VERKA MILK PLANT

INTRODUCTION OF VERKA MILK PLANT

Verka Milk Plant, Amritsar was the first Milk Plant established in the Northern region.  The
foundation stone of the plant was laid by the then Hon’l Chief Minister of Punjab, S. Partap
Singh Kairon on 20th August, 1959.  The plant was inaugurated by Dr. A.M Thomas, then
Deputy Minister of Food & Agriculture, Govt. of India on 23rd March, 1963. The equipment
of the plant was gifted by the United State of America, assisting and providing the Indian
People with a more nutritious diet containing nature’s most perfect food.In the beginning, the
processing capacity of the plant was 60000 LPD, with 5.0 MT per day drying capacity &
10000 litres Liquid Milk Supply under the control of Punjab Government. This was the first
Composite Milk Plant in Northern India and was established at the Verka village the outskirts
of the Amritsar city. Therefore the brand name of all the products was named as ‘VERKA’
which is internationally famous brand name for milk plant. In 1966, its control was
transferred to the Punjab Dairy Development Corporation Limited and then further
transferred to Milkfed Punjab under Cooperative Sector in 1983.  The Amritsar District
Coop. Milk Producers’ Union Limited was established and registered on 28.2.1979 and
started functioning on 01.7.1988. The product range includes Pouch Milk, Ghee, Skimmed
Milk Powder, Curd, Sweetened Flavoured  Milk (PIO), Paneer, Milk cake, Panjiri, Lassi &
Kheer, etc.

Keeping in view the milk production in the milkshed area of Amritsar, the processing
capacity of the plant was expanded to 1.5 Lac (LPD) in 1998 and drying capacity 10.0
MT/day  to facilitate the producers and cope-up with quality standard. The milkshed area of
this union has been covered with six established milk chilling centres namely MCC Mehta,
Patti, Lopoke, Bhathal Sehja Singh, Khadoor Sahib, Fatehgarh Churian  & four in the hired
buildings namely Bhikhiwind, Ajnala, Tahli Sahib and Kukrawala. In addition to this, Milk
Union has also installed 51 BMCs and 79 AMCs at different MPCS.  Now a days,  731
MPCS and 300 commercial dairy Farmers are pouring milk to this plant. Milk Union is
providing A.I facilities to 452 milk producers cooperative societies through 125 cluster
centres and 2 Single A.I centres.  In addition to this, 29 cluster A.I centres have been
established in the border area of District Tarntaran and Amritsar .
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.

MILK PLANT location

 Amritsar
 Bathinda
 Chandigarh
 Faridkot
 Ferozpur
 Gurdaspur
 Horshiarpur
 Jalandhar
 Ludhiana
 Patiala
 Ropar (Mohali)
 Sangrur
 MILKFED has its milk unions in almost all the districts of Punjab. These district units
are:- These plants in all these unions are being run under the brand name VERKA

PRESENT STATUS OF VERKA MILK

 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%.

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.

PROCESS CONTROL of powder

  Lumpiness in Powder
 Ensure proper cooling of powder
 Dehumidifier should be properly operating Low moisture in Final Product .
 Increase flow rate
 Adjust outlet temp Burnt Powder Particles
 Adjust inlet temp
 Check the function of feed flow controller & feed pump
 Nozzle of jets are whether chocked partially Sooty Powder
 Clean or change the filter.
 Check up air heater Very Fine Powder A Particles
 Increase in degree of concentration
 Control the feed temp. Solubility Index Increased
 Check the outlet temp.
 Control feed rate

DAHI SECTION
Milk is taken in Vat For Dahi Preparation Standardization & Homogenization Pasteurization
(80-90oc/15-30 Min) Cooling (37°C) Inoculation with Lactic Culture (from previous day
Dahi) Filling by pipe filler in polystyrene cups Sealing the Cups Putting 12 Cups in each
Card Board Box Incubation (37oc/1.5-2hr) Dahi Prepared Cooling & Storage (5oc) Dispatch
Flow diagram for Dahi manufacture

BUTTER SECTION

 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.

LASSI SECTION

Lassi is a drink made of standardized milk with 50:50 dilutions with water. Receiving milk ↓
Standardization (4.5%fat and 8.5%snf) Heating of milk 85°c /5min Cooling down to 40°c
ulation with culture at 1% at 40 °c Inoculation at 40 °c (till acidity reach 0.67%) Addition of
pasteurized chilled water 2% Breaking of coagulum ( acidity o.54%) Packaging Cold storage
less than 5°c.

KHEER SECTION

Kheer is concentrated heat desiccated indigenous dairy product. Taking milk in double
jacketed vat Heating milk to desirable reached with consistency with continuous stirring
Addition of basmati rice in boiling milk and stirring Heating it till desired consistency
reached with stirring Addition of sugar Addition of mixture of sodium benzoate and Elaichi
powder Stirring for some time and filling in cups(200 g) Storing in cold room(below 8˚C)

CREAM SECTION

Cream from separator Cram pasteurization Storage in cream tank for ageing Feeding to butter
churn (In case of table butter color is added @ 1ml/kg/fat) Churning at 1st gear up to
breaking point (30-35min) Churning at 2nd gear (30-45 min) Churning at 4th gear of white
butter Removal of buttermilk Washing at 2nd gear (6-8oC/15 min after adding water) Equal
in volume of buttermilk removed) Draining of water 2nd washing Salt @ 2.2% is added (for
table butter) Working & controlling of moisture at 2nd gear (25-30 min. 300-350mm)
Unloading (before it rotate at 2nd gear for 5 min) Packaging (500, 100, 10 gm) Storage (-17
to -29oC) Package in card board boxes Flow diagram for Table Butter manufacture.

GHEE-SECTION

Compositional & other Standards maintained :-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. 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

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 dispatched.

Paneer section
 FIELD VISIT
(VERKA MILK PLANT)
SUBMITTED to- Miss. Arpandeep kaur
Assistant pro.
M.Sc.community health Nursing

SUBMITTED BY : prabhjot kaur

M.Sc. NURSING 1ST YEAR {pediatric nursing}

Date -22/08/2020