INTERNSHIP REPORT

AAVIN MILK INDUSTRY

S. KAVYA
17BBA023
BACHELOR OF BUSINESS ADMINISTRATION
DR.G.R. DAMODRAN COLLEGE OF SCIENCE
COIMBATORE

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 CHAPTER - I

INTRODUCTION

Milk among all commodities, is the largest contributor to the economy in India. At an
all India level, the value of milk produced of per annum than the combined production of
rice and wheat is higher.

Indian dairy industry is contributing significantly to the country’s economy, besides

improving the health standard by increasing the valuable nutritional food. India occupies first
position in world milk production with 16% share of global output.

Dairy sector is important not only as the producer of highly nutritious food products, but
also for the sustenance of poor farmers and over all prosperity of the farming community.
Currently, milk production in India is around 14 core metric tones per day with the country
being the largest milk producer in the world. It is matter of great pride that a nation which
was deficit in milk has now become the leading milk producer in the world.

Dairy sector has assured much significance by generating income not only to the rural but
also to the urban and semi-urban population in the state especially to women folk by
providing self-employment opportunity. Milk and milk products provide essential nutrition
to all walks of life. It provides livelihood to millions of small and marginal farmers in the
state.

Tamil Nadu is an agricultural oriented state and majority of the farmers owns cattle.
Dairying providing the main source of income next to agriculture. In a tropical country like
India, agriculture may fail sometimes, due to monsoon failure by dairying never fails and
gives them regular, steady income.

The value of milk produced annually in TamilNadu is more than one and a half times of
value of baddy annually produced in the state. In TamilNadu, milk group contributes more
than 43% share in value of output from livestock sector milk has additional advantages in
terms of being a reasonably steady and daily source of income to rural households.

Tamilnadu ranks eight in milk production and is well on the way towards achieving the ‘
second white revolution' as envision by the honourable chief minister of Tamilnadu solutions

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to improve the economic status of the milk producers are being arrived at, by the govt. viz.,
timely payment to the producers, remunerative price, subsidy schemes and inputs like
breeding facilities, cattle feed, etc.,

Tamilnadu stands at fourth position in the country in the milk procurement through coming
operatives. Erode District Vo operation milk producer union limited is one of the main feeder
balancing dairy in Tamilnadu. The excess of milk is converted into milk products like butter,
ghee, dates, khao, badam mix powder, curd, butter milk, standardized milk, full cream milk
and milk powder.

CHAPTER - II

OBJECTIVES OF THE CO-OPERATIVE IN TAMILNADU:

Assure a remunerative price for the milk produced by the member of the milk producers
co-operative societies through stable, steady and well organized market support.

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 CHAPTER - III

PRIMARY MILK PRODUCTION:

Milk production began 6 000 years ago or even earlier. The dairy animals of today
have been developed from untamed animals which, through thousands of years, lived at
different altitudes and latitudes exposed to natural and, many times, severe and extreme
conditions. Milk is the only food of the young mammal during the first period of its life.

The substances in milk provide both energy and the building materials necessary for
growth. Milk also contains antibodies which protect the young mammal against infection. A
calf needs about 1 000 litres of milk for growth, and that is the quantity which the primitive
cow produces for each calf.

There has been an enormous change since man took the cow into his service.
Selective breeding has resulted in dairy cows which yield an average of more than 6 000
litres of milk per calf, i.e. six times as much as the primitive cow. Some cows can yield 14
000 litres or more.

Before a cow can start to produce milk she must have calved first. Heifers reach
sexual maturity at the age of seven or eight months but are not usually bred until they are 15
– 18 months old. The period of gestation is 265 – 300 days, varying according to the breed of
cow, so a heifer produces her first calf at the age of about 2 – 2.5 years.

III.A. SECRETION OF MILK

Milk is secreted in the cow’s udder – a hemispherical organ divided into right and left
halves by a crease. Each half is divided into quarters by a shallower transverse crease. Each
quarter has one teat with its own separate mammary gland, which makes it theoretically
possible to get four different qualities from the same cow.

The udder is composed of glandular tissue which contains milk-producing cells. It is

encased in muscular tissue, which gives cohesion to the body of the udder and protects it
against injury from knocks and blows.

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 The glandular tissue contains a very large number (about 2 billion) of tiny bladders
called alveoli. The actual milk-producing cells are located on the inner walls of the alveoli,
which occur in groups of between 8 and 120. Capillaries leading from the alveoli converge
into progressively larger milk ducts which lead to a cavity above the teat. This cavity, known
as the cistern of the udder, can hold up to 30 % of the total milk in the udder.

FIGURE – I
SECTIONAL VIEW OF THE UDDER

The cistern of the udder has an extension reaching down into the teat; this is called the
teat cistern. At the end of the teat there is a channel 1 – 1.5 cm long. Between milkings the
channel is closed by a sphincter muscle which prevents milk from leaking out and bacteria
from entering the udder.

The whole udder is laced with blood and lymph vessels. These bring nutrient-rich
blood from the heart to the udder, where it is distributed by capillaries surrounding the
alveoli. In this way the milk-producing cells are furnished with the necessary nutrients for the
secretion of milk. “Spent” blood is carried away by the capillaries to veins and returned to the
heart. The flow of blood through the udder amounts to 90 000 litres a day. It takes between
800 and 900 litres of blood to make one litre of milk. As the alveoli secrete milk, their
internal pressure rises.

If the cow is not milked, secretion of milk stops when the pressure reaches a certain
limit. Increase of pressure forces a small quantity of milk out into the larger ducts and down
into the cistern. Most of the milk in the udder, however, is contained in the alveoli and the
fine capillaries in the alveolar area. These capillaries are so fine that milk cannot flow

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through them of its own accord. It must be pressed out of the alveoli and through the
capillaries into the larger ducts. Muscle-like cells surrounding each alveolus perform this
duty during milking.

III.B. PROPERTIES OF MILK

Milk consists of about 87% water and 13% dry substance. The dry substance is
suspended or dissolved in the water. Depending on the type of solids there are different
distribution systems of them in the water phase.

Emulsion:

A suspension of droplets of one liquid in another. Milk is an emulsion of fat in water,

butter an emulsion of water in fat. The finely divided liquid is known as the dispersed phase
and the other as the continuous phase.

When milk and cream turn to butter there is a phase inversion from an oil-in-water
emulsion to a water-in-oil emulsion.

Colloidal solution:

When matter exists in a state of division intermediate to true solution (e.g. sugar in
water) and suspension (e.g. chalk in water) it is said to be in colloidal solution or colloidal
suspension. The typical characteristics of a colloid are small particle size, electrical charge
and affinity of the particles for water molecules.

In milk the whey proteins are in colloidal solution and the casein in colloidal
suspension.

TABLE - 1

COMPOSITION OF MILK
Whey Carbo-
Protein Casein Fat Ash
Animal protein hydrate
% % % %
% %

Cow 3.5 2.8 0.7 3.7 4.8 0.7

Buffalo 4.0 3.5 0.5 7.5 4.8 0.7

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 CHAPTER - IV

Raw Milk Silo tanks

Silo tanks for milk reception belong to the storage category and have been described
under “Collection and reception of milk”. They vary in size 150 000 litres and the wetted
surfaces are of stainless steel. They are often placed outdoors to save on building costs. In
these cases the tanks are insulated. They have a double shell with a minimum of 70 mm
mineral-wool insulation in between. The outer shell can be of stainless steel, but for
economic reasons it is usually made of mild steel and coated with anti-corrosion paint. To
make complete drainage easy, the bottom of the tank slopes downwards with an inclination of
about 6% towards the outlet. This is a statutory requirement in some countries. Silo tanks are
fitted with various types of agitators and monitoring and control equipment.

The number and size of the silo tanks are determined by such factors as the milk
intake per day, the number of days per working week, the number of hours per working day
(1, 2 or 3 shifts), the number of different product to be manufactured and the quantities
involved where based on procurement of raw milk per day.

RAW MILK SILO

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PASTEURIZATION:

The process was named after the French scientist Louis Pasteur, whose research in the
1880s demonstrated that thermal processing would inactivate unwanted microorganisms in
wine. Spoilage enzymes are also inactivated during pasteurization. Today, pasteurization is
used widely in the dairy industry and other food processing industries to achieve food
preservation and food safety.

Purpose:

 Inactivation of bacterial pathogens (target organisms Coxiella burnetti).

 Assurance of longer shelf life(inactivation of many enzymes).

Processing

 Heat treatment of 720C (1610F) for 15 seconds (HTST) or 630C (145 0F) for 30 min.
 Does not kill all vegetative bacterial cells or spores (Bacillus spp. & Clostridium spp)
 Pasteurization temperature is continuously recorded.

Definition:

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  Pasteurization is a process of heating a food, which is usually a milk, to a specific
temperature for a predefined length of time and then immediately cooling it after it is
removed from heat.
 This process slows spoilage caused by microbial growth in the food.

Thermisation

In many large dairies it is not possible to pasteurise and process all the milk
immediately after reception. Some of the milk must be stored in silo tanks for hours or days.
Under these conditions, even deep chilling is not enough to prevent serious quality
deterioration. Many dairies therefore preheat the milk to a temperature below the
pasteurisation temperature to temporarily inhibit bacterial growth. This process is called
thermisation. The milk is heated to 63 – 65°C for about 15 seconds, a time/temperature
combination that does not inactivate the phosphatase enzyme. Double pasteurisation is
forbidden by law in many countries, so thermisation must stop short of pasteurisation
conditions.

The main categories of heat treatment in the dairy industry

Process Temperature Time

Thermisation 63 – 65°C 15 s

LTLT pasteurisation of milk 63°C 30 min

HTST pasteurisation of milk 72 – 75°C 15 – 20 s

HTST pasteurisation of cream etc >80°C 1–5s

Ultra pasteurisation 125 – 138°C 2–4s

UHT (flow sterilisation) normally 135 – 140°C a few seconds

FIGURE

Production line for market milk with partial homogenisation

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1 Balance tank 9 Regulating valve
2 Product feed pump 10 Shut-off valve
3 Flow controller 11 Check valve
4 Plate heat exchanger 12 Homogeniser
5 Separator 13 Booster pump
6 Constant pressure valve 14 Holding tube
7 Flow transmitter 15 Flow diversion valve
8 Density transmitter 16 Process control

FIGURE

HEAT TRANSFORMATION

FIGURE

PLATE HEAT EXCHANGER

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CLEANABILITY REQUIREMENT

A heat exchanger in a dairy must be cleaned at the end of a production cycle. This is
done by circulating nitric acid , caustic soda and hot water the same way as the milk.

EFFICACY AGAINST PATHOGENIC BACTERIA

The Codex Alimentarius Code of Hygienic Practice for Milk notes that milk
pasteurization is designed to achieve at least a 5 log10 reduction of Coxiella burnetii. The
minimum pasteurization conditions are those having bactericidal effects equivalent to heating
every particle of the milk to 72°C for 15 seconds (continuous flow pasteurization) or 63°C for
30 minutes (batch pasteurization).

TABLE

Inactivation of the Major Milk-Borne Pathogens

PATHOGENS DESTROY AT

Staphylococcus aureus > 6.7 at 66.5 °C (151.7 °F)

Yersinia enterocolitica > 6.8 at 62.5 °C (144.5 °F)

Escherichia coli > 6.8 at 65 °C (149 °F)

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 Cronobacter sakazakii > 6.7 at 67.5 °C (153.5 °F)

Listeria monocytogenes > 6.9 at 65.5 °C (149.9 °F)

Salmonella ser. Typhimurium > 6.9 at 61.5 °C (142.7 °F)

FIGURE -

Inactivation of the Major Milk Enzymes

HOMOGENIZATION

Homogenization is the process of breaking down the fat molecules in milk so that they
stay integrated rather than separating as cream. Homogenization is a purely physical process;
nothing is added to the milk.

Homogenization or homogenisation is any of several processes used to make a mixture

of two mutually non-soluble liquids the same throughout. This is achieved by turning one of
the liquids into a state consisting of extremely small particles distributed uniformly
throughout the other liquid. A typical example is the homogenization of milk, where the milk
fat globules are reduced in size and dispersed uniformly through the rest of the milk.

Process

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 Milk is an oil-in-water emulsion, with the fat globules dispersed in a continuous phase
of skim milk. If raw milk were left to stand the fat globules would form a cream layer and
rise to the surface.

Homogenization is a mechanical process used to reduce the size of the fat globules in
the milk. The net result of this process is a decreased creaming rate according to Stokes’ Law,
reduced clustering during creaming, and better density matching with the continuous phase.

Milk homogenization is accomplished by mixing massive amounts of harvested milk to

create a constant, then forcing the milk at high pressure through small holes. Yet another
method of homogenization uses extruders, hammermills, or colloid mills to mill (grind)
solids. Milk homogenization is an essential tool of the milk food industry to prevent creating
various levels of flavor and fat concentration.

Another application of homogenization is in soft drinks like cola products. The reactant
mixture is rendered to intense homogenization, to as much as 35,000 psi, so that various
constituents do not separate out during storage or distribution.

The homogenization process reduces the globule size by passing milk under high
pressure through a tiny orifice. To understand the mechanism, consider a conventional
homogenizing valve (Figure 1) processing an emulsion such as milk at a flow rate of 20,000
l/hr. As it first enters the valve, liquid velocity is about 4 to 6 m/s. It then moves into the gap
between the valve and the valve seat and its velocity increases to 120 meters/sec in about 0.2
milliseconds. The liquid then moves across the face of the valve seat and exits in about 50
microseconds. The homogenization phenomenon is completed before the fluid leaves the area
between the valve and the seat.

Homogenization of Milk

Milk is a very complex food containing over 100,000 different molecular species.
Cow’s milk is composed of 87% water, 3.5% protein, 3.7% fat, 4.9% lactose, and 0.7% salts.
The main components of interest are protein and fat globules. The proteins, referred to as
casein particles combine together with calcium and phosphate to form aggregates with a well-
defined structure. Their typical size is in the range of 100 nm. They are white, tasteless and
odorless and are used to make food, paint, and adhesives. In contrast, the fat globules in raw

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unhomogenized milk are between 1-10 µm, while in homogenized milk the size range is 0.2-
2 µm.

CHAPTER – V

CULTURED MILK PRODUCTS

Milk products prepared by lactic acid fermentation (e.g. curd) or a combination of this
and yeast fermentation (e.g. Kefir) are called fermented or cultured milks. The generic name
of cultured milk is derived from the fact that the milk for the product is inoculated with a
starter culture which converts part of the lactose to lactic acid. Carbon dioxide, acetic acid,
diacetyl, acetaldehyde and several other substances are formed in the conversion process, and
these give the products their characteristic fresh taste and aroma. Cultured milk originates
from the Near East and subsequently became popular in Eastern and Central Europe.

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VI.A. CULTURES AND STARTER MANUFRACTURE

Bacteria cultures, known as starters, are used in the manufacture of and other cultured
milk products as well as in butter making. The starter is added to the product and allowed to
grow there under controlled conditions. In the course of the resulting fermentation, the
bacteria produce substances which give the cultured product its characteristic properties such
as acidity (pH), flavour, aroma and consistency. The drop in pH, which takes place when the
bacteria ferment lactose to lactic acid, has a preservative effect on the product, while at the
same time the nutritional value and digestibility are improved.

Cultured dairy products have different characteristics, and different starter cultures are
therefore used in their manufacture. Starter cultures can be classified according to their
preferred growth temperatures:

 Mesophilic bacteria - optimal growth temperatures of 20 to 30°C

 Eg: Lactococcus lactis ssp -> Butter making

 Thermophilic bacteria - optimal growth temperatures of 40 to 45°C

 Eg: Lactobacillus. bulgaricus ssp -> Curd production

Dairies normally buy ready-mixed starters commercial cultures from special

laboratories. These laboratories put much effort into research and development to compose
special cultures for a given product and a great number of cultured milk products. Thus the
dairies can obtain cultures with selected properties for specific product characteristics such as
texture, flavour and viscosity.

The commercial cultures in various forms:

 Liquid, for propagation of mother culture (nowadays fairly rare).

 Deep-frozen, concentrated cultures for propagation of bulk starter.
 Freeze-dried, concentrated cultures in powder form, for propagation of
bulk starter.
 Deep-frozen, superconcentrated cultures in readily soluble form, for direct
inoculation of the product.

In Aavin Daires, they buy Freeze-dried, concentrated cultures in powder form which
were commercially available.

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VI.B. CURD

The conversion of lactose into lactic acid has a preservative effect on milk. The low
pH of cultured milk inhibits the growth of putrefactive bacteria and other detrimental
organisms, thereby prolonging the shelf life of the product.

Curd is the best known of all cultured-milk products, and the most popular almost all
over the world. Consumption of curd is highest in countries around the Mediterranean, in
Asia and in Central Europe.

The consistency, flavour and aroma vary from one district to another. In some areas
curd is produced in the form of a highly viscous liquid, whereas in other countries it is in the
form of a softer gel. The flavour and aroma of curd differ from those of other acidified
products, and the volatile aromatic substances include small quantities of acetic acid and
acetaldehyde.

Curd is typically classified as follows:

 Set type incubated and cooled in the package.

 Drinking type similar to stirred type, but the coagulum is “broken down” to a liquid
before being packed.

FACTORS AFFECTING THE QUALITY OF CURD

Numerous factors must be carefully controlled during the manufacturing process in

order to produce a high-quality yoghurt with the required flavour, aroma, viscosity,
consistency, appearance, freedom from whey separation and long shelf life:

 Choice of milk
 Milk standardisation
 Milk additives
 Deaeration

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  Homogenisation
 Heat treatment
 Choice of culture
 Culture preparation
 Plant design

Pretreatment of the milk thus includes a number of measures which are all very
important to the quality of the end product. The mechanical treatment to which yoghurt is
subjected during production also affects its quality.

Type of milk used – Whole Milk : Standardized Milk

Ratio of milk taken – 1:9

Pre - treatment of milk – Homogenisation

Culture used – Active Lactic Culture (0.06g/l of milk)

HEAT TREATMENT

The milk is heat treated before being inoculated with the starter in order to improve the
properties of the milk as a substrate for the bacteria culture.

 Ensure that the coagulum of the finished yoghurt will be firm.

 Reduce the risk of whey separation in the end product.
 Optimum results are achieved by heat treatment at 90 – 95°C and a holding time of
about 5 minutes. That temperature/time combination denatures about 70 – 80% of the
whey proteins. In particular the ß-lactoglobulin, which is the principal whey protein,
interacts with the κ-casein, thereby helping to give the yoghurt a stable “body”.

INOCULATION

The Lacto bacillius bulgaricus and streptococcus thermophilus, which convert

standardized milk into curd. The starters are added to the milk @ 90 0 C with 10ml of milk.
Then starters containing milk mixture is added to tank containing culturing milk.

INCUBATION

The act of maintaining controlled environmental conditions for the purpose of

favouring growth or development of cultures reaction which conversion lactose to lactic acid.

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Incubation Temperature - 440 C – 450 C for 3-4 hours

PACKAGING

Products need to be preserved and protected in order to reach their destination

in perfect condition. The main purpose of packaging are to hold its contents securely
to prevent leakage and breakage, to protect the foods from different hazard like germs,
heat, moisture loss or moisture pick up, etc.

Packaging material used –

Details in the packet curd:

Package of 150g of curd, Rs.10

FAT – 1.5%, SOLID NON FAT (SNF) – 11.5%

NUTRITIVE VALUE per 150g

Fat 3g
Protein 3.2 g
Carbohydrates 4.7 g
Energy 60 Kcal

Manufacture date : 19.11.2019

Used Before Date: 25.11.2019

Self life : 7 days @ 50C

Details in the cup curd:

Package of 200g of curd, Rs.20

FAT – 3%, SOLID NON FAT (SNF) – 8.5%

NUTRITIVE VALUE per 150g
Fat 3g Calcium 158.4mg
Protein 3.2 g Phosphorus 124.2 mg
Carbohydrate 4.7 g Cholesterol 12 mg
s

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 Energy 60 Kcal

Manufacture date : 19.11.2019

Used Before Date: 25.11.2019

Self life : 7 days @ 50C

Certification:

FSSAI License no: 10814242 42001411

ISO License no: 22000:2005

POST TREATMENT AFTER PACKAGING:

Cold blast room Temperature - 420 C

Storage Temperature - 50 C

VI.C. BUTTER MILK

Cultured buttermilk was first commercially introduced in the United States in the
1920s. Commercially available cultured buttermilk is milk that has been pasteurized and
homogenized, and then inoculated with a culture of Lactococcus lactis or Lactobacillus
bulgaricus plus Leuconostoc citrovorum to simulate the naturally occurring bacteria in the
old-fashioned product.

The tartness of cultured buttermilk is primarily due to lactic acid produced by lactic
acid bacteria while fermenting lactose, the primary sugar in milk. As the bacteria produce
lactic acid, the pH of the milk decreases and casein, the primary milk protein, precipitates,
causing the curdling or clabbering of milk. This process makes buttermilk thicker than plain
milk. While both traditional and cultured buttermilk contain lactic acid, traditional buttermilk
tends to be less viscous, whereas cultured buttermilk is more viscous.

Pasteurization Milk

Standardized milk

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 Culturing

Packing

Incubation

Curd

Addition of cold water

Addition of ginger & chilli paste

Mixing

Manual tasting

Packaging

Details in the packet Buttermilk:

Package of 200 ml of butter milk, Rs.10

Ingredients – Milk Solids

NUTRITIVE VALUE per 200ml

Fat 1g

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 Protein 1.0 g
Carbohydrates 1.3 g
Energy 21 Kcal

Manufacture date : 20.11.2019

Used Before Date: 22.11.2019

Self life : 3 days @ 50C

Certification:

FSSAI License no: 100140 42001411

ISO License no: 22000:2005

CHAPTER – VI
OTHER MILK PRODUCTS
Butter
Butter is usually divided into two main categories:

• sweet cream butter;

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 • cultured or sour cream butter made from bacteriologically soured cream.

Butter can also be classified according to salt content: unsalted, salted and extra salted.
Until well into the 19th century, butter was still made from cream that had been allowed to
sour naturally. The cream was then skimmed from the top of the milk and poured into a
wooden tub. Butter was made by hand in churns. The natural souring process is very
sensitive, and infection by foreign micro-organisms often spoiled the result.

The invention of the separator (1878) meant that cream could be skimmed from milk
quickly and efficiently. It was also the start of large-scale butter making. Contributions to the
quality of the product and butter making economics were also made by the introduction of
pasteurisation in the 1880s, the use of pure bacteria cultures in the 1890s and the introduction
of the butter making machine at the turn of the century. Today’s commercial butter making is
a product of knowledge and experience gained over the years about such matters as hygiene,
bacterial acidification and temperature treatment, as well as the rapid technical development
that has resulted in the advanced machines now used.

General process steps in batch and continuous production of cultured butter

1 Milk reception
2 Preheating and pasteurisation of skimmilk
3 Fat separation
4 Cream pasteurisation
5 Vacuum deaeration, when used
6 Culture preparation, when used
7 Cream ripening and souring, when used
8 Temperature treatment
9 Churning/working, batch
10 Churning/working, continuous
11 Buttermilk collection
12 Butter silo with screw conveyor
13 Packaging machines

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 If the cream is produced at the creamery, the whole milk is preheated to 63°C in the
pasteuriser before being separated. The warm cream is routed into an intermediate storage
tank before being pumped to the cream pasteurisation plant. For gentle treatment of the
cream, please see the description of the Scania method.
The skimmilk from the separator is pasteurised and cooled before being pumped to
storage. When cultured butter is to be produced, part of the skimmilk should be utilised for
starter preparation. From the intermediate storage tank(s) the cream continues to
pasteurisation at a temperature of 95°C or higher. The high temperature is needed to destroy
enzymes and micro-organisms that would impair the keeping quality of the butter.
The destruction of unwanted micro-organisms is also beneficial in the case of sour
cream butter, as this creates perfect growth conditions for the bacteria culture. The heat
treatment releases strongly antioxygenic sulphhydryl compounds, which further reduce the
risk of oxidation. Vacuum de-aeration can also be included in the line if the cream has an
undesirable flavour or aroma, e.g. onion taste. Any flavouring will be bound in the fat and
transmitted to the butter unless removed.
Vacuum treatment before pasteurisation involves preheating the cream to the required
temperature and then subjecting it to flash cooling to free any entrapped gas and volatile
substances. After this the cream is returned to the pasteuriser for further treatment – heating,
holding and cooling – before proceeding to the ripening tank.

A continuous buttermaking machine

1 Churning cylinder
2 Separation section
3 Squeeze-drying section
4 Second working section

Packaging

There are basically three ways of transporting butter or dairy spreads from the machine to
packaging:
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1. The product is discharged into a silo with a screw conveyor at the bottom. The conveyor
feeds the product to the packaging machine.

2. The product is pumped direct to the packaging machine.

3. Transfer by means of trolleys filled with product. The trolleys are often fitted with screw
conveyors. A combination of these methods is also possible.

Cold storage

For the sake of consistency and appearance butter should be placed in cold storage
after packing and kept at -21°C.

GHEE:

Anhydrous milk fat and butteroil are products consisting of more or less pure milk fat.
Although they are modern industrial products, they have ancient traditional roots in some
cultures. Ghee, a milk fat product with more protein and a more pronounced flavour than
AMF, has been known in India and Arab countries for centuries.

Anhydrous Milk Fat must contain at least 99.8 % milk fat and be made from fresh
cream or butter. No additives are allowed, e. g. for neutralisation of free fatty acids.

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 Production line for AMF from butter

1. Melter and heater for butter

2. Holding tank
3. Concentrator
4. Balance tank
5. Plate heat exchanger for heating/ cooling
6. Vacuum chamber
7. Storage tank

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PACKAGING:

AMF is filled in containers of various sizes. For households and restaurants containers
of 1 kg to 19.5 kg are available. Normally an inert gas, nitrogen (N), is first injected in the
container. As the N22 gas is heavier than air it sinks to the bottom. When filling the AMF –
that is heavier than N2 – the AMF will come underneath and the N gas will create an "air-
tight lid" preventing the AMF form air induced oxidation.

CERTIFICATION

PEDA/KHOA

Khoa is a dairy product, originating from the Indian subcontinent, widely used in

the cuisines of the Indian subcontinent, encompassing India, Nepal, Bangladesh
and Pakistan. It is made of either dried whole milk or milk thickened by heating in an open
iron pan. It is lower in moisture than typical fresh cheeses.

26
 It is a milk sweet prepared using sugar. Here it is prepared in morning session and in a
day only one batch of peda is prepared. Nearly about 200 litres of standardized milk and 20
kg of refined sugar were utilized for preparation yielding about 56 kg of palkova. The amount
of package varies about 25 gms, 100 gms and 200 gms.

FACTORS AFFECTING KEEPING QUALITY:

The following factors control the keeping quality of khao:-

 Quality of raw material

Use of poor quality milk particularly sour or neutralized lowers the keeping
quality of the final product.
 Quality of khoa
Khao having high moisture (ideal is 30-50% moisture) content has very poor
shelf life. The high amount of fat (30-40%) particularly free fat, in presence of copper
and iron is very much favourable for oxidized flavour. Therefore, khoa should not be
contaminated with these pre-oxidant catalysts (The ideal moisture).

PACKAGING MATERIAL:
Parchment/Baking Paper – Made from the acid-treated pulp, the acid modifies the
cellulose to make it smoother and impervious to water and oil, to add some wet strength. It is
not a good barrier to air and moisture, is not heat sealable, and is used to pack fats.
Carton box - A carton is a box or container usually made of paperboard and
sometimes of corrugated fiberboard.
PREPARATION:
 100 litres of standardized milk is heated using the steam at 120 °C for about 3
hours.
 It is continuously agitated to prevent charring until it become thick and golden in
colour.
 When the required consistency is attained, the volume is reduced to 18 kg/100
litres of milk.
 After that about 10 kg of refined sugar is added cooked for a little timing and
removed from heat.
 Then the prepared khao is stored in room temperature and allowed for setting for
24 hrs.
 The next day of preparation the amount to be packed is measured using weighing
machine and then packed.
INFORMATIONS ON PACKAGE:
Nutritional information:-

27
 NUTRIENTS VALUES PER 100 gms
Fat 14.0 g
Protein 10.5 g
Carbohydrates( added sugar 12 g) 56.0g
Minerals 2.0 g
Energy value 402.0 kcal

Cost per 100 gms: Rs.45.

Shelf life : 7days at room temperature.
Certification:
ISO certificate no: 22000:2005
FSSAI certificate no: 10014042001411

CHAPTER – VII

GULABJAMUN MIX

The ingredients are used for the gulabjamun mix is refined wheat flour, butter, baking
soda and milk powder. Which is one of the healthy dessert made by natural ingredients. All
the ingredients are mixing together well and packed in a 175 g pack.

Nutritional values per 100 g of gulubjamun mix

Energy :406.8 kcal

Protein :14.0 g

Carbohydrate: 63.9 g

Fat :10.6 g

Trans fat :0 g

28
No artificial colour and flavor, no trans fat

Manufacturer date:16:11:2019

Rs - 99/-

Certification

FSSAI :10014042001411

BADAM MILK POWDER

INTRODUCTION:

Badam milk powder is a rich and flavorful powder prepared with badam, skim milk
and other ingredients. Badam milk powder can be consumed with hot as well as cold milk.

It can be used to make instant badam milk for even babies and toddlers.

It is rich in several healthy nutrients, but compared to whole almonds it is watered

down and mixing most of the fiber.

FACTORS AFFECTING STORAGE:

The shelf life is controlled by three general factors;

1.Product characteristics

2.Environment during distribution and storage and

29
 3. Packaging materials.

PACKAGING MATERIAL:

Plastic jar – PE( Poly Ethylene) is the most widely used type of plastic. Unpigmented
bottles are translucent, have good barrier properties and stiffness.

Aluminum film – used to cover the mouth of bottle.

PREPARATION

INGREDIENTS:

 Badam
 Refined sugar
 Skim milk powder
 Corn flour powder (Edible starch)
 Cardamom
 Saffron No.1 (Propylene Glycol 477)
 Coloring dye (lemon yellow E 102)

PREPARATION:

All the ingredients except skim milk powder were dry grinded and then mixed with
skim milk powder in the mixer.

Then the mix was measured about 200 gms and then packed in a plastic jars.

30
 Then sealed and transported to retail shops.

INFORMATION ON THE COVER:

1. NUTRITIONAL INFORMATION:

Table :- Nutritional value of badam milk powder per 100 g

NUTRIENTS VALUES PER 100g

Fat 4.0g

Protein 5.0g

Carbohydrates 85.0g

Energy 415kcal

2. CERTIFICATION:

ISO Certificate no : 22000:2005

FSSAI License no :10019042005318

3. USE BY DATE : Best before 4 months from manufacture.

4. COST: Rs.84/200g

SKIM MILK POWDER PLANT

Powdered milk or dried milk is a manufactured dairy product made by evaporating

milk to dryness. In the South India Erode Aavin are the biggest producers of skim milk
powder of about 30 metric tons. There are two purposes for manufacturing powder.

1. Drying milk is to preserve it; milk powder has a for longer shelf-life than liquid
milk and does not need to be refrigerated, due to its low moisture content.

31
 2. Another one is to reduce its bulk for economy of transportation.

In Aavin, the powder production is done by two processes.

1. Falling thin film evaporation.

2. Spray drying.

FALLING THIN FILM EVAPORATION

A Falling Thin Film Evaporator is a vertical shell and tube heat

exchanger with a vapor liquid separator mounted at the bottom.

The liquid to be concentrated is fed at the top of the heated tubes and
distributed in such a way that it flows down on the inside surface of the tube as
a thin film. As the film gets heated, the vapor generated flows co-currently. The
drag of vapors increases the turbulence and improves heat transfer performance.
The vapor and balance liquid are separated in a vapor-liquid separator.

The processed skim milk (6°C-8°C) of < 0.1 % fat is first heated upto 50°C then it is
pasteurized at three varying temperatures of 80°C, 85°C and 90°C and holded in two
chambers for 30 seconds for the complete destruction of micro-organisms.

32
 Then it is passed through 5 Galandria tubes of 38 mm diameter for the complete
evaporation of water present in the skim milk (The milk contains 91.5% of water) . Now,
45% of total solid concentrated milk is transferred to spray dryer.

SPRAY DRYER

Spray drying is a method of producing a dry powder from a liquid or slurry by

rapidly drying with a hot gas. This is the preferred method of drying of many thermally-
sensitive materials such as foods and pharmaceuticals. A consistent particle size distribution
is a reason for spray drying some industrial products such as catalysts. Air is the heated
drying medium; however, if the liquid is a flammable solvent such as ethanol or the product
is oxygen-sensitive then nitrogen is used.

All spray dryers use some type of atomizer or spray nozzle to disperse the liquid or
slurry into a controlled drop size spray.

The spray drier used in aavin is of two types,

1. Single fluid nozzle of 50-300 bars

2. Two fluid nozzle of 1-7 bars

Bar is the unit of 100 kilo pascal (unit of pressure).

33
 In spray drier, the milk is sprayed and hot air of 200°C is passed through 16 holes of
8 mm diameter at a velocity of 6,000 km/h. Here Atomizing process is carried out in which
liquid is converted to solids of fine powder.

After that the powder of 80°C - 85°C is transferred to cold bed of 20°C. Then the
temperature of powder is reduced to 40°C-60°C.

Finally it reaches 35°C - 38°C having 3 - 4% moisture then it is packed at varies

Kilograms.

About 3,60,000 liters of skim milk is processed in Aavin’s powder plant, only 30,000
kgs of skim milk powder is produced per day i.e., 30 metric tons. The ratio of the of the
production is 10:1.

In Aavin, out of 20,000 liters of skim milk 4,000 concentrated milk is produced.
Among produced concentrated milk only 1200 kgs of skim milk is obtained.

NUTRITIVE VALUES OF SKIM MILK POWDER

NUTRITIVE VALUE PER 100 g APPROXIMATELY

Fat 1.0 g

Protein 34.0 g

Carbohydrate 52.0 g

Energy value 357 kcal

34
 CHAPTER - VIII

FLAVORED MILK

INTRODUCTION:

Flavoured milk is a sweetened dairy drink made with milk and flavorings.

Here four types of flavored milks are prepared, which include;

1.Pista

2.Badam

3.Cardomon

4.Pine apple

35
PACKAGING MATERIALS:

Glass bottles (200 ml) – Glass bottles gets and stays much colder than cardboard
containers, so they don’t let as much air in.

PREPARATION

INGREDIENTS:

 Skim milk – 120 liters

 Full cream milk – 40 liters
 Skim milk powder -1180g
 Essence -25 ml

PREPARATION:

Skim milk and full cream milk both at 80°C were mixed well with skim milk powder
and essence.

The flavoured milks are then filled in 200 ml glass bottles and sealed.

36
 The filled glass bottles are sterilized with steam at 1 kg/cm² pressure for about 25
minutes.

About 750 bottles are filled and sterilized in a day. After sterilization the colour of
flavoured milk gets improved.

INFORMATIONS ON THE PACK:

1. NUTRITIVE VALUE:

Table :- Nutritive value for flavoured milk per 100 ml

NUTRIENTS VALUE PER 100 ml

Fat 1.5g

Protein 3.2g

Carbohydrates(with added sugar) 12.6g

Energy 80kcal

2. CERTIFICATION:

ISO Certificate no: 22000:2005

FSSAI License no: 10014042001411

3. USE BY DATE: Best before 45 Days from the date of manufacturing.

4. COST: 25/200 ml.

37
 CHAPTER - IX

LAB TEST

1.MICROBIOLOGY LAB:

Microbiological testing is a crucial part of quality assurance process because it anchors

the safety of the food products. The aim of the microbiology lab is to identify and count the
total quantity of micro-organisms present in the milk. Microbiological assays could be a sort
of bioassays designed to analyse the compounds or substance that have impacts on
microorganisms. They help to estimate concentration and efficiency of antibiotics. Milk
Pasteurization was introduced as a public health measure in order to destroy human
pathogens and to eliminate or reduce the activities of spoilage micro-organisms. The coliform
plate count is widely used to determine the total number of coliforms present in one mL of
milk sample. Yeast, mould and a broad spectrum of bacteria can grow in milk. Microbes can
enter milk via the cow, air. Feedstuffs, milk handling equipment and the milker. Once micro-

38
organisms get into the milk their numbers increases rapidly. It is more effective to exclude
micro-organisms than to try to control microbial growth once they have entered the milk.
Milk equipment should be washed thoroughly before and after use rinsing is not enough.
Bacterial types commonly associated with milk are

MICROBES CAUSES

Pseudomonas Spoilage

Brucella Pathogenic

Enterobacteriaceae Pathogenic and spoilage

2. QUALITY CONTROL TEST IN MILK:

Milk quality control is a use of approved tests to ensure the application of approved
practices, standards and regulation concerning the milk and milk products. The tests are
designed to ensure that milk products meet accepted standards for chemical composition and
purity as well as levels of different micro-organisms.

Quality tests for milk need a concerted effort to ensure that the whole dairy value chain
is involved. This is because dairy products are very susceptible to bacterial contamination.
Milk testing and quality control is an essential component of any milk processing industry
whether small, medium or large scale. Its high nutritive value in it are major responsible for
its rapid microbial development. Quality control is the one of the major operations in the
dairy industry and starts from the reception of the products in the diary there is two sections.
One is chemical quality analysis and other is microbial assays. there are a number of standard
manuals and textbooks on milk quality control. However these may not be easily available to
the emerging small scale to medium scale processes.

39
PROCEDURES

1. LIQUID MILK

Buffalo milk, cow milk, goat milk, sheep milk, mixed milk, standardised milk, full
cream milk, recombined milk, toned milk, double toned milk, and skimmed milk as laid
down under FSSAI Rules.

1.1. Preparation of Sample of Milk

Samples are received after few days of drawl and contain preservative (0.4% formalin).
Warm the sample to 37- 40°C by transferring it to the beaker and keeping it in a water bath
maintained at 40 - 45°C. Stir slowly for proper homogenisation. Mix sample thoroughly by
pouring back into the bottle, mixing to dislodge any residual fat sticking to the sides and pour
it back in the beaker. During mixing do not shake the bottle vigorously. Allow the sample to
come to room temperature (26- 28°C) and withdraw immediately for analysis. If small clots
or lumps are observed in the sample which cannot be dispersed, a few drops of liquor
ammonia may be used during homogenisation. If even after homogenisation the sample
shows lumps or clots or droplets of oil are visible suggestive of curdling /splitting of milk, the
sample should be deemed unfit for analysis and rejected.

1.2. Detection of Adulterants in Milk

1.2.1. Detection and Quantification of Cane Sugar in Milk

Sucrose is absent in milk and its presence in milk indicate adulteration. Presence of
sucrose in milk can be determined by the following method.

1.2.1.1. Qualitative Method: Modified Seliwanoff _ï Method

Fructose in cane sugar (sucrose) reacts with resorcinol in HCl to give red colour.

1.2.1.1.1. Reagent

40
A. Resorcinol Solution (0.5%): Weigh 0.5 g of resorcinol in about 40 ml of distilled water.
Add 35 ml of concentrated HCl (12 N) to it and make up the volume to 100 ml using distilled
water.

1.2.1.1.2. Procedure
MILK AND MILK PRODUCTS 2015
Take 1 ml of milk in a test tube. Add 1 ml of Resorcinol Solution and mix. Place the tube in
boiling water bath for 5 min. Withdraw the tube and observe the colour. Appearance of deep
red colour indicates presence of sucrose, or a ketose sugar. In pure milk samples no such red
color is developed and sample remains white in nature. The limit of detection of method is
0.1%.

1.2.1.2. Quantitative Determination of Cane Sugar in Milk

If the test for Cane Sugar (Sucrose) is positive, the quantitative estimation of sucrose is
necessary for determination of SNF in milk sample. The sucrose content in milk sample can
be determined by volumetric method (Lane-Eynon method). In this method, the milk sample
is curdled with zinc acetate and potassium ferrocyanide (Carrez Solution 1 and 2). Determine
the sugar content before and after inversion. The value before inversion indicates lactose and
after inversion total sugars.

1.2.1.2.1. Reagents

Same reagents those mentioned in Section 9.4. (Determination of sucrose content in

condensed/evaporated milk).

1.2.1.2.2. Procedure

Proceed as in described in Section 9.4 (Determination of sucrose content in

condensed/evaporated milk) and instead of condensed milk, take 40 g of milk sample. Apply
the factor 0.95 for calculating the sugar content.

1.2.2. Detection and Quantification of Starch in Milk

1.2.2.1. Qualitative method

1.2.2.1.1. Reagent

41
MILK AND MILK PRODUCTS 2015

A. Iodine Solution: Dissolve 2.6 g of iodine and 3 g of potassium iodide in a sufficient

quantity of water and make up to 200 ml.

1.2.2.1.2. Procedure

Take about 5 ml of milk in a test tube. Bring to boiling condition and allow the test tube to
cool to room temperature. Add 1-2 drops of iodine solution to the test tube. Development of
blue colour indicates presence of starch which disappears when sample is boiled and
reappears on cooling. The limit of detection of method is 0.02%.

1.2.2.2. Quantitative Determination of Starch in Milk

If test for starch is positive, quantitative estimation of starch is to be carried out for
determination of SNF in milk sample. The sample of milk is curdled with alcohol, and made
free from lactose which is naturally present in milk. The precipitated starch is washed with
50% alcohol to free it from lactose. The precipitated starch is hydrolysed to convert it into
reducing sugars. Reducing sugar is determined by Lane and Eynon method (Section 9.4
(Determination of sucrose in condensed milk) and multiplied with 0.9 to get the starch
content in milk.

1.2.2.2.1. Reagents

A. Ethanol (98%).

B. 10% sodium hydroxide.

C. Sodium carbonate.

1.2.2.2.2. Procedure

Weigh approximately 25 g sample in a 250 ml beaker. Add 20 ml of ethanol to curdle the

milk. Filter the precipitate on a filter paper and wash the precipitate with 50% ethanol till the
precipitate is free from lactose/sugar i.e. when the washings give a negative test with
resorcinol. Transfer the precipitate to a 500 ml flask with about 200 ml water and add 10 ml
concentrate HCl to hydrolyse the starch by refluxing in a boiling water bath for 2.5 hours.
Cool and neutralise with 10% sodium hydroxide and sodium carbonate towards the end using

42
litmus paper. Make up to 500 ml with water. Shake well and filter if necessary. Determine
reducing sugar by Lane and Eynon method (Section 9.4). Calculate starch as follows:

% starch = % reducing sugar x 0.9

1.2.4. Detection of Added Urea in Milk

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.

1.2.4.1. Qualitative Method

This method is based on the principle that urea forms a yellow complex with DMAB in a
low acidic solution at room temperature.

1.2.4.1.1. Reagent

A. DMAB reagent (1.6%, w/v): Dissolve 1.6 g DMAB in 100 ml ethyl alcohol and add 10 ml
concentrate HCl.

1.2.4.1.2. Procedure

Mix 1 ml of milk with 1 ml of 1.6% DMAB reagent. Distinct yellow colour is observed in
milk containing added urea. The control (normal milk) shows a slight yellow colour due to
presence of natural urea. The limit of detection of method is 0.2%.

1.3.4. Determination of Fat in Milk

1.3.4.1. Method 1. Gerber Method

43
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 followe correctly.

1.3.4.1.1. Reagents /Apparatus

A. 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.

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

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 wateror 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.
D. Iso-amyl alcohol (CH11OH): The iso-amyl alcohol shall have density of 0.803 to 0.805
g/ml at 27°C and should be furfural free.
E. Gerber butyrometer; 6, 8 and 10 percent (ISI marked).

44
F. Pipette: 10 ± 0.25 ml or automatic measure or tilt measure for sulphuric acid.
G. Pipette: 10.75 ± 0.03 ml for milk.
H. Pipette: 1 ± 0.05 ml or automatic measure or tilt measure for iso-amyl alcohol.
I. Lock stoppers for butyrometers.
J. Lock stopper key.
K. 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.

L. 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 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 (mm) Revolution Per Min (± 70 rev/min)

240 1140

245 1130

250 1120

255 1110

260 1100

265 1090
Note: The relative centrifugal acceleration ( ) produced in a centrifuge is given by the
following formula:
1.12 X 10-6r n2
where r = effective horizontal radius in mm, and

n = speed in revolutions per min

1.3.4.1.2. Procedure

45
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:

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

2. 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.

3. 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.

METHYLENE BLUE REDUCTION TEST:

AIM:
To determine the amount of bacteria present in milk and also processed or
unprocessed.
PRINCIPLE:

46
 The test depends upon ability of bacteria in milk. The dye added is a redox dye, in a
oxidized state it remains blue in color and in reduced state it remains colorless. The bacterium
in milk consumes the dissolved oxygen in milk, thereby reducing the milk. This brings about
the change; the milk gets decolorized to its original white color. The time taken for changes is
noted.
PROCEDURE:
1. One ml of reagent is added aseptically to 10ml of milk sample and closes the tube
with rubber cork.
2. Mix and place the tube in water bath at 37.5°C.
3. The color of milk in the test tubes is examined after every half an hour and the time
required for complete decolorisation is noted.
GRADING:
MBRT time in hrs Quality of milk
5 and above Very good
3 to 4 Good
1 to 2 Fair
Below 30 mts Poor

PHOSPHATASE TEST:
AIM:
This is used to detect inadequate pasteurization.
PRINCIPAL:
A phosphate is an enzyme present in milk which will be destroyed at complete
pasteurization. The presence of this enzyme in pasteurized milk is an indication of inadequate
pasteurization.
PROCEDURE:
1. Transfer 5 ml of phosphate buffer in a test tube.
2. Add 1 ml of milk sample and close the tube with stopper.
3. Incubate the tubes for exactly 30 minutes at 37°C.Note the color change to yellow
color which indicates inadequate pasteurization.
COLIFORM COUNT:
AIM:
To determine coliform bacteria present in milk.
PRINCIPLE:
This test is based on the principle that the members of the groups are capable of
producing acid and gas from lactose in the presence of bile salt.

47
PROCEDUCE:
1. Prepare serial dilution of the sample and inoculate 1 ml of 1:10 dilution into the
petri plate.
2. Add 10 to 15 ml of VRB agar, mixed well and incubate it for 37°c for 24 hrs.

MILKOSCREEN:
MilkoScreen analyses the product using FT – Infrared Technology, assessing milk
constituents, using absorption at different wavelength in the infrared spectrum to detect the
presence of specific parameters in milk like fat, SNF (Solid Non Fat) and protein.
Accuracy and repeatability of results are comparable with the chemical methods, but
with MilkoScreen, it takes far less time than conventional chemical methods. Results from
MilkoScreen are accurate, direct and not calculated, unlike some contemporary techniques.
MilkoScreen is the fastest way to ascertain purity of incoming raw milk. It takes just
45 seconds to screen the milk and pay fare price to the producer/supplier. MilkoScreen does
not use any chemicals for analysis.
MilkoScreen shows “milk abnormality” for presence of many other adulterants
(having strong absorbance in mid IR region) added in milk in various concentrations.
MILK PARAMETERS ADULTERANTS
Added water
Fat Maltodextrin
Non solid fat Ammonium sulphate
Protein Sucrose
Urea
Other absorbing adulterants is displayed as
abnormal milk

PURITY TEST:
LACTOMETER:
A lactometer is an instrument that is used to check for the purity of milk by measuring
its density. An instrument to find out the content of water in milk or to test the richness of
milk is thus termed as ‘lactometer’.
PRINCIPLE:
The lactometer works on the principle of gravity of milk.

48
 CHAPTER - X

PACKAGING

Packaging is the science, art and technology of enclosing or protecting products for
distribution, storage, sale and use. Packaging also refers to the process of designing,
evaluating and producing packages. Packaging can be described as a coordinated system of
preparing goods for transport, warehousing, logistics, sale and end use. Packaging contains,

49
protects, preserves, transports, informs and sells. In many countries it is fully integrated into
Government, Business, Institutional, Industrial and personal use.

TYPES OF PACKAGING

There are three major types of paper packaging

1. Corrugated boxes
2. Boxboard or paper board cartons
3. Paper bags and sacks

LABELLING

Labelling is the display of label in a product. A label contains information about a

product on its container, packaging or the product itself. It also has warnings in it. The type
and extent of information that must be imparted by a label are governed by the relevant safety
and shipping laws.

Labelling is also an important part of the brand of the product and the company. It
helps the product stand out in the market, identifies it as a part of a particular brand.
Labelling is a printed information that is bonded to the product for recognition and provides
detail information about the products.

TYPES OF LABELLING

There are three types of labeling

1. Brand labeling

2. Descriptive labeling

3. Grade labelling

CHAPTER - XI

EFFLUENT TREATMENT PLANT

For waste water treatment and effluent treatment plant is maintained in the dairy. The
waste will be processing a high BOD which is to be reduced before draining for various
purposes like irrigation.

50
 Waste water

Screen chamber (big particles are sieved and scum being collected)

Equaliation tank (BOD is decreased by the supply of air)

Chemical dozer

Clair – flocculate with agitator

Aeration tank

Final clarifier

Sludge is drained to the sludge bed. The clear solution which over flows is stored and
used for irrigation.

CHAPTER – XII

STORAGE

INTRODUCTION:
Storage is the place where things were stored properly with required temperature,
humidity and pressure.

51
 Almost all the dairy products need to be stored in the refrigerator. The exceptions
include powdered milk products, and products such as UHT (Ultra High Temperature)
products, which can be stored in the pantry, or ice cream which needs to be stored in the
freezer.
MILK PRODUCTS AND THEIR STORAGE TEMPERATURE:
Several products of milk has to be stored properly to ensure quality, to maintain
texture and taste and also to prevent spoilage. Different temperature are required for different
products.
Table: - Milk products and their storage temperature

Sl.N MILK AND MILK PRODUCTS TEMPERATURE

o
1. Curd and butter milk -2.6°C
2. Pasteurized and Standardized milk 5°C
3. Butter -22°C
4. Ice cream -24°C

Products stored in room temperature:

Products such as ghee, badam milk powder, skim milk powder, khoa, biscuit and
gulab jamun mix were stored in room temperature. Some of these products may lower their
self-life when stored in low temperature.

The powdered milk products are preferably stored in below 40°C for maximum
retention of solubility characteristics over long period of time.

A separate storage area with large surface area is available for storing packaging
materials (pet bottles, cardboard, tin, glass bottles, carton box, sachet rolls etc.,) for milk and
milk products. They also store spare parts for boilers, weighing machines, notebooks, records
and other requirements needed for processing units. According to the amount of stocks
present in the storage, the products were ordered in respective companies by the storage in
charge.

CHAPTER - XIII

WATER TREATMENT PLANT:

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 Water treatment is any process that improves the quality of water to make it
more acceptable for a specific end-use. The end use may be drinking, industrial water
supply, irrigation, river flow maintenance, water recreation or many other uses, including
being safely returned to the environment. Water treatment removes contaminants and
undesirable components, or reduces their concentration so that the water becomes fit for its
desired end-use. This treatment is crucial to human health and allows humans to benefit from
both drinking and irrigation use.

The plant has been designed to treat 10 lakh litres of waste water a day at an
average COD (chemical oxygen demand) load of 3,500 mg / litre. The plant consists of pre-
treatment such as screen chamber, fat remover and chemical doser.

The pre-treated waste water is being treated in Anaerobic UASB (Upflow

Anaerobic Sludge Blanket – Sand bed) Reactor as a primary treatment. The waste is further
treated Aerobic process by diffused aeration system. To achieve pollution control board
norms of 30 mg / litre BOD (biochemical oxygen demand) tertiary treatment is provided.

The treated water is crystal clear and being used for farming and gardening. The
combined treatment process of Anaerobic followed by diffused aeration system saves
substantial amount of electrical energy as compared to conventional process.

The treatment ensures clean environment, trouble-free operation and easy

maintenance, the General Manager said. During the anaerobic treatment methane rich biogas
is generated. This is being used in the boiler / canteen as fuel thereby saving fossil fuel and
generating additional revenue for the union.

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PURIFICATION OF WATER:

Water chlorination is the process of adding chlorine or chlorine compounds

such as sodium hypochlorite to water. This method is used to kill certain bacteria and other
microbes in tap water as chlorine is highly toxic. In particular, chlorination is used to prevent
the spread of waterborne diseases such as cholera, dysentery, and typhoid.

Chlorine is manufactured from salt by electrolysis or other methods. It is a gas

at atmospheric pressures but liquid at high pressure. The liquefied gas is transported and used
as such.

As a strong  oxidizing agent, chlorine kills via the oxidation of organic

molecules. Chlorine and hydrolysis product hypo chlorous acid are neutrally charged and
therefore easily penetrate the negatively charged surface of pathogens. It is able to
disintegrate the lipids that compose the cell wall and react with
intracellular enzymes and proteins, making them non functional. Microorganisms then either
die or are no longer able to multiply.

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 CHAPTER – XIV

CONCLUSION

Overall internship is a really good program and recommended to my

fellow friends. It helps to enhance and develop my skills, abilities and develop
my skills Through the period of training in Aavin, we gained more knowledge
and experience regarding Milk and Milk products. I have learned from different
units and people. I am grateful and thankful to supervisors and operators.

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