Submitted by:

Nishant Sachdeva
L-2010-A-03-B.tech FT
 Industrial Training
The Ludhiana District Co-operative Milk
Producer's Union Ltd.
 Introduction
 First Milk Plant, of the State was setup at Verka near Amritsar.
 The brand name of Milk and Milk Products was adopted as
Verka.
 The Foundation stone of Milk Plant, Ludhiana was laid by Hon.
S. Parkash Singh Badal, the then Chief Minister of Punjab in
1970.
 Commissioning of the Plant was done by Punjab Dairy
Development Corporation in 1974.
 Inauguration was done by Late Smt. Indira Gandhi the Prime
Minister of India.
 The capacity of the plant was 1.00 lac. Litre per day, and now
the milk handling capacity is 4.00 Lac Liter per day.
 MILKFED has its milk unions in almost all the districts of Punjab. These
district units are:-

• Amritsar • Horshiarpur
• Bathinda • Jalandhar
• Chandigarh • Ludhiana
• Faridkot • Patiala
• Ferozpur • Ropar
• Gurdaspur (Mohali)
• Sangrur

These plants in all these unions are being run under the brand name VERKA.
 Present Status
 No. of societies increased from 94 to 802 and its membership
from 5400 to 78500.
 Milk Procurement has increased from 10200 LPD to 2,50,000 LPD.
 Highest milk price is being paid to the milk producers as compare
to other plants in the states
 Products being manufactured by Ludhiana Plant are sold at
premium rates through out of the country and in the
International Market.
 City supply has increase from 66000 LPD to 1,98,000 LPD.
 Turnover the plant touched to 283 crores Profit of the union has
increased manifold.
 Capacity utilization of the plant is more than 85%.
Full name : The Ludhiana District Cooperative Milk Producers Union Ltd.

Foundation : Laid by Hon. Sh. Prakash Singh Badal in 1970

Capacity : Then 1 lakh L/day, Now 6 lakh L/day

Head office : Punjab State Co-operative Milk Producers Federation Ltd.

S.C.O.153-155, Sec. 34-A, Chd.
Inauguration date : 31stOctober, 1974
Chairman : Sh. Ajmer Singh
No. of societies : 816
No. of Chilling centers : 4
Brand name : VERKA
Products marketed by : The Punjab State Co-operative Milk Producers Federation.
Ltd.
Quality certificates : International Quality Certificate ISO-9002 & IS-15000
(HACCP)
• Verka milk plant (VMP), Ludhiana is known as The Ludhiana Dist.-Co-
operative Milk Producer’s Union Limited, Ludhiana . It is situated on
Ferozpur Road, about 5 km. away from both railway station and main bus
stand.

• The plant has bagged first position in Northern Zone

• It is fully equipped with modern fluid milk plant facilities. The latest state
of art technology in milk drying is available in this plant.

• The products manufactured by this Plant at present are STM, DTM, FCM,
SMP, WMP, Ghee, Butter, Paneer, Milk-Cake, Dahi, Kheer, Lassi .

Contd…
Some objectives of the Milk Plant are:-
• To uplift social and economic status of milk producers.
• To develop dairy as industry allied to agriculture.
• To provide better and remunerative prices for milk.
• To provide veterinary aids to animals of milk producers at their doorstep.
• To provide better quality cattle feed at reasonable rates.
• To educate the milk producers about lowering down the cost of milk
without compromising quality.
• To create employment opportunities for rural youth by milk production
activities.
• To provide awareness among milk producers for socio-economic change
through co-operative set-up.
Product brand name : VERKA
Milk handling capacity : 6 lakh litres per day
Production of market milk : 2.5 lakh litres per day
Production of butter : 13000 Kg per day
Production of ghee : 14 MT per day
Production of powder : 30 MT per day
Production of paneer : 400-450 Kg per day
Production of kheer : 200 Kg per day
Production of milk cake : 30-40 Kg per day
Production of dahi : 1400 Kg per day
Production of lassi : 3000 Kg per day
 POWDER SECTION
• There are definite indication of greater future
productions of dried milk & milk products due to
their better keeping quality, they require less
storage space & lower transportation costs. All
these are economically attractive.
• Dried milk provides a means of handling the
excess milk supply in a dairy factory during flush
season, while in lean season that meant for the
production of dry milk can be diverted to market
milk. Thus, dried milk is called the balance wheel
of dairy industry.
• VERKA MILK PLANT, LUDHIANA has two separate
drying plants.
 The Dairy has two separate drying plants, viz:
• Powder section with MVR unit & TVR unit (30TPD)
• Powder section with TVR unit only (6.5TPD)
Compositional & other Standards maintained :-
Parameters SMP Standard grade SMP Extra grade WMP

Moisture (%) 3.2-3.6 3.0-3.4 Max. 3

FAT (%) Max. 1.3 Max. 1.2 26.5-27.5
Acidity (%LA) 1.0-1.25 1.0-1.2.5 Max. 1
B.D. Agglomerated (gm/ml) 0.45-0.55 0.5-0.6 0.5-0.6
Insolubility Index (50ml) Max. 0.15 Max. 0.15 Max. 0.5
Ash content (%) Max. 8.2 Max. 8.2 Max. 0.5
Coliform Nil Nil Nil
 PROCESS CONTROL
Lumpiness in Powder

1. Ensure proper cooling of powder

2. Dehumidifier should be properly operating

Low moisture in Final Product 1. Increase flow rate

2. Adjust outlet temp

Burnt Powder Particles 1. Adjust inlet temp

2. Check the function of feed flow controller & feed pump

3. Nozzle of jets are whether chocked partially

Sooty Powder 1. Clean or change the filter.

2. Check up air heater

Very Fine Powder A Particles 1. Increase in degree of concentration

2. Control the feed temp.

Solubility Index Increased 1. Check the outlet temp.

2. Control feed rate

 OPERATING PARAMETERS FOR
EVAPORATING PLANT
PARAMETER STANDARD & EXTRA GRADE W.M.P CONCENTRATED MILK

Milk feed rate (lts/hr) 16000-17000 3500-14500 16000-17000

Steam pressure (kg/sq.cm) 5-6.5 5-6 5-6.5

Thermal vapor recompression 2-2.5 2-2.5 1-1.5

(kg/sq.cm.)
High heater (temp oC) 90+/-2 95-100 90+/-2

Holding heater temp (oC) -Do- -Do-` -Do-

Flush vessel temp (oC) 73-85 73-85 73-85

Jacket temp (oC) 69+/-1 69+/-1 69+/-1

Vapor Separator I (oC) 66+/-2 66+/-1 66+/-1

Vapor Separator II (oC) 58+/-2 58+/-1 58+/-1

Vapor Separator III (oC) 50+/-2 50+/-1 50+/-1

Vacuum in condenser 0.9m bar 0.9m bar 0.9m bar

T.S. % of condenser 20+/-3 20+/-3 20+/-3

 OPERATING PARAMETERS FOR DRYING
PLANT
PARAMETERS SMP WMP

Chamber inlet air temperature (oC) 170+/-10 165+/-5

180+/-10 170+/-5

Vibro fluidier air inlet temperature (oC) 90+/-5 65+/-10

Chamber outlet temperature (oC) 80-90 80-90

Vibro fluidier outlet temperature (oC) 64+/-2 65+/-2

Chamber vacuum (mm.w.c) 5+/-2 15+/-2

Atomizer load (amp) 55+/-5 55+/-5

Load on exhaust fan (amp) 95+/-5 95+/-5

Powder output (kg/hr) Min. 1375 Min. 1500

Powder Plant
Drying Chamber

Cyclone
Control Panel
 Processing Operations

• Chilling: Milk is chilled below 4 ºC. The raw

chilled milk is utilized for the various products
processing operations. The chilled milk is
stored in tank called as Silo. The chiller is plate
heat exchanger type.
• Pasteurizing: Milk is heated at 63 ºC for 30
minutes or 75-80 ºC for 15 sec and then
cooled immediately below 14 ºC.
 Make : Cast iron grid tiles, edges are of cast iron
planting
Width : To overcome heavy stresses
Types : 1.5mm
Slope : Open
Cans : 40 Liters capacity, weighing 6-6.5 kg
Material : Aluminum

Type of milk received :-

 Cow Milk :- Fat Min. 3%, SNF Min. 7.9%
 Buffalo Milk :- Fat Min. 6%, SNF Min. 8.6%
 Mixed Milk :- Fat Min. 5.4-5.5%, SNF Min. 8-8.5%
• Starting the RMRD
• Unloading and Conveying
• Opening the lids
• Grading
• Weighing and Sampling
• Cleaning & Washing of cans
• Recording of cans
• Loading
• Closing down RMRD
 Composition of Milk
Characteristic Cow milk Buffalo milk

Fat 4.0-4.5 % 6.5-7.0%

Carbohydrates 4.5 % 4.7 %

SNF 8-8.5 % 8.5- 9.0%

Proteins 3.3 % 3.6 %

Minerals 0.6 % 0.7 %

Water 87-88 % 84-85 %

 Milk

Fluid Milk Surplus Skim Milk

Fat

Packing Table White Skim Milk

Given Butter Butter Powder
Prefernce
Ghee
Lassi

Milk-cake

Kheer

Dahi
City Supply Section
 Compositional & other Standards maintained :-

Equipments used are- Steam Jacketed Vat, Trolleys, Sealing Machine, Hoops,
Automatic Machine For Processing.

• Cleaning of vats, hoops & muslin cloths is done manually, then they are
sanitized with 0.5% teepol & hot water at 55-60oC

Fat Not < 50% of dry

mater basis
Moisture Not > 70%

Texture Soft & spongy

Taste & flavor Pleasant

 Flow diagram for Paneer
manufacture
Dipped in
Cutting into pasteurized &
Whole milk chlorinated
blocks
chilled water (4-
10oC/45-60 min)

Heating (90oC) Cut into pieces

Pressing & weighing
for 15 min
(200gm
manually)

Filtration (with
clean muslin Hoping Packing in
cloth) polythene
sachets

Coagulation (1- Separation of

2% citric acid) whey Storage at butter
cold store Dispatching
 This dairy plant follows the ISI standard of dahi. Mostly it is manufactured
every two alternate days in flush seasons.

Compositional & other Standards maintained :-

Fat 4-5%

Protein 3.2 -3.4%

Acidity 0.8-1.0%
Taste Cream-sour
Flavor Acid

 Equipments used are- Steam Jacketed Vat, Weighing Balance, Cans, Incubation
Chamber, Dahi Packaging Machine.
 Flow diagram for Dahi manufacture

Milk is taken in Putting 12 Cups

Incubation
Vat For Dahi in each Card
(37oc/1.5-2hr)
Preparation Board Box

Standardization
& Sealing the Cups Dahi Prepared
Homogenization

Pasteurization Filling by pipe

Cooling &
(80-90oc/15-30 filler in
Storage (5oc)
Min) polystyrene cups

Inoculation with
Lactic Culture
Cooling (37°C) Dispatch
(from previous
day Dahi)
Ludhiana milk Plant is engaged in making two types of butter viz

 Table Butter

 White Butter (White Butter is made and stored as stock and is used
in lean season for recombination and is also used as base material
for ghee & often supplied for bulk demand).

 The dairy produces butter by batch churn method. There is also a

provision for continuous butter making machine.

 The packed butter is stored at -17 to -29oC till dispatch.

 Loading of churn 1/3rd volume of drum capacity
Loading temp (oC) < 10-12 oC
Churning temp (oC) < 10-12 oC
Color addition 1ml/kg fat
Spray water temp (oC) Max 5
28-30 rpm (1st gear)

Speed of churning 14-18 rpm (2nd gear)

7-8 rpm (3rd gear)

Salt addition (dissolved in pasteurized warm
22mg/kg of butter yield
water)
Vacuum during operation 300-350mm
FAT % in cream 40-42
 Flow diagram for Table Butter manufacture
Washing at 2nd Equal in
Cream from gear (6-8oC/15 volume of Package in card
separator min after buttermilk board boxes
adding water) removed)

Cram Removal of Draining of Storage (-17 to

pasteurization buttermilk water -29oC)

Storage in Churning at 4th

Packaging (500,
cream tank for gear of white 2nd washing
100, 10 gm)
ageing butter

Unloading
Churning at 2nd Salt @ 2.2% is
Feeding to (before it rotate
gear (30-45 added (for table
butter churn at 2nd gear for 5
min) butter)
min)

(In case of table Churning at 1st Working &

butter color is gear up to controlling of (25-30 min.
added @ breaking point moisture at 2nd 300-350mm)
1ml/kg/fat) (30-35min) gear
Compositional & other Standards maintained :-

Flavor & color Pleasant & white or yellow

Moisture Max. 0.25%
F.F.A (% Oleic Acid) Max. 0.03%
B.R. reading at 40oC 40-43
Peroxide value Max. 1
Sediment Absent
• Equipments used are- Butter Melting Vat, Pre-stratification Tank, Ghee
Boiler, Settling Tank, Filling/Storage Tank, Ghee Clarifier, Electronic
Weighing Balance, Closure Punching Machine, Pouch Filling Machine.
Pre-melting temp (oC) 75-80
Cooking temp (oC) 105-112
Batch time (hr) Max. 4
Steam pressure in kettle (kg/sq.cm.) 2
Filtration Falalin cloth
Clarification temp (oC) 95+/-5
Setting time (hr) Min. 6
Ghee filling tank temp (oC) 43+/-5
Ghee filling temp (oC) 42+/-5 °C
After packaging the packed corrugated boxes are kept in
granulation room for 24 hrs. Then the boxes are transferred into
storage room till dispatch.
 LASSI : Lassi is a drink made of standardized milk with 50:50
dilutions with water.

Receiving Cold storage less than 5°c

milk
↓
Packaging
Standardization
(4.5%fat and
8.5%snf) Breaking of coagulum
( acidity o.54%)
Heating of milk
85°c /5min
Addition of pasteurized
chilled water 2%
Cooling down to 40°c

Inoculation at 40 °c
ulation with culture at 1% at 40 °c (till acidity reach 0.67%)
 Kheer is concentrated heat desiccated
indigenous dairy product.

Taking milk in double jacketed Addition of mixture of sodium Stirring for some time and
vat benzoate and Elaichi powder filling in cups(200 g)

Heating milk to desirable

reached with consistency with Addition of sugar Storing in cold room(below 8˚C)
continuous stirring

Heating it till desired

Addition of basmati rice in
consistency reached with
boiling milk and stirring
stirring
Any question ?