A Summer Training Report

Kaira District Co-operative Milk Producers Union Ltd.

Submitted to : Kaira District Co-Operative Milk Producer‟s Union Ltd.

Submitted by : Khushal P.
Bhogayata(4051618003) P.A.E.

Polytechnic IN Agriculture Engineering,Targhadiya,

(JAU)
Training Period: 16 th FEB. to 28tth MAY, 2021.

1
 INDEX
Sr.No. Content Page No.
1 Acknowledge 3
2 List of Tables 4
3 Training Schedule 5
4 Introduction of company 6
5 Product range 10
6 Amul-3 processing plant 13
7 L&T AND F60 Powder plant & Packing 18
8 Butter Plant 23
9 Conclusion 30

2
 ACKNOWLEDGEMENT
I sincerely express my deepest sense of hearty gratitude to the following people for supporting and guiding
me ahead in the journey of making the project report of Industrial In-Plant training.
I express my profound gratitude and indebtedness to The Father of “The white Revolution, Dr.
Varghese Kurien” for envisioning this dairy and helping it becomes the stage of learning.
I would like to express my thanks to G.R. SHARMA (Principal of P o l y t e c h n i c i n
a g r i l l . E n g g . , Junagadh.) for permitting me to do my summer training in Amul Dairy, Anand.
I would also like to thank All the professors of our college for supporting & guiding us throughout
our graduation.
I am also thankful to Mr. D. R Sharma (Production Manager), Mr. Mrunal Desai (H.R
Department) without their guidelines and help I was not able to complete my In-Plant training.
I am also thankful to all section In-charges and operators who gave us positive response and guidance
during my training period.
Last but not the least, we express our deep feelings of love and affection to our beloved parents for
providing us valuable opportunities which helped us to stand out on our own feet this stage.

Thank You
Khushal
Bhogayata

3
 List of Tables

Table No. Title

i Training schedule
ii Company profile
iii Product Range
1.1 Amul-3 equipment list
1.2 Amul-3 CIP
2.1 Specification of powder
2.2 Equipment list (Powder plant)
2.3 Powder packaging
3.1 Specification of butter
3.2 Butter section equipment list
4.1 Powder analysis
5.1 Butter analysis
6.1 Sampling plans for products

4
 Training Schedule

Khaira District Co-operative Milk Producers‟ Union Ltd., Anand

AMUL DAIRY
Name of trainee:-Mr. Bhogayata Khushal P.
Name of the Institute: Polytechnic in Agrill. Engg., Junagadh Training Period
:16-02-2021 to 28-05-2021
Training Time : 8:30 am to 12:30 pm
Sr.No Section Training Reporting Officer
Period
1 A-3 Milk process 16-02-2021 to Sh.Rakesh Amin
22-02-2021
2 L&T Powder & Packing 23-02-2021 to Sh. Mayank Patel
01-03-2021
Mrs. Pinal Patel
3 F-60 Milk Powder 02-03-2021 to Sh.Gaurang Patel
08-03-2021
Ferrum Packing Sh. Ketan Mehta
4 Butter Section 09-03-2021 Sh. Kamal Prajapati
To
17-03-2021

5
 INTRODUCTION
AMUL is based in Anand town of Gujarat and has been a sterling example of a Co-operative organization‟s
success in the long term. It is one of the best examples of Co-operative achievement in the developing world.
“Anyone who has seen… the Dairy Co-operatives in the state of Gujarat, especially the highly successful one
known as AMUL, will naturally wonder what combination of influences and incentives is needed to multiply
such a model a thousand times over in developing regions everywhere.” The Amul Pattern has established
itself as a uniquely appropriate model for rural development. Amul has spurred the White Revolution of
India, which has made India the largest producer of milk and milk products in the world. It is also the
world‟s biggest vegetarian cheese brand.
AMUL means „priceless‟ in Sanskrit. The brand name “Amul,” from the Sanskrit word “Amulya” was
suggested by a quality control expert . Amul products have been in use in millions of homes since 1946 and
made Amul a leading food brand in India.

Today Amul is a symbol of many things.

 High-quality products sold at reasonable prices.
 Proven model for dairy development.
 Genesis of a vast co-operative network.

Today,there are twelve dairies producing procucts under the brand name of AMUL. AMUL is now Asia‟s
largest dairy brand and it is the world‟s second largest firm producing dairy products.
80% of profit is divided to farmers according to ratio of milk procured.

Company profile:
Name of plant Kaira district co-operative milk
producer‟s union ltd.

Date of registration 14th December 1946,under cooperative act

Registration no. p.330/1946
Brand Name Amul
Societies 1176 villages co-operative societies with
6,69,566 members
Premises 49.55 acres

Milk procurements 25 lakh liter per day

Plants  Dairy plant – Anand

 Kaira Satellite Dairy – Khatraj
 Food complex – Mogar
 Kanjari Plant – Nadiad
 Amul research & development
association.

(table no: ii)

6
  History & development of AMUL:
Amul-coperative registered on 14 December 1946 as a response to the exploitation of marginal milk
producers by traders or agents of the only existing dairy, the Polson dairy, in the small city distances to
deliver milk, which often went sour in summer, to Polson. The prices of milk were arbitrarily determined.
Moreover, the government had given monopoly rights to Polson to collect milk from Kaira and supply it to
Bombay city.
Angered by the unfair trade practices, the farmers of Kaira approached Sardar Vallabhbhai Patel under the
leadership of local farmer leader Tribhuvandas K. Patel. He advised them to form a cooperative and supply
milk directly to the Bombay Milk Scheme instead of Polson (who did the same but gave them low
prices). He sent Morarji Desai to organise the farmers. In 1946, the milk farmers of the area went on a strike
which led to the setting up of the cooperative to collect and process milk. Milk collection was decentralized,
as most producers were marginal farmers who could deliver, at most, 1–2 litres of milk per day. Cooperatives
were formed for each village, too.
The cooperative was further developed and managed by Dr.Verghese Kurien with H.M. Dalaya. Dalaya's
innovation of making skim milk powder from buffalo milk (for the first time in the world) and a little later,
with Kurien's help, making it on a commercial scale, led to the first modern dairy of the cooperative at
Anand, which would compete against established players in the market. Kurien's brother-in-law K.M. Philip
sensitized Kurien to the needs of attending to the finer points of marketing, including the creation and
popularization of a brand. This led to the search for an attractive brand name. In a brainstorming session, a
chemist who worked in the dairy laboratory suggested Amul, which came from the Sanskrit word "amulya",
which means "priceless" and "denoted and symbolised the pride of swadeshi production."
The trio's (T. K. Patel, Kurien and Dalaya's) success at the cooperative's dairy soon spread to Anand's
neighbourhood in Gujarat. Within a short span, five unions in other districts – Mehsana, Banaskantha,
Baroda, Sabarkantha and Surat – were set up. To combine forces and expand the market while saving on
advertising and avoid competing against each other, the GCMMF, an apex marketing body of these district
cooperatives, was set up in 1973. The Kaira Union, which had the brand name Amul with it since 1955,
transferred it to GCMMF.

Three tier Model of AMUL:

The Amul model of dairy development is a three tiered structure.
1. Dairy Co-operative societies(DCS) at village level. – The role of DCS is to procure & collect milk
from milk producers and transport it to the milk union at district level.
2. Milk union at district level. – The role of MU is processing & value addition in milk and to form
various processed products of milk.
3. State federation(GCMMF) – Selling & marketing of processed products is done only by state
federation.

7
AMUL LOGO
The logo of AMUL is ring of four hands, encircled by the words “KAIRA DISTRICT CO-OPERATIVE
MILK PRODUCER UNION LIMITED”. The essence of this logo is co-ordinate effort of four groups of
people.

First hand is for farmers or producers, without whom the organization would not be existed. Farmers are
the inspiration of the Amul the taste of India.
Second hand is for the representative of processors by whom the raw milk process in to different finished
products.
Third hand is for marketers without whom the products would not been able to reach the consumers.
Fourth hand is for customers without whom the organization could not carry on because they are the
people who consume the products.

Motto of AMUL
The main motto behind the AMUL moment was to help the farmers of Kaira District. The AMUL system
works with the objective of paying highest possible price to the milk supplier and lowest possible price to the
consumers. The farmers supply raw milk for which they are paid cash on daily basis for milk they bring to
milk collection centres. AMUL union is one of the pioneers which started using profit for milk supplier‟s
welfare.

8
ORGANIZATIONAL STRUCTURE OF AMUL

9
PRODUCT RANGE:
Products
Fresh milk Amul shakti (pasteurized standardized milk)
Amul T-special (standardized homogenized milk)
Amul (pasteurized homogenized tonned milk)
Amul Gold (full cream milk)
Amul Lite slim-n-trim milk(Double tonned milk)
Amul Fresh cream
Amul Snowcap softy mix

Fermented Products Amul Masti Dahi (fresh curd)

Amul lite Dahi
Amul Buttermilk
Amul Jeera Butter milk
Amul Lassi

Butter Amul Utterly Butterly delicious

Amul White butter

Bread Spreads Amul delicious

Amul lite

Ghee Amul Pure Ghee

Amul Brown Ghee
Amul Cow Ghee

Milk Powders Amul full Cream milk Powder(WMP)

Amul skimmed milk powder(SMP)
Amulya(Dairy whitener)
AmulSpray(Infant milkfood)
Whey Powder

Flavoured milk Amul kool café

Amul kool koko
Amul shakers ( mango, strawberry, saffron, cardamom, rose)

Cheese Range Amul Cheddar cheese

10
 Amul processed cheese
Cheese spread
Amul Pizza (Mozarella) cheese
Amul ETG(easy to grate) cheese
Amul Emmental cheese
Amul Gouda cheese
Amul malai Paneer

Chocolate & Amul Milk chocolate

Confectionery Amul Dark chocolate
Amul Fruit & Nut chocolate
Amul Bindazz
Amul Chocozoo
Amul ChocoMinis
Energy bar
Almond bar

Mithaee Range (Ethnic Amul shrikhand( Mango, saffron, Almond pistachio, Cardamom)
sweets) Amul Amrakhand
Amul mithaee Gulabjamun mix
Amul mithaee Gulabjamuns
Amul mithaee kulfi mix
Avsar Ladoos
Amul basundi
Amul paysum (Khir)

Sweetened Condenced Amul Mithaimate Sweetened condensed milk

Milk

Amul Ice-creams Royal Treat Range( Butterscotch, Rajbhog, Malai kulfi)

Nut-o-Mania Range (Kaju Draksh, Kesar Pista Royale, Fruit Bonanza,
Roasted Almond)
Nature‟s Treat ( Alphanso mango, Fresh litchi, shahi Anjir, Fresh
Strawberry, Black current, santra mantra, Fresh Pineapple)
Sundae Range (Mango, Black current, sundae Magic, Double sundae)
Assorted Treat ( Chocobar, Dollies, Frostik, Ice Candies, Tricone,
Chococrunch, Megabite, Cassatta)
Utterly Delicious ( Vanilla, Strawberry, Chocolate, Chocochips, Cake
magic)
Amul sugar free ice cream range
11
 Amul prolife proboitic ice cream

Malt based product Amul pro(Whey protein malt beverage)

(table no.: iii)

12
 1.Amul-3 Milk Processing Plant
Reception dock is the very first department of any dairy, where milk is unloaded & simultaneously tested.
Raw milk at Amul-3 is received only through Road tankers coming from different village chilling units &
chilling centers. There are 3 Milk Reception Line (RMRD) each having capacity of 30,000 L/hr. It has
facility of computerized reception.

Process Description:
 As milk tanker arrives in line first agitation is carried out for 15 min by using plunger. QA
staff/Process Operator after inspection of the integrity of seals; draw a sample to check temperature
and other quality parameters. The results are recorded. The QC officers permit to accept the milk
having acidity up to 0.15% L.A & temperature should be 10oC. In case of higher acidity, the same is
reported to in charge (production) for further action.
 In case, milk do not confirm to the specification, process staff consults their immediately supervisor
for further action. In case of higher acidity in milk the tanker is sent to Amul-2 dock for unloading
and immediate processing.
 The entire process of milk reception, storage, processing and dispatch is controlled through PLC
(Programmable Logic Controller).
 After all tests, the raw milk from tankers after chilling is send to raw milk buffer tank having
capacity of 15,000 L. Then this raw milk is sending to clarifier in which the undesirable solid
particles are removed by centrifugation, this particles called as sludge. After every 15min undesirable
sludge discharge in sludge tank (capacity – 5000 L).Then it sends to sludge treatment tank in which
heat treatment gives to sludge & then it used to produce casein. After clarifier milk is store in raw
milk silos at 4oC.There are 5 raw milk silos, 4 silos having 1.5lakh L capacity & 1 having 60,000 L
capacity.
 From raw milk silos milk is pumped to Balance Tank of pasteurizer & undergoes pasteurization
(77oC/18 sec). There are 5 Pasteurizers. One is for Cream Pasteurization, rest are for Milk
Pasteurization. Meanwhile after Preheating, milk is separated to Cream & Skim Milk.
 The cream is sent to cream buffer tank & milk is sent to milk silos.
 The self standardization is done in ALFAST UNIT i.e. Alfa Laval Fat Analyzing Standardization
Unit. The separated milk is used for manufacturing powder i.e. WMP, SMP, Amul Spray & Amulya.

13
Process Flow chart:
Raw chilled milk in tankers

Sampling Deaerator Empty tanker

Tankers Pump CIP of tanker

. Grading & Analysis

Acidity test OK Non-return Valve

. (if not ok)
Chiller (25 oC)

Sour Dump tank Buffer tank

Ghee Section Clarifier Sludge Sludge tank

Raw milk silos

(4-5 oC) Sludge treatment tank

PHE
(heating to 60 C,cooling to 10 oC)
o

Balance Tank of Pasteurizer

Pasteurizer Industrial Casein

Regeneration-1(50 oC)
Pre hea ting (62 oC) Cream Separator Cream

Regeration-2(73 oC) Auto Std. Chilling

Heati
ng (77 oC) Pasteurization

Holdin
tube (18 sec) Cream silos

g
Valve Balance tank
Ok if not OK

Flow diversion
Chiller (5 oC)

14
 Pasteurized milk silos

Amul-3 Amul-2 Road Tanker Rail Tanker

Equipments:

Equipments Capacity No. of

equipment
Raw milk buffer tank 15000 L 3
Cream buffer tank 15000 L 2
Raw milk chiller 10,000 L/hr 3
Rail tanker chiller 30,000 L/hr 1
Milk clarifier 30,000 L/hr 3
Balance tank 350 L 5
Cream pasteurizer 10,000L/hr 1
Milk pasteurizer 30,000L/hr 4
Homogenizer 10,000 L/hr 1
Cream separator 30,000 L/hr 3
Cream chiller 10,000 L/hr 3
Bactofuge 30,000 L/hr 1
Pasteurized milk buffer 15,000 L 1
tank
CIP tanks 1
 Rinse tank
 Lye tank 10,000 L
 Acid tank 10,000 L
 Water tank 8,000 L
CIP tanks for tankers
 Rinse tank
 Water tank
 Lye tank
Sludge tank 5000 L 1
Sludge treatment tank 1000 L 2
Rinse milk collecting (1)15000 L 2
tank (2)2000 L
Raw milk silos 1,50,000 L(4) 5
60,000 L(1)
Butter milk silos 40,000 L 2
Pasteurized milk silos 1,50,000 L(4) 5
40,000 L(1)
Cream silos 60,000 L(2) 5
40,000 L(3)
(table: 1.1)

Standardization in ALFAST UNIT:

1. Density Transmitter

15
 2. Flow Transmitter
3. Control Valve
4. Control Panel
5. Constant Pressure Valve
6. Change over Valve
7. Check Valve

In online standardization cream fat content system works on the basis of Cascade control. A
combination of accurate measurement of fat content and rapid flow metering, known as Cascade
control. In cascade control accurate fat content is measured by density transmitter and flow
transmitters.

In Cascade control, there are mainly 3 flow meters:

1. Density Transmitter:-It senses the density of flowing fluid so it indirectly helps in measuring
flow for standardization.
2. Flow Transmitter:-According to density meter, flow meter adjusts the flow of skim milk and
cream as per the required standardized milk.
3. Control Valve:-It is the heart of ALFAST system. It adjusts its opening according to required
flow for milk.

Auto Standardization in ALFAST UNIT:

Cream Separator

Cream Skim Milk

Density Transducer(to get the amount of fat) Liquid Density Transducer

Flow Meter Flow Meter

Mixing

Final heating section of Pasteurizer

Standardized Pasteurized Milk

Cleaning of Amul-3:
CIP steps Pasteurizer Silo/Tanks Transfer Lines
o o
TIME(min) TEMP( C) TIME(min) TEMP( C) TIME(min) TEMP(oC)
Rinsing with 10 Ambient 5 Ambient 5 Ambient
Water
Lye 30 80 20 80 5 80

16
 Circulation
Fresh Water 6 Ambient 7 Ambient 5 Ambient
Circulation
Acid 20 60 15 60 5 60
Circulation
Fresh Water 10 Ambient 7 Ambient 5 Ambient
Circulation
(table: 1.2)

CIP of RMRD:
CIP steps Reception Lines Milk Tankers
o
TIME(min) TEMP( C) TIME(min) TEMP(oC)
Rinsing with Water 5 Ambient 1-3 Ambient
Lye Circulation 15-20 80 5 60
Fresh Water 7 Ambient 5 Ambient
Circulation
Acid Circulation 20 60 - -
Fresh Water 10 Ambient - -
Circulation

17
 2. Powder Plant
Introduction:
L&T stands for Larson & Turbo.

L&T plant is a fully automated Tall Form Drier plant in which two stage drying of standard milk takes place
in Spray Dryer and Vibro Fluidized Bed drier.

The capacity of the plant is 60 MT/day.

Milk is received from processing site is used to make milk powder using different procedures. In the plant
Skimmed milk powder, Whole milk powder, Dairy whitener (Amulya) and Infant milk food (Amul Spray)
are produced.

AmulSpray & Amulya Agglomerated

SMP & WMP Nonagglo OR Agglomerated.

Dryer Principle:
Spray drying operation involves the conversion of concentrated liquid milk to dried powder. This is
carried out by transforming the liquid milk into milk droplets and contacting these droplets with hot air in
a controlled fashion. Due to the enormous area available for heat and mass transfer, the water evaporation
from milk droplets and drying takes place.

Process flowchart:
Standardized milk from silos ( 4-5⁰c ) +Ingredients

Balance tank

Pre heater ( 6 to 1)

Flash vessel (regeneration)

Swirl heater- HHP (90-95⁰C)

CCP
Holding tubes

Flsh vessel (flash cooling)

18
 Calendria1st (70-73⁰c)

Calendria & vapour separator (2 to 5)

Hydro cyclone

Concentrated milk (50% TS) in Concentrate tank

Scrapped surface heat exchanger

Feed pump

Homogenizer (as a high pressure pump)

Atomizer (nozzle) Fines

Nonagglo

Heated Air(1830C) Tall form drier (TFD) Cyclone Exhaust air

Agglo

Vibro fluidizer (12mmWC vacuum) Fines

Vibrating sieve Lumps

Bulk packaging (25kg) Hopper

Dense phase vessel

Pneumatic conveyor

Powder silo

19
 Vibrating tubes

Hopper

Vibrating tubes

Rotary valve &Rotary Sifter

FFS packaging machine

The whole plant is divided in the five sections:

1. Feed Preparation
2. Evaporation system
3. Drying section
4. Powder conveying & storing section
5. Packaging section
1) Feed Preparation:
Milk from milk silos first comes to the section. The section has two milk silos each having 40000 lit. Milk
capacities. In the Dairy Whitener and Infant milk food sugar is added as syrup prepared in sugar Dissolving
tanks having 3000 lit capacity. The tanks are double jacketed for heating. The prepared solution is pumped
into milk silo through inline double filters. Trisodium phosphate (for pH adjustment) and Vitamins (A, D, B,
C) & Mineral mixture ( both for AmulSpray only ) are added in the milk silo.

Preparation of various Additives:

 Addition of BHA (for WMP only) – BHA @ 50g per metric ton of milk powder is added by
dissolving BHA in 2 -3 L in lukewarm water and is added to milk in silo.
 Addition of TSP – Addition of buffering salt @ 0.2% for SMP, 0.6% for AmulSpray and 0.3 % for
Amulya. TSP is not added to IMF – 1 and 2 WMP.
 Sugar – Water is taken into sugar vats and heated to 50 - 60⁰ C. Required quantity of sugar is
added into sugar vat and dissolved. Sugar solution is pumped to milk silos through filter.
 Vitamins and minerals – Vitamin A + D mix is dissolved in milk and added into sugar solution.
Water soluble vitamins and mineral premix is mixed in lukewarm oil and added to vegetative oil
cream. Lecithin is mixed in lukewarm oil/ghee and heated to about 60 -70⁰c in order to melt lecithin
in free flowing form and added into vegetable oil cream mixture.

2) Evaporation section:
Milk is pumped from these silos into a feed balance tank of evaporator. Typically milk is concentrated from
14% solids to 48% solids in evaporator.
Here mechanical arrangement is made such that milk inside tube comes in contact with hot steam
which heats the milk and some of its water parts about 35 %, is evaporated during this section and we get 48
20
% total solid ( TS ) in milk. For concentration of the milk, Multiple Effect Evaporator (5 effect) with
Forward Feed Mode of Evaporation is used. Concentrated milk from evaporator is gathered in Concentrate
tanks. There are three tanks.

3) Drying section:
 The milk concentrate (50% TS/ 500C) is pumped through a scraped surface HE where it is further
concentrated and then to the Spray dryer with the help of a high pressure homogenizer. .
Homogenizer has 3 functions, main function to pump liquid up to the head of the dryer (fifth floor),
to raise the temperature of condensed milk to 70⁰c and to partly homogenize the milk. The Spray
dryer is of Tall Form design of 8 nozzle spraying atomizer, which consists of Air dispersing system,
Electromagnetic hammers, Cyclones, Fire extinguishing system and Vibro fluidizer.
 The drying chamber is a cylindrical vessel with 450 conical bottom. The drying process proceeds in a
co-current mode. Milk is atomized by nozzles at from the top.
 Cyclones are present for collecting fines by centrifugal force. In case of agglomeration these fine
particles are added back in the dryer along with milk.
 Vibro fluidizer is a vibrating housing which is divided into two parts by a special perforated plate. Air
is blown into lower part which is called Plenum chamber and the powder is fluidized in the upper
vibro shifter. There are three regions in Vibro
1. Initial heating region – 60oC
2. Heating with dehumidified air – 45oC
3. Dehumidified cooling - 40 oC
Vibrator mounted on the lower side produces the vibration. The vibro fluidizer operates at a vacuum of
12mmWC. At the outlet of vibro there is a sieve for removal of lums. Lums are reconstituted into milk.

4) Powder conveying section:

The powder coming out of vibro sieve enters the dense phase conveying unit and from there it is
pneumatically conveyed into powder silos. The powder from the silos is conveyed through vibrating tubes to
packing machine.

5) Packing section:
The powder is packed in pouches. The pouches are inserted in cartons. The cartons are collected & put into
cases. Cases are sealed & conveyed to stores on a belt conveyour.

Specification:
Parameter Amul Spray Amulya SMP WMP
Fat 18.5% min 20.5% min 1.5% max 26% min
Moisture 4% max 4.5% max 4% max 4% max
Protein 22% 20% 35% 15%
Lactose 31% 32% 50% 50%
Sucrose 17% 17-18% - -
Ash 8.5% 5.5% 8.2% 7.3%
(table: 6.1)
Equipment details:
EQUIPMENT CAPACITY
Milk Silos 40,000 lit ×2
Sugar dissolving vats 1000 lit ×2
Evaporator feed handling capacity 22,000 lit/hr
Balance tank for milk condensing plant 150 lit
Concentrate tank 3000 lit ×2
21
 Powder silos 30,000 kg ×2
Homogenizer 6300 lit/hr
Evaporation Capacity 30,000 lit/hr
Dryer Capacity 7400 lit/hr
(table: 6.2)
Packing:
Packaging is done in two ways:
 Manual bagging
 Automatic packaging
Manual bagging:
Powder from vibro sifter is sent to bagging line for bulk packaging of 25kg. Bags are packed manually and
sent to cold storage for Industrial use.

Automatic packaging:
For automatic packing, powder is taken into powder silos. Each silo has 30000 kg capacity. With the help of
dense phase vessel, powder is conveyed through vibrating tubes, rotary valve and rotary shifter and is taken
into packaging machine hoppers. Form, Fill and Seal machine packs 50 gm pouches of Amulya and 1 kg and
½ kg pouches for Amulspray.

Type of Weight of Net Weight Total Approx. M.R.P. Packing

product packaging wt.(gm) Capacity/min
material
1kg 15gm 1000gm 1050gm 1015-1017 340 40 packs
Amulspray,
Amulya
500g 8.5gm 500gm 509gm 509-511 178 60 packs
Amulspray,
Amulya
200g 4.5gm 200gm 205gm 205-207 72 70 packs
Amulspray,
Amulya
27g 2.2gm 27gm 29gm 29-30 10 120 packs
Amulspray,
Amulya
!3.fg 1.7gm 13.5gm 15gm 15-16 5 60 packs
Amulspray,
Amulya
13.5g 1.7gm 13.5gm 15gm 15-16 5 80 packs
Amulspray
(double head,
FFS)
(table: 6.3)

22
 3.Butter Section
Introduction: The utterly butterly delicious butter of Amul is one of the most popular product of Amul
dairy along with the famous butter girl. The Butter section is located in Amul-3 which manufactures Table
butter, White Butter. The section is completely computerized and is equipped with most morden imported
equipments. Amul white and table butter is exported to USA and Gulf countries. Amul Table butter
maintains AGMark standards.
Butter section of Amul-3 has capacity 70 MT per day. The capacity utilization in flush season is 55-60 MT,
usually it produces 20 MT per shift.
Process:
The cream for manufacturing Butter is receiving from Amul-3 processes while standardization of milk. The
milk fat will be separated at above 60oC; the centrifugal cream separators in line with milk pasteurizer
separate this as cream.

The cream thus separated is pasteurized and then pumped by positive displacement pump to the cream buffer
tank and then to the cream silo.
After ageing at 8oC for 24 hours cream is pumped to cream chilling unit in the butter section . There the
temperature of cream is adjusted to the required churning temperature (9-11 C) of continuous butter making
machine.

There are three continues butter macking machines.MB05- 2000kg/hr, CBMM1119-5000kg/hr, HMB-
800kg/hr.
Butter milk produced by churning is collected in buttermilk tank. This buttermilk
is used for washing of butter. Excess of buttermilk is stored in silo. A blender of
5 MT capacity is installed which blends butter obtained from the two CBMM.

Salt dosing is done by salt Dozer @ 10-110 lit/hr. Annatto colour is added to
brine @ 2.5%, the strength of brine being 70-80%. This is prepared in a tank and
fed to CBMM using a reciprocating pump. Working of butter is done in blender
under vacumm. Butter is then collected in butter silo of 3.5 MT capacities. Butter
is pumped into hoppers of packaging machines.

The white butter is packed in 15 kg blocks. It is utilized in ghee section for making ghee and also sent to
other co-operation for the same purpose. White butter has a shelf life of 60 days at 0⁰c or below & table
butter has a shelf life of 12 months at refrigerated storage. The butter is kept in cold store for minimum 5
days before dispatch, during which a sample of the lot is analyzed by QC lab.

Process flowchart:
Pasteurized Cream from Silos (20 hr ageing)

Cream Balance Tank (8-9 oC)

Cream Heater PHE (to adjust temp 8-10 oC )

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 Continuous Butter Making Machine (CBMM)

Churning (500-1200 RPM)

Butter Grain Butter Milk

1st Washing with BM BM Chiller (below 10 oC)

Working (30-70 RPM) BM silos

2nd Washing

Working under Vacuum (450-500 mm Hg)

Blender (17-30 RPM, Vacuum 450-500 mm Hg) Addition of Salt & Colour

Butter Silo

Packing section

10 g Blister Pack 100 g Refill pack 500 g Refill pack 400 g Tin

Butter wrapping (by vegetable parchment paper)

Secondary Packaging

CBX

Storage at below 4 oC

Process flowchart for colour & salt solution:

110 L Pasteurized Water

100 Kg Salt

2000 to 4000 ml Annatto

15min Agitation

Filtration

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 Add in to Salt dozer

Working Principle of CBMM:

The CBM machine works on the “Frits” process of continues butter manufacture, in the accelerated churning
process, there is a quick fat separation in cream (38 to 42% fat) is affected by high speed beaters followed by
draining of butter milk. In the churning section cream is subjected to high speed beater (variable speed 1200
to 1500 rpm), which guides cream to cylinder walls simultaneously causing foam formation accompanied of
fat globules tale place in cylinder during churning process, formation of pinhead sized butter granules take
place, the mixture of butter granules and butter milk falls into the screw conveyer and then into the rotating
drum where butter granules and butter milk gets separated. The butter granules fall below between a set of
rotating augers (contained chilled water jacket) where the granules are worked upon and then finally
extruded in form of a ribbon directly into butter trolleys.

 Major section of the CBMM

1. Churning section:
This section has a horizontal cylindrical with the cooling jacket and beater for churning of cream. The
churning process lasts for 2 to 3 sec during which the oil in water emulsion of the cream is broken into
water in oil emulsion existent in butter. The water content of the granules and the fat loss in the
buttermilk depend largely on beater speed and the temperature of cream at the time of churning. The
beater is driven by power transmitted from a motor through a V-belt. The speed of the beater is adjusted
so that butter granules have a suitable size when they press through the separating section.
2. Separating section:
This section has horizontally positioned cylinder resting on rollers and the other supported by a bearing.
The cylinder is fitted with paddles, which stresses the granules suspended in the butter milk to librated
most of their buttermilk content. A draining section is provided where the granules are separated from the
buttermilk and are then passed into the working section. The speed of paddles is 34 rpm.
3. Kneading section:
The kneader consists of two contra rotating augers 40 to 60 rpm that are in mesh with one another. The
front screw ends in perforated discs there are 3 agitating blend per screw operating sequentially between
the perforated discs. Spacer rings ensure the distance between the perforated discs. In the kneader the
gear unit driving the screw is driven by a v-belt through a motor. All parts of beater, draining unit,
washing unit and kneader are made up of high alloy chromium nickel steel
4. Salt dosing unit:

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 Salting for adjusting the water content or for water content or for salting the butter, water or salt solution
can be added through an opening immediately in front of the perforated plates.
Salting is carried out by injection of 50/50 salt/water slurry into butter early in working stage to avoid color
mottle in the butter a micro fined salt less than 50 micron is used. The salt slurry is loosely filtered through
wire gauze before injection. The slurry is metered to the butter maker by positive displacement pumps. The
dosing system may also be used for adding water to unsalted or slightly salted butter to maximize yield.

SPECIFICATION:
Characteristics FSSAI specification AGMARK specification
Moisture % Max. 16.0 % Max. 16.0 %
Milk fat % Min. 80.0 % Min. 80.0 %
Salt % Max. 3.0 % Max. 0.3 %
Curd SNF % Max. 1.5 % Max. 1.5 %
Acidity % L.A. - Max. 0.15 %
Total plate count Max. 5000 / gm -
Coliform coumt Max. 5 / gm Absent in 0.1 gm
E. coli Absent in 1 gm -
Yeast & mold count Max. 20/gm Max. 20/ gm
Salmonella &shigella Absent in 25 gm -
Staphylococcus aureus Absent in 1 gm -
Anaerobic spore count Absent in 1 gm -
Listeria monocytogenes Absent in 1 gm -
(table: 8.1)

Shelf life: Best before 12 months from packaging when stored refrigerated at 4 oC or below
Storage condition: At 4 oC or below

Equipments:
EQUIPMNTS CAPACITY NO. SPCIAL INFORMATION
NAME
Cream balance tank 350 lit 2
Cream chiller - 2 Temp- 8-10ºc
Plate length- 207-273
Continuous butter 2000kg/hr 3 Made- contimab
making machine 5000 kg/hr Churning speed-500-1200rmp
800kg/hr
Butter blender 1 Vacuum pressure 400-500mm hg
Butter silo 3.5 tones 1
Pasteurized water 5000 lit 1
tank
butter milk buffer 450 lit 1 Temp- 1-2ºc
tank
Wash water tank 500 lit 1 -
Fat rcovery tank 450 lit 2 -
Salt dosing unit - 1 Agitator rmp-1380/min
(table: 8.2)

Packaging machine:
1) SIG machine
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 500 gm packing – Capacity – 60-62 pack /min
2) BENHIL case packer machine
100 gm packing – Capacity – 150 pack /min

3) HASSIA butter Tub filling machine (Blister pack)

10 gm packing - Capacity – 525 packs /min
4) Tin packing machine
400 gm Tin - Capacity – 36 packs /min

Packaging machine used:

o Parchment paper – used directly for wrapping
o Carton – used for secondary packing,
a. Single laminated foil is used for INDIAN local market.
b. Double laminated is used for EXPORT.
o Tin – used for 400g, Army pack
o Card Board Box – used for tertiary packing.
o Plastic Box – used for school pack

CIP of Butter section :

CIP is done after every 24 hrs (usually in third shift).
Melting of residual butter is done with hot water for 25 min and molten butter is drained into recovery tank.
Degreasing is done for 10 min

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 Sampling plans for analysis of products:

PRODUCT PARAMETERS FREQUENCY REJECTION CRITERIA

Raw milk Plate Count 2 Tankers/ day >5000000 cfu/ml

Pasteurized Milk Plate Count, Coliform 1 sample /day >30,000 cfu/ml

from running Count
Pasteurizer Present in 0.01ml

Pathogen Test 5 samples /month Present

Railway tanker Plate Count, Coliform Every tanker >30,000 cfu/ml

milk Count
Present in 0.01ml

Sterilized Plate Count, Coliform 1 sample / shift

Flavoured milk Count
> 5 / ml
Spore Count

Various milk Plate Count Composite sample of > 40000 / g

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powders Coliform Count two / shift Present in 0.1 g

Pathogen Present

Butter Plate Count 2 samples / line / shift >5000 / g

Coliform Count >5/g

Yeast & Mold Count >5/g

Pathogen Weekly- 7 days Present

composite

Export Butter Plate Count 100 g – every 50th >5000 / g

case of each
consignment.

500 g – every 100th

case. Composite
sample for each
Coliform Count consignment >5/g

Yeast & Mold Count >5/g

Pathogen Present

Raw materials- Coliform Count Each consignment or Present in 1 g

Maltodextrin ,
Salt, Annato, Yeast & Mold Count Twice in a month Present in 1 g
Vitamins , Corn
Pathogen Present
oils, Colour

Raw materials – Coliform Count Twice in a month Present in 1 g

Sugar , TSP
Yeast & Mold Count

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 CONCLUSION
 Amul spurred India‟s White Revolution, which made the country the world‟s largest producer of milk
& milk products. In the process Amul become the largest food brand in India and has ventured in to
markets overseas.
 Amul committed produce safe and wholesome food to continually remain as the market leader by the
providing the food product delight customer expectation & best of safety.
 Here in Amul learned about the practical working at the Industrial level. The various problems that
can occur & the different ways to shoot them.
 The important of working environment and how to generate highly professional work environment.
We also learnt about how to manage the available resources to extract maximum production and the
handling of manpower to get the professional work experience.
 Working in any industry is difficult without mutual understanding, co-operate nature and team work.
 Here in Amul learned about all these things. To learn all the above things the historic unit of Amul is
one of the best place in the World.

Thank you
Khushal P.
Bhogayata

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