MOTHER DAIRY

FRUIT AND
VEGETABLE
PVT.LTD
PATPARGANJ,
DELHI-110092
 Date of Submission: 30-12-2016

In
Plant Training
Report

Submitted To

Sanjay Gandhi Institute of Dairy Technology,

Jagdeopath, Patna -14

B.Tech Dairy Technology Submitted By:

Bipin Kumar
 Table of Contents

1. Preface
2. Acknowledgement
3. Declaration
4. Executive Summary
 About the industry
 About the NDDB
 About the company
5. Fundamental knowledge of Milk
6. MILK RECEPTION
a) GRADING
b) SAMPLING
c) WEIGHING
d) TESTING AND
e) UNLOADING
7. BULK VENDING MILK
a) Milk Processing Plant
b) Ozonation Plant
c) UV Plant
d) CIP
e) Plant Automation System
8. ENGNEERING (Production Utilities)
a) Boiler Section
b) Refrigeration Section
c) Air Compressor and Air Dryer
d) Electrical Section
e) Effluent Treatment Plant
9. ECO-FRIENDLY POLICIES
a) Solar Panel
b) Rain Water Harvesting
c) ETP
10. CONSUMER AWARENESS
11. ICE-CREAM PLANT
Preface

As a Dairy Engineering Student our aim should not be

only to learn theoretical concepts in the classroom, but it becomes more
important as how we apply those concepts in practices.
In present scenario the world is developing so fast, and thus the technological
and application theory is changing at a greater pace. The study inculcates
students to think out of the box, rather than emphasizing within the box. We
are coming across many modern theories and implementation of machineries,
to start new business. We must have the knowledge of theories and practical,
through it, the student can able to know about how to apply their mind in the
business world.
This program of industrial training is to create awareness about the industrial
environment amongst the students. Such industrial training also plays vital role
in B. Tech. Dairy Program.
The importance of industrial visit and project preparation has been widely
accepted in the educational institutions. Thus knowing the importance of such
practical training ,our college is providing with such a program to enhance the
overall development of the students.
“MOTHER DAIRY” gave me the golden opportunity to carry out my training in
such a great organization. I have prepared the detail report regarding the “In
Plant training at Mother Dairy Plant”. I have tried my best to collect all
necessary information relating to the Training Report .
Acknowledgement

At the outset of my five month long In-plant training, I take this long
awaited moment of expressing our sincere and heartfelt gratitude to MOTHER
DAIRY for giving me the opportunity to do our competence training at your
esteemed factory. I am left with no words to express my thanks for the
gracious favour and valuable experiences.

It gives me immense pleasure to pass on my special thanks to Shri TAPOMAY

SAH General Manager, Mother Dairy Unit, Shri PARKASH GEORGE GM-HR,
Shri SHAILENDRA KUMAR HR Manager and Our dean Dr. S.B VERMA for
having permitted me to do the In-plant training.

My experience at the plant was endeavor of many people and hence they are
the torchbearers through whom I could see the glimpse of the working style
and scenario prevalent in the dairy plants.

I am very thankful to all the suggestions and technical knowledge and skills
which was embodied into me by the valuable support of employees at mother
dairy as this will be of immense help and importance for me in our future to
come.

I should express my most valuable thanks to all the Section In charges, Lab
Assistants, Technical, Non Technical staff, i.e. all who helped me in any way for
their working tips and practical knowledge.

I am also very obliged to my co trainees and guardian, as without their help

this manuscript could not have seen the light of the day.
Declaration
I, Bipin Kumar, hereby declare that the report on “MOTHER DAIRY” entitled “In
Plant training at Mother Dairy Plant” is a result of my own work and my
indebtedness to other work publications. Correction if any will be duly
acknowledged.

Place: Patna Bipin Kumar

Date: 30th Dec 2016 Signature of Applicant

Executive Summary

The report consists of the details on Mother Dairy India Ltd. It is one of the
most effluent company’s of India for processed milk and milk products. The
main aim of it is the welfare of the society by providing quality milk to its
consumers at an affordable price. This report also contains the detailed
information about the rise in population with respect to rise in dairy industry.
The dairy industry has being studied in details, so that can be converted into
information which can be used by mother dairy for strategies its marketing
advertisement areas.

It has various functional departments such as the Production, Engineering,

Human Resource, Finance, Marketing, Purchase and stores, Quality Assurance,
Dispatch and Logistics.

This report is descriptive in nature but contain vital data of the capacity of
Indian dairy industry and competitors to Mother Dairy. This report will help
Mother Dairy to make Strategies for their long term objective.

This will enable the company to take appropriate decision as needed to

increase as well as to retain its customers in the markets. The data has been
analyzed by presenting it in the form of graphs and tables and based on it ; the
interpretations have been made for the same. The results and findings have
also been made for the organization to help management in their decisions.
Lastly, the recommendations have also been made for the organization.
About The Dairy Industry
Introduction:-

The dairy sector in India has shown remarkable development in the past
decade and India has now become the world largest producer of milk and
value added milk products. The dairy sector has developed through co-
operative in many parts of the country. During 1997-98, the States (Delhi
Haryana-U.P) had 17574 million tones production capacity, which rose to
33379 million tons by the year 2016. In addition to many processing plants,
many government co-operatives societies and chilling centers have being
made.

About the Indian Dairy Industry:-

In India, the dairy sector plays an important role in the country’s socio-
economic development and constitutes an important segment of the rural
economic.

Dairy industry provides livelihood to millions of homes in village, assuring

supply of quality of milk and milk products to both urban and rural areas. With
view to keeping pace with the country’s increasing demand of milk and milk
products, the industry has being growing rapidly.

According to research report “Indian Dairy Industry Analysis “ India is world’s

largest milk producer accounting of around 17% of the global milk production.
Besides, India is also one of the largest consumer of milk and milk products.
Due to rich nutritional qualities, the consumption of dairy products has being
growing exponentially in the country, and considering such facts and figures,
my study anticipates that the milk production in India will grow at a CAGR of
around 4% during 2015-20.

With rising use of dairy product, the secondary market of dairy product has
been flourishing, my report observed.

Covering the necessary aspects of the Indian dairy industry, the study
facilitates knowledge about its current market scenario and future growth.
Analyzing the past and current states of the industry the report tries to find out
how trends like the entry of international companies and packaging are
attracting the consumers and heeding towards further growth in the market.
This way, it present a clear picture of the direction, in which the industry is
likely to proceed in the coming years.

The government is taking several initiatives and running plans and programs
like National Dairy Plan and Intensive Dairy Development Program to meet the
growing demand for milk in the country. Our report talks about such schemes,
and government regulation to present an objective and balanced picture of the
dairy industry.

The study also discusses the opportunities and strengths of the dairy market in
a complete SWOT analysis, and provides an insight into the competitive
landscape. We hope that our comprehensive research will help clients align
their business strategies as per market dynamics, and make sound investment
decisions.
About NDDB
 About NDDB
National Dairy Development Board (NDDB) was founded to replace …

-Exploitation with empowerment

-Tradition with modernity
-Stagnation with growth

An instrument for the development of India’s rural transforming dairying

into an instrument for the development of India’s rural people. Prior to
NDDB, the milk market was vastly governed by local private dairy and these
dairies were neither producing milk nor they were animal breeder and
hence the law of demand and supply was unheard by those intentions were
purely to make more money from both the sides – that is from producers of
milk (farmers) and consumers .
The NDDB was created to promote, finance and support producer-owned
and controlled organizations. NDDB’s efforts are co-operative principles and
Anand .

Philosophy of NDDB:-
- Co-operation is the preferred form of enterprise, giving people control
over the resources through democratic self governance.
- All beneficiaries, particularly women and under privileged must be
involved in co-operative management and decision making.
- Technological and evaluation search for better way to achieve the
objective in the dynamic market.

The NDDB was created in 1965, fulfilling the desire of the Prime Minister of
India – the Late Lal Bahadur Shatri- to extend the success of the Kaira Co-
operative Milk Producer Union (Amul).

That success combined the wisdom and energy of farmer with professional
management to successfully capture liquid milk and milk product markets
while supporting farmer investment with inputs and services.

NDDB began its operation with the mission of making dairying vehicle to a
better future for millions of grassroots milk producers. The mission achieved
thrust and direction with the launching of “Operation Flood “, a program
extending over 26 years and which used World Bank loan to Finance India’s
emergence as the world’s largest milk producing nation. Operation Flood’s
third Phase was completed in 1996 and has to its credit a number of
significant achievements.
As on March 2001, India’s 96,000 dairy co-operatives integrated through a
three tier co-operative structure – “The Anand Pattern”, owned by more
than ten million farmers, procure an average of 16.5 million lits of milk
every day. The milk is processed and marketed by 170 milk producers Co-
operative unions which, in turn, own 15 state co-operative milk marketing
federations.

NDDB also promotes other commodity – based co- operative allied

industries and veterinary biological on an intensive and nation wide basis.
Shri Dilip Rath serves as the Chairman of NDDB; Dr. Vargheses Kurien was
the founder Chairman.
About the Mother Dairy

Mother Dairy was set up under the operation flood project on second
December 1974. It is equipped with latest technology. Products are prepared
as per the FSSAI Standards.

The dairy was established on behalf of the Govt. of India, Ministry of

Agriculture (Dept. of Animal Husbandry and Daring). Mother Dairy is being
managed by NDDB as a subsidiary unit retaining its independent character.

For the purpose of managing the dairy NDDB appoints managing committee.
All the policy matters decided by the management committee but the
execution of all the policy decision and management of dairy rests with
General Manager.

The Delhi, Mother dairy is the first & largest liquid milk plant in Asia evolved as
an integral part of the operation flood programme, they procure milk in bulk
and sell it through the bulk vending booths.

• Mother dairy was the first trusted milk brand of India.

• It was one of the largest liquid milk plants in Asia.

• It was selling more than 30 lakh liters of milk per day, out of which
approximately 10 lakh litres of milk is sold as bulk vended milk and
another 20 lakh litres of milk is sold in sachets in five different variants
across six states.

• Toned

• Full cream Milk

 • Standardized Milk

• Toned Milk

• Double toned Milk

• Skimmed Milk

• Cow Milk

Mother dairy, Delhi is ISO- 9001:2008&14001:2004.ISO 22000-2005;ISO/TS

22002:2009&additional FSSc 22000. BS OHSAS 18001:2007,iSO
50001:2011.mother dairy started diversifying by marketing ice-creams through
its milk shops, fruit & vegetable shops, select retail outlets and pushcarts.

Mother dairy offers a range of delicious flavours of ice-creams to consumers at

very competitive prices.

In order to cater to the diversified need of the consumers, mother dairy has
launched other dairy products.

QUALITY POLICY
Our commitment is to excellence. The evolving needs of our customers
drive our continuous innovation in product development, application of state-
of-the art technology and selection of appropriate processes to be used by our
employees and our vendors. To ensure that we are second to none:

● We maintain a vibrant work environment that encourages excellence.

 ● We empower our people that lead to continuous improvements in
our processes and systems.

● We choose such processes that ensure quality at competitive price

while protecting the environment, in which we work and live.

● We apply HACCP (Hazard Analysis Critical Control Points) principles

for safety of our products to customers.

● We shall constantly strive to be leaders in the dairy industry in Delhi,

in India and in the World.

ENVIRONMENTAL POLICY
We are committed to be a leader in Dairy Industry in India by being a
benchmark in environment protection.

We shall continue to improve our environmental performance by:-

● Adopting processes, procedures and systems for clean production,
pollution prevention and continual improvements in all our activities.
● Optimizing resource utilization including energy and water.
● Complying with applicable environmental regulations and legislation.
● Continuing distribution of milk through environment friendly vending
systems.
● Maintain green environment through horticultural activities.
● We pledge ourselves towards providing quality and safe products under
clean and hygienic environment.

MOTHER DAIRY VISION

With total commitment and teamwork, we at Mother Dairy shall strive
to delight our customers with quality products and services.

We shall create an environment where employees feel happy to work.

Through innovation, consistent learning and continuous improvement, we shall
achieve sustained growth and excellence and provide remunerative returns to
farmers and other stakeholders.
MOTHER DAIRY MISSION
“We are the market leader in fluid milk in Delhi. Our mission is to retain the
leadership and further serve our customers in and around Delhi by providing
quality milk and select dairy and food products.

We shall strive to delight our customers by providing regular and timely

services at convenient points under clean and hygienic conditions, with a
product mix for different income segment. We shall create an environment of
commitment and teamwork where employees feel happy to work.

By innovation, continuous improvement, training and development and most

efficient use of resources we shall achieve consistent and sustained growth and
provide remunerative returns to farmers and other stakeholders.”
 Fundamental knowledge
of Milk
According to FSSAI, Milk is the
secretion derived after complete milking of healthy
milch animal, excluding that obtained within 15 days
before or after 10 days of calving.
Composition of Milk
1. Milk Fat

Milk fat is the mixtures of 19 fatty acids. The bulk of fat in milk exist in the
form of small globules with size approx. 0.1 to 22microns. It is an oil-in-water
type emulsion.
2. Proteins
Proteins are the most complex organic substances. They are vital for living
organisms as they constitute an indispensable part of the individual body
cell. The milk proteins consist of Casein, Lacto globulin and Lacto albumin. It
is in colloidal state. Casein is only found in milk. It is easily coagulated by
heat treatment.
3. Water
It provides the medium in which all the milk constituents are either
dissolved or suspended. Most of it is free and only a small portion is in
bound form, being firmly by protein and phospholipids.
4. Lactose(Milk Sugar)
It is found only in milk. It exist in true solution phase and is fermented by
LAB to yield lactic acid. It is very important for cultured milk products. It can
also cause souring in milk and its products.
5. Mineral Matter
Although it is present in small quantity, it is very essential for human body.
These are mostly salts like Mg, Na, P, N etc. It influences physico-chemical
properties of milk and also effect the nutritive value.
6. Phospholipids
There are three types of phospholipids (Lecithin, Cephalic and
Sphingomylein). Lecithin is important constituent as it helps in the
formation of outer membrane of fat globules.
7. Pigment
 There are two type of pigment present in milk, Fat Soluble and Fat
insoluble. Carotene is fat soluble and is responsible for the yellow colour of
milk. The other two are Xanthophylls and riboflavin. Carotene also acts as
an anti oxidant and as a source of Vitamin A.
8. Milk Enzymes

The important milk enzymes and their specific action are

as follows.
- Anise (diasterase) Starch

- Lipase Fat splitting, leads to rancid flavor

- Phosphatase It is capable of splitting certain phosphoric esters.
- Protease It is capable of splitting proteins.
- Catalase decomposed hydrogen peroxides.

9. Vitamins
Vitamins are present in minute quantities in milk or any other food but
play a very important role in vital functioning of human body. There are
25 vitamins present in milk. These are fat soluble e.g. Vitamin. A, D, E, K.
apart from fat soluble there are water soluble vitamins as B-complex(B1,
riboflavin or B2, niacin, pyridoxine or B6.)

Role of milk in human life

Milk is one of the most complete food available in nature for human
consumption. Milk contains all nutrients in balanced proportions to meet the
demand of humans. It is not only necessary for children but it is every essential
for adults too. Milk proteins are one of the most high quality proteins. It is
essential proper growth of body. Casein, the milk protein, is only found in milk.
Milk contains lactose (milk sugar) which is only found in milk and on hydrolysis
gives galactose and glucose. Lactose on fermentation gives butter, cheese and
dahi, which have high nutritive value and thus is very important for human life.
 1 Liter of Cow’s milk gives 720 Calorie (3000J) of energy
 1 Liter of Buffalo’s milk gives 1100 Calorie (4600J) of energy.
 1 gm of milk fat gives 9 Calorie of energy.
 1 gm of Protein gives 4 Calorie of energy
 1 gm of Carbohydrate gives 4 Calorie of energy

Most milk is composed of 80 to 90 percent water. The remaining 10 percent

consists of an abundance of the major nutrients needed by the body for good
health, including fats, carbohydrates, proteins, minerals, and vitamins.
Cow milk typically contains about 3.5 to 5 percent fat, which is dispersed
throughout the milk in globules. In addition to providing milk’s characteristic
taste and texture, fat supplies vitamins A, D, E, and K, as well as certain fatty
acids that the body cannot produce on its own.

Lactose, a kind of sugar found only in milk, gives milk its sweet taste. Making
up about 5 percent of milk’s content, lactose is a carbohydrate that is broken
down by the body to supply energy. Infants digest lactose easily, but many
adults, especially those of Asian and African ancestry, have lost some of their
ability to digest this sugar. When these adults drink milk, they often suffer
gastric distress and diarrhea.

The most important protein in milk is casein, accounting for 80 percent of milk
Protein-Casein is a complete protein, meaning that it contains all of the
essential amino acids, which the body cannot manufacture on its own. Casein
molecules and globules of fat deflect light rays passing through milk, giving
milk its opalescent appearance. Other proteins present in milk include albumin
and globulin.

Milk contains many minerals, the most abundant of which are calcium and
phosphorus, as well as smaller amounts of potassium, sodium, sulfur,
aluminum, copper, iodine, manganese, and zinc. Milk is perhaps the best
dietary source of calcium—one liter (about 1 qt) of milk supplies as much
calcium as 21 eggs, 12 kg (26 lb) of lean beef, or 2.2 kg (5 lb) of whole wheat
bread. Milk is an excellent source of vitamins A and B2 (see riboflavin). All
other vitamins are present also, but in lower doses. Vitamin D is typically
added to commercially sold milk. Vitamin A, which is found in the globules of
fat, is removed when fat is skimmed away to make low-fat or skim milk.
Generally, vitamin A is replaced during the production of commercially sold
low-fat milk.
 RECEPTION

PROCESSING OF MILK
AT DAIRY BEGINS WITH MILK RECEPTION. It is well known that the sanitary
quality of milk on the receiving platform/dock depends on its background on
the farm, viz., healthy cows, clean milk production, clean utensils, freedom
form colostrum, prompt cooling, and refrigerated transport. However, there is
need form systematic and thorough inspection of all milk supplies every day by
conscientious an experienced milk graders.

When milk is received at the Milk Plant/ Dairy, it should be at 50C or below.
The milk should be clean, sweet, of pleasant flavour, free from off-flavours and
reasonably free from extraneous material. Contamination with antibiotics,
pesticides, and other chemicals or metals is highly undesirable. No abnormal
milk should be accepted. Acid development is objectionable, for not only does
it indicate an excessive bacterial count, but it also reduces the heat-stability of
milk.

The operation performed during reception of milk at the dock lab is broadly
classified into following categories:-

1. Grading
2. Sampling
3. Weighing
4. Testing
5. Unloading

1. Grading:- This refers to the classification of milk on the basis of quality,

for price-fixing purposes. It is well known that the quality of the finished
product depends on that of the raw material used. The milk grader is the
key man for the proper selection of milk. The Principle of grading is
based on Organoleptic (sensory) tests, such as those for smell (odour),
taste, appearance and touch; acidity; sediment, etc.. These are included
under platform tests.
Actually the grading should have been done at the milk
collection-cum-chilling centre. As the milk should be cold (50C or below),
it is not possible to detect off-odours. Only the appearance can be
noted, as testing of raw milk is usually avoided. After thoroughly mixing
it for 5-10mins, a sample is taken for laboratory testing.
Note:-The term ‘Platform Test’ includes all those tests which are performed to check the quality of
the incoming milk on the receiving platform, so as to make a quick decision regarding its
acceptance/rejection. They are performed on each tanker of milk with the object of detecting milk of
inferior or doubtful quality, so as to prevent it being mixed with high grade milk. Sometimes the term
‘Rapid Platform Tests’ is used to refer mainly to the Organoleptic or sensory tests which take very
little time to perform.

2. Sampling :- The method of sampling of milk from storage tanks and road
tankers is largely governed by storage/transport conditions. It is,
therefore, difficult to lay down any rigid procedure for the sampling, but
the following is recommended:

Fig. Sampling from storage tanks and rail tankers

In all cases, the milk in the tank/tanker shall be thoroughly mixed

by a sufficiently large plunger, a mechanical agitator or by compressed air; the
uniformity of the samples being determined, when necessary, by mixing till
such time as complete agreement is obtained between samples taken at the
manhole and at the outlet cock in respect of fat and total milk solids.

NOTE- When a plunger is used for mixing the milk in road milk tankers, a
convenient and satisfactory method is to insert the plunger in the man-hole,
the operator sitting or standing astride (with the legs apart on each side) on
top of the tanker. The plunger is thrust forward and pulled back, thrust
downwards and pulled back and thrust backwards and pulled back. The cycle
of operations should be repeated for at least 15 minutes.
 Fig. Plunger

After proper mixing of the milk, the sample may be taken from the tank,
removed through the stopcock in the tank door, or from a valve on the
discharge line from the tank when it is being emptied.

Treatment of Milk Sample on Arrival at the Laboratory before Analysis

Warm the sample in the bottle to about 40°C in a water bath and mix
thoroughly. Cool to 26° - 28°C. Leave aside the sample for about 4 minutes
after mixing to allow air bubbles to rise and escape. After that, mix the sample
by inverting the bottle 3-4 times and start analysis.

3. Weighing:-The tank is mounted on the scales and weight is recorded in

computer and a receipt is provided to the driver for unloading the tanker
at the reception bay. After empting the tanker driver need to weigh his
tanker again and the difference in weight is calculated which give the
quantity of milk received at the plant. A careful observation is taken
during weighing and unloading of milk .

Fig. Weighing of milk tanker on scale dial

4. Testing of milk:- Testing of milk is done at two places –(a) The Dock Lab
(b) The QAP(Quality Assurance-Procurement) Lab.
A. The Dock Lab:- It is a place for rapid/platform test for acception or
rejection of milk quickly. It has a very important place in dairy
industry.
At Mother Dairy the milk has to pass by 23 quality tests at the dock
for acception of milk. It has developed such a system of network of
milk reception at the dock that unhygienic milk cannot enter into the
network. They have successfully identified the CCP and OPRV
applying HACCP principle to set the critical limit and the activities
before and after the hazard (if occur). They also maintain record of
those activities and the like using SAP (a software for recording data
online that everyone can access with a valid user id and password).
Thus we can say that the milk after reaching the Mother Dairy under
good condition is remain Fresh, pleasant, and healthy for human
consumption.

The tests performed at the dock lab are:-

1. Seal and Check for cleanliness

2. Presence of foreign matter
3. Temperature
4. Organoleptic evaluation
5. Clot on boiling test (COB)
6. Alcohol test
7. Neutralizer test
8. Acidity test
9. Ammonia compound test
10.M.B.R.T
11.Urea test
12.Starch and cereal test
13.Salt test
14.Sugar test
15.Glucose test
16.Maltodextrin enzymatic test
17.Detergent test
 18.Sodium ion test
19.R.M Value
20.B.R Value
21.Fat % test
22.Protein % test
23.SNF % test
24.Sorbitol test
25.Added SMP
26.Glycol test(chilling agent used in PHE)
27.Hardness of water(boiler water, feeder water, softener water,
reservoir water, UV water)
28.Formalin Test (40.0% used as a preservative of milk sample)

B. Quality Assurance Procurement Lab(QAP Lab):- The QAP lab is

accredited with NABL. NABL is a society which provides accreditation
recognition of the technical competence of a testing, calibration or
medical laboratory for a specific task following ISO/IEC 17025:2005,
ISO 15189:2007 Standards. It is associated with Asia Pacific
Laboratory Accreditation Corporation (APLAC), Mutual Recognition
Arrangement (MRA), International Laboratory Accreditation
Cooperation (ILAC).
The role of QAP Lab is to ensure that products are
within the well defined and accepted standards thereby protecting
the legal and health rights of consumers and financial interests of
producers / manufacturers. Here the raw milk as well as pasteurized
milk is tested for its quality. In addition to this various milk products
such as SMP, WMP, white butter, Butteroil, Ghee, Table butter, dahi,
etc. is also tested.
The Manual Method for Analysis of milk and milk products is
as follows:-

Manual Method for Analysis of milk and milk products

[A] LIQUID MILK:-

1. Sampling of Milk
2. Detection of Adulterants in Milk
a) Detection and Quantification of Cane Sugar
b) Detection and Quantification of Starch in Milk
c) Detection of Added Urea in Milk
d) Detection of Ammonium Compounds in Milk
e) Tests for Presence of Sulphates in Milk
f) Detection of Sodium ions in milk
g) Detection of Presence of Foreign Fat in Milk
 h) Detection of Neutralizers in Milk
i) Test for Presence of Anionic Detergent in Milk
j) Test for Presence of Skimmed milk Powder in Natural milk (Cow,
buffalo, goat, sheep)
k) Test for the presence of Sorbitol in Milk
l) Test for Presence of Formalin in Milk
m) Test for Presence of Hydrogen Peroxide in Milk
3. Other Tests for Chemical Analysis of milk
a) Alkaline Phosphatase Test for Checking Efficiency of Pasteurisation in
Liquid Milk
b) Determination of Total Solids (Gravimetric method)
c) Determination of Fat in Milk
Method 1. Gerber Method

Method 2. Rose-Gottlieb Method

Method 3. Acid Digestion Method (Werner Schmidt Method)

d) Protein Estimation
Method 1. Pynes Method
Method 2. Kjeldhal method
[B] SMP/WMP:-
a) % fat
b) % Moisture
c) Insolubility Index
d) Scorched Particles
e) Ash(on dry basis)
f) Titrable Acidity(% LA)
g) Rosalic Acid Test
h) %Protein (on SNF basis)
i) Sodium ions(on 8.5% SNF basis)
j) Bulk Density

[C] WHITE BUTTER:-

a) %Moisture
b) %Milk Fat
c) %Curd
d) Titrable Acidity(%LA)
[D] BUTTEROIL/GHEE:-

a) %Moisture
b) Free Fatty Acid (as %oleic acid)
c) BR Reading
d) PeroxideValue

[E] OTHER MILK PRODUCTS:-

a. Paneer
b. Dahi/Misti Doi
c. Lassi
d. Flavoured Milk

[A] LIQUID MILK

1. Sampling of Milk:- Milk samples are obtained from tankers, silos,

vending outlets and external customer.

a) Incoming Milk Tankers(Federation Tankers):-

 Rinse the dipper and take the milk in a dipper Check the condition of
seals on the tanker valves and manholes. Take out 10 to 15 liters of milk
in a bucket through a small hosepipe or directly from the tanker valve.
 Filter this milk through muslin cloth or plastic sieve provided for the
purpose, check for presence of foreign matter in the milk.
 If milk contains some undesirable matter, drain out some more milk and
check again. If foreign matter is found, reject the tanker.
 If no foreign matter is found, climb on the tanker, check top seals and
check the hygienic condition.
 Open the manhole, check physically for presence of foreign matter in
milk & draw 500 ml Milk sample for BR reading / RM Test etc. and get
the tanker plungered by the helper of the tanker in different direction
for atleast 10-15 minutes to mix the contents properly before sampling
the milk.
 Check the milk temperature.
 Take one plastic bottle of 200 ml / 500 ml capacity, for chemical analysis
sample and one sterilized plastic bottle of 85 ml capacity for
bacteriological analysis sample. Write tanker details (tanker no.,
compartment no., temperature and date) on both bottles.
 Rinse the 200 ml / 500 ml bottle twice with milk and then fill it with milk
using the dipper. Likewise rinse the bacteriological sample bottle and fill
it with milk sample. Get the tanker manhole lid closed and take the
sample to Dock Lab.
b) Silos
 Milk samples from the sampling cock after draining 4 – 5 liters in a
bucket and note the temperature. Take one sample for chemical
analysis after rinsing the bottle & the other samples in sterilized
bottles for MBRT, Phosphates test and keeping quality.
c) Distribution Tankers:
 Samples are drawn from filled dispatch tankers parked in the hard
parking bay from valve after draining 2-3 liters milk in a bucket
and note the temperature. Randomly take milk samples /
observations / temperature from top. Take 8 to 10 milk samples in
sterilized bottles for MBRT (Distribution Tankers filled from
different silos).
d) Return Tankers:
1. After the dispatch testing is over, keep all the samples in lab.
Fridge till all returned tankers are received and tested.
2. Draw return milk samples from valve after draining 2-3 liters in a
bucket and note the temperature of milk immediately after Weigh
bridge staff indicates completion of weighment on the remote bell.
Randomly take 3 or 4 samples for MBR test in 85 ml. sterilize plastic
bottle.
3. Check the milk sample physically for any abnormality like
separation, oiling off etc. if observed, inform In charge (Production) to
get the tankers emptied and fill after proper cleaning.
4. Confirm sampling done to weigh bridge on the remote bell.
5. Analyze the sample and compare the results with the dispatch
testing results.
6. If both the parameters (Fat / SNF) in return milk are found less
then 0.02 % in comparison with the dispatch results, then repeat the
corresponding dispatch sample and compare the results. If found less
than .02%, inform the route no./ Tanker. no. to Dairy Control for
sampling and testing the points to which milk was delivered by the
tanker
7. If any of the parameters (FAT / SNF) is found below the legal limit,
then repeat the corresponding dispatch sample and compare the results.
 If found less, then inform the route no./ Tanker no. to Dairy Control for
sampling and testing the points to which milk was delivered by the
tanker.

Testing of Milk Samples:

Specifications for Toned Milk (TM):

Sl.No. Characteristics Requirements

01 Milk fat % 3.05 (min.)
02 Milk Solids not fat % 8.56 (min.)
03 Total Solids % 11.5 (min.)
04 Clot On Boiling Negative
05 Phosphatase Test Negative
06 Rosalic Acid Test Negative
07 Starch Test Negative
08 Sugar Test Negative
09 Urea Test (PPM) 700 (max.)
10 Titratable Acidity% as LA 0.14 (max.)
11 B.R.Reading at 40OC 40-43

Specifications for Mix Milk:

Sl.No. Characteristics Requirements

01 Milk fat % --
02 Milk Solids not fat % --
03 Total Solids % --
04 Clot On Boiling Negative
05 Rosalic Acid Test Negative
06 Starch Test Negative
07 Sugar Test Negative
08 Urea Test (PPM) 700 (max.)
09 Titratable Acidity as LA % 0.1 - 0.153
10 B.R.Reading at 40OC 40-43
11 Mineral Oil Test Absent
 2. Detection of Adulterants in Milk

a. Detection and Quantification of Cane Sugar :-

Qualitative Method:-
Principle:-
Sucrose is absent in milk and its presence in milk indicate adulteration.
Presence of sucrose in milk can be determined by the Modified Seliwanoff’s
Method .Fructose in cane sugar (sucrose) reacts with resorcinol in HCl to give
red colour.
Reagents:- Resorcinol solution-0.1g Resorcinol dissolve in HCl (1:2) i.e.,35ml
concentrated HCl added to 70ml distilled water.
Apparatus :- Test tube, tube stand, beaker 250ml, spirit lamp, tong.
Procedure:-
 Take 3ml of milk in a test tube.
 Add 5ml dilute HCl (1:2) containing Resorcinol.
 Mix well & keep the test tube in boiling water for 5mins.

Observation:- Brick red colour formation indicates sugar test +ive.

b. Detection and Quantification of Starch in Milk:-
Qualitative Method:-
Principle:- It is based on simple technique that starch develop deep blue
colour in the presence of iodine solution.
Reagents:- 1% iodine solution- Dissolve 1g Iodine reagent and 1g KI in
distilled water, tap water.
Apparatus :- Test tube, tong, sprit lamp
Procedure:-
 Take 3ml milk in a test tube.
 Boil & cool under tap water.
 Add 2 drops of 1% iodine solution.

Observation:- Appearance of blue colour indicates the presence of

Starch.

c. Detection of Added Urea in Milk :-

Qualitative Method:-
 Principle:- Urea is a natural constituent of milk and it forms a major part of
the non-protein nitrogen of milk. Urea concentration in milk is variable
within herd. Urea content in natural milk varies from 20 mg/100 ml to 70
mg/100 ml. However, urea content above 70 mg/100 ml in milk indicates
milk containing ‘added urea’. The addition of urea to milk can be detected
by using para-dimethylaminobenzaldehyde (DMAB). This method is based
on the principle that urea forms a yellow complex with DMAB in a low
acidic solution at room temperature.

Reagents:- p-dimethylaminobenzaldehyde(DMAB) solution- In 1lit of Rectified

spirit dissolve 16g p-dimethylaminobenzaldehyde powder and add 100ml of
concentrated HCl.
Apparatus:- Test tube.
Procedure:-
Take 2ml milk in a test tube.
Add 2ml of DMAB solution and mix the contents.

Observation:- Appearance of yellow colour indicates the presence of

urea making the milk unacceptable.

d. Detection of Ammonium Compounds in Milk :-

Principle:- Ammonia is a non protein nitrogen present in the milk, but its
concentration above certain limit indicates the presence of ammonia as an
adulterant.
Reagents:- Nesler’s Reagents- Dissolve 8g of HgCl2 in 150ml of dilute H2O, 60g
of NaOH in 150ml of distilled water and 16g of KI in 150ml of distilled water to
make three solutions. Add HgCl2 solution and NaOH solution and mix well. Then
add KI solution and make the volume upto 500ml. Allow the solution to stand
till it becomes clear and decant to a well stoppered bottle.
Apparatus:- Test tube.
Procedure:-
 Take 1ml of homogeneous milk sample in test tube and add 2ml of Nesler’s
reagent.
 Shake the contents.

Observation:- Appearance of orange colour with brownish tinge or

darker intensity indicates presence of ammonia compounds.

e. Tests for Presence of Sulphates in Milk :-

Principle:- Presence of sulfate salts, which may be added to milk to raise its
SNF level in milk, can be detected by using barium chloride.

Reagents:-
 Barium chloride (BaCl2.2H2O) 5% (w/v) aqueous solution: Dissolve 5.0 g
barium chloride in distilled water and make the final volume to 100 ml.
 Trichloroacetic acid (TCA), 24% (w/v, aq.): Dissolve the 24 g of TCA into
distilled water and make the final volume to 100 ml obtain 24% TCA.

Procedure:-
 Take 10 ml of milk in a 50 ml stoppered test tube.
 Add 10 ml of TCA solution.
 Filter the coagulated milk through Whatman filter paper Grade 42.
 Take 5 ml of clear filtrate.
 Add few drops of barium chloride solution

Observation:- Observe for any visible precipitates in the tube.

Formation of milky-white precipitates indicates the presence of added sulfates
like ammonium sulfate, sodium sulfate, zinc sulfate and magnesium sulfate etc.
to milk. The limit of detection of method is 0.05%.

a. Detection of Sodium ions in milk (using ORION sodium ion meter):-

Principle:- It is based on principle that using ISA solution we make the other
ions of the milk in bound state while only Na+ ion is allow to move freely. Thus
enable us to calculate the sodium ion concentration (in ppm) in milk using
ORION sodium ion meter.
Apparatus :-
 Ion meter
 Glass Beaker :- 50ml,100ml,250ml
 Pipette :- 1ml,5ml,10ml
 Thermo meter

Reagent:-
 Sod. Chloride
 ppm solution with std of 100ppm & 1000ppm
 ISA solution
Procedure:-
[A]. Calibration:-

Calibration the instrument once in a day or before use if switched off switch on
the instrument & stand for atleast for 30min before Calibration.

Prepared electrode & std. solution before performing calibration of the

instrument press three display line until the arrow icon is pointing to the ISA
measurement line press calibration key instrument will ask to put the first std.
solution . open the rubber stopper of the instrument & keep 25ml std. sample
of 100ppm Na+ ( least concentration std.) with 2.5ml of ISA in a beaker lower
the sodium electrode & start the magnetic stirrer at low speed wait for ISA to
stop blink . instrument will read the std. & ask for the value , enter the value as
100 by Up & Down key & press data key to store the current changes.

Press calibration key & take out the first std. & wipe the
electrode gently then put second std. ( 1000ppm) with 2.5ml ISA after reading
the value enter the value as 1000 by up & down key & press data key to store
the current changes. Press measure save/print key to save the calibration data
& instrument will display the slope values & it should be between 50& 60 of
slope does not come in the range , then again calibration with fresh std. & if
slope is in the range then instrument is ready for use.

Note:- Slope of sodium ion Caliberation - 58±3

[B]. Estimation
Take 25ml of prepared milk sample [contain 8.5% SNF] in a 50ml beaker
with 2.5ml of ISA & take reading . take final reading when blinking will
stop . the displayed reading to be taken as sodium content in milk [ppm].

Observation:- Sodium ion in milk sample should be in between 400-500ppm.

Sodium ion greater than this indicate the presence of added sodium salts or
coloustrum milk.

b. Detection of Presence of Foreign Fat in Milk :-

i. Mineral Oil Test(Holder’s Test):-
Reagents:-Alcoholic KOH, boiling distilled water.
Apparatus:-Conical flask, boiling waterbath, hot plate,
Procedure:-
Take 1g of ghee extracted from milk in a 250ml conical flask
Add 22ml alcoholic KOH and keep it on boiling waterbath or hot plate and
sponify it till there is no oil droplets.
To this add 25ml boiling distilled water and swirl the flask.
 Observation:- Development of turbidity indicates the presence of
mineral oils. Such milk is unacceptable. No turbidity indicates absence of
mineral oil.

ii. BR Reading:-
Principle:- It is based on the principle of Refractive Index i.e., measuring the
deviation of refractive index of milk sample from standard calculated value.
Reagents:- Alcohol for cleaning the prism.
Apparatus:- BR Refractometer, Waterbath, thermometer,tissue paper.
Procedure:-
 Centrifuge about 20ml of milk in centrifuge for 5mins in an ordinary test
tube. Separate out cream plug and make ghee by heating the cream plug.
 Clean both the Prism surface of the butyrometer with the help of rectified
spirit and tissue paper.
 Set the temperature to 400C , and
 Put one/two drops of melted ghee on the prism and close the prism box
gently. Allow it to stand for 1min. Note down the reading.

Report the BR reading at 400C using formula mentioned below:-

R=R1+0.55(T1-40)
Where,
R = BR reading at 400C
R1 = BR reading at T10C
T1 = Temperature at which R1 is taken.
 After use, clean the prism
Note:-
For homogenized Milk:-
Corrected BR = observed BR + 0.08Xobserved BR
Ex- R = 39+0.08X39
= 42.2

Observation:- The BR Reading of milk fat should lies between 40.0-

45.0
iii. Determination of Reichert – Meissl Value (RM Value):

Principle:-The RM value is the number of millilitres of 0.1N sodium hydroxide

solution required to neutralize steam volatile water-soluble fatty acids distilled
from 5 gm. of oil / fat under the prescribed conditions. It is a measure of water-
soluble steam volatile fatty acid chiefly butyric and caproic acids present in fat.
The fat is saponified by heating with glycerol, sodium hydroxide and then split
by treatment with 1N sulphuric acid. The volatile acids are immediately steam
distilled. The soluble volatile acids in the distillate are filtered out and
estimated by titration with standard sodium hydroxide.
Butterfat contains mainly butyric acid glycerides. Butyric acid is volatile and
soluble in water.
Reaction
A. Saponification Step

CH2OCOR1 CH2OH + R1COONa

| |
CHOCOR2+ 3NaOH CHOH + R2COONa
| |
CH2OCOR3 CH2OH + R3COONa
Triglyceride Glycerol Sodium salt of
Fatty acids (soap)

B. Addition of H2SO4 after saponification

RCOONa + H2SO4 Na2SO4 + RCOOH

C. Titration of distilled fatty acids for determination of R.M.

RCOOH + NaOH RCOONa + H2O

Fatty acids Sodium salt of fatty acid

Reagents:- Glycerine,50% NaOH, 1N H2SO4, distilled water, N/10NaOH,
phenolphthalein indicator.
Apparatus:- Spherical flask with flat bottom, hot plate, 250ml conical flask,
measuring cylinder100ml, tong, RM Assembly, chilled water, volumetric
flask110ml and 100ml, whatman filter paper-4, burette,funnel, pumice stone.

Procedure:
 Weight accurately 5 + 0.01 gm of sample to 300-ml.-distillation flask.
 Add 20 g of glycerine and 2 ml of 50% sodium hydroxide & Saponify over a
flame. Cool the content slightly and add 90 ml of boiling distilled water,
which has been vigorously boiled for about 15 minutes. After mixing, the
solution should be clear. Add 50 ml 1N Sulphuric acid & 0.6-0.7gms pumice
stones grains/glass bids and immediately connect the flask to the distillation
apparatus.
 Heat gently first and then set the flame so that 110 ml of distillate shall be
collected in a 110 ml volumetric flask within 19-21 minutes.
 Keep the water in the condenser flowing at a sufficient speed to maintain
the temperature of the outgoing water from the condenser between 15-20°
C.
 The beginning of distillation is to be taken as the moment when the first
drop falls from the condenser in the receiving flask. Keep the 110 ml flask in
water bath maintained at 150C for 10 minutes.
 Take out & mix gently 4-5 times and filter through Whatman no.4.
 Reject the first 2-3 ml of the filtrate and collect the rest in a dry flask.
 Pipette out 100 ml and add 5 drops phenolphthalein solution and titrate
against N/10 sodium hydroxide.
 Run a blank test without the ghee.
Calculation:-

RM = (A-B) x N x 11
Where,
A : Volume in ml. of standard sodium hydroxide.
B : Volume in ml. of standard sodium hydroxide required for Blank.
N : Normality of standard hydroxide.
 Observation:- The RM Value of milk fat should not be less than 28.0

c. Detection of Neutralizers in Milk :-

Principle :-Neutralizers (NaOH, 0.1% for Na2CO3 and 0.2% for NaHCO3) are
added to milk to neutralize the developed acidity in milk. Rosalic acid
method can be used for the detection of presence of these neutralizers in
milk. Milk develop a red rose colour in the solution of Rosalic acid.

Reagents:-Rosalic Acid Solution(0.05%w/v) – Dissolve 2.5g of Rosalic acid

powder in 5 lit of 60% alcohol (to 3.166lit. of rectified spirit and 1.840lit. of
distilled water) whose density is 0.91.

Apparatus:-Test Tube

Procedure:-
Take 2ml of Rosalic acid in a test tube.
Add 2ml of Milk.

Observation:- Rose Red colour development indicates neutralizer

presence in milk and formation of flakes indicates disturbed salt balance.
Such milk is unacceptable.

d. Test for Presence of Anionic Detergent in Milk :-

Principle:- Alkyl benzene sulphonic acid (ABS) or anionic detergent may
be present in milk due to intentional addition of detergent in milk or due to
insufficient rinsing of dairy equipments. The following method is based on the
ionic interaction between the anionic detergent and cationic dye. Anionic
detergents have a property to form a complex with cationic dyes. The solubility
of dye and dye-detergent complex differs significantly as dye-detergent
complex is relatively less polar in comparison to dye alone. Formation of dye-
detergent complex between cationic dye and anionic detergents and
subsequently its extraction into the hydrophobic solvent layer (lower) is the
principle behind the method. The method is performed by addition of
methylene blue dye solution and chloroform to milk, mixing of the content
followed by centrifugation. This results in distribution of dye colour in upper
layer and lower layers. Relative intensity of the colour is noticed in these
layers. Appearance of relatively more blue colour in lower layer indicates the
presence of detergent in milk. The developed test is sensitive to detect anionic
detergent up to 0.0125% (12.5 mg/100 ml).

Reagents:-
Methylene blue dye: 12.5 mg is dissolved in 100 ml of distilled water. Protect
the solution against direct sunlight.
Chloroform (Inflammable and toxic on inhalation. Mouth pipetting is not
recommended).
Apparatus:- Graduated test tube-15ml,R-8C-REMI-Centrifuge, Vortex Shakes, 1
and 2 ml pipette, stopwatch.
Procedure:-
Pipette 1ml of milk in 15ml test tube.
Add 1ml Methylene Blue Dye.
Contents were mixed by hand tapping gently for 40 sec.
Immediately add 2ml chloroform.
Vortex the contents for 1min .
Centrifuge the test tube on 1500 rpm for 5mins.
Intensities of blue colour in lower and upper layer are noted.

Observation:- Appearance of relatively more blue colour in lower

layer indicates the presence of detergent in milk.

e. Test for Presence of Skimmed milk Powder in Natural milk (Cow, buffalo,
goat, sheep):-

Principle:- As per the law, use of skimmed milk powder (SMP) is not allowed
for adjustment of SNF in case of sale of cow/buffalo or mixed milk. A method
has been developed for the detection of presence of SMP in liquid milk. The
method is based on the fact that the coagulum obtained from reconstituted
skim milk powder by addition of acetic acid, gives intense blue colour on
boiling with phosphomolybdic acid due to certain reducing groups present in
the proteins of milk powder which are able to cause reduction of molybdenum
blue resulting in formation of blue colour.

Reagents:- Acetic acid:4%, Phosphomolybdic acid: 1% solution in water,pH

meter.

Apparatus:- Test tube, Waterbath, Whatman filter paper-4, funnel

Procedure:-
Take 5ml of milk sample.
Add 1ml of 4% Acetic Acid .
Filter and collect ppt.
Take ppt and wash till pH attain 4.0.
Put the ppt in test tube and add 2ml Phosphomolybidic acid
Put the ppt in boiling waterbath for 15mins.
Observe the colour.

Observation:- Development of Greyish green- blue colour indicate the

presence of added SMP.

f. Test for the presence of Sorbitol in Milk:-

Procedure:-
Take 20ml milk sample
Heat it for first boil.
Add 0.6ml Reagent no 1 and wait for coagulation to occur(5mins).
Filter it with whatman-4
Now take 1ml filterate in test tube.
Put test tube boiling waterbath for exactly 1min.
Add Reagent no.A 0.8ml and Reagent no. B 0.2ml.
Vortex for 30sec.
Incubate for 10mins at 300C in waterbath.
Wait 5mins and take observation.
Observation:- Development of sticky flakes on the wall of the test tube on
rotation indicates the presence of added Sorbitol in milk.
g.
 h. Test for Presence of Formalin in Milk :-
Hehner’s Test
Reagent: Concentrated sulphuric acid.
Procedure:-
 Take milk sample (2 ml) in a test tube and add 2 ml of 90 percent H2SO4
containing traces of ferric chloride from the side of the test tube slowly.
 Formation of purple ring at the junction indicates formaldehyde is
present in milk.
 If sucrose is present, distil the milk sample (25 ml) and then carry out the
test on the distillate by taking 2-3 ml of distillate and adding 2 ml of
formaldehyde free milk.

Observation:-The violet coloration does not appear usually when

relatively large quantities of formaldehyde are present.
Precaution: If H2SO4 is added from the top and not from the side of the test
tube, it may burn the milk solids and affect the end result.

i. Test for Presence of Hydrogen Peroxide in Milk :-

Procedure:- Dissolve 1 gm V2O5 (Vanadium Pent oxide) in 100 ml of 6% H2SO4
(6+94). To 10 ml of sample add 10 drops of reagent and mix. The development
of pink or red colour indicates presence of H2O2.

3. Other Tests for Chemical Analysis of milk

i. Alkaline Phosphatase Test for Checking Efficiency of Pasteurisation in

Liquid Milk:-

Chemicals Required:-
Phosphatase dye, Buffer solution.
Procedure: -
Fill 5 ml quantity of the phosphatase dye into test tubes marked at 10 ml and
bring to 37 to 38OC in a water bath. Add 1 ml of the milk to be tested, close the
tubes with rubber stoppers and invert to mix. Prepare in the same way a blank
from a boiled milk of the same type of that under test. Incubate all the tubes
at 37 to 38OC. Read the yellow colour after 30 minutes, return to the bath, and
take a second reading after incubation for a further 90 minutes.
 Interpretation of Results: -
Disc Reading after 30 minutes
Incubation Interpretation
0 or trace Properly pasteurized
6 Doubtful
10 or over under pasteurized

Disc Reading after 2 Hours

Incubation Interpretation
0 to 10 Properly pasteurized
Over 10 Under pasteurized
The 30-minute test will reveal any serious fault in pasteurization, but to
enable minor errors to be detected, readings shall be taken after further
incubation for 90 minutes.

ii. Determination of Total Solids (Gravimetric method):-

In this procedure, a known quantity of milk is dried on a boiling water bath.

Subsequently sample is dried in hot air oven at 102 ±2°C and from the weight
of the residue, the total solids content in milk is determined.

Reagents/Apparatus:-Analytical Balance having sensitivity of 0.1 mg,Desiccator

provided with an efficient desiccant (for example freshly dried silica gel with a
hydrometric indicator, Boiling water bath provided with openings of adjustable
size, Drying oven, ventilated capable of being maintained thermostatically at
102 ± 2°C throughout the total working space, Flat bottomed dishes of height
20 – 25 mm, dia 50 - 75 mm and made of appropriate material (stainless steel,
nickel or aluminium) provided with well fitted readily removable lids, Water
bath capable of being maintained at 35° - 40°C.

Procedure
 Transfer sample to a beaker, warm slowly to 35° - 40°C on a water bath
with careful mixing to incorporate any cream adhering to the sample.
 Cool the sample quickly to room temperature.
 Heat a dish with its lid alongside in the drying oven at least 1 hour.
  Place the lid on the dish and immediately transfer to a desiccator.
 Allow to cool to room temperature (at least 30 mins) and weigh to the
nearest 0.1 mg.
 Add 5 ml of prepared sample, place the lid on the dish and weigh again.
 Place the dish without the lid on the vigorously boiling water bath in
such a way that the bottom of the dish is directly heated by the steam.
Continue heating till most of the water is removed.
 Remove the dish from the water bath, wipe the underside and place it
in the oven alongside the lid and dry in the oven for 2 hours. Place the
lid and transfer to the desiccator.
 Allow the dish to cool and weigh to the nearest 0.1 mg.
 Again heat the dish with its lid alongside in the oven for 1 hour.
 Place the lid on the dish and immediately transfer to the desiccator.
 Allow to cool and weigh again.
 Repeat the operation again until the difference in the two consecutive
weighing does not exceed 1 mg. Record the lowest mass.

Calculation

M2 − M0
Total Solid Content = x 100
M1 − M0

Where

M0 = mass in g of dish + lid

M1 = mass in g of dish + lid and test portion

M2 = mass in g of dish + lid and dried test portion

Round the value obtained to nearest 0.01 % (m/m)

iii. Determination of Fat in Milk

Method 1. Gerber Method

The milk is mixed with sulphuric acid and iso-amyl alcohol in a special
Gerber tube, permitting dissolution of the protein and release of fat. The tubes
are centrifuged and the fat rising into the calibrated part of the tube is
measured as a percentage of the fat content of the milk sample. The method is
suitable as a routine or screening test. It is an empirical method and
reproducible results can be obtained if procedure is followed correctly.
Reagents /Apparatus:-

Sulphuric acid with a density of 1.807 to 1.812 g/ml at 27°C corresponding to a

concentration of sulphuric acid from 90-91 percent by weight.

Amyl alcohol for milk testing (furfural free). It should have density between
0.808 to 0.818 g/ml at 27°C.

Gerber sulphuric acid: Sulphuric acid shall have a density of 1.807 to 1.812
g/ml at 27°C corresponding to a concentration of sulphuric acid from 90 to 91%
by mass.

Preparation of Gerber Sulfuric acid: Take required volume of water in a pyrex

flask (generally 100 ml of water is required for 900 ml of concentrated sulfuric
acid) kept in a basin of ice cold water. Carefully add the commercial sulfuric
acid in small quantities at a time keeping the container sufficiently cold and
mix gently. Observe the following precautions while performing the above
experiment.

 Sulfuric acid is very corrosive. Handle it with care.

 Add acid to water. Add small quantities of acid to water at a time and cool
 the mixture by stirring. Never add water to acid.

 Use heat resistant flask for dilutions.

After cooling the flaks, check the specific gravity of Gerber acid with
hydrometer and if necessary adjust the Gerber acid to the correct specific
gravity with addition of water or acid taking same precautions as before till
specific gravity is in the range of 1.807 to 1.812 g/ml at 27°C (or 1.815 to 1.820
g/ml at 20°C). Store the prepared acid in a glass stoppered bottle to avoid
absorption of water.

Iso-amyl alcohol (C5H11OH): The iso-amyl alcohol shall have density of

0.803 to 0.805 g/ml at 27°C and should be furfural free.

Gerber butyrometer:- 10 % (ISI marked).

Pipette: 10 ± 0.25 ml or automatic measure or tilt measure for sulphuric

acid.

Pipette: 10.75 ± 0.03 ml for milk.

Pipette: 1 ± 0.05 ml or automatic measure or tilt measure for iso-amyl

alcohol.

Lock stoppers for butyrometers.

Lock stopper key.

Water-bath: The water-bath shall be made of a suitable material (e.g.

stainless steel). It shall be capable of being maintained at 65 ± 2°C and shall
be of sufficient depth as to support the butyrometer in vertical position
with their scale completely immersed. The bath shall be fitted with
horizontal perforated plates to hold the butyrometers and shall also carry a
suitable thermometer.
 Gerber Centrifuge. The centrifuge may be hand-driven or electric driven.
The centrifuge shall be capable of producing within 2 min when fully
loaded, a relative centrifugal acceleration of 350 ± 50 gn at the outer end of
the butyrometer stopper. This acceleration is produced by centrifuges with
the following effective radius (horizontal distance between the centre of
the centrifuge spindle and the outer end of the butyrometer stopper) if
operated at the speed indicated against each:

Effective Radius Revolution Per Min (± 70

(mm) rev/min)
240 1140
245 1130
250 1120
255 1110
260 1100
265 1090
270 1080
275 1070
300 1020
325 980

Note: The relative centrifugal acceleration (gn) produced in a centrifuge is

given by the following formula:

1.12 X 10 -6 r n2

where r = effective horizontal radius in mm, and

n = speed in revolutions per min

Procedure:-
Measure 10 ml of sulphuric acid into a butyrometer tube, preferably by use of
an automatic dispenser, without wetting the neck of the tube. Mix the milk
sample gently but thoroughly and fill the milk pipette above the graduation
line. Wipe the outside of the pipette and allow the milk level to fall so that the
top of meniscus is level with the mark. Run the milk into the butyrometer tube
along the side wall without wetting the neck, leave to drain for three seconds
and touch the pipette's tip once against the base of the neck of the
butyrometer tube. Add 1 ml of Amyl alcohol, close with a lock stopper, shake
until homogeneous, inverting it for complete admixture of the acid. Keep in a
water bath for 5 min. at 65±2°C taking care to have casein particles if any to
dissolve fully, and centrifuge for 4 min. at 1100 rpm. The tubes should be put in
centrifuge, so as to conform to radial symmetry, and as evenly spaced as
possible, in order to protect bearings of the centrifuge. Allow the centrifuge to
come to rest. Remove the butyrometer tubes and place in water bath for 5
min. at 65±2°C. Read the percentage of fat after adjusting the height in the
tube as necessary by movements of the lock stopper with the key. Note the
scale reading corresponding to the lowest point of the fat meniscus and the
surface of separation of the fat and acid. When readings are being taken hold
the butyrometer with the graduated portion vertical, keep the point being read
in level with the eye, and then read the butyrometer to the nearest half of the
smallest scale division.
Note:

The butyrometer must always be emptied without delay and the highly
acidic waste disposed off appropriately. The tubes may be cleaned with
chromic acid.

In homogenised milk fat separates with more difficulty and centrifuging

more than once may be required. On the other hand, holding the tubes too
long at 65°C or above, results in esterification of the amyl alcohol with a
consequent increase in the volume of the fat layer.
In case of old samples, if necessary the concentration of sulphuric acid may
be increased from 90-91% to 92-93% to felicitate better dissolution.
iv. Protein Estimation
a. Method 1. Pynes Method:-
Procedure:-
 Take 10ml of the well mixed sample of milk into a 100ml flask.
 Add 5 drops of Phenolphthalein indicator
 Add 0.4ml saturated Potassium Oxalate and keep it aside for 2-
3mins without disturbing.
 Add 2ml of Neutral formaline and mix well .
 Titrate against the standard alkali to the same end point as
before
 Record the volume of alkali used in the second titration(Vml).
Calculation:-
% Protein in the given sample of Milk = 1.7 x V

b. Method 2. Kjeldhal method:-

Apparatus :-
 Digestion unit.
 Distillation unit .
 Weighing Balance .
 Digestion tube .
 Pipette :-1ml, 10ml graduated.
 Burette:- 10ml graduated.
 Conical flask :-250ml.

Reagents:-
 Digestion catalyst mixture :- Cuso4 + k2so4(1:5)
 Concentrated H2SO4
 4NBoric Acid
 40% NaoH solution
 Mixed indicator (methyl/red +bromocresol green in ratio 2:1)
 0.1N std. HCL.
 Ammonium ferrous sulphate.

Procedure:-

[A]. Digestion process

 Place the kjeldahl tube in stand.
  Weigh approx 2g liquid milk or 0.5g concentrate milk directly in the
kjeldahl tubes.
 Add 5g of digestion catalyst mix(CuSO4 + K2SO4) in tubes.
 Add 10ml of concentrate H2SO4 in each of the kjeldahl tubes with auto
pipette & shake the tubes.
 Now place the kjeldahl tubes on the heater & put the top cover of the
digestion assembly.
 Flow of water should be checked before starting and exhaust fan the
hood shood switch on.
 The digestion unit must be switched on by pressing the power button
&set at 1000C once the set temp achieve , increase the temp gradually
with 500C increasment every step & finally at 4200C.
 When the temp is reached to 4200C ,leave it for 2hrs.
 Also water supply should be checked continuously , it should be properly
connected to the digestion system.
 In between check the water supply & also the tubes must be shaken
eithin every 10-15mins mean while you will see ammonia gas evolving
out & the colour will changes.
 Ensure frothing of sample is there ; if frothing is not there then increase
the temp.
 The person may feel uneasy if there is some leakage in the apparatus
,therefore the lids of the kjeldahl tubes should be properly placed
 Leave the tubes in the block for 2hrs after 2hrs ensure the colour of
sample turns into bluish green , if not then replace the tubes in block for
sometimes.
 Once the tubes & place them in cooling stand.
 Keep them in the cooling stand until the fumes disappear & the colour
becomes crystal clear.
 Do the black without sample by taking all chemicals & following all steps
for samples.

[B] Distillation Process:-

 Now switch on the distillation system by first pressing the main switch &
green remote button, which is present at the back, then power ,button.
 Check the water supply in the distillation unit.
 Remove the tubes from distilled water, dip it in 40%NaOH.
 Two times set alkali for 25 sec & run for flushing.
 Run the process once without sample to ready the apparatus.
  Set alkali for 6 sec & times.
 Set distillation time 11 min.
 Remove previous distillation tube &conical flask.
 Place distillation tube containing digested sample in the tube chamber&
a 250ml conical flask containing 25ml boric acid & add ten drops of
mixed indicator another side.
 Press dilution 2-3times for approx 5 sec.
 Press alkali for 5sec, 4times till black colour appear by addition of alkali
(NaOH).
 Run distillation for 11mins.

Titration:-

 Titrate distilled solution against 0.1N HCL (standized).

 Once the colour changes from bluish green to permanent pale pink note
the burette reading that is titre value.
 Now do the calculation for finding %protein by multiplying % nitrogen
with conversion factor.
 Titre valve of blank titration is substrated from the titrate value of the
samples.
 After distillation make the alkali addition time & distillation time display
zero.
 Put the pipelines from NaoH into distilled water.
 Then for 40 sec approx. that is 20 sec for two times flushing is done.
 Press the process button and set the time for 5 min for cleaning.
 Lastly switch off the power button then green remote button then main
switch.
 Close the water supply.

Distillation efficiency test can be performed by:-

 Take accurately 0.1g of ferrous ammonium sulphate in protein digestion

/distillation tube and add 10ml of distilled water.
 Distill the content in distillation unit as per protein estimation method.
 Titrate the distilled solution with 0.1N HCL.

Efficiency calculation :-
 1.4 𝑋 (𝑉𝑠−𝑉𝑏) 𝑋 𝑁
Nitrogen(%) = 𝑊

Where ,

Vs= titrate value in ml for sample.

Vb= titrate value in ml for blank.

N= normality of standard HCL.

W= weight of sample in g.

[ the idle value of nitrogen(%) is 21.19 for ammonia sulphate and 7.14 (approx
value is 5.10ml ) for ferrous ammonia sulphate. calculate efficiency with
obtained value comparing the idle value.]

Protein calculation:-

𝟏.𝟒 𝐱 (𝐕𝐬−𝐕𝐛) 𝐱 𝐍
Nitrogen (%) =
𝐖

Protein (%)= % nitrogen x 6.38

v. Acidity Test:-

Procedure:
Taking 10 ml milk in 100 ml conical flask, add 10 ml distilled water. Add 1ml
phenolphthalein indicator and titrate against N/10 NaOH till a faint pink
colour appears.
Calculate:-
the acidity %LA = volume of NaOH used X 0.09.

Observation :- Acidity above 0.153% is not acceptable.

vi. Test for the presence of Maltodextrin:-
Reagent :-
 Lactic acid solution :- 10% in distilled water.
  Enzyme solution :- 0.5% in distilled water.
 Diastix glucose strips (Bayer Diagnostic India ltd.)

Procecedure:-
 Take 20ml of milk in a 100ml beaker.
 Add approximately 1ml of lactic acid solution to adjust the PH to
4.0-4.5
 Add 1ml of enzyme solution & keep for 5 min at 62+-2 C in
waterbath
 Immerse Diastix in curded milk at ambient temp for 10sec .
 Remove excess milk from the strip by gentle gerk .
 Wait for 30sec & compare reagent area with colour chart .

HARDNESS OF WATER
Types of Water

Generally water is classified into two categories

i) Hard water and
ii) Soft water.

Water hardness is basically due to the presence of di-cations

including Ca2+ and Mg2+. These ions enter a water supply by leaching from
minerals. Water hardness is further of two
types:

i) Temporary hardness:- Temporary hardness is caused by the carbonates

and bicarbonates of calcium and magnesium. This can easily be removed
by boiling of water.
ii) Permanent hardness:- On the other hand, presence of sulfates and
chlorides of calcium and magnesium are responsible for permanent
hardness of water. This kind of hardness is not removed by simple boiling
but requires some complex operations.

 The combined effect of temporary and permanent hardness is called as

total hardness of the water.
 Temporary hardness and permanent hardness are also known as
carbonate hardness and noncarbonate hardness, respectively.
 Conventionally hardness is expressed in terms of ppm of calcium
carbonate.
 In industry, the major problem caused by hard water is the deposition of
scales in and on the pipes which can clog plumbing and interfere with heat
 exchangers. These scale, are composed mainly of calcium carbonate
(CaCO3), magnesium hydroxide [Mg(OH)2], and calcium sulfate (CaSO4).
Calcium and magnesium carbonates tend to precipitate out as hard
deposits to the surfaces of pipes and heat exchanger surfaces. This is
principally caused by thermal decomposition of bicarbonate ions but also
happens to some extent even in the absence of such ions. In boilers, the
deposits act as an insulation that impairs the flow of heat into water,
reducing the heating efficiency and allowing the metal boiler components
to overheat. In a pressurized system, this can lead to failure of the boiler.
 The following equilibrium reaction describes the
formation of calcium carbonate scales

CaCO3+ CO2 + H 2O ⇋ Ca2+ + 2HCO3

 Hard water, form white precipitate (scum) with soap solutions, instead of
producing lather. This effect arises because the dications destroy the
surfactant properties of the soap by forming a solid precipitate. A major
component of such scum is calcium stearate.

2 C17H35COO- + Ca2+ → (C17H35COO)2 Ca

(calcium stearate)
The Indian standards for water quality tolerances for processed food industry
are as

Table 16.1 Bacteriological tolerances

Si.no. Characeristics Tolerances

1 <1

2 50*

3 5

*Not applicable in the case of cooling water and of hot water supplied in dairy
industry.

Table 16.2 Physical and Chemical tolerances (BIS, 1981)

 Table 16.3 Tolerances for radioactivity

In a mother dairy at doc lab, five types of water samples comes for
different types of tests as follows :-

Si.no. Water Types of tests Range of Uses of water

Samples values

1 Boiler Water Hardness, sulphite, Nil,____,+ive In boiler

phosphate

2 Feeder Water Hardness <10ppm

3 Softener Hardness <10ppm
Water

4 Reservoir Hardness <500ppm

Water

5 UV Water Hardness,TDS <10ppm, For

250mg/lit standardization
of milk

Testing Methods:-

1. Hardness of Water:-
Aim: - To calculate the hardness of water.
Reagents:- Ammonium Buffer, Erichrome Black T indicator, N/10 EDTA
Solution.
Apparatus:- 500ml conical flask, 100ml measuring cylinder, burette or
pipette.
Procedures:-
a) Take 50 ml of water to be tested in a conical flask using measuring
cylinder.
b) Add 2.0 ml of ammonium buffer solution.
c) Add 2-3 drops of Erichrome Black T indicator.
d) Titrate with N/10 EDTA solution.
e) Transparent bluish green colour indicate the end point.
f) Note the volume of N/10 EDTA used.

Calculations:-

Hardness of water(in ppm of CaCO3) = Titrated Value X 20

2. Sulphite Test:-
Aim :- To calculate sulphite in water
Reagents:- Starch solution (1% w/v), HCl Solution(50% v/v), Iodate
Iodide solution
Apparatus:- 500 ml beaker, pipette(10ml)
Procedure:-
a) Take 50 ml of water in a 500 ml conical flask
b) Add 2.0 ml of 1% Starch Solution
c) Add 2.0 ml of 50% HCl
 d) Titrate against Iodate Iodide solution
e) Appearance of bluish colour is an indicative of end point.

Calculation:-

n
Sulphite concentration(in ppm)= Titrate Value x 16

3. Phosphate Test:-
Aim :- To check for phosphate +ive
Reagents :- Ammonium Molybedate Powder, Nitric Acid
Apparatus :- 500 ml beaker
Procedure :-
a) Take 10 ml of water in conical flask
b) Add some amount of Ammonium Molybedate Powder
c) Add 1.0 ml of Nitric acid
d) Development of yellow colour indicate phosphate +ive.

4. TDS test:-
Aim :- To calculate TDS using TDS measuring instrument
Procedure :-
a) Take 50 ml of water in 500 ml of conical flask
b) Dip the instrument pen like structure into the flask
c) click on TDS
MILK POWDER (SMP/WMP)

 On arrival of powder, draw sample from store godown

 Note down the source, batch number, date of manufacture and bag
number from which sample is drawn
 With the help of store staff keep six bags, possibly of different batches
from each truck, one bag after unloading 70 bags
 Open the bags carefully and take a composite sample of the truck from
all the six bags in polythene bags/bottles. Also take one bacteriological sample

Specification for SMP

S.N Characteristics Requirements

o
01 Fat% 1.5 (max.)
02 Moisture% 5.0 (max.)
03 Insolubility Index 2 .0 ml (max)
04 Ash (on dry basis)% 8.2 (max.)
05 Titratable Acidity 1.5 (max.)
as LA %
06 Rosalic Acid Test Negative

Specification for WMP

:
S.No Characteristics Requirements
01 Fat% 26.0 (min.)
02 Moisture% 4.0 (max.)
03 Insolubility Index 2 .0 ml (max)
04 Ash (on dry basis)% 7.3 (max.)
05 Titratable Acidity as LA% 1.2 (max.)
06 Rosalic Acid Test Negative

In all type of Powders, milk protein in milk solids not fat should not be less than
34 %.In addition to the above, Powder may be checked for Sodium Content
(Max. 550ppm in SMP & 410 in WMP), as mentioned in Test Method of Milk.
Tests to be carried

a) Organoleptic test b) Moisture Content %

c) Titratable acidity as LA % d) Rosalic Acid test
e) Insolubility Index f) Ash Content %
g) Fat % h) Malto dextrin
i) Scorched Particle j) Bulk Density

a) ORGANOLEPTIC TEST
1. Reconstitute 10 gm SMP in 100 ml distilled water maintained at 25°C in a
250 ml conical flask/beaker.
2. Reconstitute 13 gm WMP in 100 ml distilled water maintained at 40°C in
a 250 ml conical flask/beaker.
3. The sample should be prepared 1 hour before evaluation. During
evaluation, the reconstituted milk should be maintained at temperature
20±2°C. The beakers should be covered till the evaluation is completed.
4. Check for taste and flavor both for dry and reconstituted powder.

b) MOISTURE CONTENT
Method 1:- Use Infra-red Moisture Analyzer and note the Moisture percent
readings.
OPERATIONAL PROCEDURE:
1. Switch on instrument. Press ON/OFF button and put the instrument in
stand by position (TEMP – 103 0C and TIME – AUTO).
2. Clean the central dish and put it properly on the balance and press TARE
button to make balance display 0.00.
3. Spread 3 gm powder on dish.
4. Close balance cover and touch START option on screen. Wait till BEEP
sound comes out from analyzer.
5. Read out reading that indicates moisture % Clean the central dish with
brush and put it on balance back.
Method 2 :- (Gravemetric Method)
Procedure
Place the uncovered dish and its lid
 in the oven at 102±20C for 1 hours

Cool it in dessicator for 30 mins

Weight the dish and lid(M)

Mix thoroughly the sample and

take approx 1 gm (M1)

Uncover the dish and put it with its lid

in the oven at 102±20C for 2 hours

Again cool the sample in dessicator for 30 mins

And weight the disk +lid+sample(M2)
Repeat the same procedure till the difference in
2 consecutive reading is 0.5 mg
Calculation:-
M1−M2
%moisture = X100
M1−M

C) TITRATABLE ACIDITY AS LA %.
1. Weigh accurately 1 gm of the sample in a 100 ml beaker.
2. Add 10 ml of hot distilled water and make a solution using a glass rod.
Cool to room temperature.
3. Add 1 ml phenolphthalein indicator and titrate against N/10NaOH till a
faint pink color persists.
Calculate
N(NaOH)XV(NaOH)X9
Acidity( % Lactic Acid) = = VNaOH X 0.09
V(Milk)
D) ROSALICACID TEST/DETECTION OF NEUTRALIZERS.
1. Take 2 ml rosalic acid solution (0.05% in 60:40 alcohol and distilled
water) in a test tube
2. Add 2 ml of reconstituted powder.
3. Rose-Red color development indicates neutralizer presence in powder
and formation of flakes indicates alcohol test positive

E) ASH CONTENT %
1. Weigh accurately 3 gm. of powder in a well-dried silica crucible and heat
on a heater till no smoke comes out of the powder .
2. Keep it into a muffle furnace maintained at 550±20°C for three hours till
grey ash formation.
3. Switch off the muffle furnace and let the temperature fall.
4. Transfer the crucible to a desiccators, cool completely and weigh.
5. Heat the dish again at 550±20°C for 30 minutes. Cool the dish in
desiccators and weigh.
6. Repeat this process of heating for 30 minutes, cooling and weighing until
the difference between two successive weighing is less than one
milligram. Record the lowest mass.
Calculate ash percentage as follows:
M2 − M
[A] Ash % by mass = X100
M1 − M
M2 = Weight of crucible with ash. M = Weight of empty crucible.
M1 = Weight of crucible with powder.

Ash % by mass
[B] Ash % on dry matter basis = X100
100 − Moisture %

F) INSOLUBILITY INDEX:
1. The reconstituted temperature to be used in the insolubility index
method will be 24±1OC for spray-dried products.
2. Take 13 gm in case of WMP and 10 gm in SMP. Reconstitute the powder
in 100 ml distilled water at 24±1OC.
3. Add 3 drops of silicone anti-foaming agent and mix it thoroughly in the
blender for 90 seconds.
4. Further add 3 drops of silicone anti-foaming agent to the mixture and
mix thoroughly with a spoon / spatula for 10 seconds.
5. Pour the mixture into a centrifuge tubeup to the 50 ml mark.
 6. Place the centrifuge tube in the centrifuge and rotate it for 5 minutes at
20 to 25OC.
7. Hold the centrifuge tube in a vertical position and remove the
supernatant liquid.
8. Add water up to 30ml mark in the centrifuge tube, completely disperse
the sediment with the stirring rod and make up the volume up to 50 ml
mark.
9. Invert the centrifuge tube 5 times to mix its contents thoroughly. Place
the centrifuge tube in the centrifuge and rotate it for 5 minutes at 20 to
25OC.
10. Remove the centrifuge tube from the centrifuge, hold the tube in a
vertical position and read the volume of the sediment to the nearest 0.1
ml.

G) FAT PERCENT (WMP/SMP)

1. Take 10 ml of Gerber Sulphuric acid in milk Butyrometer.
2. Weigh 1.69 gm of WMP in a 50 ml beaker and dissolve it in approximate
10 ml water
3. Transfer carefully into the butyrometer
4. Add 1 ml Amyl alcohol, make the volume with water and centrifuge for 5
minutes.
5. Record fat % by multiplying the Butyrometer reading with 20/3.

H) Maltodextrin Test
Enzymatic Method
This document explains a new highly specific and sensitive method for
qualitative detection of malt dextrin, an adulterant in milk and milk products.
Maltodextrin (C6H10O5)n, is a type of dextrin, non-sweet nutritive saccharine
polymer that consists of D-glucose units linked primarily by α -1-4 bonds and
that has a dextrose equivalent (D.E.) of less than 20. The higher the DE, the
greater the extent of starch hydrolysis.

Requirements
i. Stop watch
ii. Beaker: 100ml capacity
iii. Graduated Glass Pipettes: Capacity 20 ml, 2ml.
iv. Water bath: Thermostatically controlled water bath maintained
accurately at 62.20C.
 v. pH paper:- pH paper strips suitable for pH measurement in a range of 3.5
to 6.
vi. Testing strip: Reagent strips, Diastix is used for qualitative test for
glucose incorporating a reagent area that tests specifically for glucose
and changes colour (from green to brown) if glucose is present in test
solution. Results are obtained directly from comparison with the colour
chart. Each colour block represents a range of values of the glucose
content in test solution. Diastix strips should be stored below 300C and
out of direct sunlight. It should not be stored under refrigeration.
Desiccant pouch provided in the bottle should not be removed. Strips
should not be used after six months of opening the bottle.
vii. Enzyme Solution (0.2g/100ml): 200 mg of enzyme is dissolved in 100 ml
water and stored under refrigeration (2-8C). This solution should not be
used for more than 15 days as loss of enzyme activity may result in
misleading results.
viii. Lactic acid solution: 10 ml of concentrated lactic acid is taken in 100 ml
volumetric flask and volume is made up (100 ml) with distilled water.

Procedure
1. Sample preparation:- 20 ml homogenous milk sample is taken in 100 ml
beaker. In case of concentrated milk, appropriate dilution was made so
as to adjust total solids in a range of 10 – 15 %. For milk powder, 10g of
skim milk or 13 g of whole milk powder is dissolved in 100 ml water
(400C) with the help of stirrer for proper reconstitution.
2. Thereafter pH of sample is adjusted to 4 - 4.5 with the help of dilute
lactic acid solution. Usually 0.8 to 1.2 ml of acid solution is used to
maintain pH in this range.
3. It is then dosed with 1 ml of enzyme solution and incubated the contents
at 62.20C for 5 minutes.
4. Contents are cooled at room temperature,
5. The sample is checked for glucose using Diastix strip. Open the bottle,
remove one test strip and immediately replace the cap. Hold the plastic
end of the strip and do not touch the reagent green colored reagent
area. Dip the reagent area of strip in to the test solution/sample and
remove immediately. Remove excess of liquid on strip by single jerk.
Compare the colour of the reagent area with the color chart exactly after
30 seconds of wetting. If the sample shows presence of glucose (trace
and above) the maltodextrin test need not to be performed..
Inferences
● Change in colour of glucose strip indicating +ve (+, ++, +++ and ++++ as
depicted on glucose testing strip bottle) after enzyme treatment,
indicates presence of maltodextrin and rejected.
 I) Scorched Particle:-
 Reconstitution of SMP:- 10gm + 100ml of distilled water at
(24±10C) in 250ml in conical flask.
 Reconstitution of WMP:- 13gm + 100ml of distilled water at 48-
500C in 250ml conical flask.
Procedure:-
1. Reconstitute the powder samples as mentioned above.
2. Keep undisturbed for sometimes.
3. Filter the reconstituted milk through scorched particle tester.
4. Compare the filter pad with ADMI comparision card.
5. Powder with scorched particles more than disk B should be rejected.

J) Bulk Density:-
k) Determination of Protein by Kjeldal Method:-
See kjeldal procedure of milk.

WHITE BUTTER

Specification for White Butter

S.No Characteristics Requirements
01 Milk Fat % 76.0 (min.)
02 Moisture % 16.0 (max.)
03 Curd % 1.5 (max.)
04 Titratable Acidity as LA % 0.06 (max.)

ORGANOLEPTIC TEST
Soften the white butter by keeping at room temperature/water bath
maintained at 35-40°C. Check the taste and flavor of butter at the temperature
-14±1°C. Record the observations in the prescribed register.

%MILK FAT, %MOISTURE AND %CURD

Routine Method (Validation Method)

 1. Weigh 10 gm butter in a 100 ml beaker and heat on a hot plate/ gas
flame till foaming ceases and curd attains characteristic golden brown
colour.

2. Cool the beaker in a desiccators and weigh it.

3. Warm the beaker and transfer 50 ml of petroleum ether/petroleum
spirit into it. Mix well with a glass rod.
4. Allow curd portion to settle. Decant fat portion carefully without
disturbing curd portion.
5. Give two more washings with 30 ml petroleum ether/petroleum spirit
each time. Clean the beaker with cotton soaked in petroleum
ether/petroleum spirit from out side.
6. Dry the beaker in hot air oven at 100 ± 1°C for 30 minutes.
7. Cool the beaker in a dessicator to room temperature and weigh.

Calculate as follows
Y−Z
%Moisture = x 100
A
W−X
%Curd = x 100
A
%Milk Fat = 100 - (Moisture % + Curd %)
Where,
X = Weight of empty beaker W = Weight of beaker with curd.
Y = Weight of beaker with butter A = Weight of butter = (Y-X).
Z = Weight of beaker after removing moisture.

TITRATABLE ACIDITY AS LACTIC ACID%

Weigh accurately about 20 gm of the butter sample in a dry 250 ml conical

flask. Add 90 ml of hot, previously boiled water and shake the contents.
While still hot titrate with 0.02 (N/50) sodium hydroxide using 1 ml of
phenolphthalein indicator.
Calculate
9XNXV
titratable acidity (% lactic acid) =
W

Where,
N = normality of sodium hydroxide solution,
 V = Volume of sodium hydroxide, and
W = Weight in gram of the sample.

GHEE/BUTTEROIL
S.No Characteristics Requirements
01 BR Reading at 40ºC 40 – 43
02 FFA as Oleic Acid % 3.0 (max.)
03 Reichert Meissl Value 28 (min.)
04 Baudouin Test Negative
05 Moisture Content% 0.5 (max.)
PROCEDURE:
Sampling.
To ensure that only right quality of ghee is accepted and all parameters are
tested strictly as per the test procedures and records are maintained.
This covers sealed packets, Tin.

PROCEDURE FOR SAMPLING OF GHEE SAMPLES:

Cut open the packet/open the lid of Tin, mix properly and observe for any
abnormality and transfer to a 250 ml beaker for analysis. Check for the batch
number, date of packing, Size of packing, Clarity of prints, Type of ghee.

B.R. READING AT 40°C

Maintain the temp. at 40°C with circulating hot water from water bath.
Clean the prism of B.R.Meter with distilled rectified sprit.
Place 1-2 drops of melted butter oil and close the prism and take the reading.

Make correction if temperature is not 40°C.

Calculate B.R.Reading using the formula: R = R' + K (T' - T)
Where, R = B.R.Reading at 40°C.
R' = Reading at T'°C.
K = Constant 0.55 for butter oil.
T' = Temperature at which reading R' is taken.
T = Specified temperature i.e. 40°C.
Digital Refractometer
Clean the prism of digital refractometer gently. Check the brick value of glass
distilled water at 40°C. It should be zero. Dry the prism properly and put few
drops of melted Butter Oil and take reading in nD mode at 40°C. Instrument
will show Refractive Index (R.I). Convert R.I into B.R. reading with the help of

chart given here below. After completion of work, clean the prism with
rectified spirit, glass distilled water by using soft tissue paper. Switch off the
instrument.

RI (1.4524 to 1.4552) B.R.(40 to 44 )

1.4524 40.0
1.4525 40.1
1.4526 40.3
1.4527 40.4
1.4528 40.6
1.4529 40.7
1.4530 40.9
1.4531 41.0
1.4532 41.1
1.4533 41.3
1.4534 41.4
1.4535 41.5
1.4536 41.7
1.4537 41.8
1.4538 42.0
1.4539 42.1
1.4540 42.3
1.4541 42.4
1.4542 42.5
1.4543 42.7
1.4544 42.8
1.4545 43.0
1.4546 43.1
1.4547 43.3
1.4548 43.4
1.4549 43.6
1.4550 43.7
1.4551 43.9
1.4552 44.0
Determination of FFA as Oleic Acid % by weight:
This value is the no. of milligrams of Sodium Hydroxide required to neutralize

the Free Fatty Acid present in one gram of fat.

The value is the measure of the amount of Fatty Acid, which has been liberated
by hydrolysis from their glycerides due to the action of moisture, temperature
and lipase (enzyme).

Procedure
Weigh accurately 10 gm. of Ghee in a conical flask
Add 50 / 100 ml. freshly neutralized hot ethyl alcohol; boil the mixture for 5
minute with 1 ml. 1 % phenolphthalein indicator.
Titrate while hot against standard Sodium hydroxide.

FFA as Oleic Acid = 28.2 X VN/ W

V = Volume of Standard Sodium Hydroxide
N = Normality of Sodium Hydroxide
W = Weight in gram of the sample

Determination of Moisture
Hot air-oven method
Procedure:
Weigh accurately about 10 gms. of properly mixed Ghee in a previously tared
aluminium dish.
Loosen the lid of the dish and heat in an oven at 105 1OC for 1 hrs.
Remove the dish after closing the lid and cool in a desiccator and weigh.
Heat in the oven for further period of 1 hour, cool and weigh. Repeat it till the
weight between two successive heating does not exceed 1 mg.

Calculation:
Moisture % = W1 X 100 / W
Where,
W1 = weight loss
W = weight of oil taken
Detection of Sesame Oil (Baudouin Test): The development of pink colour with
furfural solution in the presence of hydro-chloric acid indicates the presence of
sesame oil.

Procedure:
To 5 ml. of melted fat in a test tube add 5 ml. of hydro-chloric acid and 0.4 ml.
of furfural solution. Shake vigorously for 2 minute. Allow the mixture to
separate. The development of pink or red colour in the lower acid layer
indicates the presence of sesame oil. Confirm by adding 5 ml. water and shake
again. If the colour persists, sesame oil is present.

Determination of Reichert – Meissl Value:

The RM value is the number of millilitres of 0.1N sodium hydroxide solution
required to neutralize steam volatile water-soluble fatty acids distilled from 5
gm. of oil / fat under the prescribed conditions. It is a measure of water-soluble
steam volatile fatty acid chiefly butyric and caproic acids present in fat. The fat
is saponified by heating with glycerol, sodium hydroxide and then split by
treatment with 1N sulphuric acid. The volatile acids are immediately steam
distilled. The soluble volatile acids in the distillate are filtered out and
estimated by titration with standard sodium hydroxide.
Butterfat contains mainly butyric acid glycerides. Butyric acid is volatile and
soluble in water.

Procedure:
Weight accurately 5 + 0.01 gm of sample to 300-ml.-distillation flask. Add 20
gms. of glycerine and 2 ml. of 50 percent sodium hydroxide. Saponify over a
flame. Cool the content slightly and add 90 ml. of boiling distilled water, which
has been vigorously boiled for about 15 minutes. After mixing, the solution
should be clear. Add 50 ml 1N Sulphuric acid & 0.6-0.7gms pumice stones
grains/glass bids and immediately connect the flask to the distillation
apparatus. Heat gently first and then set the flame so that 110 ml. of distillate
shall be collected in a 110 ml. flask within 19-21 minutes. Keep the water in the
condenser flowing at a sufficient speed to maintain the temperature of the
outgoing water from the condenser between 15-20° C. The beginning of
distillation is to be taken as the moment when the first drop falls from the
condenser in the receiving flask. Keep the 110 ml. flask in water bath
maintained at 15º C for 10 minutes. Take out & mix gently 4-5 times and filter
through Whatman no.4. Reject the first 2-3 ml of the filtrate and collect the
rest in a dry flask. Pipette out 100 ml and add 5 drops phenolphthalein solution
and titrate against N/10 sodium hydroxide. Run a blank test without the ghee.
RM = (A-B) x N x 11
A : Volume in ml. of standard sodium hydroxide.
B : Volume in ml. of standard sodium hydroxide required for Blank.
N : Normality of standard hydroxide.

Other Dairy Products:-

a. PANEER
Appearance: -Shall be clear and free from dirt, surface discoloration and
insect's contamination. It shall not have any free moisture.

Flavor: -It shall have pleasant odor and characteristic mild acid flavor

Texture; - It shall have a closely-knit smooth texture and spongy body.

Standards

Moisture Max.60

Milk fat Min.50(db)

T.A. Max.0.5

Moisture:-2 gm-shredded paneer is weighed in a dish. Mix with 4 ml hot

distilled water with glass rod. Wash off the particles on glass rod using 1 ml
water. Mix the contents thoroughly. Heat the dish at 102 + 1 C for 4 hrs. Cool
in dessicator. Weigh with cover on. Replace for 30 min. again at 102 and 1 C.
Weigh. Repeat till difference between successive weighing is less than 1
milligram.

Calculation:

Moisture % = 100 (W1 - W2)

(W1 – W)

W1 = dish + sample before drying

 W2 = dish + sample after drying

W = Mass of empty dish

Fat - Gerber’s Method

Reagents - Sulphuric acid (1.8 – 1.812 sg), Amyl Alcohol (0.85 as

Specific gravity)

Procedure:

- Take exactly 10 ml of Gerber’s Sulphuric acid in butyrometer

- Weigh accurately 1.69 Gms of shredded paneer and added in 10
ml Sulphuric acid.
- Add 1 ml amyl alcohol
- Make up the volume by distilled water
- Close the butyrometer with rubber stopper and mix the contents
until completely digested.
- Centrifuge the butyrometer for 5 min. at 1000 rpm.
- Place in water bath.
- Read the fat column.
Acidity

Reagents: N/10 NaOH and phenolphthalein indicator

Procedure

- Grind paneer pieces in mortar and pestle

- Weigh 2 gram of paneer sample in a conical flask
- Add 20 ml hot water slowly and mix properly using a glass rod
- Add 10 ml NaOH and 1 ml phenolphthalein indicator
- Titrate against N/10 HCl. End point is disappearance of pink
color.
Calculation

Titrate able acidity % = (10 - Vol. Of HCl) x 0.9

2
b. DAHI/MISHTI DOI
Color: - Shall be white, uniform without showing any sign of visible foreign
mater.

Body and Texture: -Should be firm solid and uniform with negligible whey
separation

Flavor It shall have a pleasant and cream acid taste. It should be free from
bitterness, saltiness or other off flavors.

Standard

Fat % (Min). 4.6

TS% Dahi 15

Misty Doe 31%

TA (Max). 1.2

Fat Determination

Reagents: - 25% Ammonia, Gerber’s Sulphuric Acid, amyl alcohol.

Procedure:-

To 100 gm of curd in a beaker add 5 ml of strong ammonia to the weighed

sample and shake well to make it homogenous. Pipette out 10.75 ml of well-
mixed sample of dahi and transfer it to butyrometer containing 10 ml Sulphuric
acid. To this add 1 ml amyl alcohol. Close the butyrometer with a rubber
stopper, mix so as to digest the contents and centrifuge for 5 minutes. Adjust
the fat column and take reading. Multiply the result with dilution factor (here
1/20) and add the same to the obtained result.

Acidity

Weigh accurately 10 gm of Dahl in 40 ml beaker. To it add 20 ml distilled

water and acidity can be determined using acidometer.

c. LASSI
Color: - White, uniform, without showing any sign of visible foreign
matter.

Body & Texture: - Smooth and free from gas bubbles

Flavor: - Pleasant and sweetish aroma. It should be free from bitterness,

saltiness or other off flavors.

Specifications

Fat% 3.1 (Min)

TS% 20 (Min)

TA 0.8 (Max)

Incubation Test

PH variation 0.3 max

TA - 0.02 max

Bulging Test - Negative

i) Fat determination

Gerber’s Method
Carefully dispense 10 ml of Gerber’s Sulphuric acid in a butyrometer.
Pipette out 10.75 ml of lassie into it. Add 1 ml of amyl alcohol. Mix the
contents well. Centrifuge for 5 minutes. Place in a water bath of 65 C
and take the reading.

ii) Total Solids

Total solids can be determined using gravimetric method. Same as that

of milk.

iii) Acidity
 Weigh accurately 10 Gms of lassie in a 50 ml beaker. Add about 30 ml
distilled water. Determine the acidity under the curd mode in the
acidometer.

d. FLAVOURED MILK

Appearance: -There should be no separation of fat or sedimentation.

Flavor: - It shall conform to the designated flavor. It shall have no off flavors
and visible sediment.

Specification:

Cream plug absent

Sediment absent

Fat % 1.5 Min

T.S. % 17.2(Min.)

TA (as lactic Acid) 0.17(Max).

Incubation Test at 37 C

a) pH variation of 7 days incubation max - 0.3

b) T.P (variation of 7 days incubation) - 0.02
c) Bulging Test Negative

Fat Determination

- Take 10 ml Sulphuric Acid into a butyrometer by means of

automatic measure
- Warm to 40 C and cool to 27 C
- Mix well
- Allow to stand for 3-4 minutes
- Transfer 10.75 ml of sample into butyrometer
- Add 1 ml amyl alcohol into butyrometer
- Close the butyrometer
- Transfer to 65 + 2 C water bath for 5 min.
 - Centrifuge the butyrometer for 4 min.
- Take out butyrometer into water bath for 65 + 2 C and allow
the butyrometer to stand for not less than 3 minutes
- Take down the reading
-
Acidity

- Switch on the instrument

- System test will appear
- Wait for some time
- Check user method (3)
- Screen will show - recall method, store method, delete
method
- Use recall method by putting cursor on it
- Press enter
- Select the program milk using the forward/backward key
- Press enter and the milk program will appear
- Put beaker having 10 gm of milk and 40 ml distilled water
- Stir using magnetic stirrer
- Dip the electrode and dispenser and press screen
- Acidity will come automatically on the screen
- After completion switch off the instrument

Total Solids

Gravimetric Method

Apparatus: Shallow flat bottom dishes of aluminum alloys, nickel, stainless

steel, porcelain silica, 7-8 cm diameter, about 1.5 cm in height and provided
with easily removable and closely fitting lids.

Procedure

- Weigh accurately the clean dry empty dish with the lid, pipette into the
dish about 5 ml of the prepared sample of milk and weigh quickly with
the lid on the dish.
- Place the dish uncovered on a boiling water bath
- Keep the base of the dish horizontal to promote uniform drying and
protect it from direct contact with the metal of water bath.
- After at least 30 min. remove the dish, wipe the bottom and transfer it
to a well ventilated oven at 98 - 100 C placing the lid by the dish
- The dish shall not be placed near the walls of the oven
- After 3 hours cover the dish and immediately transfer to a desiccators
- Allow cooling for about 30 min and weigh
- Return the dish uncovered and the lid to the oven and heat for 1 hr.
- Return to the desiccators - cool and weigh as before
 - Repeat if necessary until the loss of weight between successive weighing
does not exceed 0.5 mg. Note the lowest weight

TS (% by weight) = w x 100

w = weight in gram of residue after drying

W = weight in gram of prepared sample taken for test.

BACTERIOLOGY OF MILK
BACTERIOLOGY OF LIQUID MILK
Purpose
To test the liquid milk and report the findings for -
1) Standard Plate Count (SPC).
2) Coliform Count.

Equipments used
1) Laminar Air Flow
2) Sampling Bottle
3) Auto pipette with Tips,
4) Plating Media,
5) Dilution Blank (9 ml or 99 ml),
6) Test Tube /Culture Tube,
7) Durham's Tube,
8) Petri Dish,
9) Petri Dish Container,
10) Hot Air Oven,
11) Autoclave,
12) Incubator,
13) Colony counter,
14) pH Meter / pH Strips,
15) Media Making Utensil,
16) Refrigerator.
Sterilization
Sterilize sampling and plating equipments whenever possible with dry heat in a
hot air oven at 1600C for 2 hours.
Sterilize the media and materials that are likely to be charred in dry air oven,
by autoclaving at 15 psi (1210C) for 20 minutes.
After sterilization all media should be stored in hygienic condition.

Collection of sample.
Milk sample received should be stored in refrigerator below 7OC till tested.

In-house Sampling:
Silo: Apply cotton soaked in alcohol on the sampling cock to sterilize it. Allow
approximately 2 lit. of milk to flow out into a bucket then collect the sample in
sterilized sample bottle.
Tanker (Incoming): Thrust a plunger inside the tanker in different directions
for at least 10-15 minutes to mix the contents properly. Take the sample with
sterilized dipper and transfer into a sterilized sample bottle.
Tanker (Dispatch): Take the sample with a sterile dipper from the top and
transfer into a sterilized sample bottle.
Tanker (Return Milk): Apply cotton soaked in alcohol on the surface of
delivery valve. Allow approximately two-liter quantity of milk to flow out into
the bucket then collect the sample in sterilized bottle.

General Precautions:
a. Use only sterilized bottle to collect sample.
b. Collect all samples aseptically.
c. Stoppers or lid of the bottles should not be removed from the bottles
unless necessary.
d. Replace the stopper or lid immediately after the sample is obtained.
e. Do not fill the bottle more than three fourth of its capacity.
f. Clearly label each sample bottle indicating the source, date etc.
g. Keep the sample immediately in Refrigerator below 7OC.

Standard Plate Count Test

Materials Required:
1. Plating chamber.
2. Petri dishes
3. Plate Count Agar
4. Auto pipette with tips (1.0 ml) / Pipette 2.2 ml.
5. Dilution tubes containing 9 ml of batch phosphate buffer solution.
Procedure:
1. Transfer 1 ml of well-mixed milk sample to 9 ml diluent (phosphate buffer
solution). Mix well. Transfer 1 ml of this suspension to second tube to make
second dilution. Similarly make third and/or fourth dilution as per
requirement.
2. Arrange 2 Petri plates for each dilution to be tested, mark them with Sample
No. and Date.
3. Transfer 1 ml in each plate from respective dilution of sample being tested.
4. Melt the Plate Count Agar, cool it to about 45°C and pour 10 to 15 ml of this
medium into the Petri dishes. Mix the agar by rotating the plates
5. Allow the agar to set, invert and incubate the plates at 37 ±1°C for 48 hours.
6. At the end of 48 hours remove the plate from the incubator and count the
colonies.
7. Also prepare a control plate with 15 ml media for checking its sterility.
Counting and Expression of Results:
Count the colonies grown in Petri plates. Count only those plates, which have
30 - 300 colonies.
Computation:
Count the colonies developed in each plate for respective dilution.
Multiply colonies per plate by dilution used and report the arithmetic average
as plate count per milliliter /gram.
Recording / Reporting of Results:
Record and Report the result as – Standard Plate Count / ml /gm -------- Or
SPC / ml / gm ---------

Coliform Test for Milk:

Materials Required:
1. VRB Agar 2. Dilution blank (9 or 99 ml)
3. Auto pipette with tips) 4. Petri dishes

Procedure for Solid Media

1. Transfer 1 ml of well-mixed milk sample to 9 ml diluent (phosphate buffer
solution) & mix well to make first dilution. If required make second dilution by
transferring 1 ml of first dilution into 9 ml diluent.
2. Arrange 2 Petri plates for each sample mark them with Sample No. and
Date.

3. Transfer 1 ml in each plate respective dilution of sample to be tested.

4. Add 10 to 15 ml of VRB Agar, previously melted and cooled to about 45°C.
5. Mix the contents thoroughly by rotating the plates and allow the agar to
solidify. Pour additional approximately 5 ml. of the media over the surface of
the solidified medium and allow solidifying again.
6. Invert plates and incubate the plates at 37 ±1°C for 18 -24 hours.
Counting and Expression of Results:
Count dark red colonies measuring at least 0.5 mm in diameter.
Computation: Count dark red with red precipitate colonies measuring at least
0.5 mm in diameter in each plate for each dilution plated. Multiply colonies per
plate by dilution used and report the arithmetic average as Coliform Count-----
/ml/gm of products.

Recording / Reporting of Results:

Record and Report the result as - Coliform Count / ml /gm of product.

Test of Coliform Bacteria by Liquid Media (PCT):

Materials Required:
Auto pipette with tips /Pipettes of 2.2 ml.
Brilliant green bile broth 2% in tubes.
Procedure:
Transfer 1 ml from first dilution of sample into Brilliant Green Bile Broth 2%
tube in triplicate.
Incubate for 48 hours at 37 ±1°C and observe for acid and gas production.
Production of gas and opacity in at least two tubes out of three constitutes the
positive presumptive test.
If PCT is positive and simultaneously typical colonies observed on solid media.
This confirms the presence of coli form in the sample. If required further
confirmation may be done using streak techniques on EMB agar or
microscopically.
Disposal of Used Media:
Sterilize all used Petri plates and PCT tubes with media after observation /
counting by autoclaving at 15 psi for 20 minutes.Cool plates and tubes. Collect
all solid media in polythene bags and dispose.

BACTERIOLOGY OF WHITE BUTTER

Purpose: To test the white butter and report the findings for
1) Yeast and Mould 2) Coliform
EQUIPMENTS USED: same as in Liquid Milk
STERLIZATION: same as in Liquid Milk
COLLECTION OF SAMPLE
Using sterilized spatula remove the 5 mm surface layer of the product from
sampling area using aseptic techniques and sterilized trier collect the sample in
polytheneor sterilized bottle.

YEAST MOULD COUNT TESTING FOR BUTTER

Materials required:
a) Plating chamber.
b) Petri dishes
c).Yeast Extract Chloramphenicol agar / Potato Dextrose agar,
d) Auto pipette with tips (1 ml) / 2.2 ml glass pipettes.
e) Dilution tubes containing 9ml diluent and bottles with 99ml diluent.
f) Incubator set at 25+1OC.
PREPARATION OF TEST PORTION
Soften butter and mix thoroughly and weigh aseptically 11 gm Butter into 99
ml sterilized diluent previously warmed at about 45OC to make first dilution.
Transfer 1 ml of first dilution into tube containing 9 ml sterilized diluent to
make Second Dilution. Similarly prepare Third and Fourth Dilution as per
requirement.

Procedure of Plating:
1. Select 2 consecutive dilutions of sample to plate.
2. Arrange 2 Petri plates for each dilution; mark them with Sample No., Date
and Dilution Factor.
3. Transfer 1 ml in each plate respective dilution of sample.
4. Melt the Chloramphenicol Agar, cool it to about 45°C and pour 10 to 15 ml
into the Petri dishes. Mix the agar by rotating the plates.
5. Allow the agar to set, invert and incubate the plates at 25 ± 1°C for 5 days. If
moulds grow fast and develop into large colonies plates may be incubated for 3
days only.
6. Count the number of colonies grown in each plate and compute the result.
Also prepare a control plate with 15 ml media for checking its sterility. :
Counting and computation of yeast and mould colonies to express result
Counting: Count the colonies grown on two consecutive dilutions in Petri
plates. Count only those plates which have 15-150 colonies.
If there were no colonies on plates (from initial suspension in case of solid
product and test sample in case of liquid product) the number of yeast and
mould per ml of product should be reported as less than 1.
COLIFORM TEST
Using 1st / 2nd dilution, follow same procedure as for Liquid Milk.
Express the count directly (2nd dilution) for per gram of sample.

Expression Of Result for Coliform

Express the result as the number of Coliform count / gm of Butter.
DISPOSAL OF USED MEDIA: same procedure as for Liquid Milk
Some other important tests:-
Fat and SNF Testing on using Milkoscan:-
 Heat the milk sample in a waterbath/microwave oven to 40±20C temp.
 Mix the sample by gentle inversion of the sample bottle thrice.
 Select the appropriate channel for testing on the milkoscan and keep ready for use
Note :- Also select correct option for incoming/return/dispatch milk testing formate MD-
QSP-036-TM03F01 for incoming milk tanker, formate MD-QSP-036TM03F02 for dispatch or
returned milk tankers and formate MD-QSP-036TM03F05. MD-QSP-036TM03F06 are used
for milk sent to Federation and updation thereto.
Pateela Test:-
Aim :- To check % sedimentation due to action of flame.
Principle :- When milk is heated on low flame, in the inner base of the
container(pateela ) the solids stuck because of the particular which are in the
contact of hot wall of the container can’t transfer the heat immediately to the
particle just above it.
Apparatus :- Chemical balance, Pateela (1lit.), clamp, calculator, match box,
and gas stove.
Procedure:-
 First collect milk sample in a container and allow it to stand at room
temperature .
 Now take tare wt. of pateela (A) and pour 500g milk in pateela
 Lit the stove and heat it on low flame till it comes to boil
  Now turn off the stove stir gently and replace milk from pateela with
the help of clamp.
 After this leave the pateela to dry out for some time
 Now take the wt of pateela
Calculation:-
Let the tare wt. of pateela = A
Wt. of pateela sediment = B
Wt. of sediment = A-B
( B−A )
% Wt. of sediment = x 100
𝑊𝑡.𝑜𝑓 𝑚𝑖𝑙𝑘

Microbial Drug Residue Test (MBRT)/Antibiotic Residue Test :-

Aim:- Analytical method of detection of antibiotic Residue in milk and dried

milk products.
Introduction:-
The presence of antibiotic residues in milk adversely affects processing of dairy
food and public health in terms of starter failure, development of drug
resistance in pathogenic organisms and allergic reaction. The microbial
inhibitor tests have gained popularity in the dairy industry at all level
worldwide. The analytical method can be used effectively for targeting broad
spectrum detection of antibiotic residues in milk and milk products within 2.30-
3.0 hrs at MRL/or above MRL level as recommended by codex IEU. The method
developed by NDRI (Patent No. 1PR4.9.1.4/0574/1479/DEL/2006) meeting all
desired requirement i.e. cost effectiveness, better sensitivity, semi-quantitative
detection, validation against AOAC approved system stability of products under
storage condition, consistence in colour development , wide spectrum of
application for different types of milks.
Uses:- In Vitro
Contents:- 100 tubes with solid agar seeded with bacillus stearothermophilus
together with nutrient for growth purposes and bromocresol purple.
Direction:-
 Take out the required number of tubes from aluminum pouch by using a
knife or scissors label the tubes for identification. Be careful to damage
the tubes cap.
 Open the tubes by using the flip cap.
 Add milk sample.
 Place fresh sterile pipette tip into the 200ml micro pipette for each
sample of milk to be tested.
 Place out 75ml of sample of milk to be tested and –ve control by using
200ml micropipette.
 Transfer completely 75ml of the sample and negative control in to the
tubes in the corresponding labeled tubes. This is done by slowly adding
sample straight to the agar medium.
PRODUCTION SECTION(BVM)
Production section is divided into following sections:-

Milk
Processing
Plant

Plant
Ozonation
Automation
Plant
System
Production
Section
(BVM)

CIP UV Plant

Milk Plant processing

Milk is processed in a completely computerized plant, so there is no
chances of error during processing as each and every process is operated on
computer based programmed. As well as there is no contamination by human
handling or by the people working there since every equipment is installed so
precisely with appropriate indicators wherever necessary to avoid any possibility
of quality deterioration at any stage.
Unprocessed milk may contain small dirt particles invisible to the naked eye. In
order to remove these particles the milk has to be processed.
In any kind of industry various processes are undertaken to process the raw
materials to obtain the final product. So each such process can be divided into
discrete steps which when undertaken one by one lead to the complete process.

In our case at Mother Dairy, the process is to process the raw milk in the required
standard conditions and to reach the final processed milk at the desired
standards. The milk processing plant at the Patparganj unit is engaged in receiving
any kind of the raw milk from the state dairy federations and process it to
produce Toned Milk, after doing the pasteurization. The standards for the
processed Toned Milk are as follows:

Fat contents: 3.05%

Solid non-Fat contents: 8.56%
Temperature: 2-40C
Methyl blue re-coloration (MBR) time: 5 hours (minimum)

Before reaching the final state the raw milk is subject to various processes shown
below:

FLOW AND PROCESSING OF MILK

Raw Milk Reception

To RMST

Balance Tank

Regeneration-I

Clarifier

Regeneration –II

Homogenizer

Regeneration –III

Heating section

Holding section

Flow diversion valve(FBD)

 Regeneration –II

Regeneration –I

Cooling section

To PMST

Dispatch

(1)Raw Milk Reception :- This is the first stage of the milk processing. In this stage
the raw milk being received from the dairy federation tankers/ milk being
received from distant federations by the rail route, milk prepared at the dairy
plant after reconstitution/ high fat processing is chilled and stored in the Raw Milk
Silos. When a Silo is full, then a sample is taken in the process lab and is tested for
its constituents.
(2) Regeneration-I : The milk is pumped to the balance tank from there the milk
is pumped to regeneration-I wherein it gets heated to about 40-45°C because of
outgoing milk and hence reducing its temperature. Regeneration system helps in
energy saving both for heating as well as of cooling milk.

(3) Clarification: Clarification is the process of removing suspended foreign by

centrifugal sedimentation – clarifies are used for this purpose.

(4) Regeneration-II :- The milk from clarifier is sent to regeneration-II wherein the
milk is further heated by the pasteurized milk hence raising the temperature of
incoming milk and reducing the temperature of outgoing milk and also
regeneration-II raises the temperature of milk so as to enable efficient
homogenization which is the next step.

(5) Homogenization :- Homogenization is a process wherein fat globules are

broken down to 2 microns or less under high pressure Homogenizer is a machine
which cause sub-diversion of fat globules. It consists of a high-pressure piston
pump that forces the milk and thereby subdivided into smaller particles of more
uniform size.
Effect of homogenization:- The fat globules of milk are surrounded by a
membrane 5-10 mm thick. The membrane has properties of an emulsifier and
keeps the emulsion, milk stable. During homogenization the original membrane is
destroyed and the first result is a rise in interfacial tension soon falls again. The
new emulsion therefore remains stable even after homogenization.

Homogenization effect is produced by three collaborating factors:

(a) Passage through the narrow gap in the homogenizer head at high velocity
subjects the fat globules to very powerful shear forces, which deforms elongate
and shatter the spherical globules.
(b) The acceleration of the liquid in the gap is accompanied by a pressure drop.
This creates cavitations in which the globules are subjected to powerful impulsive
force.
(c) Further shattering takes places when the fat globules impact at high
Velocity in the homogenizing head.

(6) Pasteurization:.

Here milk is heated using plate-heat chiller to a temperature of 78°C (+/-2) and
the temperature should not be less than 76°C so as to ensure proper
pasteurization and not greater than 82°C so as to ensure that overheating has not
taken place as overheating may harm the nutrients present in milk.
Pasteurization of milk is done with the help of hot water. The water in a small
tank is passed through a heater steam wherein the water is heated using steam.
The hot water is then passed through PHE to heat up milk to the desired
temperature. After the milk is heated the milk pass over to the holding section
wherein it pass for 15 seconds at that temperature. The temperature of the
outgoing milk is transmitted with the help of a temperature transmitter, which is
connected to temperatures indicating controller, which controls the flow of steam
according to the temperature. If the temperature is too high it limits steam
injection in heater and if too low the steam level is enhanced through a system of
pneumatic valves.
The milk then passes through the flow diversion valve which decides the forward
or deflected flow of milk. If the temperature of milk is below 76° C the FDV
diverts the flow of milk to balance tank and if above 76°C the forward milk flow is
maintained. But by continuous monitoring it is ensured that the temperature is
maintained at 78°C. At the same time it is also seen that the temperature do not
exceed 80°C and according to the fluctuation the steam injection is controlled.
From the pasteurization section milk flows to regeneration II and then
regeneration I and finally chilling
(7) Chilling:
Here milk is finally chilled to 3-4°C using chilled water which is being pumped
from ice silos. The chilled water temperature ranges from 1.5 – 3°C and chilled
milk temperature from 3 – 5°C. If the chilled milk temperature exceeds 9°C the
milk will be again circulated through the systems so a temperature transmitter
continuously displays the temperature on monitor so that continuous monitoring
can be done and if temperature rises continuously the refrigeration section take
necessary action in this regard so as to reduce the temperature. After chilling,
milk is pumped to the silos.
(8) Vitamin A addition:- Toned milk during processing is fortified with vitamin A.
Vitamin A addition is done using vitamin A acetate. Vitamin acetate is added in
the balance tank for each shift. The amount added is 180 ml of vitamin A acetate
in one lakh liters of milk so that the milk contains 2000 IU of vitamin A.
(9) Standardization:- The milk, which reaches the raw milk silos, is of different fat
and SNF composition. Normally raw milk silo 1, 2, 3 contains mixed milk and 4 &
5 comprises of skim milk which may contain different proportion of fat and SNF.
Now to obtain toned milk of 3% fat and 8.5% SNF different proportion of milk
from different silos is calculated and processed and are directed to processed milk
silos. For this first total amount of batch of milk is determined or fixed and
amount of SNF and fat requirement for this batch is calculated. Now amount of
mixed milk and skim milk is processed and diverted to processed milk silos and
now the remaining quantity i.e. quantity decided is made up using chilled UV
water directly into the process milk silo hence obtaining a batch of appropriate fat
and SNF values. For complete mixing of different batches of milk, agitators are
provided. Now after these samples are drawn from PM silo and tested for fat and
SNF and if found unsatisfactory it can be again corrected using calculated
amounts of water or skim milk. After assuring that the fat and SNF valves are up
to the mark silo is marked for dispatch.

(10) DESPATCH
After the fat SNF and quality testing of PM silo is done and quantity is full, the
Silo is marked for dispatch Before dispatch milk is pumped over to glycol chillers
and the milk is chilled to 2°C in glycol chillers. Here instead of chilled water,
chilled glycol of approximately –0.5°C is passed into the chillers. The chilled milk
is then filled in tankers and the tankers then go to the milk vending shops for
sales.
Processing Parameters:-
Pasteurizer:-

 Milk flow in the plant 16000-18000 LPH

 Pasteurization temperature 78-800C
 Chilled water temperature 1-20C
 Chilled milk temperature 3-50C
 Milk pressure in the plant 2-3Kg/cm2
 Regeneration Efficiency More than 90%
 Milk/water leakages No leakage
Clarifier :-
 Oil level 1/2 of level view glass
 Speed 6200 RPM
 Milk pressure in clarifier 4 Bar.
 Make up water pressure 1.5 kg/cm2
 Flush water pressure 1.5 - 2kg/cm2
 Motor current 30-34 amps
 Discharge interval 20 minutes
 Discharge qty 10 Liters (approx.)
 Abnormal sound No
 Abnormal heating No
 Abnormal vibration No
 Leakages No

Homogenizer:-

 Lubrication oil level 1/2 of level view glass

 Lubrication oil pressure 1bar(Minimum)
  Milk pressure in HVA 2000 PSI
 Cooling water for piston spray should be visible
 Cooling water for oil Visible in the drain point
 Tension of belt Normal
 Oil leakage No oil leakage
 Milk leakage No oil leakage
 Water leakage No oil leakage
 Abnormal sound No
 Abnormal heating No
 Abnormal vibration No
Specification of Equipments in milk processing plant
Sr. No. Name of the Equipments/machinary Specification
Make-IDMC Ltd.,200lit,Pneumatically controlled diaghragm
Balance Tank(BT)
1 balance sensor (7-100 psi),level sensor(high and low)
Make-IDMC Ltd., rpm-2000, HP-10, Volt-415, Freq-50Hz,
Pump
2 Capacity-20KLPH (1700LPH)
Make-IDMC Ltd., capacity-20KLPH, chilled water-
3 40KLPH,Temp of chilled water-2⁰C , Pasteurization temp-
Pasteurizer 78±2⁰C for 15 sec, Milk outlet temp- 6⁰C(max).
Make-α Laval, Capacity-20KLPH, Oil used Mobile 630, Bowl
rpm-6240, Back pressure-3-4kg/cm2, Air pr. For CPM valve-
1.5-2.0 kgs/cm2, Discaharge quantity-5-10lit, Discharge
4 Clarifier interval- 10-30mins.
Make- APV Gaulin, Capacity-18KLPH, Oil Used-Mobile 630,
Lubricating Oil Pr.Min-1.5 kgs/cm2, Oil Safty tripping-
0.8kgs/cm2, Operating Milk pr. -first stage-1800-2000 psi,
6 Homogenizer second stage-500-700 psi., Motor HP-125
7 Raw milk battery used for reception of milk
8 Pateurized Milk battery used for discharge of milk
no. of units-3, Make- IDMC Ltd,Capacity-100KL, sensor
attached-(temperature transducer,opening/closing sensor,
level sensor), Milk inlet/ outlet valve,manual valve,
manhole, sample outlet, Agitator, Angle Valve for flushing
9 Raw Milk Silo of CIP Water.
10 Skim Milk Silo NO. of units- 2, rest specification is same as RMST
11 Pasteurized Milk Silo No. of units-7, rest specification is same as RMST
Ozonation Plant:-It is a process of disinfectant to kill microorganism.The process
produces no taste and odour in water. Since ozone is made of oxygen and it can
easily be convert to oxygen without trace once it has been aged.

UV Plant:- Uses UV rays for disinfection. It purely physical, chemical free process.
Range of UV radiation 240nm -280nm . It attacks vital DNA of bacteria to kill
them.

Plant Automation System (BVM):-

 Distribution Control System(DCS):- Control the whole plant and create’s

the automation.
 Engineering Application Server:- For software programming of Plant
Control and Automation.
 Operation Work Station:- For plant control by operators and check the
running Plant Status.
 Uninterrupted Power Supply(UPS):- > hours backup.
 Remote input/output Panel(RIO):- To connect the field instruments with
the DCS System.
 Field instruments:-
a. Pneumatic Valve
b. Varriable Frequency Drive
c. Level Switch
d. Temperature Transmitter
e. Pressure Transmitter
f. Proximity sensor
g. Level Transmitter
h. Flow Transmitter

Cleaning In Place(CIP):-

Cleaning- in -place also called In-place-cleaning refers to that system of

cleaning and sanitization which does not require the daily dismantling of the dairy
equipment. Containers and machines working on milk are subject to the gradual
growth of bacteria with the passage of time. So in order to ensure the proper
processing of milk and no bacteria passes to the processed milk the milk
containers i.e. the silos and the plant have to be cleaned after eight hours. So in
order to ensure proper cleaning a proper CIP plant is required in which cleaning in
place is done. Further the CIP process is dependent on the type of the
machine/container and there are only slight variations to the general procedure.
The cleaning process in general contains the following steps:
Solution Temperature Strength
Lye
O
70 to 75 C 1.5 – 2%
Acid
O
70 to 75 C 1.5 – 2%
Hot Water 80-907OC -
Soft Water 37.5 OC -

Process of CIP:-

Circulation of Cold water (soft)

Circulation of lye solution, 30min.

Circulation of hot water, 10min

Circulation of acid solution, 20 min

Circulation of hot water, 10 min

Circulation of cold water.

CIP Automation System:-

CIP System in Automation

CIP 1 CIP 2

CIP Feed 1-
1(CF1-1)- (i)
To Silos 1-
12,(ii) To CF2-1-To Mother
Recon-1& Dairy Tankers
2(,iii) To
dispatch

CIP Feed-1-
2(CF1-2)- (i) To CF2-2-To
Pasteurizer 1-5 Mother Dairy
(ii) To butter Tankers
Section

CF2-3- To Mother
Dairy Tankers +
Federation Tankers
and Recovery

PRODUCTION (UTILITIES):-
We have discussed that the production of milk involves many processes
and to fulfill these processes there is the requirement of the hot water,cold
water,air for the operation of pneumatic valves and continuous supply of water
,so the question arises what are the sources of them.

The following utilities in the production departmant fulfill this:

1) Refrigeration - Cold water source.

2) Air compressors & Drier – Air for the operation of pneumatic valve.
3) Boilers – Steam and hot water source.
4) Nano water plant – fulfills the water requirement in pasteurizer plant.

BASIC WORKING OF PRODUCTION UTILITIES

AIR COMPRESSOR (FOR REFRIGERATION(PROVIDES

PNEUMATIC VALVE) COLD WATER )

NANO WATER TREATMENT BOILER(PROVIDES STEAM

(FOR PURE WATER) & HOT WATER)

Milk
Plant

EFFLUENT TREATMENT PLANT

(ETP) (FOR WASTE WATER
TREATMENT)
Now in the following pages , I will be discussing about all the defined utilities in
detail and covering the following topics regarding each :

1) Definition
2) Types
3) Date of visit
4) Working
5) Components
6) Application
7) Maintenance
8) Pros & Cons

AIR COMPRESSOR & AIR DRIER:

Air compressors have been in mother dairy installed in order to provide the dry
and pure air for the functioning of pneumatic valves present in the plant. As we
can understand from the word Pneumatic , which means pressure of air , these
pneumatic valves also works with the pressure of air.

BASIC WORKING:

AIR COMPRESSOR PLANT

+ (FOR PNEUMATIC
AIR DRIER VALVE)

DEFINITION:
An air compressor is a device that converts power (usually from an electric
motor, a diesel engine or a gasoline engine) into kinetic energy by compressing
and pressurizing air, which, on command, can be released in quick bursts.
TYPES:
There are generally 10 types of compressors which are generally classified as:
1. According to the design and principle of operation
1. Reciprocating compressor
2. Rotary screw compressor
2. According to the number of stages
 1. Single stage compressor
2. Multi stage compressor
3. According to the pressure limits
1. Low pressure compressors
2. Medium pressure compressors
3. High pressure compressors
4. According to the capacity
1. Low capacity compressors
2. High capacity compressors
5. According to the method of cooling
1. Air cooled compressor
2. Water cooled compressor

THE TYPE OF COMPRESSOR WHICH IS USED IN MOTHER DAIRY IS SCREW AIR

COMPRESSOR.

A rotary screw compressor is a type of gas compressor which uses a rotary type
positive displacement mechanism. They are commonly used to replace piston
compressors where large volumes of high pressure air are needed, either for large
industrial applications or to operate high-power air tools such as jackhammers.
The gas compression process of a rotary screw is a continuous sweeping motion,
so there is very little pulsation or surging of flow.

WORKING:
Rotary screw compressors use two meshing helical screws, known as rotors, to
compress the gas. In an oil-flooded rotary screw compressor, lubricating oil
bridges the space between the rotors, both providing a hydraulic seal and
transferring mechanical energy between the driving and driven rotor. Gas enters
at the suction side and moves through the threads as the screws rotate. The
meshing rotors force the gas through the compressor, and the gas exits at the end
of the screws.
Then the air is passed through the drier, from where all the moisture present in
the gas is removed and the air is completely dried.
And hence, the dried air is sent to the air compressor for the working of
pneumatic valves.
APPLICATION:
Typically, they are used to supply compressed air for general industrial
applications, and are used to power air operated construction machinery.
MAINTENANCE:
Maintenance of air compressor is being done once in 6 months and during this
the air suction vent, filter screw fans and the exhaust are dry cleaned to maintain
the efficiency.
PROS AND CONS:
1) It has low leakage levels and low parasitic losses.
2) The twin-screw exhibits internal compression which is the ability of the device
to compress air within the housing as it is moved through the device.
3) Screw type supercharger a more expensive alternative to other forms of
available forced induction.
4) Twin-screw types offer more immediate boost.

BOILER:

Boiler is used to provide the steam and hot water of the temperature range of
750C to 850C in the pasteurizing plant which plays an important role in the
pasteurizing process and it even used in ice cream plant of the mother dairy.
BASIC WORKING:
 PLANT
BOILER (FOR HOT WATER
& STEAM)

DEFINITION:
A boiler is a closed vessel in which water or other fluid is heated. The heated or
vaporized fluid exits the boiler for use in various processes or heating
applications, including boiler-based power generation, cooking.
TYPES:
There are many types of boilers which are known and some of the types are
1) Fire tube boiler
2) Water tube boiler
3) Horizontal boiler and vertical boiler
4) Balanced draft boiler
5) Natural draft boiler
6) Packaged type boiler
IN MOTHER DAIRY FIRE TUBE BOILER IS USED.
Fire-tube boiler is the type in which water is flown inside the tubes and heat is
supplied to it externally which heats up the water present in the tube.
WORKING:
Here, water partially fills a boiler barrel with a small volume left above to
accommodate the steam . The heat source is inside a furnace that has to be kept
permanently surrounded by the water in order to maintain the temperature of
the heating surface just below boiling point. The furnace can be situated at one
end of a fire-tube which lengthens the path of the hot gases, thus augmenting the
heating surface which can be further increased by making the gases reverse
direction through a second parallel tube or a bundle of multiple tubes (two-pass
or return flue boiler); alternatively the gases may be taken along the sides and
then beneath the boiler through flues (3-pass boiler).
 FUEL USED: Mixture of air and pressurized natural gas (PNG) is used and it is
burned with the help of dual fuel burner.
APPLICATION :
It is mainly used in production industry as well as manufacturing industry , where
there is a requirement of hot water and steam.
MAINTENANCE:
Its maintenance includes 1) Daily inspection , 2) Washout , 3) Periodic
examination 4) General overhaul.
PROS AND CONS:
1) Steam of higher temperature is obtained.
2) Pressure of steam can also be maintained.
3) Natural gas is used as the fuel.
4) Maintenance is costly and it also causes pollution.

REFRIGERATION PLANT:

It is the source of providing cold water of the temprature range 20C to 60C in the

HOT CONDENSOR AMMONIA RECIVER

AMMO COMPRESSOR
NIA
GAS

Chilled glycol
at -20C for
cooling
purposes at ECONOMISER+PUMP
EVAPORATOR SEPARATOR EXPANSION VALVES
different
places.
pasteurising plant for the desired operation to take place such as in cooling of
milk during the process of pasteurization.

DATE OF VISIT: 1-12-2016 to 30-12-2016

DEFINITION:
Refrigeration is a process in which work is done to move heat from one location
to another. The work of heat transport is traditionally driven by mechanical work,
but can also be driven by heat, magnetism, electricity, laser, or other means.
METHODS: There are methods of refrigeration not the types. Some of the
methods are pointed below.
1 Non-cyclic refrigeration
2 Cyclic refrigeration
 1 Vapor-compression cycle
 2 Vapor absorption cycle
 3 Gas cycle
3 Thermoelectric refrigeration
4 Magnetic refrigeration
IN MOTHER DAIRY VAPOR COMPRESSION CYCLIC REFRIGERATION METHOD
IS USED.
The vapor-compression cycle is used in most household refrigerators as well as in
many large commercial and industrial refrigeration systems.
Some main components and of vapor compression refrigeration system are:
1) Screw gas Compressor
2) Condensor(PHE) [source of water is from cooling towers]
3) Ammonia receiver
4) Expansion valves
5) Economizers
6) Pump separator
7) Water chiller(PHE)
8) Ice silo
9) Gycol chiller (PHE)[used during supply of milk in tankers]

WORKING OPERATION:
1)The thermodynamics of the cycle can be analyzed on a diagram as shown in
Figure below. In this cycle, a circulating refrigerant AMMONIA(NH3) enters the
compressor as a vapor. From point 1 to point 2, the vapor is compressed at
constant entropy and exits the compressor as a vapor at a higher temperature,
but still below the vapor pressure at that temperature.
2) From point 2 to point 3 and on to point 4, the vapor travels through the
condenser which cools the vapor until it starts condensing, and then condenses
the vapor into a liquid by removing additional heat at constant pressure and
temperature.
3) Between points 4 and 5, the liquid refrigerant goes through the expansion
valve , economiser(in which economy of refrigerant is maintained) and ultimately
through pump separator where its pressure abruptly decreases, causing flash
evaporation.
4)That results in a mixture of liquid and vapor at a lower temperature and
pressure as shown at point 5. The cold liquid-vapor mixture then travels through
the evaporator coil or tubes and is completely vaporized by cooling the warm air.
5) The cold water is then sent directly to the plant or stored inside the ice silos.
The resulting refrigerant vapor returns to the compressor inlet at point 1 to
complete the thermodynamic cycle.

APPLICATIONS:
1)For air conditioning of private homes and public buildings.
2)For refrigerating foodstuffs in homes, restaurants and large storage
warehouses.
3) Refrigeration is used to liquify gases - oxygen, nitrogen, propane and methane,
4) Metal workers use refrigeration to temper steel and cutlery.
MAINTAINENCE :
1)Body of the compressor and other projected part is cleaned everyday. Oil level
is maintained and other pars are overhaul in the interval of 3 to 6 months.
2)Plates of PHE condensors,water chillers,glycol chillers are checked for flow rate
periodically.
3)Ammonia receiving tanks , economizer , pump separator tanks are checked for
no leakage.
4)All pipelines are checked for no leakage.
PROS AND CONS:
1) Refrigeration stands useful in pasteurizing plant as it provides water of very
low temperature.
2) Installation cost is high and complicated.
3) Refrigerant used ammonia is dangerous to human life if leaked.
4) Maintenance is tiring.

NANO WATER TREATMENT PLANT:

In this plant ground water is treated thoroughly in series of filters so that it can
become suitable for use in pasteurizer plant.

PLANT
NANO WATER
TREATMENT PLANT (FOR PURE
WATER)

DEFINITION: Clearly nano means the size of the order 10-9 .So in this plant
impurities of the minute size is removed from the water when it is passed through
the series of filters places sequentially.
COMPONENTS:
1) TUBE WELL(TURBINE PUMP)
2) RESERVOIR
3) AERATION TANK
4) MULTI GRADED FILTER
5) IRON REMOVAL FILTER
6) ACTIVATED CARBON FILTER
7) MICRON CARTRIDGE FILTER
8) NANO FILTER
9) STORAGE TANK AND SUMP TANK
WORKING OPERATION:
1)Grounded water is collected in reservoir with the help of tube well. Then it is
send to the aeration tank to get aired then subsequently the chlorination of water
is done.
2) After that with the help of feed pump water is send into the multi graded filter
tank in which it is mixed up with the help of air blower which removes turbidity
then consequnetly it is send into the iron removal folter and then to the activated
carbon filter which removes chlorine from the water.
3)Then the water is passed through M.C.F (5 micron) and further with the help of
high pressure pump it is feeded into the pressure tube. Then the impure water is
drained and purified water is stored in the tanks.

APPLICATIONS:
It finds its application where the water of great purity is required so that it is
portable for drinking and free from any dirt and bacteria.
MAINTENANCE:
MCF and membranes are pressure tubes are checked weekly and are cleaned
fortnightly.
PROS AND CONS:
1)Water of great purity is obtained.
2)Filters used in it are costly.
3)This water lacks some important salts which makes it unportable for drinking.

R.O(Reverse osmosis) WATER PLANT:

This plant is used to remove sludge and impurities from the grounded hard water
which is then is to be used in the operation cooling towers(refrigeration system).

COOLING TOWERS
R.O WATER PLANT (DESCALED &
PURIFIED WATER)

DEFINITION:
Reverse osmosis is the process in which the pressure applied is greater than the
osmotic pressure which reverses the flow through the semi permeable membrane
and hence stalls the bacteria from going further onwards with the water and
hence purifies the water.
COMPONENTS:
1) DUAL MEDIA FILTER
2) DOSING(ANTI- SCALANT & SMBS)
3) MICRON CATRIDGE FILTER
4) HIGH PRESSURE PUMP AND D.G PUMP
5) R.O. MEMBRANE
6) FINAL WATER TANK OR D.G. TANK

WORKING OPERATION:
1) Hard water is passed through 2 dual media filter which removes sludge fron
the water after it dosing of water is done with anti-scalant and SMBS.
2) Then water is passed through the micron catridge filter which further
removes the harmful bacteria and at last water is fed into the R.O.
membrane which further removes all the impurities from the water.
3) At last with the help of high pressure pump water is then stored in the final
water tank from where it is send to the cooling tower for further operation.
PH OF WATER IS MAINTED AT 6 , THEN ONLY IT IS FED INTO COOLING TOWER.
APPLICATIONS:
Nowadays this process has been recognized in most of the industry and more
famely in household drinking purposes.
MAINTENANCE:
It is maintained according to the quality of water it is giving out. But it requires a
monthly checkup and its membrane is changed once every year.
PROS AND CONS:
1) Water free from dirt and bacteria is obtained with transparency of 99%.
2) it is portable for drinking.
3) Installation charges are very high and so as the maintenance cost.

EFFLUENT TREATMENT PLANT:

Effluent treatment plant is used to treat the waste water that is extracted from
milk plant ,ice cream plant and the sewage line before discarding it to the
environment.

WASTE WATER EFFLUENT TREATMENT

PLANT(E.T.P)

TO RIVER YAMUNA
FOR GARDENING PURPOSE

DEFINITION:
As clear from its name, the effluent or the waste that is present in the water is
treated and it is made free from the harmful substance before discarding it to the
outer enviornment which in turn cause enviornmental pollution.

COMPONENTS:
1) PUMP HOUSE
2) EQULIZATION TANK
3) AERATION TANK
4) CLARIFIER
5) FINAL SUMP
6) DRYING BEDS
WORKING OPERATION:
1) The waste water is collected with the help of the pumps kept in the pump
houses.
2) Then water is filled in the equilization tank where it is neutralized with the
help of air blowers.
3) After that water is collected in aeration tank where it is aired in order to
provide oxygen to the biomass present in the water.
4) Then it is filled in the clarifier from where sludge is removed than it is
collected in the final sump from where required quantitiy of water is used
for gardening purposes and the remaining water is discarded to the river
yamuna.
Hence water free from harmful impurities is removed before discarding it to
the enviornment.
WATER STANDARD BY DPCC (Regarding DAIRY EFFLUENT)
PARAMETER STD. MIN. VALUE STD. MAX. VALUE UNIT

Ph 6.5 8.5

TSS 0 150 mg/l

BOD 0 30 mg/l

O&G 0 10 mg/l

WASTE WATER 0 3 M3/Kl of milk

GENERATION

APPLICATION:
Due to government policies it is compulsory for every industry to have effluent
treatment plant before discarding the wate product out of the industry.
MAINTENANCE:
It requires maintenance on the daily basis or as per the flow rate of water through
the plant.
PROS AND CONS:
1) Its plays very crucial role in preserving of natural water bodies.
2) It removes harmful impurities from the waste water.
3) Initial cost is high and proper maintenance is required for better working of
this plant.

ECO-FRIENDLY POLICIES
a) Solar Panel:- In an effort to conserve fuel, earlier Mother Dairy utilizes the
abundant solar energies to PREHEAT the water going into the boiler. Also in
2016 it has installed solar water heater used for CIP. It is able to heat the water
to 800C which is suitable for CIP.
b) Rain Water Harvesting:- For maintaining ground water level, Mother Dairy
has installed rain water harvesting plant in the dairy premises.
c) ETP:- The water used for Cleaning equipment and tankers is treated at the
effluent treatment plant in the Mother Dairy before being discharged into the
sewage system.

CONSUMER AWARENESS
To increase consumer awareness about milk. Mother has set up a Consumer
Department to educate consumers. In its laboratories, consumers can see for
themselves how impurities and adulterants are easily detected. Mother Dairy
also has Mobile Lab that can test milk in the residential colonies. All this is part of
a commitment to provide the consumers with the purest milk Mother Naturehas
to offer.

THANKING NOTE:-
At last I describe this training of mine as a fruitful one. It yielded many
things in response and helped me to learn many things, which will
certainly be helping me in our future life in dairy industry.

At last I once again thank all those people who helped me in

completing this In-plant training successfully.
Thanking everybody
ICE-CREAM PLANT

1.Ice Cream- Defination and Composition

Ice cream is a frozen dairy product made by suitable blending and processing of cream
and other milk products, together with sugar and flavour, with or without stabilizer or colour, and with
the incorporation of air during the freezing process

DEFINITION :-

According to the FSSA (2006), Ice Cream, Kulfi, Chocolate Ice Cream or Softy Ice Cream
(hereafter referred to as the said product) means the product obtained by freezing a pasteurized mix
prepared from milk and /or other products derived from milk with or without the addition of nutritive
sweetening agents, fruit and fruit products, eggs and egg products, coffee, cocoa, chocolate,
condiments, spices, ginger and nuts and it may also contain bakery products such as cake or cookies as a
separate layer and/or coating. The said product may be frozen hard or frozen to a soft consistency; the
said product shall have pleasant taste and smell free from off flavour and rancidity; the said product
may contain food additives permitted in these regulation including Appendix A; the said product shall
conform to the microbiological requirements specified in Appendix B; the said product shall conform to
the following requirements, namely:—
Note: In case where Chocolate, Cake or similar food coating, base or layer forms a separate part of the
product only the Ice Cream portion shall conform to the requirements given above. The type of ice-
cream shall be clearly indicated on the label otherwise standard for ice-cream shall apply.

Classification of ice cream:-

No standard classification of ice cream has yet been adopted by the industry, even in
developed countrie . However , some of the important frozen desserts can be classified as
follows:-

i. Plain :- An ice cream in which the colour and flavouring ingredient together amount
to less than 5 per cent of the volume of the unfrozen ice cream . Examples: Vanilla
and Coffee ice creams.
ii. Chocolate:- Ice cream flavoured with cocoa or chocolate .
iii. Fruit :- Ice cream containing fruits , with or without additional fruit flavouring or
colour. Fruits such as strawberry, apricot, pineapple, mango, banana, etc., may be
fresh, frozen-packed, canned or preserved.
iv. Nut:- Ice cream containing nuts, such as almonds, pistachio, walnuts, cashewnut,
etc., with or without additional flavouring or colour.
v. Milk ices or milk lollies:- According to the FSSAI these refer to the frozen product
obtained from milk, skim milk or milk products with or without the addition of cane
sugar, eggs, fruits, fruit juices, nuts, chocolates, edible flavours,and permitted food
colours. It may contain ppermitted stabilizers not exceeding 0.5 per cent of the
product. The mixture should be suitably heat-treated before freezing. The product
should contain not more than 2.0 per cent milk fat, not less than 3.5 per cent
proteins and not less than 20.0 per cent total solids.
vi. Ices :- Made of fruit juices, sugar and stabilizer, with or without additional fruit acid,
colour, flavouring or water, and frozen sugar, 20 to 25 per cent overrun and no
dairy products.
vii. Sherbet:- Made of fruit juices, sugar, stabilizer, and milk products. It is similar to an
ice except that milk, either whole, skin, condensed or powdered, or ice cream mix,
are used in place of all or part of the water in an ice.
 viii. Fancy moulded :- Moulded in fancy shapes and composed either of one colour and
flavor of ice cream or a combination of colours and flavours or especially decorated.
Examples- brick ice cream, cakes, cake roll, moulds representing fruits, etc.
ix. Novelties:- A Novelty ice cream or frozen confection is an individual serving whose
main appeal consists in its shape, size, colour or convenience for eating.
x. Soft ice cream(Softy):- Sold as drawn from the freezer without hardening.

Composition:-

The ISI specifications for ice cream (IS: 2802,1964) are given in Table:-

Characteristics Requirements
Weight(g/lit)(min.) 525

Total Solids(%wt)(min.) 36.0

Milk Fat(%wt)(min.) 10.0 (Tentative)

Acidity(%LA)(max.) 0.25

Sucrose(%wt)(max.) 15.0

Stabilizer/Emulsifier(%wt)(max.) 0.5

SPC(per g.) NMT 2,50,000

Coliform count(per g.)

NMT 90

Phosphatase test
-ive
Food and Nutritive value of ice cream:-
 Depends upon the composition of ice cream and nutritive value of the ingredient from
which it is made.
 It contain two to three times as much fat slightly more protein than does milk.
 It may also contain other food products such as fruits, nuts, eggs, and sugar which
enhance it s food value.
 Ice cream is also a rich source of calcium, phosphorous, and other minerals of vital
importance in building good bones and teeth.
 Being rich in lactose, ice cream favours greater assimilation of the calcium content in the
diet.
 The protein content of ice cream also rates high, both in quantity and quality.
 The are largely derived from milk, a small amount from stabilizer (gelatin ) and from
eggs when they are used in the mix.
 The milk and egg proteins are complete; that is , they contain all the amino acid
essential to animal life and are especially important sources of tryptophane and lysine
which are lacking in many plant protein.
 Ice cream is excellent source of food energy.
 It is also an excellent source of vit. A, a good source of vit. B(Thiamine), G(Riboflavin),
and a fairly good source of Niacin, vit. E, and in fruit ice cream of vit.C.
 The digestibility and palatability of ice cream is also very high.

2. Role of the Constituents in Ice Cream:-

a) Milk Fat :- This is high in food value, but expensive. It enriches and mellows the ice
cream, giving it a full, rich, creamy flavour. If the milk fat is even slightly off-flavoured,
the defect will be noticeable. The fat also contributes to the body and melting resistance
of ice cream while producing a smoothness of texture. Fat gives stability to the ice
cream but impairs whipping ability.

Advantages- (i) Enriches the flavour (ii) Produces a characteristics smooth texture (iii) helps
give body to the ice cream

Disadvantages-(i)cost (ii) fat slightly hinders, rather than improves, whipping (iii) high fat
content may limit the amount of ice cream consumed (iv)high calorific value.
 b) Milk-solids-not-fat(MSNF) :- Also known as serum solids, they consist of milk proteins,
milk sugar, and mineral matter. They are high in food value and also inexpensive. They
add very little to the smell, but improve its body and texture. However, milk sugar adds
to the sweet taste. The milk proteins help to make ice cream more compact and
smooth. Milk-solids-not-fat should be added in as large a quantity as possible without
risking the danger of sandiness.

Advantages- (i)improve the texture (ii) help to give the body (iii) a higher overrun without
snowy or flaky texture (iv) a comparatively cheap source of solids.

Disadvantages- (i) a higher percentage causes sandiness (ii) the condensed milk flavour may
be objectionable (iii) may cause salty and cooked flavour.

c) Sugar:- The main function of sugar is to increase the acceptability of ice cream. The
desired sweetening effect is only produced by sucrose. Sugars are usually the cheapest
source of total solids in the mix.

Advantages- (i) it is the cheapest source of solids (ii) improves texture (iii) enhances the
flavour.

Disadvantages- (i) excessively sweet (ii) lower whipping ability (iii) require a lower
temperature for proper hardening.

d) Stabilizers :- These are used to prevent the formation of objectionable large ice crystals
in ice cream, especially during storage. Since they are added in very small quantities,
they have a negligible influence on food value and flavour.

Advantages- (i) very effective in smoothening the texture (ii) very effective in giving body to
the product.

Disadvantages- (i) excessive body and melting resistence.

e) Emulsifiers :- These are used mainly to improve upon and provide a uniform whipping
quality to the mixture, and to produce a drier ice cream with smoother body and
texture.

Advantages- (i) improves whipping quality of mixture (ii) gives smoother body and texture
(iii) reduces whipping time.

Disadvantages- (i) homogenization of milk is essential (ii) tends to favour shrinkage defect
(iii) excess body and melting resistence.
 f) Flavour and colour :- Flavour increases the acceptability of ice cream, and colour its
aesthetic appeal.

Advantages- (i) increases acceptability(ii) colour improves appearance (iii) colour aids in
identifying flavours.

Disadvantages- (i) harsh flavour less desirable (ii) intense flavours provided immediate
satisfaction(iii) intense and unnatural colours reduces consumer acceptability.

3. Properties of Ice Cream Mix:-

The properties of practical importance in the mix are: viscosity, acidity (lactic acid) and pH, mix
stability, surface tension, freezing point, and whipping rate.

a) Viscosity:- This is defined simply as the resistance offered by liquids to flow. Viscosity is
considered an important property of the ice cream mix, and a certain about of it seems
essential for proper whipping and the retention of air. Two types of viscosity exist in ice
cream mixes: Apparent viscosity, which is a thickened condition that disappears with
agitation; and Basic Viscosity, which remains after the Apparent Viscosity disappears.
The viscosity of an ice cream mix is influenced by :
i) Composition: Among the various mix ingredients, viscosity is more influenced by
milk fat and stabilizer than the other ingredients. Gelatin affects viscosity to a great
extent largely due to gel formation, while fat increases it slightly. Sugar, on the other
hand, decreases the viscosity of the ice cream mix.
ii) Kind and quality of ingredients: The kind of ingredient refers to whether it is a
source of fat, serum-solids, sweetening, stabilizer, etc.; the quality indicates the
emulsion stability of fat, colloidal stability of protein, etc., Those carrying the fat are
especially important. Also, heat and salts (such as calcium, sodium, citrates, etc.,)
greatly affect the viscosity due to their effect on casein and other proteins. Among
stabilizer, gelatin causes a decided increases in viscosity after ageing.
iii) Processing and handling of the mix: These include-pasteurization, homogenization
and ageing.
(1) Pasteurization:- At batch-holding temperatures followed by cooling,
pasteurization causes a decrease in viscosity, while at higher temperatures it
produces an increase in viscosity.
(2) Homogenization:- If the globules are small and individually dispersed, the basic
viscosity of the mix remains at a minimum. However, the tendency of the sub-
divided fat globules to clump or aggregate greatly increases.
 (3) Ageing:- The ageing of mixes containing gelatin considerably increases their
apparent viscosity. The increase is chiefly due to gel formation, but to some
extent to the hydration of proteins and the clumping of fat globules. Aside from
the increase in apparent viscosity, ageing causes an increase in basic viscosity as
a result of a solidification of the butter fat and hydration of the milk proteins.
iv) Total solid concentration:- As the liquid phase is replaced by a solid phase in a
mixture such as ice cream mix, the viscosity usually increases. Consequently, as the
solids content of the ice cream mix is raised, the viscosity increases although the
effect of the different solids in this respect varies with the type and source of the
solid. For example, slight increases in fat content may effect the mix viscosity to only
a limited extent, whereas a slight increase in gelatin will affect the mix viscosity
greatly. The extent to which the mix solids increase mix viscosity depends largely
upon the physical state of these solids. When the proteins are partially coagulated
and when the fat globules form clumps, the mix viscosity increases on both counts.
v) Temperature:- With a lowering of temperature, the mix viscosity increases on both
counts.
Note:- It has not been determined how much viscosity is desirable in ice cream mix . A
high viscosity was believed essential at one time, but for fast freezing (rapid whipping) in
modern equipment, a lower viscosity seems desirable. In general, as viscosity increases,
the resistance to melting and the smoothness of body increases, but the rate of
whipping decreases. Viscosity is now considered a phenomenon that frequently
accompanies rather than causes good whipping, body and texture. Therefore the mix
should be properly balanced (in regard to composition, concentration and quality of
ingredients) and then properly processed to produce the desired whipping ability, body
and texture. Under these conditions, a desirable viscosity is assured. The basic viscosity
of mix ranges from 50 to 300 centipoise.

b) Acidity(Lactic acid ) and pH: The normal acidity of ice cream mixes is dependent upon
the serum solids content, and is calculated by the formula:

% 𝑠𝑒𝑟𝑢𝑚 𝑠𝑜𝑙𝑖𝑑𝑠 𝑖𝑛 𝑚𝑖𝑥

% acidity of mix = % acidity of milk x
%𝑠𝑒𝑟𝑢𝑚 𝑠𝑜𝑙𝑖𝑑𝑠 𝑖𝑛 𝑚𝑖𝑙𝑘

A rule of thumb method to determine mix acidity , is to multiply the serum solids by 2
and divide by 100 . The normal pH of mix is about 6.3. Acidity and pH are related to the
composition of the mix and an increase in MSNF raises the percentage acidity and
lowers the pH. If fresh dairy products of excellent quality are acidity. When acidity is
above normal, it indicates that lactic acid is present in the dairy products used in the
 mix. A high acidity is undesirable as it contributes to excessive mix viscosity, a decreased
whipping rate, an inferior flavour and a less stable mix resulting in ‘cook on’ or possible
coagulation during the pasteurizing and processing stages.
If the mix acidity is higher than normal, it can be neutralized to the level of
normal acidity. Over-neutralization (below 0.15 percent titratable acidity) should be
avoided as the ice cream will tend to have a flat (or neutralized) flavour and a dull or
even grayish colour. When neutralizing, and the sugar at 320C and place all the
ingredients in the mixing vat before the acidity test is run. The neutralizer best suited to
ice cream is sodium bicarbonate. Mix the neutralizer (1kg neutralizer to 1kg acid) with
10 times its weight of water. Heat the mix to 320C, or slightly higher if butter is used.
Keeping the agitator moving, add the neutralizer solution slowly so as to distribute it
uniformly throughout the mix. The temperature should be maintained at 32 0C for at
least 10 mins before pasteurizing.

Note:- It should be remembered that good ice cream cannot be made from a highly
acidic mix.

c) Mix Stability: This refer to stability or resistance to separation by the milk proteins in an
ice cream mix. Instability results in separation of milk proteins as coagulated or on
melting. This defect is caused by various factors which affect the colloidal stability of the
milk proteins, such as high mix acidity, low citrate and phosphate content, a high
calcium and magnesium content, high homogenizing pressure, high (pasteurizing) heat-
treatment, low ageing time (resulting in poor hydration), destabilizing effect of freezing,
etc.. Particle size, charge, and hydration are important factors influencing the stability of
an ice cream mix ; the most stable mix particle is the hydrophilic suspension because it
is charged and hydrated; and the least stable suspension is that wherein the particle is
neither hydrated nor carries a charge. It is the latter which result in instability mixes.

d) Sepcific Gravity: The specific gravity or density of an ice cream mix varies with its
composition and may range from 1.05 to 1.12.It can be determined by using the
formula:

100
Specific Gravity at 160C (600F) = %𝑓𝑎𝑡 %𝑠𝑢𝑔𝑎𝑟+%𝑀𝑆𝑁𝐹+%𝑠𝑡𝑎𝑏𝑖𝑙𝑖𝑧𝑒𝑟+ %𝑤𝑎𝑡𝑒𝑟
0.93
+ 1.58
+ 1
e) Surface Tension: This pertains to the attraction between the molecules of a liquid at its
surface. The greater the attraction between the molecules, the higher the surface
tension, and vice versa. The unit of measurement of surface tension is dyne.
Investigations on the surface tension of ice cream are limited. Studies indicate that
increasing the surface tension above that of a freshly-made mix (made from fresh
ingredients) is difficult, although it may be readily decreased by the addition of products
such as emulsifiers and the like. Mixes with lower surface tension values (caused by the
addition of excessive amounts of emulsifier to the mix) have shown excessive rates of
whipping, fluffy short body characteristics, and susceptibility to the shrinkage defect.
The normal surface tension values of ice cream mix may ranges from 48 to 53 dynes
sq.cm. (At 200C the surface tension of water is 72.75, and of milk, 40 to 60).

f) Freezing Point: The freezing point of ice cream is dependent on the solubility
constituents and varies with its composition. The mix constituents which affect the
freezing point directly are sugar, milk sugar, milk salt, and other substances that may
have been added and are in true solution. Other mix constituents which affect the
freezing point indirectly by replacing water are fat, protein and any other constituents
not in true solution. Glucose depresses the freezing point almost twice as much as the
same weight of sucrose, since the molecular weight of glucose is about one-half that of
sucrose. On the other hand, corn syrup depresses the freezing point less than sucrose.
In fruit ice cream, the freezing point will depend on the type of sugar used in fruit
preparations (glucose or sucrose) and the extent to which the added sugar has
undergone hydrolysis.
An average mix (containing 12 %fat, 11%serum solid. 15%sugar,
0.3%stabilizer and 61.7%water) has a freezing point of about 27.5 0F. Mixes with high
sugar and MSNF contents may range to 26.50F; while high fat, low MSNF or low sugar
content mixes mixes may range to 29.50F.

g) Whipping rate: A high whipping rate means the ability to whip rapidly to a high overrun.
It is now definitely known that the differences in whipping ability cannot be explained
on the basis of viscosity. The present hypothesis is that whipping ability is based on
tensile strength of the lamella(i.e., walls around the air cells ). Whipping ability is
improved by a high processing temperature, proper homogenization and ageing the mix
for 2-4 hours.
Smaller fat globules and less clumping increase whipping ability. Mixes made
with butter, butteroil, or frozen cream have a less satisfactory dispersion of fat and poor
whipping ability. The usual variations in concentration of MSNF have no pronounced
effect on whipping ability, but qualitative variations in the MSNF are important. Sugar
 decreases the whipping ability except when added after homogenization, in which case
it increases it. Finally, the construction and operation of the freezer itself determine
whether the maximum whipping ability of a given mix can be obtained.
The rate of whipping is measured by calculating the overrun at 1min intervals while
the mix is being frozen in a batch freezer. Normally, within 3-4mins after the freezing
process starts, the mix is frozen and within 7mins an overrun of 90 % is obtained. In
mixes which have a rapid whipping rate, 90% overrun is may be reached in 5mins or
less. Mixes requiring 8mins or more to reach 90% overrun are considered to have a slow
whipping rate.

4. Process of Manufacturing –Flow Diagram

Selection of Ingredients

Toned Milk
SMP
Whey Protein Concentrate
Sugar
Stabilizer
White Butter

Figuring the mix

Fat
Protein
Stabilizer
Sugar
Making the mix
mix transfer pump

Duplex Filter

Homogenization of mix
I stage 1500PSI
II stage 500PSI

Mix Heater
Inlet temp. 65 – 700C
Outlet temp. 85 ± 50C
 Holding tube
25 sec.

FDV
(if not past. Properly then mix is send to
making the mix.)

Chiller
Inlet temp. 85+-5 0C, outlet temp. <9 0C.

Ageing
At < 90C for 4 to 6 hours.

Flavour tank

Continuous Freezer
At -4 to -5 0C.

Fruit Feeder machine

Packaging & Storage( at -25 to -50C)

Preparation of Mix

Milk

Preheated (35 to 40OC).

Add SMP

At 40 OC, add whey protein concentrate

 Heating (65 to 70 OC)

Add stabilizer and Emulsifier

Add Sugar

After dissolved the sugar add white butter.

Recirculation

Mix

Making the mix:

In order to make good ice cream, the milk products and other ingredients must first be selected
and combined so as to produce the desired body and a delicately blend flavour. The selection of
good, wholesome ingredients and calculation of a satisfactory composition proceed the mixing
of the ingredients in a vat, where they can be heated to facilitate dissolving, blending and
pasteurizing. The order in which ingredients are added as follows: liquid ingredients, basically
milk, are placed in the jacketed vat provided with a power stirrer and the agitation and heating
started at once. Powder is added at 350C and sugar, emulsifier and stabilizer is added while the
liquid material as agitate. Butter is added at about 60 0C. The mix is agitated and heated to 65 –
700C and then pumped to duplex filter.

Filtration

The mix is then filtered using a duplex filter in order to make the mix completely free of
extraneous matter and give the mix a smooth consistency.

Homogenization

Homogenization of the ice cream mix is essential. The main purpose of homogenization is to
make a permanent and uniform suspension of fat by reducing the size of the fat globules to a
very small diameter, preferably not more than 2 microns. Advantages of homogenization are-
· It prevents fat separation during ageing
· Produces more uniform ice cream with a smoother texture
· Improves whipping ability
· Decrease the risk of churning occurring in the freezer and
· Leads to the use of slightly less stabilizer

Here a pressure of 1500 psi at first stage and 500 psi at second stage is applied.

Pasteurization

Proper pasteurization destroys all pathogenic or disease producing bacteria, thereby

safeguarding the health of the consumer. The advantages of pasteurization are:

i) It renders the mix completely free of pathogenic bacteria

ii) It dissolves and helps to blend the ingredients of the mix
iii) It improves flavour
iv) It improves keeping quality
v) It produces a more uniform product

The pasteurization time temperature combination in the ice cream plant here is 85 + 50
C for 25 seconds.

Chilling

The mix is then chilled to about 70C to facilitate ageing and after which it is pumped over to
ageing vat.

Aging the mix

After cooling the mix the mix is pumped to ageing tanks and it should held in ageing tanks until
used. Ageing refers to holding the mix at a low temperature for a definite time before freezing.
Ageing produces the following results.

i) It improves the body and texture of ice cream

ii) Improves whipping capacity of the mix
iii) Increased maximum overrun
iv) Increases melting resistance

The purpose of this step is to allow hydrocolloids to swell, the casein to become hydrated, the
viscosity to increase, the texture to become finer, to increase the resistance to melting, the
whip ability to improve, fats to crystallize out and aroma to develop uniformity throughout.

Freezing
Freezing of the mix is one of the most important operations in the making of ice cream. The
freezing process may be divided into two parts.

a) The mix is quickly frozen in the freezer while being agitated to incorporate air in such a way
as to produce and control formation of small ice crystals so necessary to give smoothens in
body and texture and

b) When ice cream is partially frozen, it is drawn from the freezer into packages and quickly
transferred to cold storage rooms where the freezing and hardening process is completed
without agitation.

Fast freezing is necessary to obtain the desired small crystals which means that
efficient scraping off, large temperature differences, high rpm and high heat transfer
coefficients are required. The mix enters the freezer at a temperature of just above 0 C after
the amount of air necessary for the required over run has been added. The exits temperatures
are -3.50C to -70 C depending on the required consistency of the ice cream, which in turn
depends on the subsequent requirements.

5. Details of Manufacturing and Ingredients

(a) Selection of ingredients and their processing /preparation

 Dairy Products:-
i. Source of Fat:-
 Sweet Cream- This is the most desirable concentrated
source of fat for use in a mix
 Frozen Cream
 Plastic Cream
 Unsalted Butter
 Butteroil

ii. Source of MSNF:-

 Skim Milk
 Skim Milk Powder:- this is most frequently used in the
spray dried or flaked form
  Condensed skim milk (plain/sweetened)
 Sweet cream butter

iii. Source of both fat and MSNF

 Whole Milk
 Whole Milk Powder
 Condensed whole milk(Plain/sweetened)
 Evaporated

 Non Dairy Products:-

i. Sweetening Agents:- Many kind of sweeteners are used in

ice cream. These include cane and beet sugar, corn
sweeteners, brown sugar, honey, invert sugar and sugar
substitutes. Cane or beet sugars are most commonly used.
One- fourth to one third of cane or beet sugar may be
replaced by corn sugar with good results. The use of a
combination or blend of sugars in either dry or liquid forms
is a popular practice; sugar blends usually consist of 70%
sucrose and 30% corn sweeteners. The different kinds of
sugars do not produce and equal sweetening effect. Apart
from sweetening, sugars affect the properties of the mix and
the finished product. Sugars depress the freezing point of
the mix, produce a thinner mix with slower whipping rates,
and an ice cream with a smoother body and texture with
faster melting qualities. The different sweeteners commonly
used are as follows:-

 Sucrose(cane and beet sugar):- Commonly known as

granulated cane or beet sugar, this is the most widely
accepted source of sugar throughout the world. It depresses
the freezing point of ice cream.
  Corn Sweetener (dextrose):- These may be refined corn
sugar (dextrose)- a dry crystalline products; dried corn syrup
or corn syrup solids; and corn syrup –a liquid contain
variable amounts of dextrose and maltose .
 Dried Corn Syrup Solids (dextrose + maltose):- contain
dextrose and maltose together with dextrin. Usually added
to the extent of not more than one third of total
sweeteners.
 Refined corm syrup:- dextrose is 80% as sweet as sucrose. It
has a lower freezing point than sucrose and can therefore be
used to about 25% of the total desired sugar.
 Invert Sugar(glucose+fructose):- Mixture of different parts
of glucose and fructose (resulting from hydrolysis of sucrose)
and generally obtained in the form of syrup. Sweeter than
sucrose. Depresses the freezing point and hence should be
used to supply not more than one-fourth to one- third of the
total sugar in the mix.
 Saccharin:- Artificial sweetener. Sweetening effect up to
550 times that of sucrose. Used in ‘diabetic ice cream’.
Causes problems of low total solids and low overrun.
(Continued consumption of 0.3 g per day is liable to impair
digestion, because of its antiseptic properties and
preservative action. Lately, it has been suggested that it
might be a cause of cancer.)

Note:- Use of lactose as sweetener has the following problems:

lactose is one-sixth as sweet as sucrose and is less soluble; more water
portion of the mix contains as much as 9% lactose, the lactose may
form crystals large enough to be discernible, ad leave an undesirable
‘sandy’ taste in the mouth. This property definitely limits the
concentration of lactose in ice cream mix. Since the source of lactose is
MSNF of dairy products and about 54% of MSNF is lactose, the
maximum concentration of lactose that can be sagely used is directly
related maximum concentration of MSNF.

ii. Stabilizers:-
iii. Emulsifier
iv. Flavour:-
v. Colours
vi. Egg solidst
vii. Fruits and Nuts

(a)Preparation of Kulfi mix

Ingredients:

 Milk
 SMP
 White Butter
 Stabilizer
 Whey Protein Concentrate
 Sugar

Flow Diagram of kulfi mix

Milk

Preheated (35 to 40OC).

Add SMP

At 40 OC, add whey protein concentrate

 Heating (65 to 70 OC)

Add stabilizer and Emulsifier

Add Sugar

After dissolved the sugar add white butter.

Heated to 100 +-5 OC for developing brown colour.

Kulfi Mix.

Mix transfer Pump

Duplex Filter

Homogenizer
I 1500PSI
II 500PSI

Mix Heater

Holding tube
 Chiller
Inlet 85+-5 OC,
Outlet <20 OC.

Ageing tank
<9 OC for 4 to 6 hours).
Temp. of ageing tank 7+-2 OC, chilled
water 0 to 1 OC, soft water 20 OC.

Flavour tank

Continuous Freezer (-4 to -5 OC)

Fruit Feeder Machine

Packaging

Storage (-25+- 5oC)

(b) Cone Syrup

Ingredients:-

 Cocoa Butter
 Deshi ghee / butter oil
 Dark Chocolate
 Milk Chocolate

PROCESS CHART

Cocoa butter

Melt
 Add butter oil / desi ghee

Melt

Add Dark chocolate

Add milk chocolate

Melt

Heating (85+-2 OC)

Cone Syrup

(c)Cone Chocobar Mix

Ingredients

 Cocoa butter
 Lecithin
 Dark chocolate
 Milk Chocolate
 Salt

PROCESS CHART

Cocoa butter

Melt

Add Lecithin
 Add salt

Melt

Add dark chocolate

Add milk chocolate

Heating (85+-5 OC)

Cone Chocobar Mix.

Centre Filling

Centre filling (Ready made)

Maintain the temp. (65 to 70 OC)

Filter (through SS filter)

Ready to use

Note: Fat in centre filling 46%

 (d)Chocolate Mix

Milk

Preheating (35 to 40 OC)

Add SMP

At 40oC Add Whey protein concentrate

Heating to 65 OC

Add stabilizer and Emulsifier

Add sugar

Add white butter (unsalted)

Recirculation (mixing)

Maintain the temp. 65 to 70 OC)

Water

Heating (65 to 70 OC)

Add black chocolate

add milk chocolate (ratio 1:2)

Maintain at 65 to 70 OC)
 Blending
Recirculation

Chocolate mix

Mix transfer pump

Duplex Filter

Homogenizer(1500PSI, 500PSI)

Mix Heater(Inlet 65-70oC, Outlet 85+-5oC,

Holding Tube 25Sec

Chiller (Inlet 85+-5OC , outlet <9OC).

Aging (<9OC for 4 to 6 hours).

Flavour tank

Continuous Freezer

Fruit feeder machine

Packaging (cardboard)

Storage (-25 ±5 OC).

 (e)Candy Mix For Walzer
(orange, Mango, Lemon, Cola., mango resberry, Orange with strawberry at centre)

Ingredients

 Water
 Stabilizer and Emulsifier
 Citric Acid
 Sugar
 Glucose Syrup

PROCESS FLOW CHART

Water

Heating (65 to 70 OC)

Add Stabilizer and Emulsifier

Add citric acid

Add sugar ( at 70 OC)

Add glucose

Recirculation

Candy mix

Duplex Filter
 (No homogenization because fat is
not present.)
Mix Heater
Inlet 65 to 70 OC,
Outlet 85 +-5 OC
Holding tube (25 sec)

Chilling (Inlet 85±50C, Outlet <90C.)

Aging tank
< 90C for 4 to 6 hours.

Walzer

Filling doser -2 (90C)

Stick Inserter ( 2 to 30C)

Freezing (-250C)

Pincer (lifting up)

Defrosting (150C)

Through conveyer

Candy Pusher

Wrapping Machine

Packaging

Storage (-250C±5OC)
 (f)Chocolate Sauce
Ingredients:-
 Sugar
 Liquid Glucose
 Water
 Butter
 Sodium Alginate
 Cocoa Powder
 Carnval Colour
 Creamy Vanilla

PROCEDURE

Water

Preheat (35 to 40OC)

Add Cocoa Powder

Add Sodium Alginate (Mix with sugar)

Mix it with the help of plunger

Add sugar & mix it

Add white butter

Add liquid glucose

Heated to 80OC

Cooling (35 to 40OC)

 Add Carnmal Colour

Add creamy vanilla

Mix it

Chocolate sauce

Note:- Chocolate sauce is used in Jamaican almond fudge ice cream.

(g) Saffron Processing

Ingredients
 Sugar
 Liquid glucose
 Sodium Alginate
 LBG
 Kesar
 Kesar elaichi
 SS Yellow

PROCEDURE

Water

Preheating (65+-5OC)

Add sodium alginate & LBG

Mix it

Add sugar

Add liquid glucose

 Heating (80 OC)

Chilled (15 OC)

Add colour and flzvour (SS Yellow kesar elachai)

Mix it

Filter

Add kesar

Mix it with the help of plunger

Saffron extract

Temperature should be maintained below 9 0C before use in production.

(h) Milk Lollzze Mix

Ingredients
 Milk
 SMP
 White Butter
 Stabilizer & Emulsifier
 Whey Protein Concentrate
 Sugar
 Water

PROCEDURE
 Milk

Add water

Preheating (35-40 OC)

Add SMP

Add whey protein Concentrate

Heating (70 OC)

Add Stabilizer & Emulsifier

Add sugar

Add White Butter

Recirculation

Mix transfer pump

Duplex Filter

Homogenization (I stage: 1500PSI, II Stage: 500PSI)

Mix Heater (85OC)

Holding Tube (25sec.)

FBD
 Chilling (< 9OC)

Ageing

Walzer

(i)Chocolate Paste

Ingredients:-
 Sugar
 Cocoa Powder
 Water
 Carameline Powder
 Cararnal Colour

PROCEDURE

Water

Preheating(45OC)

Add (cocoa Powder + sugar mix)

Heating (85OC)

Add colour & flavour (Carameline powder & Caranal colour)

Add plain mix (1 part paste : 2 parts mix)

 Duplex Filter

Cooling (5 OC)

Mixing in Plain Mix

Note:- Temperature should be maintained below 90C before use in production.

7. Fruit And Nuts Processing

Processing of Cashewnut, Pista and Badam

 Cutting in nuts and fruits cutting machine

 heating in hot air oven at 85 +/- 5OC for 11/2 hours.
 Cool to room temperature
 Sorting based on different varities of ice cream.
 Storage of low temperature.

2. Processing of Kismiss and Tutti Fruity

 Complete washing to remove any dust extraneous matter etc.

 Washing in 25 ppm chlorine solution for 5 minutes
 Remove the water completely and store in cold store

3. Processing of Litchi

 Cutting of tin using the cutting machine and transfer the contents to clean
dish
 Allow liquid glucose which is added in proportion of 20 lichi : 1 glucose is
added and allow it act for 30 minutes.
 Wash with flow of water
 Cold storage

4. Mango Pulp

 Cut the tins and transfer the contents to a clean dish.

  Add necessary amount of sugar to mango pulp andmix well for about 62
kg pulp - 19 kg. Sugar is added
 Store under 4OC until used.

5. Processing of Saffron

 Take necessary amount of mix and dissolve it in water to make

50% concentration syrup.
 Heat to boiling.
 Take calculated amount of saffron which has been previously
treated to 50OC for 10 minutes, is taken and dissolved in the mix.
 Heat it to 30 C for 15 minutes
 Cool and filter the mixture
 Add the saffron mixture into mix and rest saffron is grinded
and added to mix itself.

6. Processing of Strawberry
The strawberry crush in tins is first opened

o The syrup is drained and the strawberry is transferred to filter then

o Flavour and colour is added and stored in cold storage

All the fruits and nuts processing is done in one day prior to the use of that particular
fruits
and nuts

Nuts and Fruit Room

Processing and Storage of Nuts

Issue of nuts from store for processing

Sorting

Cutting

Roasting (85+-50C for 90min.)

Cooling in normal temperature.

 Put in dry basket.

Weighment

Storage.

Processing of Kaju, Pista and badam.

1. Cutting the nuts by machine.

2. Keep the nuts in oven for (85+-5oC) at 1.5 hours.
3. After roasting cool the nuts at normal temperature (room).
4. Filter the nuts by steel mesh.
5. Grinding the nuts according to the different ice cream.

Processing of Chikki

1. Break the chikki strip in small pieces with the help of hammer.
2. Filter the chikki by steel mesh according to the different ice cream.

Processing of Kishmish & Tutti Fruiti

1. Wasing the fruits.

2. no dirt or dust should come on the surface of fruit.
3. Washing in 50ppm chlorine. Solution for 5 min.
4. Taking out remaining water.
5. Keep the fruit in cold storage for cooling.

Processing of Litichi

1. Open the tin of litichi by in cutting machine carefully.

2. Keep the fruits in liquid glucose and then drain out from water.
3. Keep the litichi in cold store for cooling.

Processing of mango pulp

1. Cutting the tin of mango pulp.

2. keep the mango pulp in clean utencils.
3. Mix the sugar according to the requirement (1kg pulp, 300gm sugar)
4. Store at 4OC till it is utilized.

Processing of kesar

1. Take the appropriate quantity of mix.

2. Dissolve in water of 250% concentrate/
3. Boil the solution.
4. Add roasted kesar at 50OC for 10min.
5. Heat it at 80OC for 15 min.
6. Cool the mixture and filter it.
7. Mix the solution in mixture and add remaining leaves after grinding.

Flow Chart
Kesar

Keep in Box

Keep in hot air oven (roasting, 50OC for 10min.)

Mix with kesar

Boiling

Filtration

Grinding

Mix with plain mix

Storage

Strawberry
Flow Chart

Strawberry (Box)

Open the lid

 Filter (Drain the syrup)

Plain mix

Standardized
(1:1)

Mix

Heated (85OC)

Keep the strawberry fruit in vat.

Add strawberry flavour(1kg fruit and 2 ml flavour)

Mixing

Ready for strawberry crush ice cream

Butter Scotch Crackle

50% kaju + 50% butter scotch crackle.
Mix
Ready for butter scotch ice cream

Chocolate Crackle

Chocolate crackle(5 kg)

Add cocoa butter (1kg chocolate crackle, 20gm cocoa butter)

 Mixing

Add 50% of kaju(cutting roasted kaju)

Mixing

Use in Production

Kesar (Saffaron)
Flow Chart
Saffaron (Stigma)

Spread in a Tray

Keeping in Oven at 500C for 10mn.

Stir in Hot milk for 5-6 min.

Strain saffaron extracted milk

Retenate (kesar)

Grind to paste

Mix with ice cream mix in flavour tank.

6. Details of machinery used in ice cream
manufacturing.

SPECIFICATION

 Temperature of Ageing tank: 7±20C.

 Chilled Water: 0 to 10C.
 Soft Water: 200C.

 Mix Preparation Vat: 3

Capacity: 1000 liters each

 Duplex Filter: 2
 Raw milk Tank
Capacity: 5000 liters

 Ageing Tank No.1

Company: Industrial Aiders
Capacity: 5000liters

 Ageing Tank No.2

Company: Industrial Aiders 90 & 92, HSIDC Kundli – 131028 ,Sonepat

Capacity: 5000liters

 Ageing tank No. 3

Company: Grasim Industries Ltd. Engg Development Division Birlagram – Nagda
India Equipment CR&ST
Capacity: 2KL

 Ageing tank No. 4

Company: Grasim Industries Ltd. Engg Development Division Birlagram –
Nagda India Equipment CR&ST
Capacity: 2KL

 Ageing tank No. 5

Company: Indian Dairy machinery Company Limited Vithal Udyognagar388121
Types: Syrup storage tank
Capacity: 1000 liters.

 Ageing tank No. 6

Company: Indian Dairy machinery Company Limited Vithal Udyognagar 388121
 Types: Syrup storage tank
Capacity: 1000 liters.

 Ageing tank No. 7

Company: Indian Dairy machinery Company Limited Vithal Udyognagar
Types: Syrup storage tank
Capacity: 1000 liters.

 Ageing Tank No. 8

Company: Industrial Aiders 90 & 92, HSIDC Kundli – 131028 Distt – Sonepat
Capacity 5000 liters

 Ageing Tank No. 9

Company: Industrial Aiders 90 & 92, HSIDC Kundli – 131028-Sonepat
Capacity 5000 liters

 HP Homogenizer-1
Talia FBF Italia BRL Via A Frank 10 49044 Stradella di callecchic Parma – Itlay
Machine type: TS3
Capacity: 2000LPH
Working Pressure: 210bar
Installed power: 16KW
Supply Voltage: 415V
Weight: 700kg.

 Homogenizer-2
Company: Indian Dairy machinery Company Limited Vithal Udyognagar 388121
Capacity:2000LPH
Working Pressure: 210bar
Installed power: 16KW
Supply Voltage: 415V

 Mix Heater:1
Alfa laval
Plate Heat Exchanger type: P13 HRB.
Max. Work Temperature:
Max. Working Pressure: 6kg/cm2.
Manufactured in India.
Capacity: 2KLPH

 Mix Chiller:
Alfa laval
Plate Heat Exchanger type: P13 HRB.
Capacity:2KLPH and 2.2KLPH
Max. Work Temperature:
Max. Working Pressure: 6kg/cm2.
 Manufactured in India

 Butter Melting Kettle:

Capacity:375 kg (x2)

 Balance tank:1
Capacity: 100liter

 Cane syrup tank:

Industrial Aiders: 90&92 HSIDC Kundli Distt – Sonepath (Harayana) 131028
Name: Melting Vat.
Capacity: 500 liters
Working Pressure: 3kg/cm2.
Test pressure: 4.5kg/cm2.

 Cone Chocobar tank No. 2

Industrial Aiders: 90&92 HSIDC Kundli Distt – Sonepath (Harayana) 131028
Name: Melting Vat.
Capacity: 500 liters
Working Pressure: 3kg/cm2.
Test pressure: 4.5kg/cm2.

 Chocolate tank No.:1

India Dairy machinery Company limited. Vithal Udyognagar 388121
Type: Chocolate melt tank
Capacity: 500liter

 Flavour tank No. 1

India Dairy machinery Company Vithal Udyognagar – 388121
Type: Flavour Mixing Tank.
Capacity: 600 liters.

 Flavour tank No. 2

India Dairy machinery Company Vithal Udyognagar – 388121
Type: Flavour Mixing Tank.
Capacity: 600 liters

 Flavour tank No. 3

India Dairy machinery CompanyVithal Udyognagar – 388121
Type: Flavour Mixing Tank.
Capacity: 600 liters

 Flavour tank No. 4

India Dairy machinery Company Vithal Udyognagar – 388121
Type: Flavour Mixing Tank.
Capacity: 1000 liters
 Flavour tank No. 5
India Dairy machinery Company Vithal Udyognagar – 388121
Type: Flavour Mixing Tank.
Capacity: 1000 liters

 Flavour tank No. 6

India Dairy machinery Company Vithal Udyognagar – 388121
Type: Flavour Mixing Tank.
Capacity: 1000 liters

 Flavour tank No. 7

Industrial Aidess 90492 HSIDC Kundli – 131028 Distt. Sonepat (Harayana)
Type: Flavour Mixing Tank.
Capacity: 1000 liters

 Flavour tank No. 8

Industrial Aidess 90492 HSIDC Kundli – 131028 Distt. Sonepat (Harayana)
Type: Flavour Mixing Tank.
Capacity: 1000 liters

 Flavour tank No. 9

Industrial Aidess 90492 HSIDC Kundli – 131028 Distt. Sonepat (Harayana)
Type: Flavour Mixing Tank.
Capacity: 1000 liters

 Contineaous Freezer no. 6 Line No. 7

Catta 27 40056 Crespelland(BO) itlay via Della Solid Arieta.
Voltage: 415 Volts.
Hz: 50
Ampere: 34Amp
Refregerant: Tipo R22, 8kg..

 Contineaous Freezer no. 7 Line No. 9

Catta 27 40056 Crespelland(BO) itlay via Della Solid Arieta.
Voltage: 415 Volts.
Hz: 50
Ampere: 34Amp
Refregerant: Tipo R22, 8kg.

 Contineous Freezer no. 9 Line No. 3

Catta 27 40056 Crespelland(BO) itlay via Della Solid Arieta.
Voltage: 415 Volts.
Hz: 50
Ampere: 34Amp
Refregerant: Tipo R22, 8kg.
 Contineous Freezer no. 12 Line No. 6
Constuttore manufacture Fabric ant Bauer
Sidam Indirizzo address Via Fabio Filiz 37 20032 Cormani(mi) – Itlay

 Contineous Freezer no. 13 Line No. 5

Constuttore manufacture Fabric ant Bauer
Sidam Indirizzo address Via Fabio Filiz 37 20032 Cormani(mi) – Itlay

 Contineaous Freezer no.14 Line No. 1

Catta 27 40056 Crespelland(BO) itlay via Della Solid Arieta.
Voltage: 415 Volts.
Hz: 50
Ampere: 34Amp
Refregerant: Tipo R22, 8kg.

 Contineaous Freezer no. 15 Line No. 8

Catta 27 40056 Crespelland(BO) itlay via Della Solid Arieta.
Voltage: 415 Volts.
Hz: 50
Ampere: 34Amp
Refregerant: Tipo R22, 8kg.
Capacity : 1500LPH

 Compressor:
Make: DORIN
Pressure max. 25 bar.
Prot: Thermistors PTC.

 Air Filter:
Danfoss Eliminator
Made in Maxico
Liquid Line
Filter Drier
Volts: 0.171

 Walzer No.: 1

Voltage: V 380 Fasi 3, 50Hz..

Refrigerant: NH3
Walzer pressure: 4 to 6 kg/cm2.
Temperature (Freezer): -250C.
Defrosting Temperature: 150C.
Chocolate temperature: 30 to 40oC.
Semi solid stare: -5 to -10oC.
Parts:
1. Chocolate Coating tank.
2. Filling Doser – 2.
3. Filling Doser – 1
4. Cnetre Filling. (Heating thermostate0
5. Stick inserter.
6. Solution sucker (For washing).
7. Pincer (Lifter & Droping)
8. Conveyeor
9. Candy Pusher.
10. Wrapping machine
11. no. of Molds: 1500x8 = 12000
12. Candy Speed: 150/min. (9000 candy/hour).
No. of molds: 12000 = 150x8x10
Speed: 130 Canddy/min. = 7800 Candy/hour.

 Automatic Candy Line:

Model : Walzer k80 (10 Row)
Make: Catta 27
Air Pressure Required: 6kg/cm2.
Total Power Required = 22KW.
Refrigerant – Ammonia (HN3).
Intermediate Coolant: CaCl2.
Evaporatuibe Temperatue: -38oC.
Coopling Load: 70000/Kcal nr.
Air Consumption: 90KLPH.
Speed: 150 Candy/min. = 9000 Candy/hour.

 Cone filling Machine (50ml)

Manufacturers: PWS Engineers Private Limited
PB No.: 62 Anand – Sujetra Rod. Ananad – 388001 Gujrat(India)
Formerly: The Panchal workshop

Parts (Work junction)

1. Spray Station
2. Cone Syrup Filler
3. Ice Cream Filler
4. Topping Cone Syrup
5. Nut Filling
6. Lid Cover
7. pressing
8. Printing
9. Unloading
10. Packaging
11. Storage
  Cone Filing Machine No.2 (100ml)
Gram Varsha Anand
The panchal Workshop
Speed 51Cone/min.
1 hour = 51x60 = 3060 cone/min.
Anand, Sorjitra Road PO Box No. 12
Anand – 388001 India.

 Cone Filling Machine (100ml)

Normal Speed = 3000 Cone/hour
Speed 44cone/min.
Manufacturers :PWS Engineers Private Limited PB No: 62 Anand – Sojitra
Road Anand – 388001 Gujrat India

 Cup Filling Machine No. 1 (100ml)

Cream Varsha Anand
The Panchal Workshop Anannd Sojitra Road PB No. 62 Ananad – 388001 India
Ideal Speed: 6000cup/hour

 Cup Filling machine No. 2 (100ml)

Manufacturers: PWS Engineers Provate Limited PB No. 62 Ananad Sojitra Road
Anand – 388001

 Cup Filling Machine No. 3 (50ml)

The Panchal Workshop
Gram – Varsha AnandAnand Sojitra Road PB No. 62 Anand – 388001 India

 ExtrusionLine:
Hardening Temperature: -36OC to -45 OC.
No. of plates: 600

In Extrusion line temperature is maintained in the hardening tunnel

around -45OC. Forced convection is evaporators are used in the hardening
tunnel. Liquid ammonia is in the tube and fan is rotating continuously back
side of the evaporator. Cool buddies ice cream are manufactured in this
machine.

Cool buddies:
Funny face, vanilla chocolate, vanilla orange, strawberry (vanilla strawberry) Rocket
(Vanilla mango), Panda (Vanilla Chocolate).

TESTING OF MIX
Chemical test:

 Fat Percentage (Gerber Method)

 Total Solid
 Acidity (%)
 Protein Percentage (Pyne’s method)

Fat Test:
Apparatus:
Butyrometer, pipette (10ml), stopper, centrifuge, Gerber acid (90% sulphuric acid), amyl
alcohol.
Principle:
Gerber acid dissolves all the constituents other than fat and amyl alcohol reduces the surface
tension & helps in separation of the two media.
Procedure:
1. Put 10ml of Gerber Sulphuric Acid in ice cream butyrometer.
2. Pour some amount of water in the same.
3. Now put this butyrometer in cylinder on the weighing machine and set its weight to
zero.
4. Weigh 5gm of sample into ice cream butyrometer. The sample should not tuch the
walls of the ice cream butyrometer.
5. Add 2ml amyl alcohol.
6. Now pour some distilled water to make up the volume.
7. Keep this butyrometer in a centrifuge at 1400RPM for 5min.
8. Keep out from the centrifuge and note the percentage of fat
9. Divide this reading by weighing of the sample taken & multiply this value by 5, so
exact percentage fat will come out in 5gm of sample.

Fat% = (Ice-cream butyrometer reading x 5)/wt. of sample.

Protein Test by Pyne’s Method:

Apparatus:
Beaker, Pipette, Buretter
Reagent:
Phenopthalein, Saturated potassium oxalate, Formaldehyde (natural), Std. NaOH (0.1N).
Principle:
The carboxylic group of alpha amino acid cannot be accurately titrated with alkali as it result
with basic amino group to from zwitter ion that are not decomposed completely at the end
point of the decomposed completely at the end point of the reaction. The amino acids are first
neutralized with formaldehyde which black the terminal group of amino acid and can be sharply
titrated with alkali. The amount of alkali required for the purpose is proportional to the
carboxylic group of amino acid.

Procedure:
1. Wash the beaker with water, clean it with tissue paper.
2. Weigh, clean, dry an empty beaker and set its weight to zero.
3. Weigh exactly 10gm of sample into beaker.
4. Make up the volume of 50ml.
5. Add 1ml of phenopthalein indicator into the beaker. Shake it well.
6. Add 0.4ml of saturated potassium oxalate in the beaker.
7. Wait for 2 minutes.
8. Titrate the contents with Std. NaOH solution (to pink colour).
9. Now add 2ml of neutral formaldehyde.
10. Shake it and titrate against std. NaOH solution.
11. Calculate the protein percentage by the formula.

Protein percentage: 1.7x vol. reading.

Acidity Test:
Apparatus:
Beaker, Pipette, Burette
Reagent:
Phenopthalein, Std. NaOH (0.1N)
Principle:
The titrate acidity test is employed to find out the acidity of the mix prepared, which of
higher can reduce its keeping quality. The principle is the simple acid-base titration in which
phenolphthalein is used as an indicator, which gives pink colour in alkaline medium and is
Colourless in acidic media.
Procedure:
1. Wash the beaker with water, clean it with tissue paper.
2. Weigh a clean, dry and empty beaker and set its weight to zero.
3. Weigh exactly 10gm of the sample into the beaker.
4. Make up the column of 50ml by adding distilled water.
5. Add 2 to 3drops (1ml) of Phenopthalein indicator into the beaker.
6. Titrate against N/10 NaOH solution.
7. Note the reading of the burette in terms of ml of std. NaOH and utilized multiply this
value by 0.09 and divide this fraction by the weight of sample taken to get acidity of
given sample.

Percentage Acidity: 0.09x vol. reading.

Neutralization Test:
Object: To check the neutrality of the sample.
Apparatus: Pipette, test tube, rosalic acid solution in 60% ethyl alcohol.
Reagent: Rosalic acid solution in 0% ethyl alcohol.
Principle: Mix is having slightly acidic pH of 6.5 to 6.7. Rosalic acid in acidic pH gives
orange pink colour.
Procedure:
Take 1ml rosalic acid and 1ml of sample in test tube and shake well.
Petal red indicates positive test.
Slightly orangish shade: Negative test.

Phosphatase test:
Objective: To test for pasteurization of the sample.
Apparatus: Pipette, Test tube.
Reagent: Phosphatase dye.
Preparation of phosphatase dye:
Base – Alkaline buffer (sodium carbonate and sodium bicarbonate).
2,3 para nitrophenyl phosphate + Orthophosphate indicator.
Phenyl group of indicator + Acid phosphatase of milk.
Yellow colour (phenyl derivative).
Principle:
On pasteurization of mix, enzyme acid phosphatase gets destroyed. If sample gives
fluorescent yellow colour with the sample, with 30 minutes of the set up, it shows that the acid
phosphatase is active and sample is not completely pasteurized.
Procedure:
1. Take 1ml of sample in test tube.
2. Add 5ml phosphatase dye and shake well.
3. Now incubate for 2 hours at 370C.
4. Yellow colour indicates mix is pasteurized while lemon yellow colour appears the acid
phosphatase is active.
Percent Fruit:
1. Take weigh of ice cream.
2. Dissolve in water and separate the fruits using sieve.
3. Dry the fruit in filler paper.
4. Weigh the fruit.

% Fruit = (wt of fruit/wt of ice cream) x 100.

Specific gravity:
Apparatus: Picnometer, weighing balance.
Procedure:
1. Wash the picnometer with water. Clean it with tissue paper.
2. Keep the picnometer in hot air oven (101+-10C) for 10minutes.
3. Taken out the picnometer from oven and put in desiccators at normal
temperature.
4. Weigh the picnometer and note the reading (W1).
5. Put into distilled water up to the head.
6. Stopper it with knob.
7. Weigh the picnometer (W2).
8. Drain the distilled water.
9. Put the sample in picnometer.
10. Stopper it with knob.
11. Weigh the picnomenter(W3)
12. Calculate the specific gravity by the formula.

Sp. Gravity = (W3 – W1)/ (W2 – W1)

Moisture of Sugar
Object: To determine moisture% in sugar.
Apparatus: Metal dish, weighing balance.
Procedure:
1. Heat the two metal dishes in hot air oven at 101+-1OC) for 1 hour.
2. Put into dessicator at the normal temperature.
3. Weigh the dish on the weighing balance and note the reading (W1)
4. Put the 2gm of sugar and note the reading (W2).
5. Exactly the same procedure is done for another dishes to find out the No
variation.
6. Keep in hot air oven for 1½ hours at 101+-1OC).
7. Cool in a desicator for at least 10 minutes.
8. Weigh the both dish (W3)

%TS = (W3- W1) / (W2 – W1) X 100

Moisture = 100 – TS%

Brisk
Object: To determine the brix of candy mix.
Apparatus: Refratometer, pipette.
Procedure:
1. Clean the prism where a drop of mix is
to droped by tissue paper.
2. keep the drop of mix with the help of
pipette.
3. Close the shutter.
4. Adjust the light with the help of screw.
5. Find out the brisk of candy mix.
6. Sugar% <12%.
7. RI = 1.879
8. Sugar = 28%

Free Fatty Acid (FFA)

Object: To determine the FFA of cocoa butter.
Apparatus: Beaker, pipette, hot plate, weighing machine.
Reagent: N/10 NaOH, Phenopthalein spirit.
Procedure:
1. Take 10gm of cocoa butter.
2. Melt the sample.
3. Weigh 50ml spirit.
4. Neutralize with adding 1ml
Phenopthalein.
5. Titrate against N/10 NaOH till
pink colour appears.
6. Mixing with melted cocoa butter.
7. This mixture is boiled to its
boiling point with the help of hot plate.
8. Then it is titrated against N/10
NaOH till the pink colour appears.
9. Calculate the FFA% by formula:

FFA% = 2.82x Vol. Reading / Sample weight.

=2.82 x 3.15/ (10.1- sample weight).
FFA = 0.879%.

CIP OF ICE CREAM PLANT