MRP Report Chapterwise PDF

Chapter 1
Introduction
1.1 Introduction: Milk and Milk Products are used for human diets and are considered as a
complete wholesome cereal free food for human being.It supplies proteins of high quality, liberal
amount of calcium and vitamins necessary to health. Buffaloes and cows are important animals
to produce milk products like Pasteurized milk,Shrikhand,Milk Powder,Ghee,Butter, Cheese,
Paneer,Curd,Lassi etc.in the world.
The plants which produces milk and milk products called Dairy Plants are developed in the
many countries in the world like India, Australia,Russian Federation,Switzerland,France,Italy,
Newzealand,Netherland,USA,Denmark,Sweden,Canada,China,UK,Pakistan,Japan,Germany etc.
In India Dairy Plants aredeveloped in many states like Maharashtra,Gujrat,AndhraPradesh,
Hariyana,Karanataka,Punjab,Rajastan,Tamilnadu,Uttar Pradesh,West Bengal etc.
In Maharashtra Dairy Plants are developed in many districts like Kolhapur,Solpur,Satara,Pune,
Mumbai, Jalgaon, Nashik,Naded etc.
In Kolhapur district (Western Maharashtra region)the dairy plant is one of the growing sector
near about 3% per year and the demand of dairy milk and milk products is increasing near about
6% per year so there is near about 3% gap between the demand and the supply of the dairy milk
and milk products. Therefore there is a scope for growth in this field. For proper management of
various processes of dairy plant there is need to study such dairy plant.In dairy plants there are
many processes involved in the collection of milk, production and marketing of dairy products.
Some processes are very complex in nature and their understanding and control may not be
obtained by rigid and strict rules.
There are number of dairy plants,the study of their problems and possible solutions will be
helpful to them.These plants face number of problems in milk collection process, milk
production process as well as marketing of their production. So we have made an attempt to
study these problems by using Fuzzy Control Theory.
1.2 Research Project: The title of the research project is “A STUDY OF WARANA DAIRY
PLANT USING FUZZY CONTROL THEORY”
1.3 Objectives of the Study:The objectives of the study are explained below. The project have
been undertaken
A Study of Warana Dairy Plant Using Fuzzy Control Theory 1

1. To study Transportation Network of Warana Dairy Plant.
2. To study Milk Production Process of Warana Dairy Plant.
3. To study Market Demand in various Seasons.
4. To collect the data from Warana Dairy Plant and analyze it using various Mathematical Tools.
5. To design Fuzzy Ruled Based Model for optimization.
6. To test the Fuzzy Model using the actual data.
7. To verify the reliability of the Fuzzy Model and Corrections can be made if necessary.
8. To suggest recommendations about the Transportation Network, Amount of Production of
Milk and Market Demand in various Seasons.
1.4 Methodology: The research is based on the systematic research design to meet the
objectives of the study.
1.4.1 Study Region: For research study we have selected Warana Dairy Plant at Warananagar in
Kolhapur district (Western Maharashtra region).
TheKolhapur district is situated in South west part in Maharashtra State.The total area extend is
of 7685sq.km. which is about 2.50 per cent of the total area of the state. It lies between
15°43’and 17°17’North latitudes and 73°40’ and 74°42’east longitudes. It is surrounded by
Sangli district to the north Belgum district of Karnataka state to the east and south and
Ratanagiri and Sindhudurg district to the west.The main rivers of the district are Krishna,
Warana, Panchaganaga,Doodhganga,Kumbhi-Kasari, Hiranyakeshi.This district consist 12
tahsils.Warananagar is a village place in Panhala Tahsil in Kolhapur district (Western
Maharashtra region) and theWarana Dairy Plant is located in Hathkangale Tahsil in Kolhapur
District.16.44098 Latitude and 73.84388 Longitude
1.4.2 Data Collection: For the collection of data we have two sources.a. Primary Data and b.
Secondary Data
a. Primary Data:Survey Method is used to collect the primary data. The survey is conducted in
(i) Warana Dairy Plant at Warananagar,
(ii) Tehsils Panhala,Hatkanagle, Shahuwadi,Shirala,Shirol and Miraj (Milk Collection Centers).
(iii) Gadhinlaj,Jath and Mudhol (Chilling Centers).
(iv) Kale,Bambavade,Shirala,Budhagaonand Rukadi(Bulk Milk Cooler Centers (BMC)).
(v) Kolhapur, Ichalakarngi,Pune and Mumbai(Washi) (Marketing Centers ).
This method will include the understanding of Milk Collection Process (Transportation Net

work), Production of Milk and Milk Products Process and Marketing of Milk and Milk Products
Process.
b. Secondary Data:The study is based on the reports of various centers. Other sources like
information articles published in news papers, annual reports,magazines,internet, journals,
research papers, books etc. are used as secondary data.
1.4.3 Analysis:
1. Collected data is analyzed by using the basic mathematical tools.
2. Fuzzy Rule Based Control system is developed for control process and
3.The design models are tested using the actual data and its reliability is verified. Some
correcting measures are to be taken if necessary.
1.5 Literature Review:
1. George Bojadziev and Maria Bojadziev: Fuzzy Logic for Business, Finance and Management,
Second Edition, World Scientific.
2. R. H. Bosmaetal., Assessing and Modeling Farmers Decision Making on Integrating
Aquaculture into Agriculture in the Mekong Delta.
3. M. S. Bapat and S. N. Yadav. Fuzzy sets in Sugarcane Industry Decision, International
Journal of Tropical Agriculture 27, No. 1-2 (Jan-June 2009)
4. S. Chen and C. Hwang, Fuzzy Multiple Attribute Decision Making, Springer Verlag, Berlin,
1992.
5. R. J. Clemen, T. Relly, Making Hard Decision: An Introduction to Decision Analysis, 2 nd ed.,
Duxbury, Pacific Grove, CA, 1996.
6. Da Ruan (1995): Fuzzy Set Theory and Advanced Mathematical Applications Kluwar
Academic Publishers.
7. Kai Michels, Frank Klawonn, Rudolf Kruse, Andreas Nurnberger: Fuzzy Control:
Fundamentals, Stability and Design of Fuzzy Controllers, Springer International
8. George J.Klir and Bo Yuan (2000): Fuzzy Sets and Fuzzy Logic: Theory and Applications,
Prentice-Hall of India.
9. Mamdani E.H. (1976):“Advances in the linguistic synthesis of fuzzy controllers” Intern. J.of
Man-Machine Studies 8(6) p.p. 669-678.
10. Sugeno M. (1985a): Industrial Applications of Fuzzy Control, North Halland New York.
11. Toshiro Terano, Kiyoji Asai Michio Sugeno (1994): Applied Fuzzy Systems

12. R. R. Yager and D. Basson, Decision Making with Fuzzy sets, Decision
Science, 6, 1975.
13. John Yen, Reza Langari (1999): Fuzzy Logic Intelligence, Control & Information, Pearson
14. H.J.Zimmermann (1995): Fuzzy Set Theory and its Applications
15. H. J. Zimmermann, Fuzzy Sets, Decision Making and Expert Systems, Kluwer Academic
Publishers, Bosten, 1987.
1.6 Chapter-wise Summary: This project report is divided in to eight chapters.
The first chapter is introductory and it explains the origin of the problem “A Study of Warana
Dairy Plant using Fuzzy Control Theory.” The objectives of the study are also stated along with
the methodology used. The literature referred for study is given.
In second chapter different Fuzzy Control Models and Fuzzy Control Theory are explained.
The third chapter accounted for preliminary concepts related to Dairy Plant.
In fourth chapter the problems related to various processes in Dairy Plant are stated and
processes involved in Kolhapur Zilla Sahakari Dudh Utpadak Sangh Ltd.Kolhapur are studied.
The fifth chapter is main part of the project which is devoted to Warana Dairy Plant.The
various processes involved in the plant are studied.
In sixth chapter is Data Collection.The data about Milk Collection Process, Production of Milk
and Milk Products Process and Marketing of Milk and Milk Products Process is collected by
using primary and secondary sourses.The data from the Warana Dairy Plant is collected.
The seventh chapter is Data Analysis.In this chapter the collected data is analyzed by using the
basic mathematical tools and Fuzzy Rule Based Control Models are developed for control
processes.
In eighth chapter conclusions, recommendations and limitations of the study are stated.
Finally the project ends with list of Paper Presentations, Publication and Bibliography.

MAP-1 MAP OF MAHARASHTRA

MAP-2 MAP OF KOLHAPUR DISTRICT

MAP-3 MAP OF PANHALA TAHSIL
TH_KLP_Panhala.pdf

Chapter 2
Fuzzy Control Models
2.1 Introduction:Fuzzy Control Theory (FCT) deals with control problems in an environment
of uncertainty & imprecision; it is very effective when high precision is not required & the
control object has parameters available for measurement or estimation.FCT describes the
algorithm for process as a fuzzy relation between information on the condition of the process to
be controlled & the control action.
FCT shows how control problems can be solved by rules based on appropriate reasoning
without using conventional mathematical models.
The concept of fuzzy control theory was introduced by Lotfi A. Zadeh in 1973 and then explored
by Mamdani in 1975.The Tsukamoto Fuzzy Logic was first proposed by Tsukamoto in 1979.
Takagi–Sugeno–Kang (TSK) Fuzzy logic was introduced by Takagi,Sugeno and Kang in 1985.
2.2 Basic Concepts: (i) Fuzzy Set: Let X be a non-empty universe of discourse. A fuzzy subset
A of X is defined by a membership function µA: X→[0 1].or A: X→ [0 1].
(ii) α-level cut: The set {x X/A(x)≥α} is called α-level cut of the fuzzy set A where α [0,1],It
is denoted by αA.
(iii) Support: The support of fuzzy set A is defined as the set {x X/A(x)>0}.
(iv) Normal:If A(x)=1 for some x X, then A is called normal fuzzy set.A set C in Rn is called
convex set if for every pair of points r,s C,the point t=λr+(1-λ)s C.
(v) Convex:Fuzzy set A is called convex fuzzy set every level cut of A is a convex set.
(vi) Fuzzy Number:A fuzzy number is a fuzzy set A: R→ [0 1] which satisfies at least the
following three properties (i)A is normal fuzzy set;(ii)αA must be closed interval for every
α (0,1]; (iii) the support of A must be bounded.
(vii)Trigular Fuzzy Number: A fuzzy number A: R→ [0 1] is defined as a trigular fuzzy
number if their membership function is equal to
A(x) = , for a ≤ x ≤ b,
= , for b ≤ x ≤c,
= 0, otherwise,
i.e. triangular fuzzy number is a fuzzy number whose left and right curves are straight lines.

A(x)
0 a b c
Figure 2.2.1 Triangular Fuzzy Number

Variables whose values are words or sentences in natural or artificial language are called
linguistic variables. Linguistic variables can be represented by fuzzy numbers.
(viii) Intersection: If A and B are two fuzzy sets defined on X then intersection of A and B is a
fuzzy set on X defined by (AB)(x)= min{A(x),B(x)}.
(ix) Union: If A and B are two fuzzy sets defined on X then union of A and B is a fuzzy set on
X defined by (AB)(x)= max{A(x),B(x)},for all xX.
2.3 Fuzzy Inference System: It is a process of mapping from a given input to an output using
fuzzy logic.The steps of fuzzy reasoning (inference operations upon fuzzy IF–THEN rules)
performed by the Fuzzy Inference System are as follows:
(i) Fuzzification:The input variables are compared with the membership functions on the
antecedent part to obtain the membership values of each linguistic label.
(ii) Fuzzy Rule Base: The control action is determined by the evaluation of a set of simple IF-
THEN rules.The development of IF-THEN rules requires complete understanding of the process
to be controlled. These rules are developed with the help of expert’s knowledge..
(iii) Fuzzy Inference Engine: The membership values are combined with product or min
operation on the premise part to get the degree of fulfillment of each if-then rule then generate
the qualified consequents either fuzzy or crisp.
(iv)Defuzzification: Aggregate the qualified consequents to produce a crisp output. The fuzzy
inference system is also known as fuzzy-rule-based system or Fuzzy expert system or fuzzy
model or fuzzy associative memory or fuzzy logic controller or simply fuzzy system.There are

various methods of defuzzification.The following five commonly defuzzification methods are
used (i) Centroid of area (COA), (ii) Bisector of area (BOA), (iii) Mean of maximum (MOM),
(iv) Smallest of maximum (SOM) and (v) Largest of maximum (LOM)
Fuzzy inference systems have been successfully applied in the fields such as automatic control,
data classification, decision analysis, expert systems etc.
2.4 Fuzzy Control Models (Methods):There are three important Fuzzy Control Methods
(i) Mamdani Fuzzy Control Model (ii) Takagi-Sugeno-Kang (TSK) Fuzzy Control Model
and (iii) Tsukamoto Fuzzy Control Model.
The details of these fuzzy control models are explnaied as follows.
2.4.1 Mamdani FuzzyControl Model: The most commonly used fuzzy control model is
Mamdani Fuzzy Control Model. This model was introduced by Professor Ebrahim Mamdani of
London University in 1975.Fuzzy Control (FC) consists of fuzzification interface in which each
crisp input and output parameters can be converted into fuzzy sets on universes of discourse with
the help of proper shape of membership function. Usually triangular shape membership function
is used. In fuzzy rule base the control action is determined by the evaluation of a set of simple IF-
THEN rules.The development of IF-THEN rules requires complete understanding of the process
to be controlled. These rules are developed with the help of expert’s knowledge. The general
form of fuzzy control rules is
Rl: if u is Ai and /or x is Bj and/or y is Ck then z is Dl
where i= 1,…p, j=1,…q, k =1,…r, l = 1,…pqr, u, x and y are three input parameters, z is a
output parameter, and Ai, Bj ,Ck, Dl are fuzzy sets of the linguistic variables u, x,y, z in the
respective universes of discourse U,X,Y and Z.The logical connectives ‘and’/ ‘or’are
implemented by the t-norm / t-co-norm. Usually min/ max operators are used. The number of
fuzzy terms in a input parameters determines the maximum number of fuzzy control rules.The
application of a control rule is also called firing.conflict resolution or aggregation, is the
methodology which is used to decide control action.The rules with possible fuzzy outputs are
presented symbolically on a rectangular table called decision table.
In fuzzy inference engine the measurement of input variables of a fuzzy controller must be
properly combined with relevant fuzzy information values to make inferences regarding the
output variables called evaluation of rule.

In fuzzy control output (F.C.O.), the control output of each rule is defined by operation of conjunction on
its strength & conclusions are as follows
F.C.O.of rule 1: αl (z) Dl (z) = min(αl (z), Dl (z))
The outputs of rules are combined or aggregated to produce one control output with membership
function Agg (z). For aggregation max operator is used
Agg(z)=max{min(α1(z),D1(z)),min( α2(z), D2(z)) ---min( αl(z), Dl(z)}
The defuzzification interface which acts as the interface between the FC and the system, by
providing the crisp output necessary for acceptance by the system. Defuzzification interface
converts a fuzzy set into a crisp number. There are several defuzzification methods which are
available in literature.
2.4.2 Takagi–Sugeno–Kang (TSK) Fuzzy Control Model: This model was introduced by
Takagi,Sugeno and Kang in 1985.A typical fuzzy rule in TSK fuzzy inference method has the
form
IF x1 is X1 and x2 is X2 and … and xn is Xn THEN y = f(x1,x2,…,xn)
where X= (x1,x2,…,xn) and y are linguistic variables, X1, X2, … Xn are fuzzy sets in the
antecedent and y = f(x1,x2,…,xn) is a polynomial in the input variable x, but can be appropriately
describe the output of the process within the region specified by the antecedent of the rule.
If f(x1,x2,…,xn) is a first order polynomial then the resulting fuzzy model is called first- order
TSK fuzzy control.
If f is a constant then the resulting fuzzy model is called zero-order TSK fuzzy control model.
The output of a TSK fuzzy control model is obtained by the weighted average of the crisp output
of fuzzy rules.
Graphical interpretation of fuzzy reasoning for a TSK fuzzy control model with two rules is
given in the following Figure 2.4.2.1
2.4.3 Tsukamoto Fuzzy Control Model:Tsukamoto Fuzzy Logic was first proposed by
Tsukamoto in 1979, which is one of the model of decision-making. In the Tsukamoto Fuzzy
Control Model, the consequent of each fuzzy IF-THEN rule is represented by a fuzzy set with a
monotonic membership function, as shown in Figure 2.4.3.1. As a result, the inferred output of
each rule is defined as a crisp value induced by the rule’s firing strength. The overall output is
taken as the weighted average of each rule’s output. Figure 2.4.3.1 illustrates the reasoning
procedure for a two-input two-rule system.

Min or Product
A11 A21 y1=f1(x11,x21)

X1
y2=f2(x12,x22)
A12 A22
X2
Weighted
Average
x1 x2 y = (X1 y1+ X2 y2) /(X1+X2)
Figure 2.4.2.1: TSK Fuzzy Control Model

Min or Product
A(x) B(y) C1
A1 B1 C1(z1)
w1
z1
A2 B2 C2 C2(z2)
w2 z2
x1 x2 Weighted
Average
Figure 2.4.3.1: Tsukamoto Fuzzy Control Model

Chapter 3
Preliminary Concepts: Dairy Plant
3.1 Introduction: Dairy Plant may be defined as a Collection of Milk, Production of Milk and
Milk Products and Marketing of Milk and Milk Products to earn profit.It may also be defined as
a process of minimum inputs (investment) and maximum output (return).Dairy Plant is a part of
business activity which is concerned with the various processes. Dairy Plant involves production,
procurement, storage, processing and distribution of dairy products.A dairy plant depends on
milk. Milk is raw material for dairy products. Milk is obtained from primarily cows and buffalos.
Milk is the richest source of calcium and essential amino acids which is good for human being.
The dairy plant involves processing raw milk into products such as consumer milk, butter,
cheese, Lassi, shrikhand, ghee, condensed milk, skimmed milk powder etc. using processes such
as chilling, pasteurization, and homogenization. Raw milk is collected through transportation
network from small scale dairy societies in the villages by the dairy plant with centralized
cooling facilities and marketed to the consumers in urban areas.
3.2 Dairy Plant in World: Milk and milk products have been increasing in the past 20 years in
the world. In the world milk production countries are India,U.S.A., China,
Pakistan,RussianFederation,Brazil,Germany,France, NewZealand,United Kingdom, Poland,
Netherland, Mexico,Argentina,Australia and Canada etc.
The following Table shows Milk Production (in Million Tonnes) in the the World in 2010-11
and 2013-14.
Table 3.2.1: The Milk Production (in Million Tonnes) in the World
Sr.No. Country Milk Production (in Million Tonnes)
2010-11 2013-14
1. India 117 146.31
2. U.S.A 87.46 93.46
3. China 41.14 42.58
4. Pakistan 35.49 50.14
5. Russian Federation 32.14 30.76

6. Brazil 31.82 35.28
7. Germany 29.67 32.43
8. France 24.21 26.20
9. New Zealand 17.01 21.32
10. United Kingdom 13.96 15.05
11. Poland 12.30 13.00
12. Netherland 11.65 12.73
13. Mexico 10.84 11.29
14. Argentina 10.50 11.01
15. Australia 9.02 9.54
16. Canada 8.24 8.40

17. Ireland 5.24 5.82
18. Romania 5.06 5.21
19. Denmark 4.91 4.58
20. Switzerland 4.11 4.10
21. Bangladesh 3.40 3.70
22. South Africa 3.23 3.34
23. Sweden 2.92 2.97
24. Finland 2.35 2.40
25. Afghanistan 1.82 1.77
26. Nepal 1.58 1.79
27. Norway 1.58 1.58
28. Indonesia 1.32 1.21
29. Thailand 0.85 1.07

30. Mauritania 0.39 0.42
31. Viet Nam 0.34 0.58
32. Sri Lanka 0.21 0.25
Total 531.76 600.29

(Source: The Statistics Division of the Food and Agriculture Organization of the United Nations)
In 2010-11,the total milk production in the World is 531.76 Million Tonnes and the milk
production in India,U.S.A.,China,Pakistan,Russian Federation,Brazil,Germany,France,New
Zealand,United Kingdom,Poland,Netherland,Mexico,Argentina,Australia and Canada is 492.45
Million Tonnes. There is 92.60% milk production in India,U.S.A.,China,Pakistan,Russian
Federation,Brazil,Germany,France,New Zealand,United Kingdom,Poland,Netherland,Mexico,
Argentina,Australia and Canada as compared to the World.There is 22% milk production in
India as compared to World.
In 2013-14,the total milk production in the World is 600.29 Million Tonnes and the milk
production in India,U.S.A.,China,Pakistan,Russian Federation,Brazil,Germany,France,New
Zealand,United Kingdom,Poland,Netherland,Mexico,Argentina,Australia and Canada is 559.5
Million Tonnes.There is 93.20% milk production in India,U.S.A.,China,Pakistan,Russian
Federation,Brazil,Germany,France,NewZealand,UnitedKingdom,Poland,Netherland,Mexico,Arge
ntina, Australia and Canada as compared to the World. There is 24.37% milk production in India
as compared to World.
3.3 Dairy Plant in India: India is the largest milk production country in the World. In India
there is 02.37% increase in milk production in 2013-14 as compared to 2010-11.
The following Table shows State-wise Milk Production ( in Million Tonnes) in India.
Table 3.3.1 : State-wise Milk Production (Million Tonnes) in India

Sr.No. State Milk Production (Million Tonnes)
2010-11 2013-14
1. Andhra Pradesh 11203 13007
2. Arunachal Pradesh 28 43
3. Assam 790 815
4. Bihar 6517 7197
5. Goa 60 68
6. Gujarat 9321 11112
7. Haryana 6267 7442
8. Himachal Pradesh 1102 1151
9. Jammu & Kashmir 1609 1615
10. Karnataka 5114 5997
11. Kerala 2645 2655
12. Madhya Pradesh 7514 9599
13. Maharashtra 8044 9089
14. Manipur 78 82
15. Meghalaya 79 82
16. Mizoram 11 15
17. Nagaland 76 81
18. Orissa 1671 1861
19. Punjab 9423 10011
20. Rajasthan 13234 14573
21. Sikkim 43 46
22. Tamil Nadu 6831 7049

23. Tripura 104 130
24. Uttar Pradesh 21031 24194
25. West Bengal 4471 4906
26. Andaman&Nicobar Islands 25 14
27. Chandigarh 45 44
28. D & N Haveli 11 11
29. Delhi 480 284
30. Lakshadweep 2 6
31. Punucherry 47 47
32. Chhattisgarh 1029 1209
33. Uttarakhand 1383 1550
34. Jharkhand 1555 1700
Total 121843 137685
In 2010-11, the total milk production in India is 121843 Million Tonnes and the milk
production in Andhra Pradesh, Bihar, Gujarat, Haryana, Madhya Pradesh, Maharashtra, Punjab,
Rajasthan Tamil Nadu and Uttar Pradesh State is 92554 Million Tonnes. There is 75.96 % milk
Rajasthan Tamil Nadu and Uttar Pradesh State as compared to India. There is 6.60 % milk
production in Maharashtra as compared to India.
In 2013-14, the total milk production in India is 137685 Million Tonnes and the milk
Rajasthan Tamil Nadu and Uttar Pradesh State is 113273 Million Tonnes. There is 82.26 % milk
Rajasthan Tamil Nadu and Uttar Pradesh State as compared to the India..There is 6.60 % milk
production in Maharashtra as compared to India.
Uttar Pradesh is the largest milk production state in the India. In Maharashtra there is 12.99 %
increase in milk production in 2013-14 as compared to 2010-11.

3.4. Dairy Plant in Maharashtra: In Maharashtra Dairy Development Department was
established in 1958 to increase the production and procurement of milk in the rural area, to
increase the economic condition of the milk producer and to supply wholesome and hygienic
milk to the city consumers at a fair price. The Dairy Development Department works through six
regions namely, Mumbai, Pune, Nashik, Amaravati, Aurangabad and Nagpur. The Regional
Departments controls the dairy plant of the districts coming under their region.
The following Table shows Region-wise number of District Dairy Plants, Tahsil Dairy Plants
and Primary Dairy Cooperative Societies inMaharashtra.
Table 3.4.1 Region-wise Number of Dairy Plants in Maharashtra
Region No. of District Dairy No. of Tahsil Dairy No. of Primary
Plants Plants Cooperative Societies
New Mumbai 3 2 304
Pune 4 21 11478
Nashik 2 19 2583
Aurangabad 5 13 3326
Amaravati 4 1 236
Nagpur 5 1 762
Total 23 57 18689
(Source: District Dairy Development Corporation, Kolhapur in 2008)
The number of tahsil dairy plants in Pune Region is largest than the other regions whereas it is
lowest in Amravati and Nagpur regions. The no.of primary cooperative societies in Pune Region
is largest than the other regions whereas it is the lowest in Amravati Region.

Table 3.4.2: District wise Milk Production in Maharashtra in 2010-11 and 2013-14
Sr.No. District Milk Production
2010-11 2013-14
1. Ahmadnagar 1062 1449
2. Akola 64.6 81.5
3. Amaravati 115 127
4. Aurangabad 182.3 176
5. Bid 329.4 396.2
6. Bhandara 88.6 106.1
7. Buldhana 163.1 169.3
8. Chandrapur 60.8 80.8
9. Dhule 132.2 150
10. Gadchiroli 47.1 39.4
11. Hingoli 78.2 59.9
12. Jalgaon 270.9 267.5
13. Jalna 97.7 120.1
14. Kolhapur 760.2 667.5
15. Latur 190.1 173.3
16. Mumbai 31.1 30.9
17. Nagpur 146.4 154.1
18. Nanded 209.5 284.7
19. Nandurbar 92..2 104.1
20. Nashik 356.7 367.2
21. Osmanabad 229.7 311.2

22. Parbhani 112.3 152.3
23. Pune 744.1 1090
24. Raigad 72..2 63.6
25. Ratnagiri 66 58.1
26. Sangli 490.9 518.2
27. Satara 455.5 554.7
28. Sindhudurg 46.3 45.4
29. Solapur 570.3 502.8
30 Thane 171.6 177.1
31. Wardha 84.2 92
32. Washim 62.9 85.7
33. Yavatmal 118.1 111.1
Total 7702.2 8766.8
(Source: Integrated Sample Survey Reports (1992-93 to 2013-14),Department of Animal

Husbandry , Govt. of Maharashtra.)
In 2010-11, the total milk production in Maharashtra is 7702.2 Million Tonnes and the milk
production in Ahmadnagar,Bid,Kolhapur,Nashik,Pune,Sangli,Satara and Solapur District is
4769.1 MillionTonnes.There is 61.92% milk production in Ahmadnagar, Bid, Kolhapur, Nashik,
Pune, Sangli,Satara and Solapur as compared to Maharashtra..There is 9.87% milk production in
Kolhapur District as compared to Maharashtra.
In 2013-14, the total milk production in Maharashtra is 8766.8 Million Tonnes and the milk
production in Ahmadnagar,Bid,Kolhapur,Nashik,Pune,Sangli,Satara and Solapur District is
5545.6 MillionTonnes.There is 63.26% milk production in Ahmadnagar, Bid, Kolhapur, Nashik,
Pune, Sangli,Satara and Solapur as compared to Maharashtra..There is 7.61% milk production in
Kolhapur District as compared to Maharashtra.

In Ahmadnagar,Bid, Kolhapur,Nashik,Pune,Sangli,Satara and Solapur District there is 16.28 %
increase in milk production in 2013-14 as compared to 2010-11.
Ahmadnagar is the largest milk production District in the Maharashtra. In Kolhapur District
there is 12.19 % decrease in milk production in 2013-14 as compared to 2010-11.
Table: 3.4.3 List of some Dairy Plants (Cooperative/Government/Private) in Maharashatra
Sr. No. Dairy Plants(Cooperative/Government/Private)in Maharashtra

1. ABC Farms Pvt. Ltd.
2. Adarsha Dairy Products Pvt. Ltd.
3. Ahmednagar Jilha Sahakari Dudh Sangh Ltd.
4. Akash Dairy Farm
5. Anant Doodh Pvt. Ltd.
6. Ashok Milk Processing & Allied Industries Ltd.
7. Ashtavinayak Dairy Milk Pvt Ltd.
8. B G Chitale
9. Baleshwar Milk Products Processing
10. Bansi Dairy Pvt. Ltd.
11. Baramati Taluka Sahakari Dudh Utpadak Sangh Ltd.
12. Bhairavath Milk & Agro Food Products
13. Bhandara Dist Coop Milk Producers’ Union Ltd.
14. Bhaneshwar Agro Pvt. Ltd.
15. Bhuleshwar Dairy Pvt. Ltd.
16. Brij Milk & Milk Products
17. Byculla Cold Storage
18. Cadbury India Ltd.
19. Chaitanya Milk Agro Products Pvt. Ltd.
20. Chandra Milk & Milk Products
21. Chandrabhaga Dairy’s Pvt. Ltd.
22. Chitale Bandhu Mithaiwale
23. Chitale Dairy
24. Chougule Milk Product
25. Datta Dairy products Pvt. Ltd
26. Dudhganga Coop Milk Union Ltd
27. Gagangiri Milk & Milk Products
28. Gautam Milk Pvt. Ltd.
29. Ghenashyam Dairy Products Co.
30. Godavari Khore Sahakari Dudh Utpadak Sangh Ltd.
31. Good – Day Foods Ltd.
32. Gopi Milk Products Pvt. Ltd.
33. Govardhan Milk Cooperative Ltd.
34. Govind Milk & Milk products Pvt. Ltd.
35. Gowalia Tank Dairy Farm
36. Greater Bomday Milk Scheme

37. Green Valley Food Processors Pvt. Ltd.
38. Hemant Milk Pack Industries Pvt. Ltd.
39. Hiranyakeshi Ghatprabha Multi – Purpose Multistate Coop Union Ltd.
40. Hutatma Sahakari Dudh UtpadakSangh Maryadit
41. Indapur Dairy & Milk products Ltd.
42. J D Thote Dairies
43. Jalgon Jilha Sahakari Dudh Utpadak Sangh Ltd.
44. Jyotirling Dudh Utpadak & Prakriya Sangh Ltd
45. Kolhapur Zilla Sahakari Dudh Utpadak Sangh Ltd.
46. Koyana Sahakari Dudh Utpadak Sangh
47. Krishnamata Dudh Dairy Pvt. Ltd.
48. Lokmangal Products Pvt. Ltd.
49. Mahalaxmi Sahakari Dudh Utpadak Sangh Ltd
50. Maharastra Dairy Development
51. Maharashtra Rajya Sahakari Dudh Mahasangh Maryadit, Mahanand
Dairy.(Kudal, Latur, Mumbai (Goregoan, Vashi), Nagpur, Pune)
52. Mangalsiddhi Multi Purpose Multi State Sahakari Sangh Ltd.
53. MohanraoShinde Milk Ltd
54. Mother Dairy Food Processing Ltd
55. NasikDist Coop Milk Producers' Union Natural Dairy
56. Panchamrut Dairy Pvt Ltd
57. Parag Milk & Milk Products Pvt Ltd
58. ParleAgro Pvt Limited
59. Patan Food Processors Pvt Ltd
60. PuneZillha Sahakari Dudh Utpadak Sangh Maryadit
61. Punjab Sind Dairy Products Pvt Ltd
62. Rajarambapu Patil Sahakari Dudh Sangh Ltd
63. Rajgurunagar Dairy Industry
64. S R Thorat Milk Products Pvt Ltd
65. Sahyadri Agro Produce & Dairy Pvt Ltd
66. Saikrishna Dairy Pvt Ltd
67. Sakas Milk & Milk Products Pvt Ltd
68. Samant Dairy Products Pvt Ltd
69. Sangamner Taluka Sahakari Dudh Utpadak & Prakriya Sangh Maryadit
70. Shree Warana Sahakari Dudh Utpadak Prakriya Sangh Ltd
71. Shri Bharat Dairy
72. Shrirampur Doodh Jilha Madhyavarti Sahakari Doodh Vyavasaik Sangh
Ltd
73. Siddhamrut Cooperative Union Ltd
74. Solapur Dist Coop Milk Producers' Union Ltd
75. Suruchi Dairy Industries Pvt Ltd
3.5 Dairy Plant in Kolhapur District: Geographical area of Kolhapur district is 7685
sq.kms.The land under cultivation is 5758.89 sq.kms. which is 75.56% out of the total area. It is

surrounded by Sangli district to the north Belgum district of Karnataka state to the east and south
and Ratanagiri and Sindhudurg district to the west. The main rivers of the district are Krishna,
Warana, Panchaganaga, Doodhganga, Kumbhi-Kasari, Hiranyakeshi. This district consist 12
tahsils as Shahuwadi, Panhala, Hatkangale, Shirol, Karvir, Gaganbawada, Radhanagari, Kagal,
Bhudargad,Gadhingalaj,Ajara,Chandgad. The land under irrigation is 1431.12sq.kms.which is
24% out of the total area.The land under forest is 1382.27sq.kms.which is 18.13 % .
The Kolhapur district is divided into three main parts namely Eastern ranges, Central ranges
and Western ranges. Eastern & Central ranges have black soil where as the Western ranges have
red soil.The average rainfall in Kolhapur district is 1899 mm. which is satisfactory.The Kolhapur
district has natural resources like soil, water, suitable enviornment and whether conditions,
minerals and animals. Therefore it is one of the most agriculturally advanced district in
Maharashtra as well as in India. The main crops in Kolhapur district are sugarcane, paddy,
groundnut, Nachani, Soybean etc.Therefore in Kolhapur District there are agrobased food
processing industries like Sugar industry, Edible oil mills, Rice mills,Textile and Dairy
industries.There are1723 agricultural co-operative societies working for the development of the
economy of the farmers.
Table 3.5.1 List of Some Dairy Plants in Kolhapur District
The list of Some Dairy Plants in Kolhapur District is as given below:
Sr. No. Dairy Plants
1. Kolhapur Zilla Sahakari Dudh Utpadak Sangh Ltd; Kolhapur
2. Warana Sahkari Dudh Utpadak Prakriya Sangh Ltd; Warananagar
3. Shree Chhatrapati Shahu Milk & Agro Ltd. Kagal
4. Mayur Sahakari Dudh Utpadak Sangh Ltd;
5. Shri Mahalaxmi Sahakari Dudh Utpadak Sangh Ltd;
6. Bharat Dairy Pvt. Ltd
7. Kolhapur Ice & Cold Storage, Kolhapur
8. Daphalapur Dudh Udyog, Shirol

9. Jyotirling milk & milk products Ltd; Kodoli
10. Jyotirling milk & milk products Ltd; Kodoli
11. Samrudhi Milk & Milk Product Ltd; Hunnali, Kagal
12. Sahyadri Dudh Utpadak Sangh Ltd; Chandgad
13. Shri Hanuman Sahkari Dudh Vyavsayik and Krushipurak Sewa Sanstha Maryadit
(Yalgud)
14. Hirmanyakeshi Ghatprabha Multipurpose, Multistate Co-operative Union Ltd;

Gadhinglaj.

Chapter 4
Problems related to various processes in Dairy Plant
4.1 Introduction: India is the largest milk producer in the world.The main aim of Dairy
Plant is to enhance various processes involved in the Plant using innovative technology. Dairy
Pant plays important role in the economy of the farmers in Maharashatra State. Dairy plant
mainly depends on various processes.These processes are very complex in nature. Milk is raw
material for dairy plant.
In Kolhapur District the dairy plant is one of the growing sector.There are number of dairy
plants, the study of their problems and possible solutions will helpful to them.These dairy plants
face number of problems in various processes.These processes are milk collection process, milk
production process and marketing process.There are number of problems in each process.Some
of the problems related to milk collection process, milk production process and marketing
process are observed and studied.
4.2 Problems related to various processes in Dairy Plant:
4.2.1 Problems related to Milk Collection Process:
Milk collection process depends on vehicle type,route,distance,quantity of milk, type of
Can,time etc.in Dairy Plant.There are number of problems related to milk collection
process.Some of the problems related to vehicle type, distance,quantity of milk are dicussed
here. Raw milk is very less life time and is very spoily (perishable). Therefore raw milk is
important part in milk collection process. Hence transportation network plays an important role
in collection of raw milk.Transportation network consists of route of milk collection, efficient
carring capacity vehicle type, quantity of milk, type of Can etc. In transportation network there
are problems related to
(i) selection of efficient carrying capacity vehicle which depends on distance and quantity of raw
milk.
(ii) choice of route of collection of raw milk which depends on quantity of raw milk and
distance.
4.2.2 Problems related to Production of Milk and Milk Products Process:

In Milk production process milk, milk powder,lassi, shrikhand,ghee etc. are important milk
products in Dairy Plant..The production of these milk products depends on availability of raw
milk, quality of raw milk,quantity of raw milk, cost of raw milk, various seasons and market
demand of various milk products etc.In milk production process there are some of problems
related to
(i) selection of high quality of raw milk which depends on various qualitative and quantitative
properties like Color, Odor, Appearance, Total Microorganism Count, Methylene Blue Reduction Test
Time, FAT, SNF, Proteins, and Added Water etc.
(ii) amount of production of various milk products which depends on availability of raw milk
and market demand in various seasons.
4.2.3 Problems related to Marketing of Milk and Milk Products Process:
In marketing of milk products process market of various products depends on quality of milk
product, supply of milk product, price of milk product, market demand of various dairy milk
products in various seasons.In marketing of milk and products process there are some of
problems related to
(i) maintain the market demand of various dairy milk products which depends on quality of milk
product, supply of milk product, price of milk product,
(ii) supply of various milk products which depends on quantity of milk products and market
demand of milk products.
These problems are very complex in nature and their understanding and control may not be
obtained by rigid and strict rules.The fuzzy control theory can provide a flexible model for
efficient control of these problems.
Therefore an attempt have been made to study these problems using fuzzy control models
(theory) to optimize the total cost of transportation network, to optimize the cost of production
and to optimize the profit of the dairy plant.To study these problems there is need to understand
these processes in detail.Therefore two Dairy Plants namely Gokul Dairy Plant and Warana
Dairy Plant are selected.Firstly the study of these processes of Gokul Dairy Plant is carried out.
4.3 Gokul Dairy Plant (Kolhaupur Zilla Sahakari Dudh Utpadak Sangh Ltd. Kolhapur)
4.3.1 Introduction: In Kolhapur District there are mainly fourteen Dairy Plants. Some of the
Dairy Plants such as Warana Dairy Plant, Gokul Dairy Plant, Shahu Dairy Plant, Mahalaxmi Dairy Plant
etc. are leading Dairy Plants. Gokul Dairy Plant is one of the leading Dairy Plant in the Kolhapur District.

There are various processes in Dairy Plant such as milk collection process, production of milk
and milk products process and marketing of milk and milk products which are important.The
study of these processes is important to understand the problems involved in it. So we study the
preliminary concepts in Gokul Dairy Plant.
The fulname of Gokul Dairy Plant is Kolhaupur Zilla Sahakari Dudh Utpadak Sangh Ltd.
Kolhapur and is established in the year 1963. Gokul dairy plant has four chilling centers at
Lingnur (Gadhinglaj), Borwade (Bidri),Tawarewadi (Chandgad), and Gogave (Shahuwadi), three
Milk Pakaging Centers at Gokul Dairy Plant,Manjari and Mumbai (Washi) and three Marketing
Centers at Kolhapur, Pune, Mumbai (Washi) and other parts of Western and Southern Maharashtra.
4.3.2 Milk Collection Process
4.3.2.1 Introduction: The milk is collected from near about 1433 villeges in and around the
Kolhapur District. There are 307 milk collection routes through which 9.81 Lakh Liters per day
milk is colleted.
At present the dairy has milk handling capacity of 7 Lakh Liters per day and chilling centers
have 5.25 lakh liters per day.
Table 4.3.2.1: Milk handling capacity of the dairy Plant/Chilling Centres
The milk handling capacity of the dairy plant and chilling centrewise is given below.
Sr. No. Plant/Chilling Centre Capacity in LLPD
(Lakh Liters per day)
1. Gokul Dairy Plant, Gokulshirgaon 7.00
2. Lingnur chilling Centre, Gadhinglaj 1.25
3. Borawade chilling Centre, Bidri 1.00
4. Tawarewadi chilling Centre, Chandgad 1.00
5. Gogave chilling Centre, Shahuwadi 0.50
(Source: Kolhaupr Zilla Sahakari Dudh Utpadak Sangh Ltd., Kolhapur)

4.3.3: Production of Milk and Milk Products Process
4.3.3.1 Introduction: The dairy plant produces various milk and milk products like skimmed
milk powder,butter, ghee,table butter,Shrikhand,curd,paneer and lassi etc.The Production of Milk
and Milk Products of the Dairy Plant is given in the following table.

Table 4.3.3.1: Production of Milk and Milk Products
Sr. No. Products Production in MTPD
(Metric Ton per day)
1. Skimmed Milk Powder 41
2. Butter 24
3. Ghee 06
4. Table Butter 03
5. Shrikhand 01
6. Curd 02
7. Paneer 01
8. Lassi 02

Table 4.3.3.2: Milk packing Capacity of the Dairy Plant
Packing of Milk in a pouch of Gokul dairy plant at various centres is given in the following table
Sr.No. Plant/Centre Milk Pouch Packing in LLPD
(Lack Liters per day)
1. Gokul Dairy Plant 1.00
2. Manjari (Pune) 0.50
3. Washi (Mumbai) 1.00

4.3.4. Marketing of Milk and Milk Products Process: Milk & milk products of this dairy plant
are sold under the brand name ‘Gokul’.The milk viz Classic (Buffalo) milk, Cow milk, Tonned
milk & Double tonned milk and the milk products like Ghee, Shirkhand, Milk Powder, Paneer,
Butter and dahi are marketed in Kolhapur, Pune, Mumbai and other parts of Western and Southern
Maharashtra.In Mumbai the total sale is 3,50,000 LPD and in rest of the areas sale is 1,10,000 LPD.
4.3.5 Extension Activities:The Dairy Plant provides many extension activities (sevices) as
follows

4.3.5.1 Cattle Feed Plant:The Dairy Plant has started the production of cattle feed to meet
nutritional requirement of the animals in the year 1982. In the beginning the capacity was 100
MT which was expanded to 200 MT per day.The cattle feed is marketed under the brand
‘Mahalaxmi’.
4.3.5.2 Gokul Gram Vikas Yojana:Gokul Dairy Plant has started Gokul Gram Vikas Yojanain
in 1990. It also conducts various programmes like Women’s education, Member education,
Management Committee Training, Secretary Training, Procurement & Input Training, Youth
Group Discussion, Women Group Discussion, Leadership Development, Refresher Courses etc.
Recently, it has also included adoption for villages for development. Initially,one hundred
seventy five villages were the beneficiaries and now this number has increased upto one
thousand twenty seven.
4.3.5.3 Dairy Business & Animal Husbandry Training Centre:Gokul Dairy Plant has started the
training centre for its members and employees from 1984. It provides training of the various aspects
of dairy business such as accounting, management, milk testing etc.
4.3.5.4 Preventive & Clinical Veterinary Services:A team of fourty five trained veterinary
graduates operating from thirty three different locations in the district is catering to the preventive
farmers. Each veterinarian looks after about ten villages and provides these services round the clock
at the farmer’s doorsteps. It also provides breeding services. Gokul Dairy Plant has established two
hundred fourty artificial insemination centers in its operational area. All the necessary inputs to these
centers such as liquid nitrogen, semen, sheath, cryogenic containers are made available by the Dairy
Plant.
4.3.5.5 Milko Tester:Dairy plant has supplied Milko Testers to the village Dairy Co-operatives to
get high quality of raw milk.The Milko Testers are electronically operated machines to determine the
fat percentage of the milk. The milk supplied by every individual milk producer is tested before
acceptance and the payment is made based on the quality of milk. The Dairy Plant gives the subsidy
of Rs. 3000 /- per milkotester.
4.3.5.6 Fodder Development:Availability of sufficient quantity of good and nutritious fodder is
essential prerequisite for sustained milk production milk. In view of this, a team of four agricultural
graduates with the assistance of five supervisors is working under fodder development section of the
union. Under this programme seeds of improved fodder varieties are distributed at 25 % subsidized
cost.About 10 tones of folder seed are distributed annually.

4.3.5.7 HRD Programme:Quality of the work put out by the individual staff member depends upon
his technical competency as well as his attitude towards working. These courses are conducted at
various levels from workers to managerial cadre.
The Gokul dairy offers various schemes for their dairy members. The schemes have played important
role in maintaining the quality of the milk as well increasing milk collection.

Chapter 5
Warana Dairy Plant
(Shree Warana Sahakari Dudh Utpadak Prakriya Sangh Ltd.,Warananagar)
5.1 Introduction: In Kolhapur district (Western Maharashtra region) the dairy plant is one of
the growing sector.There are some dairy plants such as Warana Dairy Plant, Gokul Dairy Plant
,Shahu Dairy Plant, Mahalaxmi Dairy Plant etc. Warana Dairy Plant is one of the successful
(leading) dairy plant in the region. In dairy plants there are many processes involved in the
collection of milk,production and marketing of dairy products. There are number of problems
related to these processes. Therefore study of these processes is important to understand the
problems involved in it. So the study of these processes of Warana Dairy Plant is carried out.
The fulname of Warana Dairy Plant is Shree Warana Sahakari Dudh Utpadak Prakriya Sangh
Ltd., Tatyasaheb Korenagar,Post:Warananagar and is established in the year 1968 by Late Shri.
Tatyasaheb Kore. The main aim of this plant is to improve the socio-economic status of milk
producer in this region. The financial assistance provided by Shareholders and State
Government. The Dairy Plant has already acquired the ISO 9001-2000 and HACCP food safety
certificate. It is one of the most hygienic plant with facilities to produce various Milk and Milk
Products like Posteurized Milk, Shrikhand, Milk Powder, Ghee, Butter, Paneer,Cheese, Curd,
Lassi etc.
The plant is expanded in the year 1975. Warana dairy plant has four chilling centers at
Hatkangale,Gandhinglaj,Jat,Mudhol, four Bulk Milk Coolers (BMC) at Kale, Bambvade,
Shirala, Budhgaon, four Milk Pakaging Centers at Mumbai (Washi), Gadhinglaj, Mudhol,
Solhapur and three Marketing Centers at Kolhapur ,Ichalkaranji, Washi (Mumbai).
5.2 Milk Collection Process:
5.2.1 Introduction: The Warana dairy plant is presently collecting milk from more than 400
villeges of Kolhapur and Sangli Districts and bordering of Karnataka State. The collection of
milk from various villeges, chilling centres and bulk milk cooler centers at Warana dairy plant is
called Raw Milk Reception Dock (RMRD).
5.2.2 RMRD: It is well equipped with the advanced equipments like Computerised and
Pneumatic Auto Sampler, Milk Testing Machines, Electronic Weighing System etc. Raw Milk is
received by the Cans and Tankers at RMRD. The collection of Cans is done by various types of
vehicles.There is spacious area in front of the dock to park the vehicles. The Can milk receiving
section has two subsections as cow milk Can subsection and buffalo milk Can subsection. In
these subsections received Cans are transferred to weighing platforms by conveyor to measure
the quantity of milk centrewise. Milk samples are taken and empty Cans are sent to washing.A
chemist analyses the sample by various tests such as Fat, ClR, COB, temperature etc. and
machine tests are also carried out in separate laboratory chamber.
Sampling is done automatically by auto pneumatic (filled with air) sampler. Sample from each
lot (Tilting tank) is taken in bottle and carried to the milk testing chamber on a sample bottle
conveyor. After weighing the milk, it is dumped into the dump tank. Then chilling of milk is
done and it is sent to airtight room called silo for further processing.
Similarly the milk from the chilling centers located at Gandhinglaj, Jath, Mudhol,etc. is
transported by Milk tankers. The milk from tanker is being tested for organoleptic tests and lab
tests. After analyzing its quality it is accepted for further processing and production. In this year
81,43,944 Km. is required for Milk Collection and the transportation cost of Milk collection is
Rs. 1.01 per liter. This cost is increased due to increased rate in Diesel.The milk handling
capacityof Warana Dairy Plant is around 7 lack liter per day.The following table shows name of
chilling center and its address.
Table 5.2.1 Addresses of Chilling Centers:
Sr.No. Chilling Centers Address
1. Hatkanagle Laxmi Auodhogik Society,
Hatkanangle.
2. Jat Jat Small Scale Industrial Area, Jat,
Dist.- Sangli
3. Gadhinglaj Gadhinglaj Road, Hanimnal, Tal.-
Gadhinglaj
4. Mudhol 136/A-1- Ballur (R/C) Lokapur Road,
Mudhol

The following table shows name of chilling center and its address.
Table 5.2.2 Addresses of Bulk Milk Centers
Sr. No. Bulk Milk Centers(B.M.C.) Address
1. Kale Kale S.T. Stand Road, Near Desai

Tiles Kale, Tal.- Panhala
2. Shirala Shirala, Gat No. 543, A/p- Biur, Tal.-

Shirala, Dist.- Sangli.
3. Bambvade Ratnagiri Road, Surve No.347,

Grampanchayat Milkat No. 1505,
Bambvade, Tal.- Shahuwadi, Dist.-
Kolhapur
4. Budhgaon Budhgaon Bulk Milk Cooler,

Indiranagar Society, Kupwad-
Bhudgaon Road, Kupwad.
5.3 Production of Milk and Milk Products Process:

5.3.1 Introduction: Milk Processing Unit is the important part of the Dairy Plant. In this unit
chilling, pasteurization, cream separation, filtration, clarification, homogenization,
standardization, reconstitution and bactofugation are carried out.The equipments such as PHE
Chillers, Vertical Silos, Storage Tanks, HTST Pasteurizers, Duplex filters, Self Cleaning
Clarifier cum Separators and Bactofuge are used in this unit.
5.3.2 Milk Standardization Process: Standardization is an important procedure for the
adjustment of Fat and SNF as per the specified standard. There are standardization tanks on the
second floor of the production building. The standardization is done by Skim milk.The tanks are
provided agitators inside for through mixing Continuously.There are different ratio for
standardized milk and whole milk.
5.3.3 Bulk Milk Dispatch through Tanker:The tankers are cleaned properly as per schedule
0
given previously in the RMRD section. The Pasteurized milk is chilled at 1.5 C to 20 C and
filled in tankers and then the sample is given for analysis. If analysis report is satisfactory then
the tanker are permitted for transportation to Washi (Mumbai) for packaging daily.

5.3.4 Fill Pack Machinery: In this section, there are five fill pack machines. The milk which is
homogenized, pasteurized or standardized from storage tanks is sent in overhead balance tank of
machine. This milk flows from it into the pouch by gravity. Machine operates on electronic and
pneumatic principle. Laboratory takes sample for each size of pack and after clearance regarding
chemical analysis, weight and length of pouch; machine is run for regular production.
The milk is pouched in various capacities with different types of milk like buffalo whole milk,
cow whole milk, and toned milk etc. Then pouches are placed in crates and placed in cold
storage at 10 C in stacks.
5.3.5 Butter Production:
Butter is churned product of cream with 40-45% FAT of Buffalo milk or Cow milk or both. In
Butter Section, two types of butters are manufactured via White Butter (without salt) and Table
Butter (with salt and color).Daily near about all cream is converted in to butter.
(i)White Butter: White butter is produced form the conversion of surplus fat, used in the
production of Ghee. Generally the white butter is prepared by using continuous butter making
machine. Average production of White butter is 20 tons per day.
(ii)Table Butter: The table butter is sold under brand name WARANA BUTTER. Average
product of table butter is 6 tons per day.
5.3.6 Curd Production: Buffelo milk is used for curd production.Curd is prepared from the
toned milk with 3% fat and 8.5 SNF. In toned milk about 0.25% culture is added and is filled in
cups. These cups are sealed by foils with the help of sealing machine. Then cups are kept for
incubation for 4 hrs. Then after sampling the cups of curd of 0.27 acidity are packed in boxes.
5.3.7 Ghee Production: Ghee is manufactured by heating butter at 1050C to 1100C. Ghee
contains about 99.5% to 99.8% fat. Average production of Ghee is 8 metric ton per day. The
Ghee is produced by creamery butter method.
5.3.8 Lassi Production: Lassi is manufactured from curd of standardized milk. Warana Dairy
has set its own standards for Lassi. It is being produced seasonally, as it has tremendous demand
in summer season. The Average production of lassi is 35000 Packets of 200 ml.per day.
5.3.9 Shreekhand Production:
Shreekhand is the most popular product of Warana Dairy. Warana is the largest producer of
Shreekhand in the World .The shreekhand production was started in the year 1985 and since then
the curve of production is continously growing in the last few years.Renowned dairy

organizations have pluged into the shreekhand production but it has shown no effects on the
demand of Warana shreekhand . There are four types of Shrikhand are produced like Badam-
Pista Shrikhand,Krshar-Elaichi Shrikhand, Amrakhand and Strawberry Shrikhand. Out of them
Badam - Pista is the largest contributor in the total production.
5.3.10 Cheese Production: Warana Dairy produces three types of cheeses viz Chedder Cheese,
Mozzarella Cheese and Processed Cheese. Chedder is not been introduced in the market. It is
used only for preparation of processed cheese.
5.3.10.1 Production of Mozzarella Cheese: Mozzarella Cheese is manufactured same as that
of Cheddar Cheese only difference in milk preheating temperature (350 c to 380 c) and cooking
temperature (Initial :38oc and Final : 41oc).The stretching is an additional process during
manufacturing of Mozzarella Cheese for obtaining desired stretching property. Stretching
property is due to the addition of HCL @100 ml/1000 lt. of milk before or after rennetting.
Stretching is done through stretching machine.
5.3.10.2 Production of Processed Cheese: Processed Cheese is manufactured from a blend of
natural fresh cheese,ripened chaddar and other milk solids.The emulsifying agents ,salt acid and
other ingredients are used to get the proper emulsification and texture..
5.3.11 Paneer Production: Paneer is manufactured from the buffalo milk of FAT less than 5%
and SNF 9°/° using citric acid as coagulation agent. Draining of whey(watery part of milk
separated from curd), moulding and pressing cheese paneer is manufactured.Paneer is packed in
polyethylene bags of 100 gm in slice form. Also bulk packing of 2kg as per demand is carried
out.
5.3.12 Milk Powder Production: There are three spray drying Powder Production Units in the
Dairy .
1. NIRO ATOMIZER having capacity of about 35 tons Powder per day.
2. Multy Stage Milk Powder Plant having capacity of about 20 tons Powder per day.
3. VULCAN-LAVAL ANHYDRO having capacity of about 5 tons Powder per day.
These units are accompanied with evaporator assemblies these evaporators are of falling type. In
this section Skimmed Milk Powder (SMP) and Full Cream Milk Powder(WMP) are
manufactured.
The Dairy Plant provides complete range of equipments to manufacture fermented milk
products Shrikhand, Paneer, Lassi, Ghee, Milk Powder, Curd etc. The equipments used in the

plant are Storage tank, Pasteurizer, Homogenizer, Double jacketed multipurpose vat,incubation
chamber etc to made these products.
The following table shows the Production Capacity of Warana Dairy Plant per Day.
Table 5.3.1 The Production Capacity of Warana Dairy Plant:
Sr.No. Production Capacity

1. Milk processing 7,00,000 lit/Day
2. Plain Butter 25 MT/Day
3. Table Butter 5 MT/ Day
4. Ghee 8 MT/Day
5. Milk Powder 35 MT/Day
6. Shrikhand 15 MT/ Day
7. Lassi 30,000 Packet / Day
8. Paneer 1.5 MT/Day
9. Cheese 1.5 MT/Day
5.3.13 Malted Food section: In this section Bornvita, Coco Powder and Hot Chocklet are
produced.
5.4 Marketing of Milk and Milk Products Process: There is a separate section of marketing
of Milk and Milk Products through which Milk and Milk Products are supplied to the following
Marketing Centers
The following table shows the marketing centers and address

Table 5.4.1 Addresses of Marketing Centers
Sr.No. Marketing Centers Address
1. Washi Branch,New Mumbai Plot No. 18&21,APMC Yard
Turbhe,New Mumbai-400705
2. Kolhapur Shahu Sadan, Congress Committee
Bhavan, Station Road, Kolhapur-
416001.
3. Ichalkaranji 1. Ambedkar Putla Sales Center
Industrial Estate, LIC Building Gala
No.3, In front of Ambedkar Putla,
Station Road Ichalkaranji.
2. Apte Vachan Mandir Sales

Center Apte Vachan Building, Shop
Gala No.2, Zenda Chouk, Sangali
Road. Ichalkaranji.
5.5 Supporting Services:

5.5.1 Introduction:Milk producer is the important or base of the milk business. The Dairy Plant
always put him in front while designing training and extension activities. With the purpose of
development and expansion of milk business, Industry tries inventory program techniques and
motivational subsidy offers. The Industry provides the following services:
5.5.2 Feed and Fodder Seeds Supply Servies: Feeding is the most important part of the dairy
management’s. The good quality cattle feed is supplied to the farmers on one month credit.
The good quality cattle feed is supplied to the farmers on one month credit. The cattle feed is
manufacture in Warana Cattle feed plant, which is run on no profit, no loss basis.
5.5.2.1 Cattle Feed Supply Service: The Plant provides cattle feed to the producers with best
quality on no profit no loss basis. It is available in two types – mash in 65 kg bag and and pallet
60 kg bag.
5.5.2.2 Green Fodder Development Program Service: The main fodder available is sugar cane
leaves and sugar cane tops. But fodder program has its own limitations, due to small land
holding. So the farmers were given hints for intercropping in sugar cane. Lot of work has been

done for successful green fodder development program. So presently the fodder seeds are
supplied on 50% cost, to attract the farmers. Also the farmers are taken to the fields, where
fodder plantation is done. The plant offers 90% subsidy to promote this green fodder
development on fodder seeds like Lucerne, and Bar seem. About 50-55 MT seeds has been made
available throughout the year. Other fodder crops like Napier, (CO3 variety), Guinea grass,
Marvel, African tall maize, the seeds of these crops are also made available.
5.5.2.3 Urja, E-sac powder and Mineral Mixture Supply Service: The Plant provides mineral
mixture to reduce the infertility, to improve the milk quality and health of the animal by charging
only Rs. 30/kg. For health and energy improvement Urjabypass fat and e-sac powder is also
made available on no loss no profit basis.
5.5.3 Different Extension Services: Different subsidized items are made available for the milk
producers and Primary Dairy Society. Like milking machine and chaff cutter , Travis, milco
tester, Emergency power system, Computer and Electronic Weighing Machine, Society
building construction scheme etc.
5.5.4 Training and Educational Services:
Milk producer is the important or base of the milk business. Warana Cooperative Milk Union
always put him in front while designing training and extension activities. The Union organizes
inventory program techniques and motivational subsidy offers for the development and
expansion of milk business

Plate 5.1: Warana Dairy Plant Building
Plate 5.2 Milk Collection Process(1)
Plate 5.3 Milk Collection Process(2)

Plate 5.4 Milk Can Washing Process

Plate 5.5 Milk Production Machinery
Plate 5.6 Milk Standardization Machinery

Plate 5.7 Bulk Milk Dispatch through Tanker
Plate 5.8 Milk Fill Pack Machinery

Plate 5.9 Butter Processing Machinery
Plate 5.10 Ghee Processing Machinery

Plate 5.11 Lassi Packing Machinery
Plate 5.12 Shrikhand Packing Machinery
Plate 5.13 Various Famous Warana Dairy Products (1):

Plate 5.14 Various Famous Warana Dairy Products (2):

Chapter 6
Data Collection
6.1 Introduction: Dairy Plant collects the raw milk from milk societies and then processed to
produce various milk products like Shrikhand, Ghee,Lassi, Milk Powder,Paneer,Butter,Cheese etc. and
sales out these products in various market places in Maharashtra.The primary data of milk collection
process, production of milk and various milk products and marketing of these products are collected from
the Warana Dairy Plant for the specific period.
6.2 Milk collection Process:
6.2.1 Introduction: The Warana dairy plant collects milk from more than 400 villeges of
Kolhapur and Sangli Districts and bordering of Karnataka State.
The scheme of collection of milk from these milk societies is divided into 145 Routes. These
routes are grouped (distributed) into nine milk centers. These nine milk centers are divided into
five bulk milk coolers, three chilling centers and one head office center.
The following table shows the centerwise distribution of route numbers.
Table 6.2.1 Centerwise Distribution of Route Numbers
Sr. Centers Route Numbers Total
No.
1. Head Office 1 to 4,6,7,10,14 to 21, 23 to 26, 28 to 30, 32 to 49
(Warana Area) 42, 48, 52, 54, 56, 57, 58, 61,63, 64, 71.
2. BMC
i) Kale 67, 73, 75, 76, 77, 78, 79 07
ii) Bamberwadi 44,60, 68 to 70, 74 06
iii) Shirala 31, 45, 46, 47, 49, 50, 51, 53 08
iv) Budhagaon 05, 57, 62, 65, 66, 80, 81, 102,103,105,106 10
v) Rukadi 11,13, 22, 82, 83, 84 06
3. Chilling Centers
i) Gadhingalaj 151 to 172 (except 167,168,170) 19
ii) Jat 251 to 274 (except 265,272,274) 21
iii) Mudhol 301 to 324 (except 302,305,306, 309, 324) 19
Total Number of Routes 145

In the following table primary data of milk collection process for the specific period is
recorded.
Table 6.2.2 Routewise Milk Collection Process for the specific period.
Sr.No. Route No. Quantity of Milk in Distance Vehicle Type

No. of Cans from H.O.in
Morning Evening Kms.
1. 1 105 77 14 608 Tempo
2. 2 91 60 72 608
3. 3 100 75 56 608
4. 4 74 60 77 608
5. 5 44 33 58 407
6. 6 106 71 60 608
7. 7 81 54 28 608
8. 8 68 40 79 608
9. 9 50 42 98 407
10. 10 71 50 42 407
11. 11 63 44 32 407
12. 12 37 24 112 Pick Up
13. 13 43 34 30 Tata Ace
14. 14 85 63 16 608
15. 15 79 52 39 608
16. 16 25 24 100 Tata Ace
17. 17 63 38 23 407
18. 18 86 63 41 608/407
19. 19 35 24 55 Pick Up
20. 20 66 42 36 407
21. 21 91 59 38 608/407
22. 22 21 17 71 Tata Ace
23. 23 75 45 28 407
24. 24 58 44 82 407
25. 25 101 85 31 608
26. 26 105 63 50 608
27. 27 49 38 95 407
28. 28 49 34 68 407
29. 29 81 55 29 608/407
30. 30 55 39 51 407
31. 31 41 23 21 Pick Up
32. 32 64 49 88 407
33. 33 62 46 73 407
34. 34 106 60 27 608
35. 35 79 45 48 608/407
36. 36 54 44 53 407

37. 37 30 22 59 Pick Up
38. 38 100 72 26 608
39. 39 57 39 13 407
40. 40 86 70 26 608
41. 41 84 53 51 608
42. 42 95 62 46 608
43. 43 58 46 79 407
44. 44 35 26 66 Pick Up
45. 45 41 23 34 Pick Up
46. 46 29 16 29 Pick Up
47. 47 54 30 35 407
48. 48 55 38 22 407
49. 49 22 19 74 Pick Up
50. 50 31 16 60 Pick Up
51. 51 37 16 62 Pick Up
53. 53 29 22 121 Pick Up
54. 54 64 40 35 407
55. 55 37 30 106 Pick Up
56. 56 65 51 94 407
57. 57 54 35 22 407
58. 58 80 52 12 608
59. 59 43 32 66 407
60. 60 19 16 39 Tata Ace
61. 61 35 34 100 Pick Up
62. 62 27 17 156 Tata Ace
63. 63 33 24 83 Pick Up
64. 64 60 45 38 407
65. 65 26 20 80 Tata Ace
67. 67 46 37 50 407
68. 68 30 25 18 Tata Ace
69. 69 33 30 39 Pick Up
70. 70 33 23 100 Pick Up
71. 71 34 32 74 Pick Up
72. 72 63 40 32 407
73. 73 11 10 87 Riksha
74. 74 31 24 88 Pick Up
75. 75 41 34 83 Pick Up
76. 76 36 28 105 Pick Up
77. 77 29 27 61 Pick Up
78. 78 33 27 87 Pick Up
79. 79 38 33 174 Pick Up
80. 80 34 28 58 Pick Up
81. 81 35 25 75 Pick Up
82. 82 31 19 62 Pick Up
83. 83 31 21 63 Pick Up
84. 84 25 22 107 Tata Ace
85. 102 42 31 142 Pick Up
86. 103 34 26 74 Pick Up
87. 105 19 12 143 Tata Ace
88. 106 25 21 64 Tata Ace
89. 151 27 20 87 Pick Up
90. 152 48 35 117 Pick Up
91. 153 26 26 87 Trax
92. 154 24 22 46 Pick Up
93. 155 28 29 110 Pick Up
94. 156 10 11 70 Tate Ace
95. 158 20 19 100 Tate Ace
96. 159 25 28 96 Pick Up
97. 160 22 16 136 Pick Up
98. 161 35 33 100 Pick Up
99. 162 20 23 78 Tata Ace
100. 163 21 16 76 Pick Up
101. 164 23 17 60 Pick Up
102. 165 28 20 105 Pick Up
103. 166 38 31 63 Pick Up
104. 169 21 17 87 Pick Up
105. 171 19 12 88 Tata Ace
106. 172 07 09 40 Tata Ace
107. 251 60 38 82 407
108. 252 41 27 102 Pick Up
109. 253 26 16 97 Pick Up
110. 254 37 18 160 Pick Up
111. 255 46 39 74 407
112. 256 50 27 59 Pick Up
113. 257 37 27 130 Pick Up
114. 258 60 42 146 407
115. 259 36 23 86 Pick Up
116. 260 36 25 96 Pick Up
117. 261 35 25 110 Pick Up
118. 264 41 28 128 Pick Up
119. 266 32 23 150 Pick Up
120. 267 31 22 123 Pick Up
121. 268 38 20 126 Pick Up
122. 269 39 25 102 Pick Up
123. 270 31 19 67 Pick Up
124. 271 42 31 123 Pick Up
125. 272 40 24 90 Pick Up
126. 273 34 25 157 Pick Up
127. 301 35 23 130 Pick Up
128. 303 24 15 119 Pick Up
129. 304 35 31 114 Pick Up
130. 307 31 22 117 Pick Up
131. 308 27 26 98 Pick Up
132. 310 23 20 145 Tata Ace
133. 311 32 19 118 Pick Up
134. 312 25 21 134 Pick Up
135 313 50 28 104 Pick Up
136. 314 27 22 75 Tata Ace
137. 315 21 12 150 Pick Up
138. 316 30 25 74 Pick Up
139. 317 35 26 150 Pick Up
140. 318 32 24 117 Pick Up
141. 319 24 25 90 Pick Up
142. 320 35 24 160 Pick Up
143. 321 53 42 150 407
144. 322 39 27 150 Pick Up
145. 323 27 20 160 Pick Up
In the following table the primary data of total milk collection is recorded in the year 2013-14.
Table 6.2.3 Total Milk Collection
Sr. Particulars Buffalo Milk Cow Milk Total Milk
No. (Liters) (Liters) (Liters)
1. Milk collection from local 3,94,86,236 4,26,33,387 8,21,19,623
area of Main Center
2. Milk collection from 1,76,65,076 3,22,94,914 4,99,59,990
Bordering area and Other
Dairy Plants
3. Total Milk collection 5,71,51,312 7,49,28,301 13,20,79,616
(Liters)
4. Daily Average Milk 1,56,579 2,05,283 3,61,862
collection
5. Conversion 64,69,152 39,85,113 1,04,54,265
6. Total Milk Handling 6,36,20,464 7,89,13,414 14,25,33,878
7. Daily Milk Handling 1,74,303 2,16,201 3,90,504
(Ref. Yearly Report of the Warana Dairy Plant, 2013-14)

The milk is collected from nearly 763 milk co-operative societies which are functioning in
more than 400 villages of Kolhapur, Sangli Districts and bordering Karnataka area by various
types of vehicles based on various efficient carrying capacity such as Riksha (Three
Wheller),Tata Ace, Pick Up,407 Tempo,and 608 Tempo.
Table 6.2.4 The following table shows the vehicle type,its capacity and its rate.
Sr. Vehicle Type (Model) Efficient Carrying Capacity in Rate per Km

No. Metric Tons No. of Cans
1. Riksha(Three Wheller) 0.75-1.25 0-20 6/-
2. Tata Ace 1.25-1.75 24-30 7/-
3. Pick Up 1.50-2.25 35-40 9/-
4. Tempo 407 2.00-2.75 45-65 12/-
5. Tempo 608 2.50-3.25 80-100 16/-
A milk is collected in a pot called as Can. The following table shows Can type, its weight and
its capacity. (1 Lt. = 1.03 Kg.)
Table 6.2.5 Can Type, Weight and Capacity
Sr. Type of Can Weight of Capacty of Can in Total Weight of Can

No. Can in Kg. Liter Kg. & Milk in Kg.
1. Metal (Aluminum) 06.200 40 41.2 47.400
2. Fiber 02.800 40 41.2 44.000
The period in which quantity of milk of both Buffalo and Cow is LARGE, is called Flush
Period and if it is LOW,then the period is called Lean Period. This is shown in the following
table.

Table No. 6.2.6
Sr. No. Months Period

1. January to June Lean Period
2. July to December Flush Period
6.3 Milk and Milk Product Production:
6.3.1 Introduction: In this section collected raw Milk is processed using ISO,HACCP.Food
Safety Act etc. Standards and Rules, Regulations. In production of milk and milk products
process various types of milk packages and various milk products like Warana Shrikhand,
Ghee,Lassi, Milk Powder,Paneer,Butter,Cheese etc. are produced.The production of Milk
Products in the years 2011-12 and 2012-13 is shown in the following Table.
Table 6.3.1 Production of Milk and various Milk Products in 2011-12 and 2012-13
Sr. No. Products Year 2011-12 (MT) Year 2012-13 (MT)

1. Ghee 1635 1575
2. Shrikhand 2870 2629
3. Skimmed Milk Powder 4732 3960
4. Whole Milk Powder 1445 2026
5. White Butter 1601 925
6. Yellow Butter 1288 1205
7. Lassi (200 ml Bag) 3798400 3642108
8. Table Butter 573 553
9. Cheese 90 155
10. Curd 1135 1117
11. Paneer 332 346
th
(43 Yearly Report 2013-14 of Warana Dairy Plant)
6.3.2 Quality of Milk: In production of milk and milk products process various types of milk
packages and various milk products like Warana Shrikhand, Ghee,Lassi, Milk
Powder,Paneer,Butter,Cheese etc. are produced by the raw milk.The raw milk is classified by various
qualitative and quantitative properties like Color, Odor, Appearance, Total Microorganism
Count, Methylene Blue Reduction Test Time, FAT, SNF, Proteins, and Added Water etc. The
following tables shows Total Microorganism Count Std. and Methylene Blue Reduction Test
Time for Raw Milk.

Table 6.3.2.1 Total Microorganism Count Standards for Raw Milk
Std.Plate Count(SPC)/ml Quality or Grade

of Milk
Less than 200000 Very Good
200000 to 10,00000 Good
10,00000 to 50,00000 Fair
Above 50,00000 Poor
Table 6.3.2.2 Methylene Blue Reduction Test Time for Raw Milk
Methylene Blue Reduction Test Quality or Grade

Time in hours of Milk
5 hrs. and above Very Good
3 hrs. to 4 hrs. Good
½ hrs. and below hrs. Poor
6.4 Marketing of Milk and Milk Products:

6.4.1 Introduction Marketing of Milk and Milk Products is the most important activity of the
Dairy Plant. The marketing of Milk and Milk Products in the year 2012-13 is shown in the
following Table.
6.4.2 Market Demand (Sale) of Milk and Milk Products: Centerwise Market Demand (Sale)
of Milk and Milk Products are recorded in the following Tables

Table 6.4.2.1 Centerwise Market Demand (Sale) of Milk
Centerwise Market Demand (Sale) of Milk

Month Beffelo Cow Tonned Double Std. Total
Milk Milk Milk Tonned Milk
Head Office
April12 2613155 200132 343145 27360 226510 3420301
May 12 2692297 200616 431272 42160 240340 3606685
June 12 2662697 196258 320509 27700 231240 3439403
July 12 2879836 203975 286035 49340 229760 3648946
Aug. 12 3001534 207237 312747 48630 244280 3814428
Sept.12 2818864 805762 357641 41350 214471 4238088
Oct. 12 2990504 812453 368335 43380 287459 4502131
Nov. 12 2652547 584499 495914 40400 252388 4025748
Dec. 12 2835690 454568 260563 76971 241491 3951855
Jan.13 2881586 340781 292446 50912 243013 3808738
Feb.13 2898732 336345 299661 117711 227650 3580099
Mar. 13 2996271 418970 415931 73315 248085 4153162
Gadhinglaj Center
April12 207696 146460 325974 40340 - 720470
May 12 222183 149140 236705 42160 - 650139
June 12 211540 143520 223150 47480 - 625690
July 12 220600 146930 235704 49340 - 652574
Aug. 12 232619 150920 242299 48630 - 674468
Sept.12 236447 147480 239827 41350 2500 667604
Oct. 12 235260 154499 245699 43380 76370 755208
Nov. 12 224662 147060 231896 40400 73000 717018
Dec. 12 225421 156980 244425 40750 71040 738616
Jan.13 223484 158930 247745 39610 79020 746487
Feb.13 206051 141990 215080 36640 69410 669251
Mar. 13 235339 158090 241719 38880 69970 743998
Total 2631301 1801999 2121123 506960 441390 8361574
Washi Centre
April12 1422116 2427481 216848 212810 352815 4712070
May 12 1369262 2371783 249240 94965 341317 4426567
June 12 1389065 2501004 243249 88048 357376 4578742
July 12 1369262 2371783 249240 94965 341317 4426567
Aug. 12 1511467 2728321 272235 133010 688016 5033049
Sept.12 1452036 2576782 241664 59151 364674 4694307
Oct. 12 1573695 2750756 251339 81865 385535 5044190
Nov. 12 1570919 2400541 221193 64105 332203 4588961
Dec. 12 2661059 2613105 223282 46928 379604 4795393
Jan.13 1472233 2695411 240034 42897 388945 4839512
Feb.13 1370572 2432854 215855 37760 351423 4407464

Mar. 13 1558796 2763469 237696 40050 395685 4995696
Mudhol Centre
April12 30540 226510 257050
May 12 31250 240340 271590
June 12 28890 231240 260130
July 12 31250 240340 271590
Aug. 12 22460 244880 266740
Sept.12 20572 211971 232543
Oct. 12 18782 211089 229871
Nov. 12 15761 179388 195149
Dec. 12 12851 170451 183302
Jan.13 12540 163993 176533
Feb.13 11765 158160 169925
Mar. 13 13444 178116 191530
Table 6.4.2.2 Centerwise Market Demand (Sale) of Baffelo Milk Powder
Month Head Office Whole Sale Hydrabad Washi Total
April12 88950 3000 65900 6914 164764

May 12 80891 19000 62500 5269 167660
June 12 73508 7108 69400 5157 155173
July 12 65244 3900 55100 4542 128786
Aug. 12 65995 8900 74500 3815 153210
Sept.12 65107 6790 54500 4423 130820
Oct. 12 51510 12170 59675 7522 130877
Nov. 12 54034 5500 53400 8613 121547
Dec. 12 59397 8500 44500 6394 118791
Jan.13 65818 5500 55200 3230 129748
Feb.13 62646 7250 53500 3661 127057
Mar. 13 68998 14475 77500 4897 165870
Total 802098 102093 725675 64437 1694303

Table 6.4.2.3 Centerwise Market Demand (Sale) of Cow Milk Powder
Month Head Whole Washi Total

Office Sale
April12 1000 75000 - 76000
May 12 875 - 302 1175
June 12 2000 166525 - 168525
July 12 6120 327525 25 3336670
Aug. 12 13942 77500 - 91442
Sept.12 4257 9000 100 13357
Oct. 12 4393 9750 - 539143
Nov. 12 136 6000 - 358136
Dec. 12 4048 256025 250 385073
Jan.13 4054 538500 - 717804
Feb.13 768 60000 - 260518
Mar. 13 167 225000 - 275160
Total 41753 1750825 675 3220003
Table 6.4.2.4 Centerwise Market Demand (Sale) of Cheese and Pneer

Month Market Demand (Sale) of Cheese Market Demand (Sale) of Pneer
Head Washi Total Head Washi Total
Office Office
April12 7718 720 8438 14397 14733 29130
May 12 7207 779 7986 15782 11250 27032
June 12 10898 530 11428 13608 14922 27830
July 12 11103 569 11672 12987 17232 30219
Aug. 12 8183 565 8778 15299 18478 33777
Sept.12 6943 717 7663 11034 17180 28214
Oct. 12 9028 905 8833 10485 16470 26955
Nov. 12 8410 715 9125 12663 14990 27633
Dec. 12 13025 940 13965 15457 17720 33177

Jan.13 13636 990 14626 18395 16260 34655
Feb.13 11012 755 11767 11821 14346 26167
Mar. 13 6249 735 6984 11114 14788 25902
Total 113415 8920 122335 163042 187649 350691
Table 6.4.2.5 Centerwise Market Demand (Sale) of Curd and Table Butter
Month Market Demand (Sale) of Curd MarketDemand(Sale) of Table Butter

Office Office
April12 8667.4 97792 106459.4 24460 16490 40950
May 12 9420.6 92146.6 101567.2 36760 19831 56591
June 12 6554.1 80617.4 87171.5 16695 17430 34125
July 12 6717.7 80996.6 87714.3 33852 18054 51906
Aug. 12 6683.2 82327.8 89011 21212 19310 40602
Sept.12 6578.1 83206.7 89784.8 15382 26511 41893
Oct. 12 10428.1 98061.1 108489.2 21909 14960 36869
Nov. 12 6824.2 76787.5 83111.7 27568 13700 41268
Dec. 12 6025.8 83691.2 89717 33611 19970 53581
Jan.13 5897.9 74637 80534.9 44293 15182 59475
Feb.13 5607.1 72018.7 77625.8 35366 14968 50334
Mar. 13 7032.8 96591 103623.8 40959 13212 54171
Total 85937 1018873.6 1104810.6 352147 209618 561765

Table 6.4.2.6 Centerwise Market Demand (Sale) of Lassi and Shrikhand
Month Market Demand (Sale) of Lassi Market Demand (Sale) of Shrikhand

Office Office
April12 656419 212544 868963
May 12 529173 229229 758402
June 12 127294 144173 271467 91486.5 73398.5 164885
July 12 20892 81158 112050 133136.5 107589 240725.5
Aug. 12 19501 80408 99909 109744 108876 218620
Sept.12 34983 84211 119194 91048 90652 131700
Oct. 12 88267 137050 225317 124378 162157 286535
Nov. 12 86127 104654 190781 103354 73373 176727
Dec. 12 94608 97185 191793 105291 80554 185845
Jan.13 99433 77985 177418 118474 94708 213182
Feb.13 143414 85746 229160 97444 60498 157942
Mar. 13 363373 169199 532572 130071 91826 221897
Total 2263484 1513542 3777026 1421524.8 1104527 2526051.8
Table 6.4.2.7 Centerwise Market Demand (Sale) of Baffelo Ghee and Cow Ghee
Month MarketDemand(Sale) of Baffelo Ghee Market Demand (Sale) of Cow Ghee
Office Office
April12 47958 6369 54327 42040.32 22554 64594.32
May 12 45412 4530 49942 20781.29 14867 35648.29
June 12 53307 5789 59096 50269.16 19823 70092.16
July 12 68259 8207 76466 49645.37 19603 69248.37
Aug. 12 70329 6739 77068 41756.47 24587 66843.47
Sept.12 65696 7613 73309 29719.46 22299 52018.46
Oct. 12 80491 7299 87790 100720 28410 129130
Nov. 12 73299 9735 83034 25204.43 19039 44243.43

Dec. 12 66412 6088 72500 70885.92 22073 92958.92
Jan.13 62809 6468 69277 8345.44 16427 24772.44
Feb.13 42914 5821 48735 29549.55 20635 50184.55
Mar. 13 41041 4970 46011 5318 11009 16327
Total 717927 79628 797555 474235.41 241326 715561.41
Table 6.4.2.8 Total Market Demand (Sale) of Milk and Milk Products in 2012-13
Sr. No. Products Year 2012-13
1. Baffelo Milk 51476625 Lts
2. Cow Milk 39461496 Lts
3. Standard Milk 7309799 Lts
4. Tonned Milk 7402725 Lts
5. Double Tonned Milk 1906092 Lts
6. Skimmed Milk 60750 Lts
7. U.H.T. Milk 8856481 Lts
8. Ghee 1508 MT
9. Milk Powder 4910 MT
10. Shrikhand 2505 MT
11. Lassi 200 ml 3726895 Bags
12. White Butter 737 MT
13. Yellow Butter 949 MT
14. Table Butter 559 MT
15. Cheese 121 MT
16. Paneer 349 MT
17. Curd 1101 MT
(43th Yearly Report 2013-14 of Warana Dairy Plant)

Chapter 7
Data Analysis
7.1 Introduction: The data of milk collection process, production of milk and various milk
products and marketing of milk and milk products is collected in the sixth chapter. The analysis
of the collected data by using Fuzzy Control Model is discussed.
7.2 Data Analysis of Milk Collection Process:
7.2.1 Introduction: Milk collection process is controlled by various parameters like quantity
of milk, distance, season (lean and flush period), air temperature,vehicle type,time and demond
etc. These parameters are affecting in the milk collection process.There is always ambguity in
choosing the vehicle type for milk collection process depending on distance and quantity of the
milk..Therefore analyazing collected data of milk collection process i.e. analyazing the Tables
6.2.1 to 6.2.6, we have developed Mamdani and TSK Fuzzy Control Models with two inputs and
one output parameter which controls the cost of transportation, full utilizaton of transport facility
and considers time factor also.Control rules are derived by modeling the collection process.
7.2.2 Mamdani Fuzzy Control Model for Milk Collection Process:
7.2.2.1 Development of Mamdani Fuzzy Control Model:
We develop (study) Mamdani Fuzzy Control Model of transportation network of Milk
Collection Process with two inputs and one output as follows.
Consider Quantity of Milk and Distance from processing unit are two input parameters and the
output parameter is Vehicle Type.
(i) Modeling the Control Parameters: The input & output parameters are modeled by the sets
Input parameters: Quantity of Milk (in no. of cans), Distance from processing unit (in Kms.)
Output parameter: Vehicle Type (based on efficient carrying capacity in metric tons)
These parameters can be described by linguistic variables as follows:
Quantity of Milk (in no. of cans):
{VL (Very Low), L (Low), M (Medium), H (High), VH (Very High)}
Distance (in Kms): {VC (Very Close), C (Close), M (Medium), F (Far), VF (Very Far)}
Vehicle Type (based on efficient carrying capacity in metric tons):
{VL (Very Low), L(Low), M(Medium), H(High), VH(Very High)}
These linguistic variables can be represented by a fuzzy sets as given below
1 VL L M H VH
0 25 50 75 100
Figure 7.2.2.1: Quantity of Milk (in no. of cans)
The membership function for this fuzzy set of quality of milk can be obtained as follows:
VL(x) = , for 0 ≤ x ≤ 25,
=0 otherwise
L(x) = , for 0 ≤ x ≤ 25,
= , for 25 ≤ x ≤50,
= 0, otherwise,
M(x) = , for 25 ≤ x ≤50,
= , for 50 ≤ x ≤75,
= 0, otherwise,
H(x) = , for 50 ≤ x ≤ 75,
= , for 75 ≤ x ≤ 100,
= 0, otherwise,
VH(x) = , for 75 ≤x ≤ 100,

= 1, for x ≥ 100,
Fuzzy Membership Functions:7.2.2.1 (For Quality of Milk)
1 VC C M F VF
0 25 50 75 100
Figure 7.2.2.2 Distance from processing unit (in Kms.)
The membership function for this fuzzy set can be obtained as follows:
VC(y) = , for 0 ≤ y ≤ 25,
C(y) = , for 0 ≤ y ≤ 25,
= , for 25 ≤ y ≤ 50,
= 0, otherwise
M(y) = , for 25 ≤ y ≤ 50,
= , for 50 ≤ y ≤ 75,
= 0, otherwise
H(y) = , for 50 ≤ y ≤ 75,
= , for 75 ≤y ≤100,
= 0, otherwise

VH(y) = , for 75 ≤ y ≤ 100,
= 1, for y ≥ 100
Fuzzy Membership Functions:7.2.2.2 (For Distance from Processing unit)
1 VL L M H VH
0 0.75 1.5 2 2.25 2.5 3
Figure 7.2.2.3 : Vehicle Type (based on efficient carrying capacity in metric tons)
VL(z)= 0.75-z , 0 ≤ z ≤ 0.75
L(z) = , for 0 ≤ z ≤ 0.75,

.
.
= , for 0.75 ≤ z ≤ 1.50,
.
= 0 , otherwise
.
M(z) = , for 0.75 ≤ z ≤ 1.50,
.
.
= , for 1.50 ≤ z ≤ 2.25,
.
= 0, otherwise
.
H(z) = , for 2.00 ≤ z ≤ 2.50,
.
.
= , for 2.50 ≤ z ≤ 3.00,
.

= 0, otherwise,
.
VH(z) = , for 2.50 ≤ z ≤ 3.00,
.
= 1, for z ≥ 3.00.
Fuzzy Membership Functions: 7.2.2.3 (For Vehicle Type)
(ii) Fuzzy Rule Base:
The selected rules are presented in Table 7.2.2.1

If…and…then rules for milk collection process
Distance
VC C M F VF
VL VL VL L L L
L L L M M M
M M M M H H Quantity
H M M H H H
VH VH VH VH VH VH
The rules can be presented as follows:

1. The quantity of milk is VERY LOW and distance from the processing unit is MEDIUM then
vehile type is VERY LOW efficient carrying capacity.
2. The quantity of milk is LOW and distance from the processing unit is FAR then vehile type
is MEDIUM efficient carrying capacity.
3. The quantity of milk is MEDIUM and distance from the processing unit is FAR then vehile
type is HIGH efficient carrying capacity.
(iii)Fuzzy Inference Engine and Defuzzification Interface:
For x= 25 cans and y= 55 Kms. ,the vehicle type is 0.75 metric ton carrying.

7.2. 3 TSK Fuzzy Control Model for Milk Collection Process:
7.2.3.1 Development of TSK Fuzzy Control Model:
We develop TSK Fuzzy Control Model of transportation network of Milk Collection Process
with two inputs and one output as follows
The quantity of milk and distance are taken to be in the ranges of 0 to 100 (no. of Cans) and 0
to 100 (in Kms.) respectively.
Each of the inputs has three triangular membership functions as shown Figure 7.2.3.1and
Figure 7.2.3.2
1 S M L S M L
Xi1 (x1) 1 Xi2 (x2) µ (y) 1
0 50 100 0 50 100
Fig.7.2.3.1 Quantity of Milk membership functions(in no. of cans) Fig.7.2.3.2 Distance from processing unit membership functions
(in Kms.)
The input-output relations(implications) of the milk collection process are taken in the form of
fuzzy IF-THEN rules as
Ri : IF x1i is Xi1 And x2i is Xi2 THEN yi = ai0 + ai1x1+ai2 x2 [1]

i= 1,2,…9, where ai0, ai1, ai2 are coefficient parameters.
The final output y for the inputs x1,x2 is given by
y= [2]
Suppose that two sets of Input-Output Data for the milk collection process are given below

Table 7.2.3.1
Input Data Output Data

j
Quantity of milk (x1 ) (No. of Distance from Vehicle Type based on
Cans) processing unit (x2j) (in efficient carrying capacity
Kms.) (in metric tons) B
SMALL 10 SHORT 10 0.75
SMALL 20 MEDIUM 40 0.75
SMALL 30 LONG 70 1.25
MEDIUM 40 SHORT 20 2.00
MEDIUM 50 MEDIUM 50 2.25
MEDIUM 60 LONG 80 2.25
LARGE 70 SHORT 30 2.25
LARGE 80 MEDIUM 60 3.00
LARGE 90 LONG 90 3.00
LARGE 100 LONG 100 3.00
To determine the coefficient parameters { ai0 , ai1,ai2 } by using the given data, we use Least-
Squares Method .
Putting the given data into a system of algebraic equations AX=B,
Where β11 … β91 x11 β11 … x11 β91 x21 β11 … x21 β91
A= . [3]
β1,10 … β9,10 x110 β1,10 … x110 β9,10 x210 β1,10 … x210 β9,10 10x27
βkj = k= 1,2,…9, j= 1,2,…10, [4]
X= [a10,…, a90, a11,…, a91, a12,…, a92] T 27x1 , [5]
B= [y1, y2, y3, y4, y5, y6, y7, y8, y9, y10,]T10x1 [6]
Then from Least-squares Method the optimal coefficients are given by
X=[AT A ]-1 AT B

This is the pseudo-inverse solution of the least-squares optimization.
First we compute the membership values of inputs (x1) & (x2) in the following tables
Table 7.2.3.2
x1j x11 x12 x13 x14 x15 x16 x17 x18 x19 x110
Xi1(x1j) 10 20 30 40 50 60 70 80 90 100
X11 0.8 0.6 0.4 0.2 0 0 0 0 0 0
X21 0.8 0.6 0.4 0.2 0 0 0 0 0 0
X31 0.8 0.6 0.4 0.2 0 0 0 0 0 0
X41 0.2 0.4 0.6 0.8 1 0.8 0.6 0.4 0.2 0
X51 0.2 0.4 0.6 0.8 1 0.8 0.6 0.4 0.2 0
X61 0.2 0.4 0.6 0.8 1 0.8 0.6 0.4 0.2 0
X71 0 0 0 0 0 0.2 0.4 0.6 0.8 1
X81 0 0 0 0 0 0.2 0.4 0.6 0.8 1
X91 0 0 0 0 0 0.2 0.4 0.6 0.8 1
Table 7.2.3.3
x2j x21 x22 x23 x24 x25 x26 x27 x28 x29 x210
Xi2(x2j) 10 20 30 40 50 60 70 80 90 100
X12 0.8 0.6 0.4 0.2 0 0 0 0 0 0
X22 0.2 0.4 0.6 0.8 1 0.8 0.6 0.4 0.2 0
X32 0 0 0 0 0 0.2 0.4 0.6 0.8 1
X42 0.8 0.6 0.4 0.2 0 0 0 0 0 0
X52 0.2 0.4 0.6 0.8 1 0.8 0.6 0.4 0.2 0
X62 0 0 0 0 0 0.2 0.4 0.6 0.8 1
X72 0.8 0.6 0.4 0.2 0 0 0 0 0 0
X82 0.2 0.4 0.6 0.8 1 0.8 0.6 0.4 0.2 0
X92 0 0 0 0 0 0.2 0.4 0.6 0.8 1
Then we compute βkj by using [4] and putting in [3] and obtain the matrix A as follows
0.57 0.14 . . .0 5.7 1.4 . . . 0 5.7 1.4 . . . 0

. .
A= . . [7]
. .
0 0 . . . 1 0 0 100 0 0 . . . 100 10x27

Then find pseudo-inverse of A as follows
4.6510 -9.0906 … -0.3451 0.1056
. .
pinv(A) = . . [8]
. .
0.0001 -0.0002 -0.0502 0.0203

27x10
B=[0.75,0.75,1.25,2.00,2.25,2.25,2.25,3.00,3.00,3.00] T10x1 [9]
X= pinv(A)*B gives
X= [0.8881,-3.4760,0,-3.4760,4.2052,0.7191,0,0.7191,- 2.1505;0.0404,0.0398,0,0.0398,-
0.0196,0,0.0274,0.0258; 0.0404,0.0398,0,0.0398,-0.0196,0,0.0274,0.0258]T 27x1
0.8881 0.0404 0.0404

-3.4760 0.0398 0.0398
0.0000 0.0000 0.0000
-3.4760 0.0398 0.0398
X’= 4.2052 -0.0196 -0.0196 [10]
0.7191 0.0274 0.0274
0.0000 0.0000 0.0000
0.7191 0.0274 0.0274
-2.1505 0.0258 0.0258 9x3
If Quantity of milk, x1= 43 no. of cans and Distance from processing unit x2 = 80 kms.
then final output y can be determined as follows
First we find membership values of x1 = 43 and x2 = 80 using Fig.[2] and compute
yi = [1 43 80]* X’ and put in the following table

Table 7.2.3.4
Xi1(x1) Xi(x2) Xi1(x1) Xi1(x1) yi Xi1(x1) Xi1(x1) * yi

0.14 0 0 5.8573 0
0.14 0.4 0.14 1.4194 0.1987
0.14 0.6 0.14 0 0
0.86 0 0 1.4194 0
0.86 0.4 0.4 1.7994 0.7177
0.86 0.6 0.6 3.6219 2.1731
0 0 0 0 0
0 0.4 0 4.0893 0
0 0.6 0 1.0229 0
Sum=1.28 Sum=2.8909
Using [2] we find the final value y as
y=
= 2.8909/1.28
= 2.25 metric ton carrying capacity Vehicle Type i.e. 407 Tempo can be used
7.2.4 TSK Fuzzy Control Model for Milk Collection Process:

We develop TSK Fuzzy Control Model of transportation network of Milk Collection Process
using least-squares method with two inputsand one output as follows
The quantity of milk and distance are taken to be in the ranges of 0 to 100 (no. of Cans) and 0
to 100 (in Kms.) respectively.
Each of the inputs has five triangular membership functions as shown Figures 7.2.4.1 and
7.2.4.2 The output i.e. Vehicle Type based on efficient carrying capacity in range from 0 to 3(in
metric ton) and have five triangular membership functions as shown Figure 7.2.4.3

1 VL L M H VH VC C M F VF
µ(x) 1 µ (y) 1
x y
0 25 50 75 100 0 25 50 75 100
Fig.7.2.4.1 Quantity of Milk membership functions(in no. of cans) Fig.7.2.4.2 Distance from processing unit membership functions
(in Kms.)
VL L M H VH
1
µ (z)
0 0.75 1.5 2 2.25 2.5 3
Fig 7.2.4.3 Vehicle Type based on efficient carrying capacity (in metric tons)
The rules included for milk collection process are obtained in Table 7.2.4.1
Distance from processing unit
VC C M F VF
VL VL VL VL L L
Quantity of Milk L L L L M M
M M M M H H
H H H H H H
VH VH VH VH VH VH
Table 7.2.4.1: Fuzzy Rule Base
Suppose that two sets of Input-Output Data for the milk collection process are given below

Table 7.2.4.2: Input-Output Data
Input Data Output Data Input Data Output Data

Qt. of Milk Distance Vehicle Type Qt. of Milk Distance Vehicle Type
x11 x21 y1 x11 x21 y1
25 12.5 1.5 50 12.5 2.25
25 25 1.5 50 25 2.25
25 50 1.5 50 50 2.25
25 75 2.25 50 75 2.5
25 100 2.25 50 100 2.5
Let y1 = a01 + a11 x11 + a21 x21 be a formula for the Input-Output Data (1) where a01 ,a11, a21 are to
be determined by using Least-Squares Method as follows
Let 1 25 12.5 a0 1 1.5
1 25 25 a1 = a11 1.5
X1 = 1 25 50 a21 y1= 1.5
1 25 75 2.25
1 25 100 2.25
X1’X1 a1 = X’y1 => a1 = [X1’X1]-1 X1’y1
a01 -0.1332
a1 = a11 y1 = 0.0539
a21 0.0102
Hence y1 = -0.1332 + 0.0539 x11 + 0.0102 x21
Similarly for the Input-Output Data (2) we can find y2 = -0.0447 + 0.0440 x12 + 0.0034 x22
Suppose the milk collection process is estimated by the following fuzzy IF-THEN Rule
R1: IF x1 is LOW and x2 is MEDIUM THEN y1 = -0.1332 + 0.0539 x1 + 0.0102 x2

R2: IF x1 is MEDIUM and x2 is FAR THEN y2 = -0.1332 + 0.0539 x1 + 0.0102 x2
The graphical interpretation of fuzzy reasoning for TSK fuzzy control with two inputs x1= 40
Cans & x2 = 65 Kms with two rules is given in the following Figure 7.2.4.4
A11 B11 Min/Prod.
L M
w1 = 0.4&y1(as above)
0
A12 B12
M F
w2 =0.6&
y2(as above)
x1 x2
Weighted
Average
y = (w1 y1+w2 y2)/(w1+w2)

=(0.4x2.6+0.6x1.9) /(0.4+0.6)
y = 2.18 m.t.(carrying capacity)
Thus if quantity of milk is 40 no. of cans and distance from processing unit is 65 Kms. then
2.18 metric ton efficient carrying capacity vehicle type is required. i.e. we use 407 tempo
Vehicle.
7.3 Data Analysis of Production of Milk and Milk Products Process:
7.3.1 Introduction: In production of milk and milk products process various types of milk
packages and various milk products like Warana Shrikhand, Ghee,Lassi, Milk
Powder,Paneer,Butter,Cheese etc. are produced by raw milk. The quality of raw milk is the most
important factor in the production of milk and milk products process.The quality of raw milk is
classified by various qualitative and quantitative properties like Color, Odor, Appearance, Total
Microorganism Count, Methylene Blue Reduction Test Time, FAT, SNF, Proteins, and Added
Water etc. These properties affects on the quality of raw milk.There is vegness and ambiguity in
the process to maintain the quality of raw milk.Fuzzy sets can be used to describe these
properties. Therefore analyazing collected data of production of milk and milk products process
i.e. analyazing Tables 6.3.2.1 and 6.3.2.2 we have developed Mamdani and TSK Fuzzy Control
Models with three input parameters and one output parameter which controls the quality of milk
and milk products. Fuzzy control rules are derived by modeling the qualitative and quantitative
properties.
7.3.2 Mamdani Fuzzy Control Model for Quality of Milk
7.3.2.1 Development of Mamdani Fuzzy Control Model:
We develop (study) Mamdani Fuzzy Control Model of quality of raw milk in the production of
milk and milk products process with three inputs and one output as follows.
Consider Total Count, FAT and Acidity are three input parameters and grade of raw milk
quality is taken as output parameter.
(i) Modeling the Control Parameters: The input & output parameters are modeled by the sets
Input parameters: Total Count, FAT and Acidity
Output parameter: Grade of raw milk quality
These parameters can be described by linguistic variables as follows:
Total Microorganism Count ( 105 spc/ml) (TC)  Low (L), Medium (M), High (H), Very
High (VH)}
FAT (%)  Low (L), Normal (N), High (H)}
Acidity (%)  Low (L), Normal (N), High (H)}
Grade of raw milk quality  Poor (P), Fair (F), Good (G), Very Good (VG)}
These linguist variables can be represented by a fuzzy set as given below
1L M H VH
A(u)
u
0 5 10 20 30 40 50
Figure 7.3.2.1 Total Microorganism Count ( 105 spc/ml) (TC)

L(u) = , for 0 ≤ u ≤ 5, H(u) = , for 5 ≤ u ≤ 30,
= 0, otherwise, = , for 30 ≤ x ≤ 50,
M(u) = , for 0 ≤ v ≤ 5, = 0, otherwise,
= , for 5 ≤ u ≤ 10, VH(u) = , for 30 ≤ u ≤ 50,
= 0, otherwise, = 1, for u ≥ 50,
Fuzzy Membership Functions: 7.3.2.1 (For TC)
1 L N H L N H
B(x) 1 C(y) 1
x y
4.5 7.5 10.5 0.05 0.10 0.15 0.20
Figure 7.3.2.2 FAT (%) Figure 7.3.2.3 Acidity (%)
. .
L(x) = , for 4.5 ≤ x ≤ 7.5, L(y) = , for 0.05 ≤ y ≤ 0.10,
.
= 0 , otherwise , = 0 , otherwise ,
. .
N(x) = , for 4.5 ≤ x ≤ 7.5 N(y) = , for 0.05 ≤ x ≤ 0.10,
.
. .
= , for 7.5 ≤ y ≤ 10.5, = , for 0.10 ≤ y ≤ 0.15,
.
= 0, otherwise = 0, otherwise

. .
H(x) = , for 7.5 ≤ x ≤ 10.5, H(y) = , for 0.10 ≤ y ≤ 0.20,
.
= 1, for x ≥ 10.5 = 1, for y ≥ 0.20
Fuzzy Membership Functions:7.3.2.2 FuzzyMembership Functions:7.3.2.3
P F G VG
1
D(z)
z
0 0.35 0.70 1.05
Figure 7.3.2.4 Grade of Raw Milk Quality

.
P(z) = , for 0 ≤ z ≤ 0.35,
.
= 0, otherwise,
F(z) = , for 0 ≤ z ≤ 0.35,

.
.
= , for 0.35 ≤ z ≤ 0.70,
.
= 0, otherwise,
.
G(z) = , for 0.35 ≤ z ≤ 0.70,
.
.
= , for 0.70 ≤ x ≤ 1.05,
.
.
VG(z) = , for 0.70 ≤ u ≤ 1.05,
.
= 1, for z ≥ 1.05,
Fuzzy Membership Functions: 7.3.2.4

(ii) Fuzzy Rule Base:
The selected IF…and…THEN rules for quality of milk are presented as follows:
Table:7.3.2.1
TC FAT Acidity Quality TC FAT Acidity Quality

of Milk of Milk
L L L G M L L G
L L N G M L N F
L L H F M L H F
L N L G M N L G
L N N G M N N G
L N H F M N H F
L H L VG M H L G
L H N VG M H N G
L H H G M H H F
H L L F VH L L F
H L N F VH L N F
H L H F VH L H P
H N L G VH N L F
H N N F VH N N F
H N H F VH N H P
H H L G VH H L G
H H N G VH H N G
H H H G VH H H P
The rules can be presented as follows:

1. IF Total Microorganism Count is LOW and FAT is LOW and Acidity is LOW THEN
Grade of Raw Milk Quality is GOOD.
2. IF Total Microorganism Count is HIGH and FAT is NORMAL and Acidity is NORMAL
THEN Grade of Raw Milk Quality is FAIR.
3. IF Total Microorganism Count is LOW and FAT is HIGH and Acidity is NORMAL THEN
Grade of Raw Milk Quality is VERYGOOD.
4. IF Total Microorganism Count is VERY HIGH and FAT is LOW and Acidity is HIGH
THEN Grade of Raw Milk Quality is POOR.
(iii)Fuzzy Inference Engine and Defuzzification Interface:
Example: If u=7 and x=6.5 and y= 0.12 then z= 0.7. i.e. if TC is MEDIUM and FAT is
NORMAL and Acidity is NORMAL then quality of milk is GOOD.

7.3.3 TSK Fuzzy Control Model for Production of Milk and Milk Products
Process:
We develop TSK Fuzzy Control Model of quality of raw milk of Production of Milk and Milk
Products Process using least-squares method with three inputs and one output as follows
Consider Total Count (TC)(x1), FAT(x2) and Acidity(x3) are three input parameters and the
output parameter is Grade of Milk Quality(y).
Total Count(TC)(x1), FAT(x2) and Acidity(x3) are taken as three input parameters with
different linguistic variables as follows
Total Count (TC)  Low (L), Medium (M), High (H), Very High (VH)}
FAT  Low (L), Normal (N), High (H)}
Acidity  Low (L), Normal (N), High (H)}
The Total Count,FAT and Acidity of raw milk are taken to be in the ranges of 0 to 50 ( 105
spc/ml), 4.5 to 10.5 (%) and 0.05 to .20 (%) respectively.
1L M H VH
Xi1(x1)
u
0 5 10 20 30 40 50
Figure 7.3.3.1 Total Microorganism Count (TC)( 105 spc/ml)

1 L N H L N H
Xi2(x1) Xi1(x1) 1 Xi3(x3) 1
x y
4.5 7.5 10.5 0.05 0.10 0.15 0.20

The input-output relations (implications) of the quality of milk are taken in the form of fuzzy IF-
THEN rules as
Ri : IF x1i is Xi1 And x2i is Xi2 And x3i is Xi3 THEN yi = ai0 + ai1x1+ai2x2+ ai3 x3 (1)
i= 1,2,…5, where ai0, ai1, ai2, ai3 are coefficient parameters.
The final output y for the inputs x1,x2 is given by
∑ ( ) ( ) ( )
y= ∑ ( ) ( ) ( )
(2)
Suppose that three sets of Input-Output Data for the quality of milk are given below
Table 7.3.3.1
Input Data Output Data
TC (x1j) FAT (x2j) Acidity (x3j) Grade of Milk Quality

LOW (0-5) LOW(4.5-7.5) LOW(0-0.10) 0.75
LOW (0-5) NORMAL(6-9) HIGH(0.10-0.20) 0.50
MEDIUM (0-10) LOW(4.5-7.5) NORMAL(0.075-0.125) 0.50
HIGH (5-50) NORMAL(6-9) HIGH(0.10-0.20) 0.50
VERYHIGH (30-50) NORMAL(6-9) LOW(0-0.10) 0.50
To determine the coefficient parameters { ai0 , ai1,ai2, ai3 ai3 } by using the given data, we use
Least-Squares Method .

Putting the given data into a system of algebraic equations AX=B,
Where
β1,1 … β5,1 x11 β1,1 … x11 β5,1 x21 β1,1 … x21 β5,1 x31 β1,1 … x31 β5,1
A= . (3)
β1,5 … β5,5 x15 β1,5 … x15 β5,5 x25 β1,5 … x25 β5,5 x35 β1,1 … x35 β5,1 5x20
∑ ( ) ( ) ( )
βkj = ∑ ( ) ( ) ( )
k= 1,2,…5, j= 1,2,…5, (4)
X= [a10,…, a50 ;a11,…, a51; a12,…, a52; a13,…, a53] T 20x1 , (5)
B= [y1, y2, y3, y4, y5]T5x1 (6)
Then from Least-squares Method the optimal coefficients are given by
X=[AT A ]-1 AT B
This is the pseudo-inverse solution of the least-squares optimization.

First we compute the membership values of inputs (x1) & (x2) in the following tables
Table 7.3.3.2
x1j x11 x12 x13 x14 x15

Xi1(x1j) 2.5 7.5 15 25 45
X11 0.5 0 0 0 0
X21 0.5 0 0 0 0
X31 0.5 0.5 0 0 0
X41 0 0.1 0.4 0.8 0.25
X51 0 0 0 0 0.75
Table 7.3.3.3
x2j x21 x22 x23 x24 x25

Xi2(x2j) 5.25 6.75 7.50 9.00 9
X12 0.75 0.25 0 0 0
X22 0.25 0.75 1 0.5 0.25
X32 0.75 0.25 0 0 0
X42 0.25 0.75 1 0.5 0.25
X52 0.25 0.75 1 0.5 0.25

Table 7.3.3.4
x3j x31 x32 x33 x34 x35

Xi3(x3j) 0.75 0.10 0.125 0.150 0.175
X13 0.5 0 0 0 0
X23 0 0 0.25 0.5 0.75
X33 0.5 1 0.5 0 0
X43 0 0 0.25 0.5 0.75
X53 0.5 0 0 0 0
Then we compute βkj by using (4) and putting in (3) and obtain the matrix A as follows
0.5 0 0.5 0 0 1.25 0 1.25 0 0 2.6 0 2.6 0 0 0.375 0 0.375 0 0
0 0 1 0 0 0 0 7.5 0 0 0 0 6.75 0 0 0 0 0.10 0 0

A= . . (7)
. .
0 0 0 1 0 0 0 0 45 0 0 0 0 9.75 0 0 0 0 0.175 0 5x20
Then find pseudo-inverse of A as follows
0.0495 -0.0132 0.0000 0.0000 -0.0000
. .
pinv(A) = . . (8)
. .
0.0000 0.0000 0.0000 0.0000 0.0000 20x5

B=[0.75; 0.50; 0.50; 0.50; 0.50]T5x1 (9)
X= pinv(A)*B gives coefficient parameters {a10,…, a50;a11,…, a51; a12,…, a52; a13,…, a53}
0.0305 0 0.0191 0.4996 0

X= 0.0764 0 -0.0095 0 0 (10)
0.1588 0 0.0875 -0.0002 0
0.0229 0 0.0218 0.0146 0 4x5
If Total Count (TC), x1= 7 ( 105 spc/ml) and FAT (%) x2 = 6.5 and Acidity (%) x3 = 0.12 .
then final output y can be determined as follows
First we find membership values of x1 = 7 and x2 = 6.5 and x3 = 0.16 using Figs.(1),(2)&(3) and
then using input values and (10)compute
yi = [1, 7, 6.5, 0.16 ]* X and put in the following table
Table 7.3.3.5
Xi1(x1) Xi2(x2) Xi3(x3) Xi1(x1) Xi2(x2) yi Xi1(x1) Xi2(x2) Xi3(x3) * yi

Xi3(x3)
0 0.33 0 0 1.6002 0
0 0.66 0.2 0 0 0
0.6 0.33 0.6 0.33 0.4850 0.16005
0.08 0.16 0.2 0.08 0.5001 0.04000
0 0.33 0 0 0 0
Sum=0.41 Sum= 0.20005
Using (2) we find the final value y as
∑ ( ) ( ) ( )
y= ∑ ( ) ( ) ( )
= 0.20005/0.41 = 0.49
Thus if Total Count (TC) is 7 ( 105 spc/ml) and FAT is 6.5 % and Acidity is 0.12 %
then the final output y i.e. the grade of raw milk is 0.49 i.e. the quality of raw milk is fair.

7.3.4 Tsukamoto Fuzzy Control Model for Production of Milk and Milk
Products Process:
7.3.3.1 Development of Tsukamoto Fuzzy Control Model:
We develop Tsukamoto Fuzzy Control Model of quality of raw milk of Production of Milk and
Milk Products Process with three inputs and one output as follows
Consider Total Count (TC)(x1), FAT(x2) and Acidity(x3) are three input parameters and the
output parameter is Grade of Milk Quality(y).
Total Count(TC)(x1), FAT(x2) and Acidity(x3) are taken as three input parameters with
different linguistic variables as follows
Total Count (TC)  Low (L), Medium (M), High (H), Very High (VH)}
FAT  Low (L), Normal (N), High (H)}
Acidity  Low (L), Normal (N), High (H)}
The Total Count, FAT and Acidity of raw milk are taken to be in the ranges of 0 to 50 ( 105
spc/ml), 4.5 to 10.5 (%) and 0.05 to 0.20 (%) respectively.
Total Count A(x), FAT B(y) and Acidity C(z) are described by fuzzy membership functions in Figures
7.3.4.1 to 7.3.4.3 and one output parameter grade of raw milk quality D(u) is defined by monotone
functions D1,D2,D3 and D4 and described in Figure 7.3.4.4
1 A1 A2 A3 A4
A(x)
x
0 5 10 20 30 40 50
Fig. 7.3.4.1 Total Microorganism Count ( 105 spc/ml)
A1(x) = , for 0 ≤ x ≤ 5, A3(x) = , for 5 ≤ x ≤ 30,

= 0, otherwise, = , for 30 ≤ x ≤ 50,
A2(x) = , for 0 ≤ x ≤ 5, = 0, otherwise,
= , for 5 ≤ x ≤ 10, A4(x) = , for 30 ≤ x ≤ 50,
= 0, otherwise, = 1, for x ≥ 50, ------(1)

Fuzzy Membership Functions: 7.3.4.1 (for TC)
B1 B2 B3 C1 C2 C3
B(y) 1 C(z) 1
y z
4.5 7.5 10.5 0.05 0.10 0.15 0.20
. .
B1(y) = , for 4.5 ≤ y ≤ 7.5, C1(z) = , for 0.05 ≤ z ≤ 0.10,
.
. .
B2 (y) = , for 4.5 ≤ y ≤ 7.5 C2(z) = , for 0.05 ≤ z ≤ 0.10,
.
. .
= , for 7.5 ≤ y ≤ 10.5, = .
, for 0.10 ≤ z ≤ 0.15,
. .
B3(y) = , for 7.5 ≤ y ≤ 10.5, C3(z) = , for 0.10 ≤ z ≤ 0.20,
.
= 1, for y ≥ 10.5 -----(2) = 1, for z ≥ 0.20 -----(3)

Fuzzy Membership Functions: 7.3.4.2 Fuzzy Membership Functions: 7.3.4.3

D1 D2 D3 D4
1
D(u)
u
0 0.175 0.35 0.525 0.70 0.875 1.05
Figure 7.3.4.4 Grade of Raw Milk Quality
.
D1(u) = , for 0 ≤ u ≤ 0.35,
.
D2(u) = , for 0 ≤ u ≤ 0.525,

.
.
D3(u) = , for 0.35 ≤ u ≤ 0.875,
.
.
D4(u) = , for 0.70 ≤ u ≤ 1.05,
.
(i) Rule base for Tsukamoto Fuzzy Logic Control System :

The selected IF…and…THEN rules for quality of milk are presented in Table 7.3.4.1:
TC FAT Acidity Quality TC FAT Acidity Quality

of Milk of Milk
A1 B1 C1 D3 A2 B1 C1 D3
A1 B1 C2 D3 A2 B1 C2 D2
A1 B1 C3 D2 A2 B1 C3 D2
A1 B2 C1 D3 A2 B2 C1 D3
A1 B2 C2 D3 A2 B2 C2 D3
A1 B2 C3 D2 A2 B2 C3 D2
A1 B3 C1 D4 A2 B3 C1 D3
A1 B3 C2 D4 A2 B3 C2 D3
A1 B3 C3 D3 A2 B3 C3 D2

A3 B1 C1 D2 A4 B1 C1 D2
A3 B1 C2 D2 A4 B1 C2 D2
A3 B1 C3 D2 A4 B1 C3 D1
A3 B2 C1 D3 A4 B2 C1 D2
A3 B2 C2 D2 A4 B2 C2 D2
A3 B2 C3 D2 A4 B2 C3 D1
A3 B3 C1 D3 A4 B3 C1 D3
A3 B3 C2 D3 A4 B3 C2 D3
A3 B3 C3 D3 A4 B3 C3 D1
(ii) Fuzzy Inference:

If Total Count, x =7 105 spc/ml FAT, y = 6.5 % and Acidity, z = 0.12% then compute
the Grade of Raw Milk Quality D(u) as follows
From (1),(2) and (3), the membership values of x, y and z are in Table 7.3.4.2
Table 7.3.4.2
A2 (x) = 0.6 B1(y) = 0.33 C2(z) = 0.6
A3(x) = 0.08 B2(y) = 0.66 C3(z) = 0.2
Using the minimum rule of inference of the Tsukamoto Fuzzy Logic Control System described
as above.
The Eight fired rules for x =7 105 spc/ml, y = 6.5 % and z = 0.12% are as follows:
1. IF x is A2 AND y is B1 AND z is C2 THEN u is D2
The corresponding minimum membership values and outputs are given in the following
Table 7.3.4.3
A(x) B(y) C(z) Min w Output (u)

A2(x)=0.6 B1(y)=0.3 C2(z)=0.6 w1=0.3 u1=0.1575
A2(x)=0.6 B1(y)=0.3 C3(z)=0.2 w2=0.2 u2=0.1050
A2(x)=0.6 B2(y)=0.6 C2(z)=0.6 w3=0.6 u3=0.6650
A2(x)=0.6 B2(y)=0.6 C3(z)=0.2 w4=0.2 u4=0.1050
A3(x)=0.08 B1(y)=0.3 C2(z)=0.6 w5=0.08 u5=0.0420
A3(x)=0.08 B1(y)=0.3 C3(z)=0.2 w6=0.08 u6=0.0420
A3(x)=0.08 B2(y)=0.6 C2(z)=0.6 w7=0.08 u7=0.0420
A3(x)=0.08 B2(y)=0.6 C3(z)=0.2 w8=0.08 u8=0.0420
The final output is

1 1+ 2 2+ 3 3+ 4 4+ 5 5+ 6 6+ 7 7+ 8 8
=
1+ 2+ 3+ 4+ 5+ 6+ 7+ 8
( . )( . ) ( . )( . ) ( . )( . ) ( . )( . ) ( . )( . )
z=
. . . . . . . .
. . . . .
= =
. .
z=0.3096%
Thus if Total Count, x =7 105 spc/ml FAT, y = 6.5 % and Acidity, z = 0.12% then the
Grade of Raw Milk Quality D(u) is 0.3096
7.3 Data Analysis of Marketing of Milk and Milk Products Process:
7.3.1 Introduction: Marketing of Milk and Milk Products Process is an important
activity.Dairy Plant produces various milk and milk products viz. Pasteurized Milk, UHT
Aseptic Packaging Milk, Milk Powder, Shrikhand, Lassi, Ghee, Butter, Paneer, Cheese, Curd
etc. The production of these products depends on various parameters like Supply of Raw Milk,
Season, Market Demand of various products, Cost of Production, Skill of Labour, Capacity of
Machines installed, Management Policy and Government Policy etc. These parameters often
arise in the planning of amount of production of various products and increases uncertainty in the
plant. Therefore analyazing collected data of Milk Collection Process,Production of Milk and
Milk Products and Production of Milk and Milk products process and Marketing of Milk and
Milk Products Process i.e. analyazing Tables 6.2.3, 6.3.1(7) 6.4.2.6 and 6.4.2.8 we have
developed Tsukamoto Fuzzy Control Models with two input parameters and one output
parameter which maintain the amount production of Lassi product.Fuzzy control rules are
derived by modeling the quantitative properties.

7.3.2 Tsukamoto Fuzzy Control Model for Marketing of Milk and Milk
Products Process:
7.3.3.1 Development of Tsukamoto Fuzzy Control Model:
We develop Tsukamoto Fuzzy Control Model of market demand of Lassi with two inputs and
one output as follows
Consider two input parameters i.e. Supply of Raw Milk and Market Demand of Lassi and one
output parameter i.e. amount of production of Lassi.
Let x be Supply of Raw Milk (in Crore Liters ), y be Market Demand of Lassi (in Lakh Liters)
and z be amount of production of Lassi (in Lakh Liters). The fuzzy sets for Supply of Raw Milk
(x), and for Market Demand of Lassi (y) are described by membership functions in Figures
7.3..3.1 and 7.3.3.2 and amount of production of Lassi (z) is defined by monotone functions
C1,C2 and C3 and described in Figure 7.3.3.3.
A1 A2 A3 B1 B2 B3
A(x) 1 B(y) 1
x
5 6 7 5 6.5 8 10 25
Figure 7.3.3.1 Supply of Milk(x)(in Crore Lts.) Figure 7.3.3.2 Market Demand of Lassi(y)(in Lakh Lts)
The membership functions for these fuzzy sets can be obtained as follows:
.
A1(x) = , for 5 ≤ x ≤ 6, B1(y) = , for 5 ≤ y ≤ 6.5,
. .
= 0 , otherwise , = 0 , otherwise ,
A2(x) = , for 5 ≤ x ≤ 6 B2(y) = , for 5 ≤ x ≤ 6.5,

.
= , for 6 ≤ y ≤ 7, = , for 6.5 ≤ y ≤ 8,

.

= 0, otherwise = 0, otherwise
.
A3(x) = , for 6 ≤ x ≤ 7, B3(y) = , for 6.5 ≤ y ≤ 25,
.
= 1, for x ≥ 7 = 1, for y ≥ 25
Fuzzy Membership Functions: 7.3.3.1 Fuzzy Membership Functions: 7.3.3.2
C1 C2 C3
1
C(z)
z
5 6 7 8 18
Figure 7.3.3.3 Amount of Production of Lassi (z) (in Lakh Lts.)
C1(z) = , for 5 ≤ z ≤ 7,
C2(z) = , for 5 ≤ z ≤ 8,
C3(z) = , for 6 ≤ z ≤ 18,
(i) Rule base for Tsukamoto Fuzzy Logic Control System:
The selected IF…and…THEN rules for market demand of Lassi are presented in Table 7.3.4.1:
Table 7.3.3.1 describes the Rule base of the Production Planning System
Supply of Milk(x) Market Demand of Lassi(y)

B1 B2 B3
A1 C1 C1 C2
A2 C2 C2 C3
A3 C2 C2 C3

(ii) Fuzzy Inference
If Supply of Milk(x) is 5.97 crore lits. And Market demand of lassi(y) is 7.9 lakh lits. then we
compute the Amount of Production of Lassi (z) as follows:
From (1) & (2), the membership values of x and y are
A1(x)=0.03, A2(x)=0.97,A3(x)=0 and
B1(y)=0, B2(y)=0.07, B3(y)=0.07,
using the minimum rule of inference of the Tsukamoto Fuzzy Logic described as above.
The Four fired rules for x= 5.97 and y= 7.9 are as follows:
1. IF x is A1 AND y is B2 THEN z is C1
The corresponding minimum membership values are given in the following Table 7.3.3.2
Min B2 B3
A1 w1=0.03 w2=0.07
A2 w3=0.07 w4=0.07
Also the corresponding Outputs are z1=6.94,z2=5.21,z3=5.21 and z4= 6.84
The final output is

1 1+ 2 2+ 3 3+ 4 4
=
1+ 2+ 3+ 4
( . )( . ) ( . )( . ) ( . )( . ) ( . )( . )
z=
. . . .
. . . .
=
.
z= 5.9 lakh liters
Thus if Supply of Milk (x) is 5.97 crore lits. and Market Demand of lassi (y) is 7.9 lakh lits. then
the Amount of Production of Lassi (z) is 5.9 lakh liters.

Capter 8
CONCLUSION, RECOMMENDATIONS AND LIMITATIONS
8.1 Conclusions:
The data analysis and its interpretations leads to the following conclusions
1. The study will helpful to understand the preliminary concepts in Dairy Plant.
2. The study will helpful to understand the various processes like milk collection process,
production of milk and milk products process and marketing of milk and milk products process
in the Dairy Plant.
3. The study will helpful to understand the problems related to these processes in the Dairy Plant.
4. The study will helpful to understand the importance of fuzzy control models in the problems
related to these processes in the dairy plant.
5. The study will helpful to select efficient carrying capacity vehicle type to minimize the cost of
transportation of milk per liter in the Dairy Plant.
6. The study will helpful to detemine quality of raw milk to increase the quality of milk and milk
products in the dairy plant.
7. The study will helpful to plan the production of milk and milk products to fulfill the
reqirment of market demand of various milk products the dairy plant.
8. The study will helpful to understand the applications of Mamdani, TSK and Tsukamoto Fuzzy
Control Models in the dairy plant.
9. The study will helpful to design Fuzzy Ruled Based Models for optimization.
10. The study will helpful to test the fuzzy control models using the actual data.
11. The study will helpful to verify the reliability of the fuzzy control models and to make the
corrections if necessary.
12. The study will helpful to understand optimization techniques for the various processes in the
dairy plant.
13. The study will helpful to suggest recommendations about the transportation network, the
quality of raw milk and the amount of production of milk products and the market demand of
milk products.

8.2 Recommendations:
Based on the study we recommend the following suggestions to the dairy plant to optimize the
cost of milk collection process, production of milk and milk products process and marketing of
milk products process in the dairy plant.
1. In milk collection process, use of efficient carrying capacity of vehicle for transportation
network is important to minimize the cost of transportation per liter.
2. In production of milk and milk products, the quality of raw milk is important factor to increase
the quality of milk and milk products and market demand.
3. In production and marketing of milk products, the planning of production of milk and milk
products is helpful to fulfill the reqirment of market demand of various milk products.
4. The fuzzy control models namely Mamdani, TSK and Tsukamoto are helpful to solve the
problems related to milk collection process, production of milk and milk products process and
marketing of milk and milk products process.
5. These fuzzy control models have an advantage that these can be integrated with other optimization
techniques.
6. These fuzzy control models can be verified with the help of various processes in the dairy
plant.
7. These fuzzy control models can be tested with the other problems in the dairy plant.
8. These fuzzy control models are enable to solve the problems related to the other processes of
the dairy plant.
9. These fuzzy control models are helpful to solve the problems related to the various processes
of the other Plants or Industries.
10. The number of input parameters can be increased in fuzzy control models for more realistic
model.
11. Some different t-norms can be used in fuzzy control models for effective control.

8.3 Limitations:
We have worked under some limitations. Some of the key limitations are given below.
1. The date of collected data is kept unkown.

2. The information may be approximate.
3. It may be difficult to determine the accuracy of secondary data.
4.The survey and research has been carried out on the data collected from Warana Dairy Plant in
Kolhapur District. Therefore the results maynot be similar to all Dairy Plants in Maharashatra.

LIST OF PUBLICATIONS
1. Fuzzy control for milk collection process in dairy plant:S.N.Golgire,
M.S.Bapat,Proceeding of International Conference on Recent Advances in Statistics and
Their Applications,Dec.2013,ISBN:978-1-312-60946-4
2. Quality of milk in dairy plant by Fuzzy control: SN.Golgire, M.S.Bapat,Souvenir of

National Conference on Fuzzy Mathematics and its Applications, Feb.2014,ISBN 978-93-
5196-779-8
LIST OF RESEARCH PAPERS PRESENTED IN INTERNATIONAL AND

NATIONAL CONFERNENCES /WORKSHOPS:
1. Fuzzy Control for Milk Collection Process in Dairy Plant.
2. Milk Collection Process in Dairy Plant by using TSK Fuzzy Model.
3. TSK Fuzzy Control for Milk Collection Process.
4. Quality of Milk in Dairy Plant by Fuzzy Control.
5. Application of TSK Fuzzy Control in Dairy Plant.
6. Model of Tsukamoto Fuzzy Logic Control System for Quality of Milk in Dairy Plant.
7. Application of Tsukamoto Fuzzy Logic in Production Planing in Dairy Plant.
8. Stability Analysis in Fuzzy Control.

BIBLIOGRAPHY
1. Anandkumar, Control Systems,PHI
2. Bhupendra Singh,Numerical Analysis,Pragati Prakashan,Meerut
3.D.Driankov, H.Hellendoorn, An Introduction to Fuzzy Control,Narosa
Publishing
4.Da Ruan (1995): Fuzzy Set Theory and Advanced Mathematical Applications
Kluwar Academic Publishers
5. Dr. G.Kannan, Fuzzy Logic & Fuzzy Decision Making,Galgotia
6. Dr. Shailendra Jain, Modeling and Simulation using MATLAB-Simulink,Wiley
India
7.George J.Klir and Bo Yuan: Fuzzy Sets and Fuzzy Logic: Theory and
Applications, Prentice- Hall of India.(2000)
8. George Bojadziev and Maria Bojadziev: Fuzzy Logic for Business, Finance and
Management,Second Edition, World Scientific.
9. H.J.Zimmermann: Fuzzy Set Theory and its Applications (1995)
10. H.T.Ngnyen, E.A.Walkar ,A First Course in Fuzzy Logic,CRC
11. .John Haris: An Introduction to Fuzzy Logic Applications, Springer
12.. Jain M.K.,Numeriacal Methods,
13.. Kai Michels, Frank Klawonn, Rudolf Kruse and Andreas Nurnberger: Fuzzy
Control:Fundamentals, Stability and Design of Fuzzy Controllers, Springer
International
14. Kwang H. Lee: First Course on Fuzzy Theory and Applications, Springer
International Edition (2005)
15. M.Ganesh: Introduction to Fuzzy Sets and Fuzzy Logic, PHP (2012)
16.M. S. Bapat and S. N. Yadav. Fuzzy sets in Sugarcane Industry Decision,
International Journal of Tropical Agriculture 27, No. 1-2 (Jan-June 2009)

17. M. S. Bapat and S. N. Yadav: On Fuzzy Individual Decision making in
Agricultural Products,International Journal of Tropical Agricultural,2010.
18. M. S. Bapat and S. N. Yadav: Multi person decision making based on Fuzzy
Relations,Journal of Mathematical Sciences,(2012).
19.Michael P.Marder,Research Methods for Science,Combridge,2011.
20. M.K.Rampal,S.L.Gupta, Project Report Writing,Galgotia Publishng Copy.
21.Mamdani E.H. (1976):“Advances in the linguistic synthesis of fuzzy
controllers” Intern. J.of Man-Machine Studies 8(6) p.p. 669-678.
22. Robert Ajay, How to write and publish Scientific Paper,Vikas Publishing
House,1996.
23.R. R. Yager and D. Basson, Decision Making with Fuzzy sets, Decision
Science,6, 1975.
24. Sugeno M.: Industrial Applications of Fuzzy Control, North Halland New
York. (1995)
25.Timothy Ross Fuzzy Logic with Engineering Applications,Wiley Ediucation.
26. Toshiro Terano, Kiyoji Asai Michio Sugeno (1994): Applied Fuzzy Systems
27.Witold Pedrycz,Fuzzy Control and Fuzzy Systems,Overiseas Press
28.The Statistics Division of the Food and Agriculture Organization of the United
Nations
29. Integrated Sample Survey Reports (1992-93 to 2013-14), Department of
Animal Husbandry , Govt. of Maharashtra.
30. District Dairy Development Corporation, Kolhapur in 2008
31. Kolhaupr Zilla Sahakari Dudh Utpadak Sangh Ltd., Kolhapur
32. Yearly Report of the Warana Dairy Plant.
33. www.wikipedia.org.
34. www.gokuldairyplant.org
35. www.waranadairyplant.org

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Chapter 1

A Study of Warana Dairy Plant Using Fuzzy Control Theory 1

A Study of Warana Dairy Plant Using Fuzzy Control Theory 2

A Study of Warana Dairy Plant Using Fuzzy Control Theory 3

A Study of Warana Dairy Plant Using Fuzzy Control Theory 4

A Study of Warana Dairy Plant Using Fuzzy Control Theory 5

A Study of Warana Dairy Plant Using Fuzzy Control Theory 6

A Study of Warana Dairy Plant Using Fuzzy Control Theory 7

A Study of Warana Dairy Plant Using Fuzzy Control Theory 8

Figure 2.2.1 Triangular Fuzzy Number

A Study of Warana Dairy Plant Using Fuzzy Control Theory 9

A Study of Warana Dairy Plant Using Fuzzy Control Theory 10

A Study of Warana Dairy Plant Using Fuzzy Control Theory 11

A11 A21 y1=f1(x11,x21)

x1 x2 y = (X1 y1+ X2 y2) /(X1+X2)

Figure 2.4.2.1: TSK Fuzzy Control Model

Figure 2.4.3.1: Tsukamoto Fuzzy Control Model

Sr.No. Country Milk Production (in Million Tonnes)

1. India 117 146.31

2. U.S.A 87.46 93.46

3. China 41.14 42.58

4. Pakistan 35.49 50.14

5. Russian Federation 32.14 30.76

A Study of Warana Dairy Plant Using Fuzzy Control Theory 13

7. Germany 29.67 32.43

8. France 24.21 26.20

9. New Zealand 17.01 21.32

10. United Kingdom 13.96 15.05

11. Poland 12.30 13.00

12. Netherland 11.65 12.73

13. Mexico 10.84 11.29

14. Argentina 10.50 11.01

15. Australia 9.02 9.54

16. Canada 8.24 8.40

18. Romania 5.06 5.21

19. Denmark 4.91 4.58

20. Switzerland 4.11 4.10

21. Bangladesh 3.40 3.70

22. South Africa 3.23 3.34

23. Sweden 2.92 2.97

24. Finland 2.35 2.40

25. Afghanistan 1.82 1.77

26. Nepal 1.58 1.79

27. Norway 1.58 1.58

28. Indonesia 1.32 1.21

29. Thailand 0.85 1.07

A Study of Warana Dairy Plant Using Fuzzy Control Theory 14

31. Viet Nam 0.34 0.58

32. Sri Lanka 0.21 0.25

Total 531.76 600.29

Table 3.3.1 : State-wise Milk Production (Million Tonnes) in India

A Study of Warana Dairy Plant Using Fuzzy Control Theory 15

1. Andhra Pradesh 11203 13007

3. Assam 790 815

4. Bihar 6517 7197

6. Gujarat 9321 11112

7. Haryana 6267 7442

8. Himachal Pradesh 1102 1151

9. Jammu & Kashmir 1609 1615

10. Karnataka 5114 5997

11. Kerala 2645 2655

12. Madhya Pradesh 7514 9599

13. Maharashtra 8044 9089