2. 2
ACKNOWLEDGEMENT
This program is not an endeavor of a single individual. It takes the co-operation and
effort of many other people who have directly or indirectly been involved in the work. I hereby
take an opportunity to thank all those who have helped me in the successful completion of
this task without any terms and condition.
I express my sincere and deep-felt sense of gratitude & thanks to Dr. A.K. Chhabra
(Dean, College of Agriculture, Hisar) to give us a chance for being a part of this program to get
an exposure to practical work.
I would certainly like to extend my deep sense of sincere gratitude & indebtedness to
Dr. S.S. Punia (HOD, Agronomy) & Dr. A.K. Dhaka (Coordinator of AIA Program) for his sincere
guidance mingled with constant encouragement, personal care, supervision and constructive
creation during the course of my AIA program.
I take privilege to acknowledge Mr. Sanjay Setia (CEO, Vita Milk Plant, Jind) and Mr.
Narender Dhania (Production Manager) for their enormous efforts and guidance for their
support and enlightenment during the period of AIA programme.
I also express my profound thanks to Dr. Meena Sehwag (Agronomy), Dr. Veer Sain
(Agricultural Economics) and Dr. Ratimukteshwar (Extension Education) and other teachers
who directly or indirectly helped us by showing their keen interest & valuable suggestions
during this program.
I am also very much grateful to Sh. Satyavan Ji (Superviser, Production Deptt, Vita Milk
Plant , Jind) and Mr. Kapoor for his co-operation. I take privilege to acknowledge abyss
gratitude to all employees of the Milk Plant who co-operated with me & gave me all the
information, which I needed.
I also wish to acknowledge the help, support, & cooperation that I received from my
group members (Amit and Ajeet). Last but not the least I wish to record my deep heartfelt
love & gratitude to my parents, teachers, friends and other AIA mates whose support has
been my strength & by my side at every single point of time.
SUMIT JANGRA
2015A58BVI
3. 3
PREFACE
Agriculture is the most important sector of Indian Economy. Indian agriculture sector
accounts for 16.1% of India’s gross domestic product (GDP) and provides employment to 50%
of the countries workforce. India is the world’s largest producer of pulse, spices, spice
products and holds 2nd rank in production of Wheat, Rice, Vegetables. India ranks first
globally with highest net cropped area followed by US and China.
However, the agriculture sector which accounted for more than 30% of total GDP at
the beginning of reforms, failed to maintain its pre-reform growth. On the contrary, it
witnessed a deceleration in growth after the mid-1990s as the per annum growth in
agriculture sector dropped to 1.9 percent during 1996-97 to 2001-2002 from 3.2 percent in
the period 1980- 81 to 1995-1996. This happened despite the fact that agricultural
productivity in most of the states was quite low, as it were, and the potential for the growth
of agriculture was high. The 12th five-year plan target of growth of 4 percent per annum in
agriculture and allied sectors, set to reverse the sharp deceleration of 1996-1997 to 2001-
2002 has not been achieved.
With the rising agricultural production in the country and introduction of modern
technology in the production and processing of agricultural produce, the concept of farming
is shifting from survival and growth to value added agri-business approach. An important step
in this connection was taken by the ICAR by appointing 2nd Dean's Committee in April 1979.
The Dean's Committee pointed out weakness in terms of need of practical training in the
curricula of agriculture graduate degree. The third Dean's Committee (1995) suggested model
academic regulations and curriculum for agriculture graduates. Special emphasis was given
to practical training to inculcate skill and confidence among the undergraduates to enable
them to meet the new challenges. Further in 2017 5th Dean Committee made some major
changes in the curriculum of UG studies of Agriculture which made the final year of graduation
of completely experiential learning naming it READY(Rural Entrepreneurship Awareness
Development Yojana) comprising 1st semester for RAWE and Industrial Attachment and 2nd
semester for Experiential learning and Students’ Proects.
4. 4
There is no occupation as agriculture, in which experience is essential and exposure
to farming situation is necessary to learn the required skills, the students should be able to
understand the socio-economic constraints pertaining to the adoption of new agricultural
technologies developed by the agricultural scientists. The agricultural education should be
AIA - 2020 meaningful and practical oriented to fulfill the much-felt inner urge of agriculture
students to be at a take-off and ready to act stage when they complete their graduation. The
main objective of AIA is to teach the student practically which the student learnt theoretically
in college. It is the opportunity to gain the experience of problem faced by the Industries in
growing crops and other enterprises. This report owes its preparation to the sincere and
meticulous analysis of situation of Milk Plant, Jind. This report contains general information
of HDDCF and Milk Plant, Milk Production, Operation Flood, Milk Processing, Production of
various dairy products, economic status, experience of intern and work done by intern etc.
5. 5
CONTENT
1 History and Development of HDDCF
3. Organization Structure
4. Introduction
5. Production and quality control of Milk
6. Analysis of Milk Products
7. Manufacturing process of Butter
8. Manufacturing Process of Ghee
9. Manufacturing Process of Paneer
10. Manufacturing Process of Dahi.
11. Manufacturing Process of Milk Powder
12. Machinery used for Ghee Production
13. Machinery used in Powder plant
14. Packaging, Labeling, storages, Distribution and Marketing of Products.
15. Sanitization of Equipments and Container
16. Water Supply and Disposal.
6. 6
HISTORY OF HARYANA DAIRY
DEVELOPMENT CO-OPERATIVE
FEDERATION LIMITED (HDDCF)
From ancient times, Haryana is known as home of milk as a famous saying tells us
"Deshon mein dash Haryana Jit doodh dahi ka khana". Cattle of Haryana world famous for
their high yielding capacity for instance Haryana cows and murrah buffaloes are among the
best yielder of milk in the country.
Milk plant (Located in Jind district at Hansi Road covering 23-acre area) was installed
in 1970 by Haryana dairy Development co-operating later it came out as a composite milk
plant in the year 1996 with handing capacity of 2 lakh liters per day.
Dr. Verghese Kurien known as the "Father of the White Revolution" in India, was a
social entrepreneur whose "billion-liter idea", Operation Flood, made dairy farming India's
largest self-sustaining industry and the largest rural employment sector providing a third of
all rural income. It made India the world's largest milk producer, doubled the milk
available for each person, and increased milk output four-fold in 30
years.
He pioneered the Anand model of dairy cooperatives and
replicated it nationwide, based on various "top-down" and "bottom-
up" approaches, where no milk from a farmer was refused and 70–
80% of the price by consumers was paid in cash to dairy farmers who
controlled the marketing, procurement, and processing of milk and milk products as the
dairy's owners. An invention at Amul was the production of milk powder from buffalo milk
instead of from cow milk, which was in short supply in India.
He also made India self-sufficient in edible oils and fought against the "oil kings", who
used underhanded and violent methods to enforce their dominance over the oilseed industry.
7. 7
Haryana Dairy corporation is converted into federation in 1979 under operation flood –I.
In Nov. 1982, the responsibility of milk procurement through societies and tip was
handed over to milk unions under operation flood 2. Before Nov. 1982 milk was collected
directly from collection centers and system was not full proof.
In 1991 ten milk unions were converted into 5 milk unions by amelioration to increase
the area of operation behind each milk plant for capacity flooding.
In April 1992, milk plants were leased out to milk unions to remove the confrontation
between milk unions and plants to make the system similar to NDDB. Anand pattern which
has been applicable in whole India in dairying field. This step stopped commission system
applicable to unions. Autonomy of milk purchase price was also given which was withdrawn
later on the Nov. 1992.
8. 8
ORGANIZATION STRUCTURE
The head of HDDCF limited is situated at Chandigarh which books after the functioning
of all the six milk plants and chilling centers. At the top level there is board of directors to
manage the activities of federation. The board is headed by chairman, chairman of co-
operative unions of different districts and registrar, co-operative societies is member of the
board of directors. The chairman's post is held by person nominated by Haryana Govt.
Managing director is head of the institution in the top executive position.
The business of plant is managed by general manager subject to control and
supervision of managing director, HDDCF Ltd. General Manager of all five milk plants come
directly under the control of managing director general manager takes care of all the milk
functional departments at the plants except the milk procurement department. Which is
directly controlled by head office through district milk unions.
State
Milk Federation
as an Apex Body
Milk Producers
Cooperative Unions
Milk Producers
Cooperative Societies
9. 9
FUNCTIONING
The village level societies collect milk from milk producers and sell it to Milk Union.
Earlier Milk Unions were selling milk to the plants run by the Federation. Since 1-4-92 the
Federation has leased out the Plants to the Milk Unions. So now Milk Unions process the milk
and convert the same into products at Milk Plants taken on lease by them from Federation.
The sale of Milk and Milk products is undertaken by milk unions through distributors, milk
booths & retailers.
Dairy Cooperatives in Haryana functioning on three tier system
Societies at village level
Milk producers in a village join together to form village Dairy Cooperatives Societies.
The society is managed by the producers themselves
Milk Unions at District level
The Milk Cooperative Societies of one or more district come together to form Milk
Unions. These are managed by the representatives of milk producers elected from amongst
the chairman of Coop. societies. At present, there are six
1. Milk Union Ambala
2. Milk Union Kurukshetra Karnal
3. Milk Union Hisar- Jind
4. Milk Union Ballabgarh
5. Milk Union Rohtak
6. Milk Union Sirsa.
State Dairy Federation: Milk Unions combine to form Dairy Federation
10. 10
MILK UNIONS IN HARYANA
District Milk Producers Co-Operative Unions
The Primary Milk Societies (PMS) functioning at the village level join to form a Milk
Union for carrying out such activities which are conducive and essential for the socio-
economic development of milk producers, by procuring and processing of milk and marketing
of milk products. The Board of Directors comprising 9 members elected out of the Chairmen
of affiliated Primary Milk Societies run the day-to-day administration through Chief Executive
Officer.
These Unions either process milk at their own level or pass the same to the milk plants
of other milk unions for processing. They also organize new Primary Milk Societies at the
village level. A brief matrix of the Milk Unions is as follows:
Sr.
No.
Name of the Union Date of
Registration
1. The Ambala District Co-operative Milk Producer Union
Ltd.,Ambala
10.03.1973
2. The Rohtak District Co-operative Milk Producer Union
Ltd.,Rohtak
01.04.2003
3. The Hisar-Jind Co-operative Milk Producer Union Ltd,Jind 10.07.1991
4. The Kurukshetra-Karnal Co-operative Milk Producer Union
Ltd.,Kurukshetra
05.07.1991
5. The Sirsa District Co-operative Milk Producer Union,Sirsa 10.01.1978
6 The Ballabgarh Co-operative Milk Producer
Union,Ballabgarh
01.04.2003
11. 11
INTRODUCTION
Milk Plant, Jind
HARYANA is one of the most progressive states of Republic of India. In the domain of
dairy development, it is well known for its productive milch cattle particularly the 'Murrah'
Buffaloes and Haryana Cows. The economy of the state is predominantly based on agriculture.
People rear and breed cattle as a subsidiary occupation.
The essence of various programmes launched in the State has been to adopt the
Anand pattern of Milk Co-operatives. Under this system, all the functions of dairying like milk
procurement, processing and marketing are controlled by the Milk Producers themselves. It
has three tier system comprising milk Producers Societies at the village level, Milk Producers
Co-operative Union at the district level and the state Milk Federation as an apex body at the
State level.
The Haryana Dairy Development Co-operative Federation Ltd. registered under
Haryana Co-operative Societies Act came into existence on April 1,1977. Its authorized share
capital is Rs.4000 lacs. It was established with the primary aim to promote economic interests
of the milk producers of Haryana particularly those belonging to weaker sections of the village
12. 12
community by procuring and processing milk into milk products and marketing thereof by
itself or through its unions. In furtherance of the above objects, the Federation undertakes
various activities for sales promotion of VITA Brand for the Milk Unions. It also extends
technical guidance to the Unions in all spheres of personnel, technical, marketing and
financial management as well as makes them quality conscious, through use of modern
methods of laboratory testing of various products.
Quality - VITA the Hallmark of Quality
As part of stringent quality measures, milk required for processing VITA products is
procured from Dairy Cooperative Societies only. It is ensured that the milk is transported to
chilling centers/ bulk milk coolers and plants in clean and sterilized milk cans/milk tankers as
quickly as possible. All quality measures as per FSSAI are being applied before the products
are marketed. VITA Milk Plants are ISO 9001:2008 & ISO 22000:2005 and HACCP certified
units. Well-equipped laboratories are functioning in the chilling centers/Bulk Milk Coolers and
milk plants to maintain ideal quality standards. VITA is the endorsement of quality, a
commendation we are Proud of.
Marketing Network
Marketing of VITA brand milk products is being done through a network of distributors
spread throughout INDIA. These products include ghee, butter, milk powder, paneer,
sweetened milk, pasteurized milk, etc.
14. 14
INTRODUCTION TO MILK
Milk may be defined as the whole, fresh clean, lacteal secretion obtained from
complete milking of healthy milk animals, including that obtained within 15 days before or
after calving or much periods as may be necessary to render the milk practically colostrum
free and containing the minimum the prescribed percentage of milk fatty and milk solid non
fats.
Properties
Sweet in taste, specific gravity 1.032, boiling point 1010C. Freezing point 0.50C viscous
than water. White to golden yellow in color composition of Milk
16. 16
MILK PRODUCTION
Milk Reception
Milk plant, Jind is handled by Jind co-operative milk producer's union limited, Jind.
Milk is collected from the village through MCS (milk performance co-operative society) milk
docks are used for entry of milk from trucks. A sample is taken from each container for testing
and sample giving positive test rejected and left of the milk is put into tub from which through
pipes milk goes for the further processing. Payment is made to milk producer by weigh in and
measuring fat percentage. After reception two types of tests are done to judge the quality of
milk.
1. Platform test/organoleptic test
2. Laboratory test
17. 17
Platform Tests
At reception site different test known as platform test are performed including all
those tests done to reject/accept milk at receiving platform. They are performed on each can
or tanker of milk with objective of detecting milk with inferior quality. Tests usually include
organoleptic tests.
Organoleptic Tests
Remove the lid from the container or can and small immediately observe color of milk.
• Color and flavor of milk should be acceptable and taster palatable.
• Milk having any foul odor or any abnormal color should be rejected immediately.
• Test is done at reception of milk at dock.
• Person should not be suffering from common cold and cough.
Laboratory Test
Milk is received in the plant at the reception dock and weighed and samples are sent
to quality control lap for further checking. Quality control implies prescribed standards of a
product and then correcting these deviations so that the required standards are maintained.
18. 18
Milk is highly perishable commodity so necessary to test quality at various steps till final
product is attained. A separate quality control department has been set up in organization.
Various test carried out are
1. Microbiology tests
2. Chemical tests
3. Adulteration tests
Microbiology Tests
a) Standard plate count test
b) Coliform test
MBRT test
General
This test is based on the principle that methylene blue dye that is blue in color in its
oxidized state is reduced to a colorless compound as a result of metabolic activities of bacteria
in milk this test is useful in judging the hygienic quality of milk and grading raw milk and for
detecting post pasteurized contamination of milk.
Apparatus
a) Sterilize test tubes with marking at 10ml.
b) Sterilize rubber bungs to fit in to test tube.
c) Graduate pipette (10ml and 1ml) and incubator.
Procedure
a) Take 10ml. milk in sterilize test tube.
b) Add 1ml of methylene blue solution to the milk in the test tube and replace the cotton
plug with sterilized rubber bungs using sterilized screw.
c) Mix the methylene blue solution and milk by inverting the test tube twice and then
kept in incubator.
d) Observe the test tube after every 30 min.
e) When the reduction of color takes place, note the time of reduction of colour.
19. 19
Interpretation
In the time reduction of color is more, then number of bacteria is less and vice versa.
Standard plate count test
General
This method is used for determining the total number of viable bacteria in milk and
consists of mixing appropriate quantity of milk with a suitable nutrient agar medium in a Petri
dish and counting the bacterial colonies developed after incubation at specific temperature.
From a definite period of time. This method in especially for detecting sources of
contamination.
Apparatus
a) Incubator maintained at 370C
b) Bacteriological pipette (1.2 with marking at 1ml)
c) Dilution test tubes with marking at 1ml.
d) Putridity, ethyl alcohol spirit, conical flask.
Procedure
a) Shake the bottles containing the sample of milk several times by up and down
movements.
b) Sterilize the equipment first.
c) Prepare required dilution with help of 1ml. dilution blanks.
d) To each plate add 10-15ml of media containing diluted sample and cool to 450C.
e) Invert plates and incubate at 370C for 48h after that count the colonies with the help
of colony counters.
Coliform Test
General
If coliform bacteria are found in milk products it is an indication of possible
contamination although some species may be derived from feeding material and soil. This
test is based on the principle the number of this group is capable of producing acid gas from
lactose in presence of salt. The test is commonly employed to detect presence of coliform
bacteria in milk and milk products.
20. 20
Chemical Test
1. COB test
2. Alcohol test
3. Acidity
4. Fat
5. SNF
COB test (Clot on Boiling Test)
Principle
COB test is positive is more than 0.2%.
Procedure
Take about 5ml of well mixed sample in a test tube or at bottom indicates poor keeping
quality.
Interpretation
Clothing of milk on the sides of tube or at bottom indicates poor keeping quality.
Procedure
1. Fill 5ml. of buffer sub state solution into test tubes.
2. Head to 37 to 380
C in a water both.
3. Add 1ml. of milk to be tested.
4. Mix well and incubate at 37 to 380
C
Alcohol test
This test is done for detecting abnormal milk such as colostrum milk. Milk from animals
in late lactation period milk, from animals suffering from mastitis and milk in which the
mineral balance has been disturbed.
21. 21
Interpretation
A negative test indicates low quality and good heat stability of the milk sample milk
showing +ve test is not good for manufacture of evaporated milk which has to be sterilize to
ensure its keeping quality.
Fat Test (By Gerber Method)
Principle
This test is devised by Dr. Gerber. In this method the milk fat is separated from milk
by strangely acidifying and rotating the milk in butyrometer tubes in centrifuge.
Reagents
(i) Sulphuric acid (H2SO4)
(ii) Amyl alcohol
Procedure
(i) Take 10ml of gerber Sulphuric acid.
(ii) Pipette out 10.75ml of well mixed milk sample and transfer it to butyrometer
gently.
(iii) Transfer 1ml of amyl alcohol from tilt measure into same butyrometer.
(iv) Tigfiten the stopper and mix the contents.
(v) Keep the butyrometer in the water bath for 3min at 650C+20C
(vi) Put the butyrometer in the centrifuge machine and allow the machine to run for
5min at 1100 rpm.
(vii) Take out butyrometer and place it in water path at 150+20C for 3min and read
columns.
Standards Acc. to PFA
22. 22
Sr. NO. Type of Milk Fat%
1 Cow Milk 3.5
2 Buffalo Milk 6.0
3 Standardized 4.5
0
SNF Test By Lactometer Method
Procedure
A. Adjust the milk samples at 300
C
B. Mix the milk gently and pour sufficient quality of milk in a cylinder and allow lactometer to
float freely.
C. Allow the lactometer to come into stationery position.
D. Read the lactometer scale and note the temp. of milk.
E. SNF= CLR/4+0.21F+0.66
F. Where CLR-Correct lactometer Reading
G. F-Fat% in the milk sample.
H. SNF Value comes near about 8.34. This value is different states. Payment is done on the bases
of SNF value.
Acidity
Principle
The quality of acid in milk is measured by the amount of standard alkali needed to
neutralize it using phenolphthalein indicator. It is assumed that the acid is lactic acid, but
actually acidity of milk is due to normal constituents of milk, which are normally equivalent
to lactic acid like albumin citrates and casein. This type of acidity is known as original acidity
or apparent acidity.
Procedure
A. Take 10ml of thoroughly mixed sample in a beaker or glass & add 1ml. phenolphthalein
indicator solution.
B. Mix it & titrate against N/9 NaOH, while adding NaOH stir the mixture slowly till the first colour
change to a pink colour persist for 10 to 15 second.
23. 23
C. Note the vol. of N/9 NaOH used.
D. This test is used for both raul & processed milk.
E. Use freshly prepared standardized N/9 NaOH solution.
3. Adulterants
A- Sugar
B- Salt
C- Urea
D- Starch
E- Maltose Dextrin
A- Sugar
Principle
Sugar is added to increase the density to prevent detecting of added water
Procedure
1. Take 10ml of milk in a test tube.
2. Add 1ml of con. HCL & mix.
3. Add some traces resorcinol & mix.
4. Place the tube in boiling water both for 5 min. & observe the colour.
Interpretation
Dark brick red colour indicates adulteration.
B - Salt
Procedure
a) Take 5ml silver Nitrate (AgNo3) + 1 to 2 drops K2 Cr2O4 (potassium pomades).
b) Add 1ml. milk & mix well & observe the colour.
Interpretation
Yellow colour indicates presence of salt.
24. 24
C - Urea
Procedure
a) Take 2ml of milk in a test tube.
b) Add 2ml DMAB (Dimethyle Alcohol benselx).
Interpretation
Yellow colour indicates the presence of urea .
D- Starch
Principle: Starch is added to musk adulteration of milk with water to increase viscosity &
lactometer reading.
Procedure
a) Take about 10ml of milk in test tube.
b) Boil the milk.
c) Cool & add 1ml. of SN iodine solution & observe the colour.
Interpretation
Blue clr indicates the presence of starch.
E- Maltose Dextrin
Procedure
1. Take 20ml milk in a beaker.
2. 10 drops of lactic acid.
3. 10 drops of enzyme.
4. Keep in hot water at 620
C for 5min.
5. Cool it for few min.
Interpretation
Deep the diastic & observe the colour after 30 sec & match with standard chart.
25. 25
WHOLE MILK PROCESSING
Raw Milk
Taste & flavour
after grading
•Lab
Weighment &
sampling
Dumping in
dump tank
Filtration
Store in tank
•Store
•Separation
Pasteurization
720C for 15 sec
26. 26
MILK CHILLING &
PASTEURIZATION
Milk chilling
The milk coming from dump tank is passed from the narrow capillaries having water
at 3-40F milk chilling preserve it by inactivating the bacteria which spoil the milk.
Pasteurization
Pasteurization refers to the process of heating each & every particle of milk at least
for 630C for 30min or for 720C for 5 sec. In approved & proper equipment & immediately
cooling it to 50 C or below.
Purpose
(a) To render milk for human consumption by destruction of percent pathogenic
micro-organism.
(b) To improve the quality of milk by destruction of almost all spoil aging organism.
27. 27
Separation of milk
Pasteurized and chilled milk is then going to
the cream separator where cream is separate from
the milk by centrifugation. The separates from the
milk in to parts cream & skim milk.
Now cream is more centrifuge for
separation of butter & lassi.
Machinery used in plant for production
Roller conveyor- It is a device which functions on
the principle of gravitation & used for transporting
the milk can of 40 liters capacity from reception
dock. This method of transportation provides
economy of space & requires little manual labour milk weighing machine-
This machine has the capacity of 500 kg.
Dump tank
The dump tank has the capacity of 2000 liters & after weighing the milk it is stored into dump
tank & from dump tank it is pumped into plate chiller for further processing
Can Drip saver
After the milk has been transferred to the dump tank the milk cane are inverted over can drip
saver to store the milk remained in can or adhered to its walls
Milk can Scrubber
It consists of a tank & eclectically operated brush. The tank container solution of caustic soda
& hot water in which the cans are cleaned from inside & outside.
28. 28
Can washer
In Jind milk plant one can washer was used to clean the can washer was used to clean the can
with the help of the steam. It was purchased from Kariya Dairy Machinery.
29. 29
ANALYSIS OF MILK PRODUCTS
1. PANEER
2. GHEE
3. SKIM MILK POWDER
1. Paneer
4. Taste and flavour
5. Texture
6. Fat
7. Acidity
8. Moisture
Fat
Take 2g of grate paneer in a milk butyrometer Add 10ml Sulphuric acid add 1ml amyl
alcohol put the lock stopper mix well centrifuge 3 to 4 min in not the butyrometer reading-
Acidity
Take 4 to 5g paneer in a flask add 4ml of N/10 NaOH +1ml of indicator then titrate
with N/10 Hcl. Note the volume of consume N/10 Hcl 10ml distilled water.
2. Ghee
• Taste and flavour
30. 30
• Acidity
• BR (Butyro-Refractor meter Reading)
Skim Milk Powder
1. Taste and flavor
2. Moisture (TS)
3. Acidity
4. Fat Content
5. Ash Content
6. Scorched particles
Moisture
Weight the pre dry dish witt of empty dish. Take the well mixed powder sample
(approximately 2 to 3g.) wt. of dish+SMP sample=wt. Place the dish into a hot air oven holding
temp of +100 for 2h. Then put the dish into a dassicator for 20 to 30min for cooling. Weight
the dish after evaporation weight of dish after evaporation=w3g
Acidity (ISI Method)
Take 5g of SMP sample in a conical flask + 50 ml distilled water +1m P. Indicator (1%
solution) Mix well and titrate with N/10 NOH. Note the volume of consume N/10
Fat%
Take 10g of SMP sample in a flask + 100ml distilled water mixed well and pipette
10.75ml and pour into a milk butyrometer containing 10ml of H2So4 +1ml Amyl alcohol and
lock stopper mix well and centrifuge for 3 min. Note the butyrometer reading.
Ash
Take 2gm of SMP in a china dish or crucible put the dish into a muffle furnace holding temp
at 500 to 5500C for 2h. Then aling and dish into a desicator for 20min. For coaling and weight
the dish.
31. 31
S.P. (Scorched Particles)
Procedure
Take 10g. SMP in a flask +100 ml of distilled water mixed well and passed. This
reconstituted milk through a cotton disc with the help of sediment tester.
32. 32
MANUFACTURING PROCESS OF
BUTTER
Butter means the product obtained from cow or buffalo milk or a combination there
of, with or without addition of common salt and annatto or carotene as coloring matter. It
should not contain not less than 80% milk fat, not more than 16% moisture, 2.5% common
salt max and 1.5% curd. No preservative is permissible in butter.
Process
Pasteurized Milk passes through the cream separator and then cream and skimmed
milk are separated from whole milk. The cream is stored in tank & pasteurization of cream is
done. The cream from storage tank is transferred to butter churner. The capacity of butter
churner is 3000kg cream. It separates butter from butter milk after continuously 3 ½ -4 yrs.
of churning.
33. 33
Then the butter milk is separated from the butter through a sieve. Then the butter is
washed with pasteurized water to remove all lose butter milk and to decrease intensity of off-
flavor if present. The salt is added at the rate of 2% annatto color is added. Then these are
mixed well. Then the quality tests are done and if tests are positive then marketing and
packaging of butter are done.
Composition of butter
S.No. Constituent Percentage (Max.)
1 Milk Fat 80
2 Moisture 16
3 Salt 2.5
4 Curd 1.5
35. 35
MANUFACTURING PROCESS OF
GHEE
Ghee means the pure clarified fat derived slowly from milk or curd desk butter or
cream to which no coloring mater and preservative has been added. Ghee is manufactured
by preratification method. Raising the temp. at 108-1100C. When the product with mild flavor
is obtained.
Process
36. 36
Butter is passed through boiling vat at about 1000C i.e. heated by steam. The moisture
from ghee is completely removed then the ghee is pumped into setting tank in which any
impurity remained in ghee is settled down. Now the ghee is transferred to another tank in
which it cools down to 350C to 400C Cooling is important process for granulation of ghee.
Ghee is packed in poly pack and tin.
37. 37
PROCESS FLOW CHART
Butter Boiling (1000C)
(Moisture
remove Less than
3%)
Settling tank
(2hrs. Impurities
settle down)
Clarifier
(Residue
separate)
Cooling and
granulation
(350C-450C)
Packing and
storage
38. 38
MANUFACTURING PROCESS OF
PANEER
Definition
Paneer refers to indigenous variety of rennet – coagulated; small sized soft cheese.
Process
Paneer is the product obtained from cow or buffalo milk or a combination there of by
precipitation with sour milk, lactic acid or citric acid, milk is heated with starter culture. During
boiling precipitates are farmed. After complete precipitation, mixture is cooled at room temp.
After that filtration take place. Paneer and whey separate out through muslin cloth. After
pressing cooling take place in cold water. Then cutting & storage of paneer take place at 5-
100C Temp.
40. 40
MANUFACTURING OF DAHI
Dahi
Dahi or curd is the product obtained from pasteurized or boiled milk by souring,
natural or otherwise, by a harmless lactic acid or other bacterial culture.
Procedure
Milk is boiled at 800C and cooled at 400C and inoculated with 1.3% of specific culture.
It is then filled in suitable plastic cups of the required capacity and incubated at 35-400C hrs.
after in incubation dahi is stored at storage temperature around 5-100C.
41. 41
PROCESS FLOW CHART
Milk Boiling (800C) Cooling (400C)
Culture
Filling in Plastic
Cups
Incubator (35-
400C for 2-3
hrs)
Dahi Storage (5-100C)
42. 42
MANUFACTURING PROCESS OF
MILK POWDER
Milk Powder means the product obtained from cow or buffalo milk or a combination
there of or from standardized milk by removal of water.
Process
After pasteurization milk is homogenized, milk is passed from condensers again and
again till they concentrate milk and reduce moisture level up to 55% in milk. This concentrated
milk is then sprayed into drying chamber with hot air blast. This temp of air is 1800C and
sterilized air is used for this process. Here, the milk thorns into small particles of milk powder
and is passed through cylinders where extra moisture dries and milk powder cools down to
room temp. Milk Powder is tested by QC lab and if found correct then it is packed and
marketed.
Pasteurizer
Device used for pasteurization is called as pasteurizer. It has a capacity of 10,000 liters
per hour. The capacity can be varied by slight modifications when needed.
The plant has
1. 2 storage tanks for pasteurized milk of capacity 33000 liters.
2. 3 storage tank for raw milk of capacity 33000 liters.
3. 3 raw milk tanks from which milk to pasteurizer is forced of 10000 liters capacity.
4. 2 tanks of 10000 liters capacity each for cream.
The tanks are insulated in order to avoid the rise in temperature of milk and thus spoiling.
Each tank is provide with an agitator used for maintaining a uniform temperature.
43. 43
Plate Chiller
The instrument is used for chilling the milk. The milk is chilled up to 30C to 4.50C.
Cream Separator and Cream Pasteurizer
Cream separator is used to separate cream from milk. Cream is pasteurized at the
cream pasteurizer which is same as that of milk pasteurizer. Cream separator also works as
milk clarified.
Machinery Used For Ghee Production
1. Butter Churner: - Butter churner is an electrically operated device which has sharp
blades inside it and used for churning cream to produce butter and separate butter
milk.
2. Melting Tank: - It is a double walled tank in which steam is used to heat the tank. The
steam passes through the space between the two walls, which heat the tank to a
temperature 400C at which butter melts completely.
3. Boiling Tank: - The melted butter after filtration is boiled in boiling tank. The tank is
heated up to 1080C to 1100C. Its capacity is 1000 kg per lot.
4. Ghee Storage and Setting Tank: - The tank fulfils the purpose of settling ghee, storing
and cooling it down to 400C before filling it into packs.
5. Filling, Weighing and Sealing Machine The liquid ghee is filled in desired tins and
weighed in weighing machine. The by sealing machine, these are sealed. The machine
is operated by operator. For packing of ghee into pouches automatic sealing and
packaging machine is installed.
44. 44
MACHINERY USED IN POWDER
PLANT
Homogenizer
Homogenization is formation of a stable emulsion of milk fat and milk serum. The
instrument used for homogenization is called homogenizer.
Milk contains fat globules of size between 0.1 to 10 microns. When the milk is passed
through the homogenizer there is fixed reduction in size of fat globules. No cream line is
formed on milk after homogenization nor will butter granules will be formed by churning it.
Furthermore there is increase in viscosity of milk.
Condensing Unit
The evaporation capacity of this unit is 3000 kgs. of skim milk concentrates up to 45%
of skim after condensing.
Drying Chamber
It is big round chamber in which concentrated skim milk is sprayed by atomizer with
blast of hot air. Here skim milk turns into small particles of skim milk.
45. 45
PACKAGING, LABELING,
STORAGE, DISTRIBUTION AND
MARKETING OF PRODUCTS
Brand Name
All the products produced by all five plants of HDDCF Ltd.are being sold under brand
name "VITA". The brand name "VITA" has gained popularity among public at large.
Products and Packaging
Milk plant is producing paneer, ghee, skimmed milk powder (SMP), Ghee is packed in
1liter, 5liter and 15liter Packs. All are meant for domestic use. SMP is packed in 25kg bag for
bakeries etc. Paneer packed in polythene bag in 200 gm. & 1 kg.
Distribution of Products
There are twelve registered distributors at least one in each district of its operational
region registered under head office. The goods for domestic use are supplied to dealers,
retailers to Ultimate consumers through registered distributors. Besides these their sales
office of plant in Chandigarh and Delhi. Which receive orders and supply good.
46. 46
Channels of Distributions
Following Pattern has been adopted by the Plant for transferring goods to ultimate
consumers.
(a) Direct selling to consumer.
(b) To consumers through distributors.
(c) To Consumers through retailers.
47. 47
Store Department
The main function of store deportment one receipt of stores and issue of materials
when need and keeping proper record of all incoming and outgoing materials.
The stores department has two main branches.
(i) General Stores.
(ii) Finished Good Stores.
(a) Ghee store.
(b) Panner store
(c) Milk Powder Store
Ghee and Powder can stored at room temp. but panner can be stored in refrigeration
or cold temperature (-30C).
SANITIZATION OF EQUIPMENTS
AND CONTAINERS
Improved, cleaned and sanitized, equipment and containers constitute major sources
of contamination of milk & milk products. Therefore, routine cleaning and sanitization of plant
should receive proper and careful attention. Surfaces of equipments which come in contact
with should be tested for sterility from time to time. Following methods are recommended:
1. Rinse method – For cans.
2. Swab method – For tanks, plates of pasteurizer and pipe
***
48. 48
WATER SUPPLY AND DISPOSAL
A regular supply of water is must in the pant because of the nature of products and
production process. The two tube wells in the plant serve this purpose. There is plant which
converts hard water into soft water on the basis of ion-exchange principle. Soft water is used
for all purpose in plant.
Disposal
Water is cleaned by E.T.P. (Effluent Treatment Plant) and then moves to disposal tank
and from here it is disposed off in the field with the help of two disposal pumps of 30 and 40
H.P. respectively. This treated water is good for crops and at present supplied free of cost to
the farmers.
