Report on industrial attachment in Uttarakhand Co-operative Dairy Federation Ltd:

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INDUSTRIAL ATTACHMENT PROGRAMME
Carried out
at
“NAINITAL MILK PRODUCER COOPERATIVE LIMITED, LALKUAN”
REPORT
By
VIKAS TIWARI
UUHF/16031
Submitted to
COLLEGE OF HORTICULTURE
V.C.S.G. UTTARAKHAND UNIVERSITY OF HORTICULTURE & FORESTRY
BHARSAR, PAURI GARHWAL, UTTARAKHAND – 246123
in
Partial fulfilment of the requirements for the course
of
“Horticulture Work Experience (HWE- 101,102, 103)”
B.Sc.Horticulture (Hons.)
4th
year
March,2020

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Other information:
Supervisor name:
Mr. Atul Kumar Gupta
Place:
Lalkuan, Distt.-Nainital
Course coordinator:
Er. Tejas Ashok Bhosale

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ACKNOWLEDGEMENTS
“Words can never express my sincere feeling and unfathomable gratitude that fills my heart for the invaluable
guidance, inspiration, encouragement and assistance that I have received during my work.”
I was placed at AANCHAL DAIRY for Industrial training purpose. I am highly thankful to my college
COLLEGE OF HORTICULTURE, V.C.S.G. U.U.H.F. BHARSAR from where I got an opportunity to
explore industrial working culture and learn about the know-hows of an organization through Student
READY (Rural Entrepreneurship Awareness Development Yojana) programme.
For finishing 70 days of my INDUSTRIAL ATTACHMENT PROGRAMME Carried out at “NAINITAL
MILK PRODUCER COOPERATIVE LIMITED, LALKUAN”I would like to give my warm and heartiest
thanks to our respected course coordinator ER. TEJAS ASHOK BHOSALE for providing best support and
guidance for training.
I would like to thanks MR. AJAY KWEERA- GENERAL MANAGER, AANCHAL DAIRY LALKUAN
for allowing me to learn from the organization in form of industrial training, who enlightened us by his
knowledge, guidance and cooperation.
Also I want to express my sincere gratitude to all the associates of The Aanchal Dairy Farm, Lalkuna,
Nainital, Uttarakhand.
Also, I would like to thanks MR. ATUL KUMAR GUPTA- FACTORY MANAGER, AANCHAL DAIRY,
for his kind help and support and his valuable guidance through my project. My special thanks to the
production unit operators who gave me detailed information about the working of units- Mr. Satish (Weighing
unit operator), Mr. Kanchan (Pasteurization unit operator), Mr. Harish (Curd production unit operator), Mr.
Gopal (Butter production unit operator), and other employees present at packing units of paneer, ghee, milk,
mattha, curd, butter.
At last my sincere gratitude and thanks to my parents who supported and helped me throughout my
training financially.
Needless to mention, errors and omissions are mine.
Place: Bharsar
Vikas Tiwari
Dated: 02.03.2020

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TABLE OF CONTENTS
Chapter TITLE Page
1. INTRODUCTION 5-6
2. COMPANY’SPROFILE/BACKGROUND 7-14
3. PROCURATION OF MILK 15-17
4. AANCHAL MILK MARKETING 18-21
5. WEEKLY JOBS SUMMARY 22-24
6. TECHNICAL CONTENTS/REPORT 25-38
7. COMPARATIVE SALE REPORT FROM 1st
Jan 2019 TO 31st
Jan
2020
39-40
8. CLEANING-IN-PLACE(CIP) & EFFLUENTTREATMENT PLANT (ETP) 42-43
9. FINDINGSAND SUGGESTIONS 44
10. CONCLUSION 45
11. REFERENCES 46
12. CERTIFICATE 47

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1. INTRODUCTION
The Student READY (Rural Entrepreneurship Awareness Development Yojana)
programme aims to provide rural entrepreneurship awareness, practical experience in real-life
situation in rural agriculture and creating awareness to undergraduate students about practical
agriculture and allied sciences.
The programme will help in building confidence, skill and acquire Indigenous Technical
Knowledge (ITK) of the locality and thereby, preparing the pass-out for self-employment.
It also aims to provide opportunities to acquire hands-on-experience and entrepreneurial skills.
To reorient graduates of agriculture and allied subjects for ensuring and assuring employability
and develop entrepreneurs for emerging knowledge intensive agriculture, it was felt necessary
to introduce this program in all the AU’s as an essential prerequisite for the award of degree to
ensure hands on experience and practical training.
The Fifth Deans committee has given detailed curriculum of student READY programme
for all the disciplines in agriculture and allied sciences. The course curricula have been
restructured to develop much needed skills and entrepreneurial mind-set among the graduates
to take up self employment, contribute to enhanced rural livelihood and food security,
sustainability of agriculture and be propeller for agricultural transformation.
The following components are proposed for carrying out one year Student READY
programme in all the Under graduate (UG) disciplines:
1. Experiential Learning on Business Model / Hands on Training
2. Experiential Learning on Skill Development
3. Rural Awareness Works Experience (RAWE)
4. Internship / In-Plant Training / Industrial attachment
5. Students Projects
INDUSTRIAL TRAINING:
To enrich the practical knowledge of the students, industrial training shall be mandatory
in the last semester for a period of up to 10 weeks. Industrial attachment is a component of
horticulture work experience. It consist total duration for which students may approach

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industrial units as per their interest to get hands on training and understanding of various
aspects of industrial activities. They have accepted the work offered by the Units as per their
terms and conditions. In this training, students will have to study a problem in industrial
perspective and submit the reports to the university.
Such in-plant trainings will provide an industrial exposure to the students as well as to
develop their career in the high-tech industrial requirements. In-Plant training is meant to
correlate theory and actual practices in the industries. It is expected that sense of running an
industry may be articulated in a right way through this type of industrial attachment mode.
The major objectives of In Plant Training (IPT) are:
 To expose the students to industrial environment.
 To familiarize the students with various Materials, Machines, Processes, Products and
their applications along with relevant aspects of shop management.
 To make the students understand the psychology of the workers and approach towards
problems and practices followed in industries.
 To make the students understand the scope, functions and job responsibility in various
departments of an organization.
 Exposure to various aspects of entrepreneurship during the programme period.
In-plant training of short duration in relevant industry is useful to gain the knowledge
and experience of the work culture. In Plant training in reputed organization / MNC’s/ other
organised sectors provides an industrial exposure to the students for developing their career in
the Argo based industries.

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2. COMPANY’S PROFILE/ BACKGROUND
2.1. About
Uttarakhand Co-operative Dairy Federation Ltd. (abbreviated as UCDF Ltd.) is an apex level
State Federation of District Milk Co-operative Unions in the state of Uttarakhand .It was
established in the year 2001, under registration no; 555, dated12-03-2001, with its head office at
Mangal Parao, Haldwani (Nainital) for the successful implementation of the dairy programme
within the state. Organization has registered brand name, known as “AANCHAL".
The Uttarakhand Co-operative Dairy Federation Ltd. (UCDF Ltd.) came into existence as a
successor body to the Uttar Pradesh Cooperative Dairy Federation Ltd., after the formation of
Uttarakhand as 27th state on 9th Nov 2000.The UCDF Ltd. was registered under the Uttarakhand
State Co-operative act in 2001.Currently in the state's dairy business “AANCHAL” is known as the
Dairy Cooperative Brand of Uttarakhand.
To eliminate middle men from state dairy business and providing employment to the rural
people at the village level, Aanchal has covered all 13 districts in the state through its 11 District
Level Member Co-operative Milk Unions (District Rudraprayag and Bageshwar are included
under Pauri Garhwal and Almora Milk Unions respectively) and to maintain a continuous growth
in milk production, it is doing collective efforts with the help of concern associated Member Milk
Unions.
Schemes under State and Central Government like IDDP, RKVY,NPDD etc are being
implemented by organization for the economic and social up-liftment of farmers. Other schemes
like Big Dairy, Mini Dairy, Women Dairy Development Programme etc. are also being successfully
conducted. With the help of its own cattle feed factory, organization provide cattle feed, fodder
and seeds to its associate co-operative members at reasonable price.
Animal medical facilities like animal health services, emergency veterinary services, Artificial
Insemination, Natural Conception, Vaccination, Deworming, animal feeding knowledge,
veterinary medicines, and other types of technological investments are being served at village
level societies with help of organization’s member milk unions within the state.

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2.2. Brief Information:
Establishment-1963
Chairperson : Smt. Rekha Devi
General Manager: Mr. Ajay Kweera
Factory Manager: Mr. Atul Kumar Gupta
Quality assurance manager: Mr. Vijay Padiyar
Area of industrial: 3.9 ha
Turnover of the Industry : 149 crore
Investment / year : 149 crore
No. of employees: 150
2.3. VISION OF ORGANISATION:
As the motto of the co-operation “of the people, by the people and for the
people” organization system works in “Three Tier System” i.e. village, district and state level
and every tier of the system works together to ensure organization's long term vision in the
following terms –
1. To ensure prosperity of the rural milk producers who are ultimate owners of the
Federations/Unions/Village Dairy Co-operatives.
2. To promote producers oriented viable cooperative structure in the state to impart an
impetus to the dairy productivity, rural income generation and employment.
3. To march forward with a missionary zeal enabling UCDF a vanguard of exemplary
performance and achievement beckoning other milk federations in the country in
pursuit of total emulation of its good deeds.
4. To reduce the price spread between the procurement and the sale price of milk.

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5. To develop business acumen in marketing and trading discipline so as to serve
consumers with quality milk.
6. To compete with multinational companies and private dairies with better quality of milk
and milk products and in the process sustain invincibility of cooperatives safe guarding
the interests of both milk producers and consumers.
2.4. ORGANISATIONAL OBJECTIVES:
1. To build and develop village level institutions as cooperative model units to manage the
dairy activities.
2. To ensure assured and remunerative market round the year for the milk produced by
the farmer members at their doorsteps.
3. To channelize marketable surplus milk from the rural areas to urban deficit areas to
maximize the returns to the producer and provide quality milk and milk products to the
consumers.
4. To ensure provision of inputs for milk production inputs, processing facilities and
dissemination of technical know-how.
5. To carryout activities for promoting Production, Procurement, Processing and Marketing
of milk and milk products for economic development of the farming community.
6. To facilitate rural development by providing opportunities for self-employment at village
level, preventing migration to urban areas, introducing cash economy and opportunity
for a sustained income from dairy enterprise.
7. To provide technical consultancy to its member milk unions for upgrading their
infrastructure and product range.
8. To carryout research and development activities to bring out with the different product
ranges according to the market needs.

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9. Strengthening of veterinary infrastructure in the village and provide training in cattle
management at village level.
10. Skill Enhancement of dairy workers and associate producer members, through
organized training programme at state/out of state level in different time interval.
2.5. SITE AND PREMISES LAYOUT
FIG.:SITE AND PREMISES LAYOUT

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2.6. TRAINING &PROGRAMMES:
A. NATIONAL PROGRAMMEFOR DAIRYDEVELOPMENT:
 Establishment of Milk outlets.
 Purchase of Deep freeze and Cooler.
 Establishment of village cooperative societies.
 Establishment of milk and milk product testing lab.
 Manpower Skill Development Programme like Farmer Induction Programme, Staff training,
societies board director training program.
B. RASHTRIYA KRISHI VIKAS YOJANA:
 Strengthening of Dairy Infrastructure.
 Renovation of the Dairy plants.
 Modernization of Milk Co-operative Societies.
 Construction of Water storage Tank & SMP Godown.
 Installation of ATMs- Mobile Milk Vending Machine.
 Construction of Milk Rooms.
 Installation of DPMCUs (data processing milk processing units).
C. INCENTIVEPROGRAMMES:
1. Ganga Gaya MahilaDairy Yojna
 Under this scheme, Dairy Development Department is providing subsidy and facilitating
bank loan to women member of milk co-operative society for purchase of a milch cattle.
 launched : 2014
2. Milk Price Incentive toMilk Producers
 District Level Milk Unions procure milk from producers through village level milk co-
operative societies.
 State Govt. has announced Rs.4 per Liter subsidy for milk producers as milk price incentive.

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 The subsidy amount would be given to milk producers on the basis of per liter of milk
poured by them in milk cooperative societies.
2.7. PRODUCTS SALE AND PRICES:
PRODUCTS SALE:
Milk 71,087 Lt./ Day
Curd 11,38,686 kg/year
Paneer 2,42,247 kg/year
Butter 22,316 kg/year
Ghee 1,20,721 kg/year
PRODUCTS PRICES:
Product Quantity Market price(Rs)
Milk
Full cream milk 1 lit 50
500 ml 27
Standard milk 1 lit 42
500ml 24
Toned milk 1 lit 39
500ml 22
Double toned milk 1 lit 40
500ml 19
Skimmed /janta milk 200ml 25
Curd 100gm 10

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200gm 17
400gm 32
1kg 60
5kg 250
Paneer 200gm 62
500gm 145
1kg 310
Butter 100gm 37
500gm 180
1000gm 350
Ghee 200ml 90
500ml 215
1 lit 430
Cream 1 kg 320
Khoya 1kg 300
2.8. PAYMENTTO THE SOCIETIES
 Payment to the societies is made based on the Fat and SNF part of the milk.
 Societies then distribute money to individual farmers.
 Payment is made ₹35/litre of milk having 6% Fat and 9% S.N.F. .
 ₹280 is paid per kilogram of Fat and ₹186 is paid per kilogram of SNF part in the milk
 Amount is paid on weekly basis in the bank accounts of societies
 Money can be withdrawn only when signature of both incharge and field supervisor is
present

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Fig.: REVISED PRICES OF PRODUCTS.
Source:-Aanchalrevised price report, Jan 2020.

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3.PROCURATION OF MILK
3.1. INTRODUCTION
The milk is procured through the village dairy operatives, which collects milk from different
areas-
Ramnagar, Bazpur, Rudrapur, Kiccha, Khatima, Halduchaur, Chorgalion, Lamachaur, Jamrani,
Haidakhan, Shantipur, Champawat, Bhowali, Almora, Pithoragarh
78,000 litres of milk is procured per day from following centres –
1.Lalkuan – maximum contribution including 20,000 litres at night,21,000 to 22,000 litres in the
morning .
Rest milk is procured from 3 chilling centres .
2. Choi (Ramnagar) -16,000 litres
3. kaladhungi-13,000 litres
4. Hedia gaon (Near bhowali) -14,000-15,000 litres .
3.2. GROUND LEVEL INFORMATION OF PROCURATION
A visit to local procurement center of Aanchal at Ratanpur Village, kaladhungi was made.
The Milk is collected two times a day within each Procurement center, mainly in morning and
evening hours.
Process:-
• Milk is firstly weighed in cans while filtering it with sieve.
• A sample of mixed milk taken in viles.

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• The sample is then homogenized and mixed well.
• The sample is placed then in “MILK ANALYZER MASTER MINI” used for testing Fat, SNF,
Protein, Density, Temperature of milk.
• A light frequency sound indicates the completion of process.
• A Printed slip with all exact values and price of milk obtained is provided to farmer.
• A record of all the milk suppliers is made.
All the collected milk is then transported to the nearby chilling centres in big cans
FIG.-QUALITY EVALUATION WITH LACTOSCAN.
FIG.: SCREEN DATA AND SLIP PROVIDED TO FARMER.

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Fig.: Milk procurement and sale in avg lit/day

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4. AANCHAL MILK AND MILK PRODUCTS
MARKETING
3.1. Introduction
Local sale of milk at the society level should be encouraged to increase the popularity of
Aanchal brand. Focus should be on institutional sales.Active participation during farmers’ fairs,
festivals and exhibitions isrequired to increase the popularity. There should be monthly
meetings at the village level where the people should be provided proper guidelines to increase
milk production. Aanchal can go for sponsorship of events related to animal husbandry and pet
shows.
Milk vending machines should be installed in the main district towns and tourist locations like
Haldwani, Bhimtal, and Nainital, etc. Awareness programs were required in areas where
dudhiyas were more in number. Customers should be given live demonstrations of the milk
adulterations done by dudhiyas. Locations of Aanchal bars have to be decided strategically.
Business development services (BDS) were required in the whole region because there were
very few service providers in this region. Focus has to be given on value-added products,
region-wise, and had to follow consumer’s taste and preferences. To popularize products like
ice cream, butter, paneer, mattha, lassi in the rural areas, a regular supply of these products
(after properly analyzing the demand) was required. These could be started by providing
subsidized sale of refrigerators to the societies for keeping these products.
3.2. Marketing Strategies
 It has been found that all the existing players employ different strategies to attract the
target groups of customers.
 The points for comparing the strategies of different players.
 The different points taken for comparison were both back-end and front-end related,
where the Aanchal was actually failing.

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 The points were procurement, transportation, timings of procurement, middlemen
involved, margin of agents, point of sale, target customers, mode of payment, etc.
3.3. MARKETING STRATEGIES vis-a-vis OTHER PLAYERS:
Points for comparison Aanchal Dudhyias Pvt. Dairies Local sales
1.Procurement Penetration in
villages through
societies in the
villages
Collections from
households
Collections from
other places
where it is cheaper
Collection from
own households
2.Transportation Van Cycles or bikes Middleman
through vans
Cycles or walk
3.Time ofprocessing Once/twice Twice Twice Twice
4.Selling through Agents Self Dealers Self
5. Points of sale Outlets Home delivery Outlets Home delivery
6. Customers Salaried Class, tea
stall, restaurants,
Institutional sales
Salaried Classes,
tea stalls
Salaried
Class, institutional
sales
WageClass,
restaurantsand
hotels
7.Mode of payment Cash Monthly system Cash Monthly system
8.Bargaining on MRP NO Yes Yes Yes

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Fig.: Performance Over Years-Members
3.4. MARKETING RELATED PROBLEMS :
 Absence of screening system – Zoonotic, adulteration, contaminants- spoilage of entire
batch if one can go undetected.
 Gap in information- Era of IT- Dairy sector is unorganised ; No proper record keeping-
No back tracking
 There were two prominent seasons when demand supply fluctuations were very
prominent. From Oct- Jan, production was more and hence forth supply was more but
demand was less. Hence, excess milk was supplied to Mother Dairy via NMG
agreements at lower prices. This led to a crash in procurement prices from farmers and
paved the way for farmers demotivation.
 Leakage loss was 1.0 to 1.5 per cent in the polythene packs.
 Crate leakage was 0.1 per cent.
 Vehicles going to distant places depicted leaking problems higher than average due to
friction in crates.
 Lack of Infrastructure, Chilling plants and Bulk coolers to prevent spoilage.
 From April to June, milk procurement decreased due to decline in productivity. But
demand increased and rates started sky rocketing. Again, this led to entrance of private
players in the market for earning more profits through the channel.

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 The margins provided to the agents were not sufficient.
3.5. ANNUAL TURNOVER
FIG.: ANNUAL TURNOVER OF AANCHAL
FIG.: SALE OF GHEE IN LTR.
1572.51 1715
1975.33
2193.552254.99
2684.22
3121.03
3490.09
3768.21
TOTAL
TURNOVER
RS.
LAKH

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5. WEEKLY JOBS SUMMARY
WEEKS WORK SCHEDULE
1st week  Meeting with general manager Mr. Ajay Kweera and
factory manager Mr. Atul Kumar Gupta.
 Interaction with factory working staff.
 Collected information about factory and its products;
about input and output of factory from factory manager.
 Collected information about marketing from marketing
specialist Mr. Sanjay Bisht.
2nd week  Mr. Satish took on the visit of the whole factory and
different processing sections of the dairy.
 He told in brief about the processing of different
products.
 Learned about the pattern of milk flow.
 Learned about the chilling centers of dairy.
 Learned about the collection and procurement of milk.
3rd week  Learned about the receiving of milk at DMR and grading
of milk and weighing of milk.
 Observed and learned about the mechanical registration
of data of milk collected and weighed.
 Learned about the adulteration of milk.
 Learned about pasteurization, homogenization and
standardization of milk.
4th week  Learned about the testing of milk and performed sample
testing.
 Learned about processing of milk.
 Learned about types of milk.

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 Learned about packaging of milk.
 Learned about marketing of milk.
 Visited to laser printing units where curd packing cups
were printed.
5th week  Visited pasteurization and cream separation unit.
 Learned about the know- how and operation of unit.
 Learned about the cleaning of unit and later storage of
pasteurized milk in storage containers.
6th week  Visited the curd processing and observed in detail about
the curd preparation.
 Learned about the cleaning methodology adopted by
dairy of the curd preparation unit.
 Learned and performed the laser printing on curd
packing cups.
 Also observed and performed the mechanical packing of
the curd.
 Learned about the storage of the packed curd for
curdling.
7th week  This week covered the butter preparation and packing
section.
 Learned about the preparation of butter from cream.
 Also observed and performed the butter packing with
the factory staff members.
8th week  This week I covered the paneer preparation section.
 I learned about the preparation of paneer from milk
using citric acid.
 Also observed and performed the weighing and packing
of paneer with staff members.
9th week  This week I learned about the preparation of ghee from

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butter.
 Visited to the ghee preparation section and collected
information from the staff.
 Also learned about the mechanical packing of ghee.
10th week  Meeting with the factory manager and collected
information about annual turnover of the dairy.
 Prepared a report about the industrial training and
submitted to factory manager.
 Collected the industrial certificate form general manager
office.

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6. TECHNICAL CONTENTS/REPORTS
Aanchal Products:
LiquidMilk
 Skimmed Milk
 Double Toned Milk
 Toned Milk
 Standard Milk
 Full Cream Milk
HighFat Milk Products
 Ghee
 Butter
CulturedMilk Products
 Dahi/Curd
 Mattha
CoagulatedMilk Products
 Paneer
Other Milk Products
 Khoya

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6.1. Fate of Milk:
Farmer
Chilling centers (Adulteration check)
Milk tanker
Milk plant ( Dairy)- Adulteration check
Platform + laboratory tests
Tankers
Pasteurization
Chilling-Packing
Retailer
Consumer
6.2. Adulterationof Milk:
Adulteration reduces the quality of milk and can even make it hazardous but some greedy
people add Urea, Starch, Soap salbutamol, detergent, acid, table sugar and preservation like
sodium, washing soda, formalin etc.
Synthetic milk: It is not milk, but entirely different component, with high degree of
adulteration.
Procedure/ingredient used:
 Vegetable oil/ refined oil (butyrometer reading <42)-act as milk fat
 Detergent – Emulsifier
 Hot water- till density of milk is achieved
 Urea/ glucose / N2 based fertilizer –act as SNF
 NaOH – to neutralize acidity.

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Test for adulteration:
A. Starch:
 Add few drops of I2 solution to milk sample.
 Adulterated milk forms blue colour.
B. H2O2(HydrogenPeroxide) :
 Add potassium iodide starch reagent solution to 1 ml milk sample.
 Appearance of blue colour indicates presence of H2O2.
C. Platformtests:
It includes all the tests that are performed to check the quality of milk sample /
incoming milk on the receiving platform so as to make quick decision regarding its
acceptance or rejection.
Following type of platform tests are conducted-
I) Organoleptic / sensory / rapid platform test: These require very little time to
perform.
a) Smell /odour – Must be free from acidic odour.
b) Taste – Must not have any off flavor.
c) Appearance – Free from any fat globule or floating material.
II) Sediment test: Low sedimentation is desirable.
10 ml milk is taken in sediment tube which is graduated up to 15ml. tube is corked and
placed in a centrifuge for 5-6min. High density sediments settle at base.
III) Acidity test-Natural or apparent acidity does not make milk sour, however developed
acidity affects milk quality.
Acidity is tested by-

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I. Titration
II. Alcohol test
III. Alcohol index
IV. Alcohol alizarin test
V. Clot on boiling test
IV) Lactometer test -Lactometer is a small glass instrument that is used to check for
purity of milk by measuring its density.
 Lower the density, farther the lactometer will sink.
 Mix milk sample
 Pour the sample in measuring cylinder
 Put the lactometer in the cylinder
 Take the reading at the top of the meniscus
 CLR (Corrected Lactometer Reading ):
Lactometer reading is taken at 60 °C, but if temperature is more or less than 60°C,
then it is corrected as follows-
 If temperature >60°C: Add 1/10th to the LR for every degree it is above 60°c.
 If temperature <60°C: Subtract 1/10th from the LR for every degree it is below
60°C.
 If the lactometer reading or CLR is approximately 30, then milk is considered pure.
Below 30 is considered impure.
V) Methylene blue reduction test –Determine the extent of bacterial contamination
growth in milk.
2) Laboratory test-
i) Determination of fat in milk
Fats are hydrophobic and soluble in organic solvents but insoluble in heater.

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Fat is determined by –
Gravimetric method
 Place clean and dry butyrometer in stand
 Add 10ml H2SO4
 Add 10.75ml of milk sample through pipette
 Add 1ml amyl alcohol
 Put the cork on butyrometer tightly
 Mix well till red colour is appeared.
 Place the butyrometer in gerber centrifuge machine (1100rpm for 4-5min).
 Keep the butyrometer in hot water bath, till it attains 149 ℉/65℃.
 Adjust the fat column, which will appear clear and yellowish colour and other
components will turn black.
ii) SNF (Solid not Fat)-Substance in milk, other than water and butterfat. It includes protein,
energy, vitamin, carbohydrates, minerals etc.
For cow’s milk (21°C)
SNF (%) =CLR/4 +0.2F% +0.14
*CLR=corrected lactometer reading
F%= fat%
For buffalo milk
At 21°C:
SNF (%) = CLR/4+0.21F%+0.36
At 27°C:
SNF (%) = (CLR + F%)/4 +0.44

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• At Aanchal dairy, for bulk sampling “MILK ANALYZER MASTER MINI” is used for testing
Fat, SNF, Protein, Density, and Temperature of milk.
Fig.: MILK ANALYSER MASTER MINI
6.3. Milk:
Milk is an agricultural product which is extracted from farm animals. India is the world’s largest
producer of milk and leading exporter of SMP (skimmed milk powder).
Physical properties:
 Acidity pH: 6.5-6.6 (cow)6.7-6.8 (buffalo)
 Density: 1.028 – 1.030
 Freezing point : - 0.549 °C
 Colour: White (Buffalo ), cream yellow (Cow)
Classifications of milk:
Milk can be classified as–Standardized, full cream, toned, double toned, recombined, and
skimmed on the basis of fat% and SNF%.
1) Full cream milk – It is much thicker and creamier and contains high amount of fat. Ideal for
children, growing teenagers and body builders.
2) Standard milk – It contains balanced proportion of cream content. Useful for drinking as well
as making tea, coffee and lassi.

31
3) Toned milk- It contains the same amount and type of nutrition as whole milk does, only
minus the fat-soluble vitamins. It restricts the body from absorbing cholesterol from the milk to
quite an extent.
4) Double toned milk- Its consistency is much thinner than toned milk, deal for those who are
trying to maintain weight and is recommended for heart patient.
Also Powdered milk is also prepared in Dehradun branch of Aanchal.
Milk Powder is two type:
1) Skimmed milk powder (SMP)-no or very low sugar.
2) Whole milk powder (WMP)-more sugar used in baby food.
Table : Nutritional value of milk:
Type Colour
of
packet
Fat%
(max)
SNF%
(Min)
Energy
(k cal)
Protein
(g)
Carbohyd
rate(g)
Fat(g
)
Ca(mg)
Full cream milk Green 6 9 89 3.3 5.1 6.0 150
Standard milk Red 4.5 8.5 73 3.1 4.8 4.5 142
Toned milk Blue 3 8.5 59 3.1 4.8 3.1 142
Double toned
milk
Yellow 1.5 9 46 3.15 5.1 1.5 150
Skimmed milk/
janta milk
Violet 0.5 8.7 33 3.2 4.9 0.1 145

32
6.3.1. Pasteurizationof Milk:
 Pasteurization is the process of heating milk up and then quickly cooling it down to
eliminate certain microbes for increasing shelf life.
Process:
 Stored chilled milk is pumped to pasteurization unit.
 Milk is heated at 74-75°C by process of conduction in pasteurization unit which contains
heating zone, hold tube and cooling zone.
 Vitamin A and D are also added to milk to increase nutritional value of milk.
 The pasteurized milk is lastly stored in containers of 10,000 L capacity.
 Pasteurized-stored milk is forwarded to packing unit and for further processing.
 Pasteurization is done at 2 temperatures-
1. HTST (High temp, short time) -72°C /15 sec
2. LTLT (Low temp, long time) -63°C/30 min.
Fig.: PASTEURIZATION UNIT AND STORAGE CONTAINERS
6.3.2. Homogenization:
It refer to the use of homogenizer, which break down milk fat into uniform particle
(2<=u). This ensures that there won’t be visible cream separation, even after 48 hours of
storage.

33
6.3.3. Standardization:
It refers to adjustment (lowering or raising) of fat or SNF of milk to a desired level to
meet the legal standards by adding cream or milk powder.
For standardization of single component, Pearson’s square method can be used.
6.3.4. Packing of Milk:
 Packing of dairy product is done for environment.
 Most of the products are packed in plastic (food grade), either pouches or cups.
 Milk is packed in packet made up of 3 layer and having a thickness of 55µ 5%.
 The material is made up of High Impact Polyethylene (HIP)
 The cost for milk packet is approximately Rs 150/kg.
Fig.: PACKING UNIT
6.4. Other Aanchal Products:
Milk is the major product sold from Nainital Milk Producers Cooperative Ltd. The cooperative
also prepare-
 Curd
 Paneer
 Ghee
 Butter
 Buttermilk
 Cream
 Yogurt

34
 Khoya
 Chocolate, Bal mithai are also prepared on demand basis.
6.4.1. Curd:
Curd is a dairy product obtained by lactic acid fermentation of milk. It is generally consumed in
its original form. It has been reported that lactic acid culture increases the vitamins and free
amino acids (fat) content in curd.
Curd Culture
 Bacterial cultures is known as starters use in the manufacture of curd/dahi. The starters
is added to the product and allowed to grow under controlled conditions, resulting in
fermentation.
 Fermentation of lactose by these bacteria produces lactic acid which acts on milk
protein to form curd which drops the pH and has a preservative effect.
Culture usedin Aanchal dairy are –
Lactococuslactis, Streptococcus thermphilus, Lactobacillus bulgaris
Preparation:
 Standardization of the milk is done while pasteurization.
 The pasteurized-stored milk is transferred in special curd making tank of capacity 600 L.
 The pasteurized milk is further heated up to 90°C.
 Then the boiled milk is transferred to 2 tanks of 300L capacity each.
 The curdling culture @ 1kg/600L is added in the tank both tanks equally.
 Then the culture mixed milk is transferred through pipelines to packing unit.
 The culture mixed milk is packed in cups of 100gm, 200gm, 400 gm as per demand.
 After packing in cups, it is stored in hot room at 40°C for 2 hrs.
 After 2 hrs. the filled cups are transferred to cool storage at 3-5°C for 8 hrs.
 When then milk gets coagulated and curd is prepared, it is dispatched for sale to
market.

35
Fig.: CURDLING TANKS Fig.: PACKING UNIT
LASER PRINTING:
 It is an electrostatic digital printing process. It produces high quality text and graphics by
repeated passing a laser beam.
 It is used in printing the manufacturing date, expiry date and price of product.
 The date to be printed is fed manually to the machine which can be altered according to
the need.
Fig.: LASER PRINTING IN CURD
Transportation:
The transportation of milk in crates is done as follows-
400gm -15 packets /crate

36
200gm -30 packet / crate –highest demand
100gm – 56 packet / crate
6.4.2. Yogurt:
It is made by blenching fermented milk with various ingredient that provide flavor and colour.
Bacterial culture –Streptococcus thermophiles
Lactobacillus bulgaricus
Preparation:
1. Adjust milk composition and blend ingredients.
2. Pasteurize milk at 185℉/ 85℃ for 30 min or at 203℉/ 95℃ for lesser time.
3. Cool the milk to 108℉/42.2℃, until a pH of 4.5is reached (it is the ideal growth temp for
starter culture, which is added in the milk.
4. Yogurt is cooled to 7℃to stop fermentation process.
5. Add desired fruits and flavors:
 Pineapple and mango flavored yogurt is prepared in the Aanchal dairy
 The fruit are cut in small pieces and the juice is extracted. The dried fruit pieces are
added in yogurt.
6.4.3. Paneer:
It is the indigenous variety of acid coagulated milk solids. The process of paneer preparation
to packing is fully manual.
Preparation:
 The pasteurized-stored milk is boiled @ 80°C in paneer preparation section in
containers.
 After boiling milk, citric acid (200ml of citric acid in 100 lit. of milk) is added to the boiled
milk.

37
 After acid is added and little stirred, if required, acid is removed along with the liquid
part by filtering the milk with a muslin cloth.
 Then collect solid part obtained on muslin cloth.
 The solid part (paneer) is placed under empty milk cans to pressurize it for removal of
excess water.
 Kept under cans for about 15 mins, then cut into cuboidal shapes & placed in cold
water.
 Finally packing is in packets of 200gm and 1kg is done manually after weighing as per
demand.
6.4.4. Butter:
Butter is made by churning of fresh or fermented cream /milk to separate the butterfat
from buttermilk. It is a water in oil (W/O) emulsion resulting from inversion of cream, where
the milk proteins are emulsified. Butter fat is a mixture of triglyceride , triester , freefatty acid.
Preparation:
 Butter is prepared from cream.
 The cream undergoes churning process inside the churner where milk is heated with
water.
 This churning process takes place at 9-10°C and after butter preparation, water and SNF
are separated.
 So butter contain good amount of fat approx. 80.5%.
 After separation, butter is sent for packing.
 It is packed in the 15gm, 100gm, and 500gm packets in the markets.
 Butter is packed manually using a wooden board called scoth hand.
6.4.5. Ghee:
Ghee is a class of clarified butter. It is prepared by simmering butter. The colour and texture of
ghee depends on the quality of butter, milk source and duration of boiling.

38
Preparation:
 The prepared butter is used to prepare ghee.
 Butter is heated @ 30℃ in containers and when it comes in liquid form it is clarified in
clarification unit.
 After clarification the prepared ghee is received in cans and sent to packaging unit.

39
7. COMPARATIVE SALE REPORT FROM 1st
Jan 2019
TO 31st
Jan 2020
Source:-AanchalComparativesalereport1st
Jan 2019 TO 31st
Jan 2020
S.NO. Particulars Year 2019 Year 2020 Growth
%
1 Milk Standard 1438532 1338664.2 - 6.94
2 Full Crème 181764 201845 11.05
3 DTM 500 ml 6511 7940.5
21.96
4 Milk Tonned 500
ml
10985 15071.5 37.20
5 Milk Tonned 1000
ml
2642 2454 -7.12
6 Skim Milk 40808.4 40877.1 0.17
7 STM Milk 1000 ml 743039.5 962208 29.5
Total 2424281.9 2569060.3 5.97

40
Jan 2019 TO 31st
Jan 2020

41
Jan 2019 TO 31st
Jan 2020.

42
8. CLEANING-IN-PLACE (CIP) & EFFLUENT TREATMENT
PLANT (ETP)
Steps for CIP:-
1. Alkali Solution
2. Hot Water
3. Acid Solution
4. Hot Water
5. Alkali Solution
6. Cold Water
Preperationof solutions:
• Alkali Preparation
2.5 to 3 kilograms of Caustic is mixed with 700-800 litres of potable water.
• Acid Preparation
35-40 litres of Nitric Acid are mixed with 700-800 litres of potable water.
Timings for CIP:
• Done before and after each batch of milk processing.
• Done four times a day.
• Morning shift CIP involves cleaning of whole plant and takes one hour.
• Other CIP’s take half an hour each.
• Potable water treatment is done at the end of the evening shift.

43
EFFLUENTTREATMENTPLANT
• Anaerobic Biological Systemis the mode of Effluent Treatment being used in the dairy
plant at Lalkuan.
• Capacity of ETP is 20000 litres per day.
Steps for CIP:
1. Waste water
2. Bar Screen
3. Fat, oil, grease skimming tank
4. Equalization Tank
5. Aeration Tank
6. Anaerobic Lagoon Tank
7. Outlet
Fig.: EFFLUENT TREATMENT PLANT

44
9. FINDINGS AND SUGGESTIONS
Findings:
The location of dairy is very best situated as it is located at the center of the nearby
areas and chilling centers from where the raw milk is procured. also the people working there
are punctual, laborious, dedicated and helpful. The dairy’s processing unit operates 24x7 hrs.,
even on the holidays employees work in shifts. One of the main concerns of the dairy is to
maintain sanitation inside the processing area and also among the people working there. The
working algorithm and system is very excellent to make the final processed products to reach
public on time. One drawback of the AANCHAL dairy which I found is the loss of processed milk
during transportation must be taken into consideration and reduced.
Suggestions:
 Focus on strengthening the indigenous breed to help significantly enhance productivity.
 Ensure good prices of milk to farmers.
 Encourage farmers for good feeding, hygienic milking & planned infrastructure housing
for milking animals.
 Provide effective services related to quality feed, germplasm and vet. Services.
 Increase number of member farmers.
 Decrease losses - due to poor management at village levels, which leads to heavy losses
and ultimately loss in faith.

45
10. CONCLUSION
 During my training period, I Iearned about How an industry process maybe controlled by
automation system.
 About the vivid process and infrastructure by an industry to produce according to public
interest.
 I learned about the different sources of the dairy for procurement of raw milk and chilling
centres.
 I learned about the complete processing of milk from receiving the milk and weighing till its
final processed products reaches consumers.
 I learned about the processing of different milk products i.e. curd, butter, paneer, ghee etc
in bulk.
 Also I learned about different departments which manages the complete working of the
dairy unit.
 The training helps me to develop social aspects of public meeting and people interaction.
 The training gave me the exposure to learn about the know-how of such a cooperative
society so that I can use this knowledge in coming future if willing to setup or work in any
such firm.
 Overall the training gave me an opportunity to gain a lot of knowledge and develop
practical skills.

46
11. REFERENCES
1. www.ucdfAanchal.org
2. Sharma, M.L.; Saxena, R.; Mahato, T. and Das, D. 2007. “Potential and Prospects of
Dairy Business in Uttarakhand: A Case Study of Uttaranchal Cooperative Dairy
Federation Limited”. Agricultural Economics Research, 20: 23-25p.
3. Rajendra, K.and Samarendu, M. 2004. “Dairy Co-operatives and Milk Marketing in
India: Constraints and Opportunities”. Journal of Food Distribution Research, 35(2): 34-
35p.

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