Industry- 1

KOLAR-CHIKKABALLAPURA DISTRICT CO-OPERATIVE MILK

PRODUCERS’ UNION LTD., (KOMUL)

➢ Brief history:

The Karnataka Milk Federation (KMF) sells product as cheese, pedha, paneer, curds and
milk under the brand name of Nandini. It is a federation of milk producers association working on
cooperative principles. Almost every district in state of Karnataka has milk producing co-
operatives. The milk is collected from farmers who are its members, processed and sold in the
market by the brand of Nandini. It is the second largest milk co-operative in India after Amul.
Chairman- Balachandra Jarkiholi.

The first of the dairy co-operatives that make up KMF started in 1955 in Kudige, Kodagu
District. KMF was founded in 1974 as Karnataka Dairy Development Corporation (KDDC) to
implement a dairy development project run by the World Bank. In 1984 the organisation was
renamed KMF. KMF has 14 milk unions throughout the Karnataka State which procure milk from
Primary Dairy Cooperative Societies (DCS) and distribute milk to the consumers in various urban
and rural markets in Karnataka State with 1,500 members.

➢ Functional Departments:
1) Procurement and input department
The operational efficiency is reflected on procurement prices paid to the member producers.
KOMUL is offering the most remunerative milk procurement price to member producers. Annual
average Milk procurement for the years 2009-2010 is 7.30 lakhs liters per day. During the seasonal
time it has procured to the peak of 8.0 lakhs liters per day.

2) Production department
The production department of the Kolar dairy performs the function of developing
procedures to transform a set of input elements of raw material like milk, money, machine
into specified output like curds, butter, ghee, Peda, masala butter milk etc. in assigned
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quality and best in order to achieve the organizational goals successfully.

3) Marketing department
KOMUL has a well-established marketing department, under the control of the marketing
manager. The manager is responsible for marketing and sales of milk and milk products.
The manager is responsible for selling to the target markets, framing the plans
and policies to achieve the marketing goals and manager is also responsible for forecasting
the demands for their products in the market.

4) Finance department
Finance department is very important in an organization. It is not just confined to raising
funds, but extends beyond it to control the over utilization of funds and helps to monitor
the utilization of funds rose. This function influences the operation of other essential
functioning areas of the firm such as production, marketing and personal.

5) Administration and personal department

The administrative manager heads the administration department. The manager comes
under the general manager. The administrative department of KOMUL holds all the
official work. The administrative manager reports to the general manager, then the general
manager to the managing director (who is the chief of administrative department).
6) Quality control department
The quality control department in the plant performs the function of using the best raw
materials and other inputs, measuring and checking for maintaining then assured standards.
KOMUL represent quality, purity and freshness. The quality policy of KOMUL is to maintain
a leading position and also to build high level of customers over
their products by providing high consumer surplus

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 ➢ Production Process:

At present the dairy is equipped with a processing capacity of 6.0 LLPD. Packing and selling
about 5.0 Lakh liters per day. Apart from this, the dairy is producing Curds, Spicy butter milk,
Peda(Regular,Kesar) , Cashew Burfy, Paneer, Nandini bite, Mysore Pak,Sweet Lassi, Khova and
Ghee. In its fold, there are chilling centers located in Hunsur and HD Kote. For the past few years,
the milk procurement and sales increased beyond our expectation.

Cows are milked using vacuum cups which are attached to the cow's teats. The milk is sent through
stainless steel pipes to large refrigerated vats, then stored at 5°C or less. Within 48 hours, milk is
taken in tankers to a milk factory where it's pasteurised and homogenised.

• Pasteurisation:
This technique heats milk to 72°C for no less than 15 seconds, then cooled immediately to
destroy any harmful bacteria and micro-organisms. This also extends the shelf life.

• Homogenisation:
Milk is put under pressure through fine nozzles, which evenly disperses fat globules. This stops
the cream separating and rising to the top, allowing a more consistent texture and taste. Some
manufacturers produce unhomogenised milk for people who prefer the cream to separate and rise
milkholder.

Today's farm technology, cattle management and factory methods allow for greater consistency
of milk, and milk composition can be adjusted for year-round consistency. Milk composition is

standardised so elements like fat content are made consistent no matter the season or breed of cow
the milk comes from.

The composition of milk is governed by the Food Standards Australia New Zealand Food
Standards Code. These standards are consistent with international standards – milk consumed in
nearly all developed countries will have very similar standards. The Code allows manufacturers to
add or withdraw milk components to standardise the composition of milk sourced from dairy
farms, as required, to produce nutritionally consistent and safe products. Under the Code, the
standard for packaged full-fat milk requires that it contain at least 3.2% of fat and 3.0% of protein

• Centrifugal separation:
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This removes some or all of the cream to make reduced-fat, low-fat or skim milk. Skim milk solids
can be added back to improve the test and texture, and increase nutrients like protein and calcium.
• Ultrafiltration:
This moves milk across a membrane under moderate pressure, which holds back protein, fat
globules, and a large amount of calcium complexes.

Water and lactose (the sugar in milk) pass through, leaving behind a very protein and calcium-
rich product. The fat content can be adjusted to suit consumer preference.

• Reverse osmosis:

This is very similar to ultrafiltration, but the membrane holds back most of the milk solids and
only lets water pass through. Lactose remains in the product. There is no impact on flavour.

• Ultra-osmosis:

This is a combination of ultrafiltration and reverse osmosis, but it holds back milk solids and
allows both water and salt to pass through.

• Spray drying:

This removes water from milk in order to make powdered milk products. Milk’s nutritional value
remains the same.

• Permeate:

In order to standardise milk year-round, some manufacturers use a process called ultrafiltration
where a membrane filter separates certain elements from milk Milk is passed through a very fine
filter, and the lactose (milk sugar), vitamins and minerals that filter through are referred to as
"permeate". Permeate is a technical term which applies to all membrane filtration processes used
across food production and other industries. For example, when producing apple juice the fruit is
put through a similar filtration process where permeate is the clear juice, we end up buying and
consuming.

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 ➢ Learning Outcome:

The goal was to provide students an inside look at how Nandini works and to provide them
the opportunity to learn via hands-on experience about milk collecting, transportation, testing,
processing, and manufacturing of other dairy products. The technical instructor began by
describing the milk procurement procedure in order to make pupils aware of and better
comprehend the operations. He explained how the milk is collected at a very low temperature using
insulated road/rail tankers, preserving the freshness of the milk. Silos are the containers used to
collect milk.

The students ended their visit by having a look and understanding the functioning of the
processing units which the instructor had discussed with the students through video while he was
describing the whole functioning of the plant. Exposure to Solar Panel & Nano Water tank was
very exciting & fruitful for students.

The visit was very useful for the students as they could now relate their theoretical knowledge
with the practical exposure which they have gained after visiting this plant. It was a good learning
experience for the students.

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 INDUSTRY-2

ANAND MILK UNION LIMITED (AMUL)

➢ Brief History:

Amul is an Indian dairy cooperative society, based at Anand in the Indian state of Gujarat.
Formed in 1946, it is a cooperative brand managed by a cooperative body, the Gujarat Co- operative
Milk Marketing Federation Ltd. (GCMMF), which today is jointly owned by 36 lakh (3.6 million)
milk producers in Gujarat, and the apex body of 13 District Milk Unions, spread across 13,000 villages
of Gujarat. Amul spurred India's White Revolution, which made the country the world's largest
producer of milk and milk products.
Kaira District Milk Union Limited (later renamed to Amul) was founded in 1946 through the
efforts of three men, Tribhuvandas Patel, Verghese Kurien and Harichand Megha Dalaya. Amul's
foundation was a significant contributor to the white revolution in India.
Tribhuvandas Patel under the guidance of Sardar Vallabhbhai Patel became the founding
chairman of the organization and led it until his retirement in 70s. He hired Dr. Verghese Kurienin
1949. He convinced Dr. Kurien to stay and help with the mission. Under the chairmanship of
Tribhuvandas, Dr. Kurien was initially the general manager and helped guide the technical and
marketing efforts of Amul. Dr. Kurien was the chairman of Amul briefly after Tribhuvandas Patel died
in 1994. Kurien, founder-chairman of the GCMMF for more than 30 years (1973–2006), is credited
with the success of Amul's marketing. Amul has ventured into markets overseas.

➢ Functional departments:

AMUL dairy has five main departments like finance, personnel, commercial, milk procurement
and production.

Financial department: is Asia’s no. 1 and world’s second number co-operative dairy. It has
large market and dairy network in every state of India and across the India, like central Asian
countries, Bangladesh, Thailand, Indonesia, Malaysia, Singapore, etc. It was started with 250 liters
of milk and 2 societies and now, it produces 10 lakhs litters milk per day and has 1113 societies
and more than 6 lakes farmer members. It produces milk and milk products. The main motto of
AMUL is to help farmers. Farmers were the foundation stone of AMUL. The system works only
for farmers and for consumers, not for profit. The main aim of AMUL is to provide quality products
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to the consumers at minimum cost. The goal of AMUL is to provide maximum profit in terms of
money to the farmers. Vision of AMUL is to provide and vanish the problems of farmers (milk
producers). The AMUL apparition was to run the organization with the co- operation of four main
parties, the farmers, the representatives, the marketers, and the consumers.

The basic philosophy of production management is to launch a frontal attack on direct costs
and effective use the availability manpower weaving new techniques in to the whole to keep the
production unit efficient and developing production management is the process of planning,
organizing, directing and controlling. The Amul is started with only 250 liters of milk per day. But
now Amul collect average 9 lakhs of liters milk per day. At the initial stage, Amul has not any
problem regarding milk, but in the winter season there was excess supply of milk. So, Amul has
to sell out that excess milk at the low price or Amul hasto faceloss. To removing these problems
Amul take decision to set up a plant to process the surplus milk butter and milk powder.

➢ Production process:

• Butter Process: Amul butter is made from Butter common salt, permitted natural
color. Annatto capacity of 50,000 K.G per day. In that section, there is a machine
called continuously bath. It churns the milk & separates butter milk. Then the second
process starts. There the butter is made. Also, the butter milk is considered as by
product & not a waste. In the second process the butter is processed by water & later
only butter is left in the plastic tube. The yellow color is very pleasant. Amul butter is
very delicious again here too not policy is followed. In this section the room
temperature in 20 Celsius but after packing the butter is manufactured at 8 Celsius. It
is transferred through trolley. It is packed in different sizes of packets 100g.m, 200
gm., and 500g.m. 100 gm. packets made 100 packets per mint. 500 G.M. packets made
35 packets per mint. There are special packing machines for this it is called a BLOCK
CUTTER MACHINES. After a packet is packed if falls into a box billed it is moved
into the trolley work is done 3 shifts

• Dark chocolate: The journey of chocolate starts with the harvesting of cocoa trees.
The fruits which are tufts broken and beans are separated from each cocoa fruit. Now

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 separated beans are formatted for 3 to 4 days in shaking. After fermentation beans are
sun-dried in the open for a few days. Next these dry beans are shifted to the local
cocoa factory for further processing. Roasting makes perfect flavor and taste in cocoa
beans.

• First cocoa chips are put into multi machines where high temperature melts the chips.
At the same time, cocoa butter breaks for melting. Now this melted cocoa butter and
cocoa mass are stored in big steel tanks. Sugar is an integrated part of chocolate that
needs careful handling. Sugar is a port in big safe to remove any foreign material
present. From here this moves to sugar silo.

• All these ingredients go to the wings silo. Then the ingredients mixed in a continuous
mixture this source to reduced human handling. As per the production plan, different
ingredients like milk powder, cocoa butter, and cocoa powder are controlled and sent
to the mixing line. A continuous mixture finally blended with required ingredients
thoroughly prepared.

• Next, this mix is stored in a buffer tank through a palm. Now, this mixture goes to the
refining station. Refining is the most important step to create a silky-smooth texture.
Refining is the process of reducing the particle sizes of both cocoa solids and sugar
crystals in the finish chocolates. In this process temperature and moisture are
controlled all trough.

• Now, this mix moves to a setup conch the process involves heating and mixing of the
chocolate makes for a few hours. At this stage, my new quantity of lecithin which is
a kind of vegetable source fat is added. Lecithin is very important to chocolate because
it produces viscosity improve the flowability of the chocolate and can improve self-
life as well. During couching, the chocolate heated at high temperature to remove
unwanted flavour.

• Now from the conch chocolate mixture is stored in silos to send to the moulding
station. However, before sending it to the moulding station the chocolate mix is sent
to a tempering machine for recrystallization to provide smooth consistency. The
recipe for each variety of chocolate is programmed blended mixes stored in the
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 chocolate tanks from where flows continuously from the line.Mounding is the final
procedure for chocolate processing. This step allows the blended mix to cool and
harden into different shapes of all the mould. The automatic mould distances dispose
of the moulding trays on the conveyer. Different size and shape chocolates have
different moulds. Every mould passes through a mould camera checking station. At
vertical distances station, the trays automatically placed in empty slots. Next, these
trays pass- through heating and cleaning station where the chocolate drops on the
edges of the tray is removed.

• Now, these trays reached the rotary depositor station to get filled with a precise
quantity of chocolate mix. The mix is poured in depositor from the tank and at the
bottom, a competitive control system poured through the nozzle in the moving
moulds. One by one all trays are filled with chocolate. Now the moulding trays go
through the cooling chambers where the line supervisor ensures the right temperature
for cooling to get perfect consistency and the texture of the chocolate.

• These trays stay for a certain time on moving conveyer and it gets cooled at a
temperature of 4 – 8 degree C. Then the chocolates go through a metal detector. Then
colourful raping paper are fade into the packing fibres. The folding machine folds the
Nutley so the chocolate remains airtight. Next, the bars are picked up by a Roberts
arm and drops on a packing conveyer.

➢ Learning outcome:

Amul's founding has not only produced a long-lasting national brand, but it has also altered
India's dairy industry and given back to underprivileged communities in terms of socioeconomic
impact. According to data, the underserved account for 74% of India's population.
Chocolate, which is one of the most loved products among all the age groups, it was a great
experience to learn about the manufacturing process of chocolate. Due to the pandemic the
industrial visit of Amul was conducted virtually, nevertheless it was an enriching experience. I
have learnt about the history of Amul, how it was incorporated and its significance for farmers to
be self-reliant. Millions of livelihoods in India depends on Amul. From milk, ice cream to
chocolate, Amul has created a great brand value among the Indians.
All its products are pocket friendly which makes most of the Indian consumer to purchase it and

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most of its consumers are loyal to its products, maintains the good quality of the products all the
time. We were shown videos of how dark chocolate is manufactured and how it is supplied to the
different consumers across the country. I learnt the different stages in the manufacturing from the
stage of collecting cocoa beans to how it is packed.

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 INDUSTRY 3:
UNIBIC INDIA LTD

➢ Brief History:

UNIBIC a brand, which is heading successfully in the last 10 years, is of Australian

origin. With the thought-provoking line “Why have a good day when you can have a great day!”
they started their journey and by their delicious and delightful cookies, they have owned the
heart of thousands. Unibic Foods Pvt. Ltd. started in 2004 and it headquarter is situated in
Bengaluru.

It is a joint venture of cookie maker Unibic Australia and Dhruv Deepak Saxena who is
a Melbourne-based serial entrepreneur. Hence it is a subsidiary of Unibic Australia Pvt. Ltd.
Initially, they set up their business by importing cookies from Australia and by the end of 2005
they set up their manufacturing unit in India. A five-year deal with Amalgamated Bean Coffee
Trading Co. to ensure its supply to the Cafe Coffee Day outlets was the first step towards its
branding. In addition to it, an investment of 7.5 crores for advertisement in the media also played
a significant role. Nikhil Sen, the Managing Director of UNIBIC believes that they are
somewhere in between Britannia’s good day and the expensive cookies. He has 20 years of
experience as Chief Operating Officer in Britannia till 2005. After that, turn over concentrated
on popularizing the Australian based brand Unibic in India to bring about changes in the sector.
By the financial year 2013 the reached up to 100 crores of revenue and it seems that they had a
turnover through the years.
They have a very high team spirit and efficient employees. They believe in creating futures
by working hard for it in a fruitful way. Everybody is passionate about their work and they are
more centered to the “we can and we will” attitude. They consistently focus on enhancing the
entrepreneurial skill of their workers. So that they will be able to compete in the global race by
taking advantage of every single chance. They are on the way to prove themselves as leading
cookies maker.

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Production Process:

• The Unibic factory brings the science of food technology to the art of creating
delicious cookies. The facility located in Bangalore is the largest integrated
cookie manufacturing plant in the country, with 5 production lines and a capacity
of 30,000 tons a year.

• Wire-cut, not molded Unibic was the first in India to manufacture cookie with
wire-cut technology. Thanks to the unique wire cut technology along with use of
richer ingredients and dough with softer consistency, Unibic is able to produce
cookies with real home-made taste and feel coming raw materials, such as flour,
can be measured to insure proper quality and to verify vendor specifications. The
mixed dough can be analysed to insure that individual ingredients were added in
proper proportions or that major ingredients were not missed. Finished product
can also be analysed for moisture to verify that the process is operating optimally.
Improper moisture content in the cookie could lead to poor taste and possible
bacteria growth. A proper analytical testing procedure can help to insure
consistent product quality and to save money by reducing re-work and improving
cycle time.

• Currently, many cookie manufacturing companies are either performing little

analytical testing or are using time consuming methods that do not provide “real
time” analysis. Little or no testing is performed on incoming raw materials.
Manufacturers tend to rely on the vendor to provide them with the proper
ingredients. This is a recipe for disaster as there is no proof that the vendor is
sending the proper material or a particular quality. Little is also being done at the
mixer. Manufacturers trust that all ingredients are added properly based on
weight.

• Moisture content is analysed as the product comes out of the oven using a variety
of methods. Primary methods to analyse moisture include a 16 hour vacuum oven
method or a moisture balance. Both methods use loss on drying to measure
moisture content. The drawback to the vacuum oven method is that the testing
time is 16 hours, meaning this test will have no impact on real time process

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 control. The moisture balance can analyse a sample in approximately 15 minutes,
but it almost 2-3 times less accurate than a vacuum oven.

• NIR analysis has long been used in the baking industry to analyse incoming
ingredients, intermediates and finished products. At-line NIR analysers can
supply accurate moisture, total sugar, fat, protein and many other properties at
any stage of the process in 30 seconds. This information enables more efficient
production, more consistent products and higher profits.

➢ Learning outcome:

Unibic has a gained a lot of popularity in the Indian market from the last few years. We learnt about Unibic
in detail. Some of the countries to which the company makes its exports are Australia, China, UAE, Qatar,
Bahrain, Oman, Jordan, Kuwai. They have capitalised on their marketing and packaging style to attract
the consumers. They have given consumers a wide variety of options to choose from. Some of its flavours
are butter cookies, fruit and nut, choco-chip cookies, oats, milk cookies etc. We had the opportunity to
learn about the different stages of how a cookie is produced. It goes through various stages like dough
making, fermentation, cooling and testing process after which the cookies are packed and supplied to
different retail outlets in the country.

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 CONCLUSION

The main objective of the industrial visit is to provide an opportunity of undergraduates to

identify, observe and practice how management is applicable in manufacturing industry.

The industrial visit to KOMUL, Amul and Unibic was a wonderful visit from the college.
The visit was highly educational, helped the students giving a deep understanding about its
functional departments like finance, marketing and production and also on how the organization
ran successfully. The visit high lightened about the process of manufacturing milk, ghee, butter,
butter milk, chocolates and biscuits of different varieties and also the problems encountered
during the process.

The three industrial visits were lot more useful throughout the 2nd year and final year of
the college. Students has gained lot of knowledge and experience needed to be successful in a
great challenge of industrial world in future.

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