Amul Plant Layout - October 18th, 2010

Plant layout is the overall arrangement of the machine tools, handling equipments,
storeroom and other various accessories required for facilitating production in a factory.
These arrangements are pre-planned with the results that the building has been
constructed to fit a layout of a given process.

AMUL plant is indigenously worked out with facilitation of various production processes
and production of multi products under one plant. The total plot is nearly about 2.27 kms.
Separate buildings are provided with required arrangements of machine tools handling
and computers connection through the control room to fit for varying product-
manufacturing departments.

The plant is engaged in producing milk, ice creams, milk powder and ghee. Entire
department is uniquely provided with facilities for the processing each product. There are
4 production departments and packaging departments pertaining to each product
respectively.

Thus, plant layout encompasses all production and service facilities and provides for the
most effective utilization of the men, materials and machines constituting the process. It
is the master blue print of coordinating all operations.

AMUL PLANTS
1.
First
plant is at
ANAND
, which engaged in the manufacturing of milk, butter, ghee,milk powder, flavored milk
and buttermilk.2.
Second
plant is at
MOGAR
, which engaged in manufacturing chocolate, nutramul,Amul Ganthia and Amul lite.3.
Third
plant is at
Kanjari
, which produces cattelfeed.4.
Fourth
plant is at
Khatraj
, which engaged in producing cheese

3.4 Department Information

3.4.1 Production Department:

Production means creation of utilities and energy to satisfy the wants and
requirements of the people. It covers all the activities of the allocation and utilization of
resources such as laborer’s energy, material equipments etc.

Production is a basic function of the firm as an output.

As there are so many products of the dairy, the production
department’s staff is quite intelligent and hard working.
Production is a combination of the four factors land, labors,
capital and entrepreneur. In the dairy, the four factor are
combined and so the production goes high day-to-day.

LIST OF PRODUCT

AMUL MILK
Raw Material – Milk given by the villages
 Quality - 16 Lacs liter/day

Nutrition- 1.5 to 6.0 Fats

SAGAR/BANAS GHEE
Raw Material – Milk Butter
Quality - 6547 M ton’s

SAGAR MILK POWDER

Raw Material – Milk
Quality - 30,554 M ton’s

AMUL BUTTER
Raw Material – Milk Fat
Quality - 15,212 M ton’s

AMULYA INSTANT MILK MIX

Milk Fat 20%

PRODUCTION PROCESS DEPARTMENT

There are different kinds of process doing in the different department of the
production process.

 Milk receiving Department

 Milk pasteurization Department

  Milk Storage Department

 Milk Pouch Packing Section

 Butter Making Department

 Ghee Making Department

 Powder Making Department

MILK RECEIVING DEPARTMENT:

In this department, the following processes are being done:
A. This is the first process done into this unit

B. First all the trucks take to the “Milk Receiving Dock”.

There is a special quality of every unit is that throughout
every process Nil & is No one person doesn’t touch the
product
C. All the canes stands in the truck are put on the chain.
Which is circular following?
D. Then all the canes weighted by the weighting machine.
Also, some milk taken into the bickers for testing.
E. Then all the empty canes are taken into machine for
washing on the chain. All the canes are washed by steam &
hot water. At the end all the canes goes to end rout of this
unit & sprayed a chemical named “ Sodium Silicate” to at
clean
F. This department is checked by the food product
organization.

 MILK PASTEURIZATION DEPARTMENT

 In this process Milk is heated up to 80 c & after immediately cooled it because of it
become microbes free. This process is done twice in a day after cream removed from it &
stored it.
 MILK STORAGE DEPARTMENT
a) After pasteurizing, the milk & cream are stored into the insulated tank.

b) In this department there are tanks stands & they are used for filling Milks. The capacity
of each tank in 20,000 litres.

c) Also, for filling cream the tanks are available.

d) Standardize milk is used for making milk powder.

e) Cream is used for making table butter & ghee.

 MILK POUCH PACKING SECTION

a) In this department the milk pouch for 500ml are filled.

b) Each machines can fill 60 pouch per minute

c) All the pouches are put into the cold storage.

d) The pouches in the cold storage are send to district head quarters,

 BUTTER MAKING DEPARTMENT

a) In this department the table butter is made from the pasteurized cream.

b) This butter is made with the help of condiment butter making machine.

c) It is paked in 500gm & 100gm packet.

d) The capacity of the machine is to make butter is 40 tonnes/day.