacuum pumps 5 3 1 Vacuum Pumps General a The vacuum pump shall have adequate airflow capacity to meet the requirements for milking and cleaning including air used by all ancillary equipment operating during milking and cleaning whether continuously or intermittently b If more than one vacuum pump is used it shall be possible to isolate pump s not in use 5 3 2 Influence of altitude Vacuum pump capacity decreases with alt
75. uum recovery time to within 4kpa of system vac in 4 seconds Automatic Cluster Removers Are the ACR cords in good condition Milk Meters Are the valves diaphragms in good condition Has a service kit been fitted Have the meters been calibrated Diversion valves Have the diaphragms been changed in accordance with the recommended service intervals Centrifugal Milk Pump Was a new seal kit non return valve fitted Is the non return valve in good condition Is the wiring in good condition Are all unions and joints tight and leak free 74 Check Diaphragm Milk Pump Belt in good condition Rectified Yes No Belt tensioned correctly Belt guard checks Are pulleys tight and in good condition Is there adequate oil in the pump on arrival Is the pump timed correctly Record strokes min Manual liquid level operation Variable speed Non return valves ok Is diaphragm s condition good Are all unions and joints tight and leak free Wash line Are entries into wash line into the top or top third Jetters Are jetter manifolds clean Autowasher Are autowasher dosing tubes in good condition Is the autowasher functioning to the manufacturer s guidelines Has the autowasher been calibrated for dosing volumes 75 sas puaddy Appendix C Laboratory and Parlour Tests of Vacuum in the Milking Unit
76. ve Sanitary Wash Main Estimated Bore Reserve Reserve Trap E Line Airline Pump mm for for Volume Bore Bore Capacity Washing Milking 1 mm mm l min l min l min Minimum 38 272 320 10 38 48 5 789 443 380 10 38 48 5 1128 443 440 10 38 60 1337 443 500 10 48 5 60 1606 443 520 10 48 5 60 1831 443 540 20 60 2057 443 560 20 60 2282 678 580 20 7 2612 678 600 20 2816 678 620 20 75 3021 678 640 20 73 3225 1004 660 20 78 3772 1004 680 20 98 3976 1004 700 20 98 4181 1004 20 98 4385 1004 20 98 4590 1004 20 98 4794 1004 20 98 4999 1004 20 98 5203 The pump capacity is informative value only and incorporates a large safety factor the adequacy of a vacuum pump should be determined by verifying the system meets the effective reserve requirements Note The above table shows reserves for milking and cleaning The cleaning reserve or air demand for cleaning may be reduced where cleaning by air injection is not used or where the air cleaning system does not use the assumed demand In the ISO standards and IMOCS recommendations it is only necessary for the machine to either meet the reserve requirement during milking or pass the attachment and fall off tests If energy saving technologies are used which can reduce the effective reserve e g variable speed vacuum pumps then the plant should pass the attachment and fall off tests 55 Tab
77. without those devices 8 11 Long milk tubes a b c d Means shall be provided to minimise the risk of flattening Where milk is lifted by means of airflow the maximum internal diameter of the long milk tube shall be i 16 mm for cows ii Where long milk tubes are attached to single teatcups it is advisable to use tubes with a smaller diameter The length and the internal diameter of long milk tubes shall be specified in the user s manual with the airflow at the end of the long milk tube measured in accordance with ISO 6690 The long milk tubes shall be short as is practicable 37 CLEANING 9 CLEANING a b c The cleaning system shall be designed and installed so that cleaning and disinfecting solutions cannot enter the milk Methods of verifying that the cleaning system is operating properly and any components that shall be manually disassembled or hand cleaned shall be specified in the User s Manual The success of a circulation cleaning system depends on design and installation ensuring adequate circulation volume velocity and contact time of cleaning solutions temperature and concentration appropriate to the type of cleaning and sanitizing solutions used A velocity range of 7 m s to 10 m s is preferred for the cleaning of pipelines containing liquid slugs It is expected that any cleaning procedure will i Leave milk contact surfaces visibly free from milk residues and other deposi
78. ws may be designed for simultaneous or alternate pulsation Double or single pulse tube claw spigots shall be installed for alternate or simultaneous pulsation respectively The use of Y pieces to convert alternate claws to simultaneous is not allowed f Shells shall have pulse nipples fitted at the short milk tube end and shall have clear identification marks g Only Moorepark recommended liners should be fitted Liners clusters with independent data on milking characteristics including slip data shall be acceptable h All liners shall have a brand name an identification number and alignment indicators i Only liners recommended by the manufacturer for the specific installation shall be fitted Means shall be provided to limit the airflow through the cluster or teatcup until attachment a Means shall be provided of shutting off the vacuum to the liner before teatcup removal b If vacuum is reduced only as a result of the air vent s the leakage of the claw shut off shall be less than 2 l min for a claw and less than a quarter of the air vent admission for individual teatcups 35 c Teatcup removal shall be initiated by one of the following i If milkflow is not present after a specified time ii When the milkflow has ceased or has gone below a specified flow iii When a specified total machine on time has elapsed iv By human intervention d This initiation together with the limits shall be described in the User s Manual
79. x 5 100 5 95 l min Total 1804 l min 95 l min 1899 l min The minimum nominal capacity of the vacuum pump must therefore be 1899 l min 66 Appendix B Test procedures Calibration Test report and Inspection Service Check List Testing Procedures Requirements a Itis recommended that milking machines be tested at least twice per year b Maintenance should not be carried out before testing an installation where a known or perceived problem exists c The test results shall be recorded in a Test Report which contains at a minimum the information in the recommended IMOCS Test Report d Where faults are found in a milking machine the faults and appropriate recommendations shall be indicated in the Test Report e Post installation instrument testing of any milking machine shall be carried out in order to fully complete the Test Report Subsequent routine instrument testing may be confined to the items in bold italic type in the IMOCS Test Report f A post installation visual examination of the milking machine for compliance with installation standards shall be completed and included in the Test Report If a specific problem is being investigated the appropriate tests to be carried out shall be at the discretion of the tester h Visual examination of milking machine parts needing routine maintenance and or replacement shall be completed at all routine tests and included in theTest Report i Visual examination f
80. y ancillary equipment fits into dairy and clarification of who does what with regard to any building work plumbing electrical or modifications to milking machine 90 Notes Appendices Notes 92

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