Internship Report of Masooma

INTERN
NSHIP REPO
ORT ATT
Noon Pakisttan Ltd wal, Saargodha
d. Bhalw

SUBM
MITTED TTO:‐
M
MALIK IZZHAR HU
USSAIN
(G
G.M OF NURPUR)
MITTED B
SUBM BY:‐
M
Masooma
a munir
BS((Hons)FO
OOD SCIENCE A
AND TECH
HNOLGY
Y

DURA
ATION OFF INTERN
NSHIP:‐
ONTHS (MARCH AND AP
2 MO PRIL)

1
Sr.# Outlines
1. Acknowledgement, Abstract
2. Introduction
3. International Certifications
4. Departments
5. Milk collection system
6. Milk Reception
Test Performed in Reception Lab

Organoleptic tests
7. Qualitative tests
Quantitative Tests
Adulteration tests
8. Dairy processing
Pasteurization section
9. Flow diagram of pasteurization

Pasteurization step
Standardization and toning
10. Powder plant
Butter Section
Flow diagram of ghee and butter
White Butter
11. Yellow Butter
Salted Butter
Slightly Salted Butter
Shelf life
Cheese
12. Cheddar Cheese

Spicy Cheese
Mozzarella Cheese
13. UHT Section
2
UHT flow diagram
UHT Process Steps
Aseptic Packaging
Capacity
14. UHT Lab Analysis
15. Tests For Insuring Packaging Safety
16. Keeping quality lab
17. Microbiology lab
CIP (Cleaning In Place) Section

18.
Function Of Various Cleaning Agents In CIP
C.I.P STEPS
19. Technical Data sheet
20. Suggestions

3
ACKNOWLEDGEMENT

In the name of Allah who is the most merciful and beneficial. All and every kind of praises is
upon Allah Almighty, the strength of universe, ever help in darkness and difficulties. All and
every kind of respect to Holy Prophet Muhammad (PBUH) for being a unique,
comprehensive and everlasting source of guidance and knowledge for humanity
I am also thankful to the general management of NURPUR, MALIK IZHAR HUSSAIN , all the
Managers, officers and employees of Noon Pakistan Limited for their co‐operation and
support during my internship.
I would like to pay sincere thanks to my Director Dr. Sarfraz Hussain, Institute Of Food
Science and Nutrition, UOS of his sincere cooperation during my internship.
Words do not come easy for me to mention the feelings of humble obligations towards my
sweetest and affectionate parents who have been models of human values for me, who
always encouraged me throughout my career and remember me in prayers and always
wished to see me glittering high on the skies of the success.
4
ABSTRACT
I did my internship in Noon group of industries. This report covers the activities and
responsibilities that I performed during my internship at Noon diaries. Noon dairies are the
National Company with a burning passion to take on the national market. In the culture of
dairy industries Nurpur has distinguished place in Pakistan.
The report starts with the prologue of the company, the intention, its products, and its
structure covering all the departments, furthermore it includes information about labs and
processing section of different products. The assignment was to work with a professional
organization to get professional experience of the office routines and the working of the
organization at the initial level. I worked there as an intern for the 2 months. I learned a lot
of things related to its product and there production. I leant many other things that will help
me a lot when I will start my professional career. I was assigned to work from reception lab
where I performed practices related to raw milk which includes qualitative analysis,
quantitative analysis and adulteration tests on milk to check the quality of milk in order to
maintain the high quality of milk and products. Then I was assigned in Quality control lab in
Chemical Lab. All the analysis regarding physical and chemical properties of line and finished
product were performed. Then I visited different sections of processing area started from
processing pasteurized milk and then processing of butter, Desi ghee, cheese section UHT
milk and processing of fruit drinks and nectars. Then I learnt to testify UHT products in UHT
Lab. Then I started my work in Microbiological Lab In order to ensure a microbiologically
safe product the Quality Assurance department has a well‐established Microbiological
section for analysis of line and finished product. Here I performed tests on different dairy
products juices to ensure microbiologically safe products.
All these areas are hygienically clean. They are properly sanitized regularly. Members of
processing section wear lab coats and cap to maintain hygienic conditions.
5

NOO
ON DAIRIES ´S CHR
RONICLE AND PRO
OLOGUE
Noon Pakk limited (Nooon Dairies) is part of No
oon Group o
of Industriess started by N
Noon
Dynasty in 1968. NURPUR is the brand namee of NPL. Thee NPL is producing a num mber of food
d
productss both for consumers and industrial users.
Nurpur stands for with Health, EEnergy and Taste, beingg the vital in
ngredients. N
National team
of collectors, packerrs, processors and emp
ployees are committed
c tto consisten
ntly providin
ng
safe, high‐quality Hyygienic Milk,, Pure Juicess, Healthy N
Nectars, Buttter, Cheese, milk powdeer
and otheer dairy pro
oducts whilee protecting the environment in which
w these products arre
manufactured and processed. Nurpur got the award
d of “Brand
d of the year 2008” fo
or
ng best quality Butter in competition
producin n held by ISO
O Certificatio
on Companyy.
This won
nderful succeess is due to
o strategic planning of achieving goaals through devoted harrd
work and
d commitme
ent.
Nurpur iss dealing in ffollowing product rangee;
i. D
Dairy Product
ts
ii. Processed Pro
oducts
iii. Frruit Products

6
COMPA
ANY AGEES:
1972 Milk powder
p SMMP & FCM MP, Butteer oil(Ghee),Butter
1984 Cheesse(Cottagee & Processsed Chedddar cheese)
1998 Pasteuurized millk
2003 Butterr 10g, Jam
m 15g(strawwberry, apple), Maarmalade,
Honey y
2004 UHT Cream,
C U
UHT Milk (brik)
(
2005 Flavorred Milk(SStrawberrry, Mangoo)250 ml
2006 Nectars & Puree Juices 10000ml
2008 Fruit Drinks 2550ml,ISMP P,FCMP,M Mozzarellaa Cheese
2009 Nurpu ur Chai Mix(Dairy
M W
Whitener))(250ml,2000ml)
Juicess & Nectarrs 200ml
2010 Flavorred Milk(CChocolatee, Badam Zafran)
Z
2011 YOG
GO YOGO
O Drinkingg yogurt
NTION OF
INTEN F INDUST
TRY:
Nurpur iss committedd to supply the

t consumeer and our cuustomers witth the finestt, high-qualitty
products and to lead
d the industrry in healthyy and nutritiious productts. Nurpur supports
s thesse
goals witth a corporatte philosophhy of adherinng to the highhest ethical conduct
c in all
a its businesss
dealings, treatment of
o its employyees, and soocial and envvironmental policies. Thhe Companyy's
ment is baseed on increeasing revennue by improving saless strategy, focusing annd
commitm
investingg in profitab
ble and poppular brandss and to proomote mutuual trust witth customerrs,
supplierss, employeess, shareholdeers and comm
munity.

7
INTERN
NATIONA
AL CERTIFFICATION:
NOON PA AK LIMITED is the only ddairy compan ny that undeertakes 21 rigorous quality tests to

ensure th
he best quality of the en
nd products. This is the o
only Food Co ompany in Pakistan
which haas following international certification.
1 ureau Verittas)
ISO-22000:2005 (Bu
2 ISO‐900
01:2000 Ce
ertification
n
3 Halal Cerrtified (Bu

ureau Verittas)
4 PSQCA

8
5 HACCP

.

RTMENTS
DEPAR
Mainly nurpur
n possessed 5 de paartments whiich are;
1. Adm
ministration
n block;
In this, tthese departm

ments are included
 Mannagement
 Hum
man resourcees
 Marketing
 Finaance
2. Quallity assuraance deparrtment;

In this, thhese departm
ments are inccluded
 Receptiion lab
 Qualityy control lab
 UHT LA
AB
 Microbiiological labb
9
3. Production department;
In this, these departments are included
 Reception
 Pasteurization
 Standardization
 Ghee & butter making
 Milk powder production
 UHT
 UHT milk
 UHT drinks & nectars
 UHT cream
 UHT chai mix
 Packaging of jam & marmalades
 Cheese making
4. Maintenance department
 Electrical
 Mechanical
 Utilities
 Maintenance of compressor
 Ammonia compressor
 Ice water compressor
 Air compressor
 Maintenance of boilers
5. Milk Procurement Department (MPD)
The Milk Procurement Department (MPD) has responsibility to collect the milk from the area
& maintain the supply the milk in the adequate quantity.
MPD ensure and streamline the regular supply of milk according to quality standards and
budget requirements of NOON DAIRIES.
10

MILK RECEPTION AND

QUALITY CONTROL LAB

11
MILK COLLECTION SYSTEM
According to following system the collection of milk in NOON DAIRIES takes place,
Farmer Mini Supplier Contractor
↓ ↓ ↓
VMC VMC VMC
↓
Sub Center
↓
Main Center
↓
Factory
VMC is the abbreviation of Village Milk Collection Centers. In VMC’s from Farmers, Mini
suppliers and Contractors the collection of milk takes place. These VMC’s provide milk to
Sub Milk Collection Centers. From these Sub Milk Collection Centers the milk is providing to
Main milk Collection Centers like Bhera, Mandi Bhawaldin, and Sahiwal Centers etc. These
main centers have the chilling facilities. In these main centers the basic analysis of milk takes
place for checking their quality. After that the good quality milk is transferring to the
Factories via Milk Collection Tankers.
MILK RECEPTION
When the tanker enters into the NPL premises, a token is a lot to driver that has following:
1 Name of the supplier/Area.
2 Number of the tanker.
3 Token # allotted by the gate keeper.
12
4 Anything attached to the truck e.g. Tire, bag.
Then the truck goes to the parking area from where sample is taken by the Reception Lab
technician. Then reception lab technicians perform the tests needed, if the results are ok,
milk is graded as A and B, the stamp (ACCEPTED) is marked on the token, while C grade milk
is rejected then the accepted truck goes to the Weigh Bridge where it is weighed. Then truck
comes to the receiving area where finally the reception of the milk takes place by the
centrifugal pumps, chilled at 10°C and is stored into the silos. Then the empty truck again
goes to the weigh Bridge & again weighed & finally goes out of the NPL.
Weight of milk = Total Weight ‐ Empty tanker weight
Volume in liters of milk = weight in kilogram /specific gravity of that milk
Reception Lab Activities
Reception lab is a place where the composition of milk and milk adulteration is usually
determined by a number of tests on arrival and adulterated milk is not accepted.
A) Sampling of Raw Milk
Milk is thoroughly mixed with the plunger for 1‐2 minutes, then the sampling is done by lab
technician with the help of sampler, called knoppy.
Types of Sample:
Composite Sample:
Mixed sample is taken from all the portions of a tanker in equal amount. The amount of
composite sample is 1000ml.
Separate Sample:
Sample taken from a single portion of the tanker is called separate sample. The amount of
separate sample is 1000ml.
13
TESTS OF MILK IN QUALITY ASSURANCE LAB
Reception Lab
In reception lab 4 types of tests are performed which are given below;
1. Organoleptic tests
2. Qualitative tests
3. Quantitative tests
4. Adulteration tests

Quantitative Tests:

o Salt test
o Fat test
o Lactometer reading
o Solid not fat (SNF)
o Protein test
Adulteration Tests
It includes determination of
o Glucose
o Sucrose
o Detergent
o Starch
o Urea
o Sorbitol
o Boric acid test
o Formalin test
14
ORGANOLEPTIC TESTS
 Taste
Check taste of milk. It should not give odd taste.
 Smell
Take in the aroma of milk. It should be of milky odour.
 Appearance
Milk should be of uniform color and texture.
QUALITATIVE TESTS
1- To check temperature of milk

Apparatus:
Glass Thermometer, glass beaker
Procedure
Thoroughly mix the sample to get representative sample.
Dip calibrated thermometer bulb in it in such a way that it should not touch the
bottom and walls of beaker.
Allow to stay thermometer in sample for a time that no more move up and down.
Note the reading of thermometer.
Temperature of milk should be between 4 - 6 degrees Celsius.
Precaution:
The thermometer should be clean and properly calibrated.
2- pH:
pH of milk is checked by dipping pH meter in the milk.
For raw milk the best pH is between range of 6.60 ‐ 6.80
15
Precaution:
The pH meter should be clean and the probe should not touch walls of beaker or its bottom.
3- Clot on boiling test:
Scope:
It is done to check the quality of milk for its fitness for processing.
Apparatus
Test tube, spirit lamp, pipette, test tube holder.
Procedure:
Take 4‐5ml milk sample in test tube with pipette.
Heat the milk on burner spirit lamp to boiling point.
Result:
After boiling if test tube is clear note it as "‐ve" and if clots appear then note it as "+ve".
4‐ Determination of Acidity
Apparatus:
Pipette, beaker and burette
Procedure:
Take 9ml milk sample in beaker with help of pipette.
Add 3‐4 drops of 1% phenolphthalein solution, as indicator.
Slowly add 0.1 NaOH from burette drop by drop with constant stirring of sample in beaker.
Titrate till light pink end point.
Note the burette reading and multiply with 0.1 to get acidity
16
5- Alcohol precipitation test:
Scope:
To Check the Heat Stability of milk during heat treatment.
Apparatus:
Test tube, pipette
Reagents:
Ethanol 68%
Procedure:
Take 2ml milk sample with the help of pipette in a clean dry test tube.
Add 2ml of ethanol in test tube.
Invert the test tube 2‐3 times.
Observe the grain or precipitate formation along the walls of the tubes
Results:
If precipitation occurs, then record the test as "+ve"
17
QUANTITATIVE TESTS
1‐ Determination of Fats in Milk

Apparatus:
Butyrometer, pipette (10.94mm), Butyrometer stopper, Butyrometer stand, Centrifuge

machine, Auto measure,
Reagents:
Sulphuric Acid, Iso‐Amyl Alcohol
Procedure:
Warm milk sample up to 40 °C and thoroughly mix it.
Cool it at 20°C.
Measure out 10 ml of sulphuric acid in a butyrometer.
Add 10ml of milk and 1ml of isoamyl alcohol into butyrometer.
Insert stopper into the butyrometer.
Mix the content well by inverting the butyrometer several times.
Place butyrometer in centrifuge machine (1100 ppm for 3 min) for raw milk.
And 10 min in case of homogenize milk.
Note the fat column in the neck of butyrometer.
Express the result in percentage of fat in milk.
18
2‐ Determination of %Salt (NaCl) in Milk:
Apparatus:
Burette, pipette, beaker (100ml), flask (1000ml)
Reagents:
0.1N silver nitrate solution,
10% potassium chromate solution
Procedure:
Take 9ml well mixed sample of milk in a 100ml beaker with pipette.
Add 3‐4 drops of potassium chromate solution being used as indicator.
Titrate the sample against 0.1N AgNO3.
Before titration make sure that level of 0.1N AgNO3 is at "0" mark.
Add 0.1N AgNO3 solution drop by drop from burette until light brown color appears.
This is the end point and no more AgNO3 should be added.
Note reading from burette.
Calculate the percentage as below:
Number of ml of N/10 AgNO3 solution used multiply by 0.065 = %salt

19
3‐ Lactometer Reading
Apparatus:
Cylinder
Procedure:
Heat the sample to 40°C and then is cooled down at 20 °C.
The cylinder and lactometer are rinsed with milk, cylinder has capacity of 300‐350 ml. now
pour milk in cylinder and then place lactometer.
Then add little more milk to remove the foam and then check the reading. If temperature of
milk is 20 degrees Celsius then reading is correct but if increases or decreases then add or
minus 0.2per each degree rise or fall in temperature.
For raw milk LR reading should be in range of 19‐28.
SNF Calculations:
For SNF calculations we require to know the values of LR and FAT.
We can find SNF of milk by putting values in the formula
(LR/4+0.72)+0.22 multiply by FAT%)
20
4) Determination of Protein
Apparatus:
Pipette, Stand, Beaker, Burette
Reagents:
0.1N NaOH, Phenolphthalein, Formalin
Procedure:
 Take 10ml milk in beaker.
 Add 1ml Phenolphthalein indicator.
 Titrate it against 0.1N NaOH
 Then note reading as V1 then add 2ml of formalin and stay for 5 minutes.
 Then titrate against 0.1 N NaOH (note reading for 0 – V1).
 Then take 10ml distilled water and add 1ml phenolphthalein and titrate against 0.1 N
NaOH and note it as V2.
Formula:
V1‐V2*1.94 protein
If on the basis of SNF is calculated by
Answer of above multiply by 9/SNF of milk.
21
ADULTERATION TESTS
1‐ Detergent Determination in Milk

Purpose:
To determine the adulterations in the milk like carbonates and bicarbonates.
Apparatus:
Petri dish, Pipette
Reagents:
10% Rosalic Acid, 95% Ethyl Alcohol
Procedure:
 Take 5ml of milk sample in a clean and dry pipette.
 2) Then add 5ml of 95%Ethyl Alcohol in it.
 3) At last 2‐3 drops of rosalic acid in it.

Result:
Positive Test:
If the color is blue then test is positive.
Negative Test:
If the color remains unchanged like the color of Rosalic acid then
the test is negative.
22
2‐ Starch Determination
Apparatus;
Pipette, Petri Dish, Water bath, beaker
Reagents:
0.1 N Iodine: Weigh 12.69g Iodine and add sufficient quantity of ethanol to make total
solution 1000ml.
Procedure:
 Take 4‐5 ml of milk sample in the clean and dry test tube.
 Warm the milk sample near to boil in the water bath.
 Pour the milk sample in the Petri dish.
 Then add 2‐3 drops of Iodine in the milk sample.
 Shake the Petri dish slowly and gently.
 Carefully observe the color of Petri dish.
Results:
Positive Test:
If the black or dark blue spots appear the test is positive.

Negative Test:
If no black spots or precipitations then test is negative.
3) Glucose Determination in Milk
Apparatus:
Glucose Strip, Beaker
Procedure:
 Take the milk sample in the beaker.
23
 Dip the Glucose strip in the beaker containing the milk sample.
 Observe carefully the color of the glucose strip.
Result:
Negative:
If color is yellow then test is negative.
Normal:
If color of the strip changes to light green then glucose contents are in
normal range.
Positive:
But if color is highly green then it is positive.
Urea Determination in Milk
Appratus;
Volumetric flask, Test Tube, Pipette
Reagents:
 Phenol Red
 Urease 0.2%: Take 0.2g urease and 10 ml of K2HPO4 (10% in distilled water) and add
sufficient quantity of distilled water to make total solution 100 ml.
Procedure:
 Take the 2ml mixed milk sample in the test tube.
 Add 2ml urease solution in the test tube containing the milk sample.
 Add 0.2ml phenol red in the test tube containing the milk sample and urease
solution
 Incubate the test tube at 40‐45˚C in the water bath for 10 min.
 Observe carefully the color of the test tube contents after incubation.
Result: Negative:
24
If color of the test tube contents does not change (i.e. if it retains the
previous color) then test is negative.
Positive:
If color of the test tube contents changes from orange to pink then it is
positive.
1‐ Sorbitol Determination of Raw Milk
Apparatus:
Pipette, Test Tube
Reagents:
Reagent A (NaOH), Reagent B (Ferrous Sulphate)
Protocol:
 Take 1 ml of milk sample in the clean test tube at 15‐ 20˚C.
 Then add 1ml of reagent A and 2ml of reagent B in the test tube containing milk
sample.
 Shake well and stay for 3 min.
 Carefully examine color, sticking and settling of test tube contents.
Results:
Positive Test:
Light yellow color
Sticking with wall of test tube.
Settling of viscous solution at the bottom of test tube
25
5‐ Sugar(Sucrose) Determination in Raw Milk
Apparatus:
Pipette, Water bath, Test tube, Pipette 1ml,
Reagents:
 HCl
 Naphthol 10%: Dissolve 10g naphthol in ethanol and add sufficient quantity of
ethanol to make total solution 100ml.
Procedure:
 Take 0.5 ml of milk sample in the clean and dry test tube.
 Then add 3ml of conc. HCl in the milk sample
 Then add 2‐3 drops of naphthol10% in the test tube.
 Place the test tube in the water bath for 10 sec.
 Let the test tube to cool down.
 Carefully observe the color of test tube contents.
Results:
Positive Test:
If the violet deep color appears then the test is positive.
FINAL PRODUCTS TO BE EVALUATED IN QUALITY CONTROL LAB.
o Milk Powder:
It includes;
I. Skimmed milk powder.(SMP)
II. Full cream milk powder.(FCMP)

26
1‐ Acidity of Milk Powder

Purpose:
To determine titratable acidity in dry milk powder.
Apparatus:
Balance (sensitivity = 0.01 gram), Burette (0‐25ml),Stirring rod of solid glass, Pipette, Glass
beaker (100 ml).
Reagents:
1% Phenolphthalein solution, 0.1 N NaOH Solution.
Procedure:
 Using mixer dissolve in 100 ml of distilled water.
o 10 grams in case of skim milk powder.
o 13 grams in case of whole milk powder.
 Allow the sample to stand for approximately 1 hour, and then stir gently.
 Pour 17.6ml of sample solution using a pipette into a 100ml beaker.
 Add few drops of phenolphthalein and titrate with 0.1N NaOH solution until a faint
pink colour persists for 30 seconds.
 Note and record the volume of NaOH used and calculate the titratable acidity as
Acidity (as % lactic acid) = ml of 0.1N NaOH used / 20
2‐ Fat Test – Milk Powder

Purpose:
Apparatus:
Butyrometer (0‐4% scale for SMP & 0‐35% for FCMP), Butyrometer stopper, Butyrometer
stand, Weighing balance, Pipette, Centrifuge Machine.
27
Reagents:
Sulphuric acid (density = 1.820 ‐ 1.830 gm/ml) clean, colourless, free from fat.
Iso‐ Amyl alcohol (density = 0.811 gm/ml) free from water, acid and fat.
Procedure:
 Pour successively into Butyrometer, 10 ml of sulphuric acid.
 Add 2 ml of distilled water, Add 2.5 grams milk powder sample 1 ml of Iso Amyl
Alcohol.
 Stopper the Butyrometer and mix well the contents by shaking.
 Spin in centrifuge for 10 minutes.
 After centrifugation, take butyrometer out of the centrifuge machine.
 Note the fat column in the neck of the butyrometer.
3‐ Moisture Test – Milk Powder

Purpose:
To determine moisture percentage in milk powder with the help of moisture analyzer
Apparatus:
Moisture analyzer, Aluminum boat, Spoon.
Procedure:
 Set the temperature of moisture analyzer to 90 °C and timer to 6 minutes.
 Take 2 ‐ 4 grams of sample in aluminum boat place it on the balance in the moisture
analyzer.
 Distribute sample evenly over the entire aluminum boat for quick evaporation.
 Close the chamber of moisture analyzer.
 Push ON/OFF switch to set the equipment in operation.
 After specified time, screen will display the reading showing percent loss in initial
weight (i.e. moisture percentage).
28
4‐ Bulk Density – Milk Powder

Purpose:
To determine the bulk density of dry milk powder.
Apparatus:
Balance (sensitivity 0.1 gram),Brass cylinder with detachable top, volume of cylinder
should be exactly 100 cubic centimeter, Spatula.
PROCEDURE:‐
 Weight the cylinder without the top.
 Put the top on the cylinder and fill up to the rim with Powder using a spoon.
 Rotate BD machine 25 times, remove the top and scrap off Powder with the help of a
spatula.
 Weigh the cylinder, the weight of the powder indicates Powder Bulk Density.
 Powder Bulk Density = Weight of the powder / 150

5‐Solubility Index‐ Milk Powder
Purpose: To determine the solubility index (ability to dissolve in water) of dry milk powder.
Apparatus:
Balance (sensitivity 0.1 gram), Solubility index tubes (15 ml), Centrifuge machine
Procedure:
 Weigh out 10 grams of Skim Milk Powder or 13 grams of Whole Milk Powder and
transfer to
 100 ml of distilled water at 24 °C in a 500ml beaker.
 Mix the contents, wait for 15 minutes.
 Fill in solubility index tubes with samples and place them in centrifuge machine for 5
minutes.
29
 After first centrifugation, take out tubes ,drain OFF sediment free liquid carefully.
 Fill in the tubes with distilled water up to the marked point and disperse the
sediment in tubes with a piece of wire.
 Place the tubes in centrifuge machine for 5 minutes and then check the amount of
sediment in mille liters.
6‐SCORCHED PARTICLES TEST:
 Sample is mixed to make 10% solution in distilled water and stayed for 5 minutes.
 Then check black particles.
 If Black particles present then milk powder is of B‐grade.
 If not then it’s A‐grade
o CHEESE ANALYSIS
Types of cheese evaluated in QC lab
1. Cheddar cheese
2. Mozzarella cheese
3. Spicy cheese
4. Green cheese
1. Fat test;
Take 10 ml sulphuric acid in butyrometer (87‐90%)
Then add 2.5g of minced cheese sample
Add amyl alcohol 1ml then volume is raised by adding 3 – 5 ml distilled water
Fit the cork
Then place in gerber machine, its temp is 63‐65ºc and rpm is 1100
Place it 4 mins
30
After this constant fat reading is achieved
2. Acidity test;
3g of minced sample of cheesed is mixed with 10ml distilled water
1 ml of phenolphthalein indicator is added.
This sol is titrated against 0.1 normal NAOH reading is multiplied with 0.3.
3. Salt test;
Take 2.5g of cheese sample and add 9ml distilled water in it with the addition of2‐3 drops of
potassium chromate as an indicator.
Titrate it against silver nitrate.
Final reading is multiplied with 0.234.
End point
Brick red color or yellowish brown color
4. Moisture test;
2.5g of sample is taken.
Wt of empty dish is w1.
Wt of empty + sample is w2.
Place this on oven at 4 hrs at 100ºc,
Then remove it and place it in dedicator for cooling.
Then weight it again.
W3 = wt after drying.
31
D RY PRO
DAIR OCE
ESSIING
G,

3
32
MILK PROCESSING
Storage of milk for production lines:
Milk is brought to inner silos or holders from the outer large silos through
pumps to be used for production of dairy products and is stored at less than
10°C.
Raw Milk Silos Capacity
Raw Milk Silo 1 75000 Lt
PASTEURIZATION SECTION
Pasteurization
Introduction
The process of pasteurization was named after Louis Pasteur who discovered that spoilage
organisms could be inactivated in wine by applying heat at temperatures below its boiling
point. The process was later applied to milk and remains the most important operation in
the processing of milk.
Definition:
The heating of every particle of milk or milk product to a specific temperature for a
specified period of time without allowing recontamination of that milk or milk
product during the heat treatment process.
Milk is pasteurized in order to inactivate the enzymes and destroy the pathogenic
microorganisms. The extent of microorganism inactivation depends on the combination of
temperature and holding time .The shelf life of the milk is increased up to 7‐8 days after
pasteurization.. Milk is pasteurized by plate heat exchanger. which has 4 sections i.e.
33
I. Heating section
II. Regeneration 1
III. Regeneration 2
IV. Cooling section
Separator and homogenizer also used to separate and to homogenize the cream
respectively
The following steps take place in the process of Pasteurization:
1)Balance tank:
From the silo milk comes in balance tank through a centrifugal pump. Balance tank have a
central float ball, which controls the quantity of incoming milk by a valve & maintain the
milk level as needed by the process.
2)Filter
Milk comes through the sieve filter passing through centrifugal pump goes to the
Regeneration No.1 (Pump functions to create greater pressure in milk as compared to
the heating media to prevent mixing in case of leakage of gaskets.)
3)Regeneration No.1
By passing through the filter milk goes to regeneration no.1, where the
temperature of the milk is raised to 50‐55oC by regeneration method.
4)Separator
From regeneration no.1 milk goes to separator that will separate the extra butterfat
from the milk in the form of cream and it will also remove the unwanted material in the milk
(Sludge). Separator works at 5400 RPM.
5) Homogenizer
From deodorizer milk goes to homogenizer in which milk is passed through nozzle at high
pressure of 100‐150 bar as a result fat globules are converted into smaller particles
(1micrometer).
34
6) Regeneration No.2
Then the milk goes to regeneration no.2. It is also part of plate heat exchanger (PHE)
in which milk is heated to 65oc.
7) Heating Section:
In the heating section temperature of milk is increased to 88‐90oC with help of hot water.
 Flow Diversion Valve:
If temperature of milk is less than 85oC, it will not go towards holding tubes, it is delivered
back to balance tank by flow diversion valve for reprocessing. It is manually operated.
8) Holding Tubes:
Here milk stays for 11‐15 seconds at 88‐90oC, so that enzymes like phosphatase, lipase etc.
are inactivated and microbes are killed.
9) Regeneration no.2
Now milk moves back in regeneration no.2. to warm the incoming cold milk of balance tank.
So in this way energy is conserved. Here temperature of milk drops to 60‐65oc.
10) Regeneration no.1
Pasteurized milk heated the incoming cool milk to save the energy. Here the temperature of
the milk drops to 45‐50oc.
11) Cooling Section:
In cooling section the temperature of the milk drops to 4‐6oc due to chilled water.
Pressure Differential
For contiunuous pasteurizing, it is important to maintain a higher pressure on the
pasteurized side of the heat exchanger. By keeping the pasteurized milk at least 1 psi higher
than raw milk in regenerator, it prevents contamination of pasteurized milk with raw milk in
event that a pin‐hole leak develops in thin stainless steel plates.
35

Plate heatt exchanger
Standard
dization & To
oning:
Here thee milk is stan
ndardized acccording to tthe standard
ds of NOON DAIRIES. Staandardizatio
on
(adjustm
ment of SNF)) and Toningg (adjustment of Fat) aalways take place in thee silos havin
ng
agitatorss so fat and SSNF of pasteeurized milk with cream, water, milk powder an
nd condenseed
milk adju
usted to a set
s level for each prod
duct . The condensed
c (
(condensed skim milk) is
added to
o increase the SNF & LR w
while cream
m is added to
o fat.
The Stan
ndardization Plant:
In Stand
dardization Plant, milk is standardizzed, i.e. the recipe ratio of the product which w
we
want to
o make, is se
et. The most important ccomponent o
of the recipee is the fat percentage
Standardization Ap
pparatus:
3
36
Separattor is used fo
or the purpo
ose of standardization.
A separrator is a cen
ntrifugal devvice that sep
parates milk into cream aand skim milk.
Separattor also acts as a clarifier.
Separattor’s speed aand time of centrifugatio
on give requ
uired standards of fat in milk.

3
37
PASTEURIZED MILK PACKING
Pasteurized milk is packed in 1000ml, 500ml volumes in handy and hygienic packaging.
Nurpur Whole Pasteurized Milk has 3.5% Butter Fat and 9% SNF, free from additives. Nurpur
fresh pasteurized milk has been its guarantee quality label for many years.
Process Flow Diagram of Pasteurized Milk
Receiving of raw milk
↓
Weighing
↓
Out ← Rejected ↑
← Lab. Sampling and analysis
↓
If Accepted
↓
Reception ↓
↓
Chilling
↓
Raw milk storage
↓
Balance tank
↓
Pre‐ heating 1
50‐55°c
↓
Storage
Cream ← Skim milk / cream separa on
38
↓
Homogenization
100‐150 bars
↓
Pre‐ heating 2
65°c
↓
Pasteurization
(88‐90)°c
↓
Holding section
(88‐90)°c for 11‐15 sec
↓
Regeneration ‐2
(temp. drop upto 60‐65°c)
↓
Regeneration – 1
(temp. drop upto 45‐50°c)
↓
Cooling section
4°c
↓
Storage in
Pasteurized standardized milk in pasteurized milk tank
↓
Packing machine
39
POWDER
PLANT
40
MILK POWDERS
There are mainly THREE types of powders produced in powder plant.
 Skimmed milk powder (SMP)
 Instant skimmed milk powder (ISMP)
 Full cream milk powder (FCMP)
There are two powder plants in Nurpur
 Old milk powder plant
It has tubular evaporator
 New milk powder plant
It has plate heat exchanger double effect evaporator
There are two main sections of powder plant
 Evaporation section
 Drying section
. Evaporation
The heat-treated milk is then fed into an evaporator. In the evaporator the preheated milk
is concentrated from around 9.0%
Milk is taken in balance tank of evaporator at 5 to10 C with the help of pump. Milk is
then reaches to condenser with the help of flow control valve, through density transmitter
which determine specific gravity of the milk. In condenser heating of milk start and
reaches to41C. In condenser milk is milk is fed in to holding tubes 180sec now the milk is
filtered and then goes to homogenizer at 80 bar pressure and then to 40 bar pressure
Homogenization can be carried out in one or two stages. The pressure of the first stage of
the homogenizer is from about 50 to about 250 bars. . It is important in this case that the
fat part of the milk is completely homogenized together with an appropriate part of the
non-fat solids and water.
41
Drying Section
Condensed milk goes to drying chamber through four nozzles of a spray drier at a
temperature of 155‐190˚C .Spray drying involves atomizing the milk concentrate from
the evaporator into fine droplets .
This is done inside a large drying chamber in a flow of hot air (up to180˚C) using high
pressure nozzles.
Much of the remaining water is evaporated in the drying chamber, leaving a fine powder
of Around 6% moisture. Final drying takes place in a fluid bed in which hot air
Is blown through a layer of fluidized powder removing water to give product with
moisture
Content of 2‐4% the powdered milk leaves the chamber at temperature of 55‐65˚C.
Packaging and Storage
Milk powders are immensely more stable than fresh milk but protection from moisture,
Oxygen, light and heat is needed in order to maintain their quality and shelf life. Milk
Powders readily take up moisture from the air, leading to a rapid loss of quality and
caking or
Lumping.
Milk powder is packed into either plastic bag in bulk. WMPs are often packed under
nitrogen gas to protect the product from oxidation and to maintain their flavor and
extend their keeping quality. Packaging is chosen to
Provide a barrier to moisture, oxygen and light.
In Nurpur WMP and SMP is packed in 25 kg of bags

42
NEW POW
WDER PLANT

Silo+Holder

8°°C
13°C 6
66°C 64°C
C
75°C 58°C
W L
78°C
W LL
Waater Line
Cond
denser
Full Crream Milk

k Powder
For over 30 years, Nuurpur FCMP

P because off its high quaality is a largge selling braand of Nurpuur
in market. With 25-2
28% fat, it meets
m the requuired quantitty of essentiial fatty acid
ds and caloriees
obtain esspecially from butter fatt plus all thee same impoortant vitamiins and mineerals found in
i
other millks. It is pack
ked in 25 kgg bags.
4
43
Skimmed Milk Powder:
Nurpur is one of the major market shareholders of SMP in Pakistan, mainly because of its
quality. As “Nurpur SMP” has less than 1.5 % Butterfat so Nurpur Skim/Slim Milk has
virtually less fat and cholesterol and very few calories, plus all the same important vitamins
and minerals found in other milks.
Process Flow Diagram of MILK POWDER
FC milk/ skim milk in tank
↓
Balance tank
↓
Condenser
↓
Pre- heater -1
↓
Pre- heater -2
(90-95)ºc
↓
Calendia – 1
↓
Calendia -2
↓
Atomizer
↓
Dryers
↓
↙↘
Cyclone ‐1 cyclone‐2
↘ ↙
Transport system cyclone
↓
Bagging hopper
↓
Final packing
↓
Storage
44

CHEESE & BUTTER

45

BUTTTER

Butter is essentially the fat of the milk. It iss usually maade from sw
weet cream and is salted
d.
Howeverr, it can also
o be made frrom acidulatted or bacteeriological so
oured cream
m and salt lesss
(sweet) butters
b are also availab
ble. Well intto the 19th century buttter was still made from
cream th
hat had been
n allowed to stand and sour naturally. Today's co
ommercial b
butter makin
ng
is a prod
duct of the knowledge and experieence gained
d over the yyears in succh matters aas
hygiene, bacterial accidifying and
d heat treatm
ment, as welll as the rapiid technical developmen
nt
that has led to the advanced machinery
m no
ow used. Th
he commerccial cream separator waas
introduceed at the en
nd of the 19
9th century; the continu
uous churn h
had been commercializeed
by the middle of the 20th centurry.
Nurpur iss one of the leading pro
oducers of butter and bu
utter produccts in Pakistaan, processeed
from thee best fresh milk. With 80% fat in Nurpur
N Buttter, not onlyy you will geet energy bu
ut
also bodyy required eessential fattty acids. Nurrpur butter is made from
m cow’s milkk, which roam
m
freely an
nd eat fresh green grass all year ro
ound. That’ss what givess Nurpur bu
utter the rich,
creamy ttaste that naature intendeed. Nurpur b
butter is avaailable in con
nsumer packkaging and fo
or
industrial processorss. Innovation is the maain focus. Primary exam
mples includ
de the yellow
butters in tubs avaailable undeer the “Nurrpur butter”” brand nam
me. In Pakiistan, Nurpu
ur
markets a range of p
premium buttters. Nurpur also exportts butter to many counttries.
Spread the golden ggoodness of Nurpur Buttter and relissh the very special deligght of its ricch
creamy taste. You neever had it b
better.
Types off Butter
Two Typees of Butter::
i. W
White Butter packed in 1
1 Kg and 5 Kgg packing
ii. Yellow Butterr packed in 1
10 gms, 20 ggms, 50 gms,, 100gms, 20
00 gms in 1 K
Kg and 5 Kg
packing
4
46
PROCESS DISCRIPTION
If the cream is separated by the butter manufacturer, the whole milk is preheated to the
required temperature in milk pasteurizer before being passed through a separator. The cream
is cooled and led to a storage tank where the fat content is analyzed and adjusted to the
desired value, if necessary. The skim milk from the separator is pasteurized and cooled before
being pumped to storage. It is usually destined for concentration and drying
From the intermediate storage tanks, the cream goes to pasteurization at a temperature of
95°C or more. The high temperature is needed to destroy enzymes and micro-organisms that
would impair the keeping quality of the butter.
In the aging tank, the cream is subjected to a program of controlled cooling designed to give
the fat the required crystalline structure. The program is chosen to accord with factors such as
the composition of the butterfat, expressed, for example, in terms of the iodine value which is
a measure of the unsaturated fat content. The treatment can even be modified to obtain butter
with good consistency despite a low iodine value, i.e. when the unsaturated proportion of the
fat is low.
As a rule, aging takes 12 - 15 hours. From the aging tank, the cream is pumped to the churn
or continuous breakdown via a plate heat exchanger which brings it to the requisite
temperature. In the churning process the cream is violently agitated to breakdown the fat
globule, causing the fat to coagulate into butter grains, while the fat content of the remaining
liquid, the buttermilk, decreases.
Thus the cream is split into two fractions: butter grains and buttermilk. In traditional churning,
the machine stops when the grains have reached a certain size, whereupon the buttermilk is
drained off. With the continuous butter maker the draining of the buttermilk is also
continuous.
After draining, the butter is worked to a continuous fat phase containing a finely dispersed
water phase. It used to be common practice to wash the butter after churning to remove any
residual buttermilk and milk solids but this is rarely done today.
Salt is used to improve the flavor and the shelf-life, as it acts as a preservative. If the butter is
to be salted, salt (1-3%) is spread over its surface, in the case of batch production. In the
47
continuouus butter maaker, a salt slurry is addded to the butter.
b The ssalt is all disssolved in thhe
aqueous pphase, so thee effective salt concentraation is apprroximately 10% in the water.
w
After sallting, the buutter must bee worked viigorously to ensure evenn distributioon of the sallt.
The workking of the butter
b also innfluences thee characterisstics by whicch the produ
uct is judgedd -
aroma, taste,
t keepin
ng quality, appearancee and color. Working is required to obtain a
homogennous blend of butter grranules, waater and saltt. During working,
w fat moves from
m
globular to free fat. Water
W dropleets decrease in size durinng working and should not be visible
in properrly worked butter. Oveerworked buutter will bee too brittle or greasy depending
d o
on
whether the
t fat is harrd or soft. Soome water may
m be addedd to standarddize the moiisture contennt.
Precise ccontrol of com
mposition iss essential foor maximum yield.
The finisshed butter iss dischargedd into the pacckaging unit, and from thhere to cold storage.
Butteer Churn
B
Butter grain
ns and butteer milk read
dy for separration
4
48

Removal of b
butter into trrolley
Flow line of Butter

4
49
CHEESE:
According to the National Dairy Council, "All cheese is made from milk, but different
manufacturing and aging processes are used to produce the array of cheese available today.
Cheese is made by coagulating or curdling milk, stirring and heating the curd, draining off
the whey (the watery part of milk), collecting and pressing the curd, and in some cases
ripening.
Three types of Cheese
1. Cheddar cheese packed in slices with weight of 200gms, and 1000gms while in cakes
with 225gms and 2000gms
2. Cottage cheese packed in cakes with weight of 200gms
3. Spicy cheddar cheese packed in cakes weight 225gms
Rich source of protein especially casein protein deficiency is fulfilled by cheese. Cheddar and
Cottage cheese produced from fresh milk. For making Cheddar cheese first of all Green
cheese is made. Nurpur offers a wide range of delicious cheeses in market. Nurpur’s
deliciously unique Cheddars are slow matured for a superior taste.
They’re made the right way for a fuller flavor and a taste you can trust. All cheeses are made
from fresh pasteurized cow milk, each subject to a different process to ensure unique taste
and presentation.
The basics of cheese making
The process of cheese making is an ancient craft that dates back thousands of years. By
today's standards of industrial technology, the process of cheese making is still a
complicated one which combines both "Art" and "Science" together. The subject of cheese
has been extensively investigated by many research groups in many countries, and in‐depth
information has been reported, for example, by Kosikowski (1982), Scott (1986), Robinson
(1993) and Fox (1993).
50
Making GGreen Cheesse from Curd dled Milk
Cheese making
m capitalizes on the curdling of milk. Firrst, the milkk is carefully selected to
t
make surre there are no antibiotics or harmfful agents th
hat could afffect the proccess. The milk
is then heated
h and held
h at a givven temperaature for a short period
d to destroyy any harmful
bacteria (i.e. pasteurization). Sp
pecial starterr cultures arre then addeed to the warm milk an
nd
change aa very small amount off the milk su
ugar into lacctic acid. Th
his acidifies the milk at a
much fasster rate and
d prepares itt for the nexxt stage. Ren
nnet (mainlyy chymosin) is then addeed
to the m
milk and with
hin a short ttime a curd is produced
d. The resulttant curd is then cut intto
small cubes, and heat
h is applied to start a shrinkin
ng process which, with
h the stead
dy
on of lactic aacid from th
productio he starter cu
ultures, will cchange it intto small size
ed grains. At a
carefully chosen point the curd grains are aallowed to ffall to the bo
ottom of the cheese vaat,
over liquid, which consiists of water, milk sugar and album
the left‐o men (now caalled whey) is
drained off and the curd grainss allowed to
o mat togeth
her to form large slabs of curd. Th
he
slabs aree then milled
d, and salt is added to prrovide flavorr and help preserve the cheese. Lateer,
it is presssed, and subsequently packed in vvarious sized
d containers for maturin
ng.That is th
he
basic method for maaking what iss known as aa hard‐presseed cheese.
Cheese milk culture
e and renne
et addition and mixing in
n cheese vatt

Curd
d setting
5
51

Cuttin
ng the curd

Cooking the curd
Draining of wheyy

eddaring
Che
52

Salting after milling

Cheesee block fillingg and preparing for presssing

Pre
essing:

Vacuu
um sealing o
of Green che
eese block
53
Process Flow Diagram of Green Cheese
Pasteurized & → Lab analysis
Standardized Cheese milk

↓
Temp setting
↓
Culture addition
↓
Rennet addition
↓
Ripening
↓
Cutting of coagulum
↓
Cooking
↓
Block cutting at 0.3% acidity
↓
Milling
↓
Salt addition
↓
Cheese block filling & pressing
↓
Storage
↓
Vacuum sealing
↓
Storage for purpose of Green cheese aging at < 10°C
↓
Cleaning of Aged Green cheese block
54
↓
Cutting Of green cheese
↓
Mincing
↓
Cooking and Addition OF additive
↓
Filling Cheddar cheese in moulds
↓
Storage at <10°C
↓
Cutting in small blocks
↓
Slicing
↓
Vacuum packing
↓
Storage at<10°C

Process Flow Chart of Mozzarella Cheese
Pasteurized & Standardized Cheese milk
↓
Heat upto 34˚C
↓
Add Culture & Leave for 30 min.
↓
Rennet addition & Leave for 40 min.
↓
Cutting of coagulum
↓
Cooking 38‐40˚C until pH 5.2
55
↓
Hanged in Cold Store

↓
Milling
↓
Hot Water @90˚C
↓
Chilled Water @ 4˚C for 2‐3 Hrs
↓
Brine 2‐3 Hrs
↓
Packing
Spicy cheese:
It is produced in assume way as cheddar cheese is produced but difference is that when
whole batch of cheddar cheese is produced green chilies are added in it. Green chilies are
grinded and then added according to taste and flavor
Types of cheese Acidity pH
Mozzarella cheese 0.90 5.10
Green cheese 0.80 ‐
Cheddar cheese 0.10 5.40
56
UHT SECTION
57
UHT SECTION
UHT treatment is a process of heating the milk at temperature 137‐140°C to increase the
shelf life by killing the microbes. The product passes through heating and cooling stages in
quick process and then aseptic filling to avoid the re‐contamination of the product.
Ultra High Temperature treated milk products will easily keep for more than three months
outside the refrigerator.
Process Steps of UHT plant with aseptic homogenizer:
1) Balance Tank:
Standerdized milk from silos moves towards the balance tank which controls
the quantity of incoming milk.
2) Booster Pump:
It pumps the milk from balance tank to regeneration #1.
3) Tubular heat exchanger (THE) coil # 1:

Booster pump will sent the milk to THE coil 1 where milk temperature will
raised upto 50 oC by outgoing water whose temperature is upto 75 o C.
Here the milk temperature increases upto 75 oC by the outgoing water whose
temperature is upto 85-90 oC.
5) Deaerator :
Milk enters in deaerator at temp 75oC where all fowl odorous volatile compounds
and vapors are removed.
Here milk temp increases upto 125 oC by water whose temp is upto 132‐135 oC.
7) Tubular heat exchanger (THE) coil # 4 :
Here milk temp rises upto 130 oC by hot water.
58
8) Tubular heat exchanger (THE) coil # 5 :
It is the main heating unit where required temp 137 oC is achieved. Milk is heated by
hot water whose temp is upto 139‐140 oC
9) Holding tube :
Milk is held at temp 137 oC for four secs in holding tubes.
10) Regeneration coil 1 and 2:
Milk temperature starts decreasing in regeneration coils 1 and 2. When milk leaves
regeneration coil 2 its temperature will be 72 oC
11) Homogenizer :
Here homogenization is done to break the fat globule under a pressure of 200 bar in the
1st stage of homogenizatin. In 2nd stage it is done at 50 bar to break the remaining globules.
Here the fat is uniformly distributed in the milk. Here milk temp slightly increase upto 3 oC
due to homogenizer pressure.
12) Regeneration Coil # 3:
Here the temperature of the milk decreases up to 50oc by incoming water.
13) Chilling Section:
Milk in this section is cooled upto 28‐30oC with the help of cold water.
Aseptic Tank Storage: (Al‐ Safe Tank)
These tanks are used to store the UHT milk if it is not delivered to Tetra Pak.
Milk can stay there for 24 hours.
Aseptic Filling:
It is done by Tetra Pak Filling machines.
Packaging of UHT Milk:
Packed in 250ml, 500ml, and 1000ml volumes in Tetra Brik Aseptic Packing
59
UHT PRODUCTS IN NURPUR:
1. NURPUR UHT PLAIN MILK
2. NURPUR DAIRY WHITNER CHAI MIX
3. NURPUR FLAVORED MILK
4. NURPUR DRINKS & NECTARS
5. NURPUR DRINKING YOGURT
Flavored Milk:
Packing in 1000ml volumes in Tetra Aseptic Packing
Flavored Milk is made from the highest quality standardized milk (3.5% fat) and is carefully
formulated and processed to produce an unparallel high quality, great tasting flavored milk.
While using different flavored milk, you will enter in world of flavors.
Flavored milk is a cool way to get in your daily intake of important nutrients such as calcium,
vitamins A and D and minerals like phosphorus, magnesium and zinc; it helps build a strong
body, healthy teeth and bones.
Currently Nurpur is producing six types of Flavored Milk, nutritional fact of some are
Given below;
Strawberry Flavored Milk:
Packed in 250 ml volumes in Tetra Aseptic Packing
Mango Flavored Milk:
Banana Flavored Milk:
Chocolate Flavored Milk:
60
Ice cream Flavored Milk:
Badam zafran Flavored Milk:
Process Flow Diagram of Flavored Milk
Raw milk
↓
Standardization
↓
Pasteurization
↓
Add color & flavor
↓
Homogenization
↓
Ultra heat treatment
↓
Filling
↓
Aseptic packaging
61
Chai Mix (Dairy Whitener)
Process Flow Diagram of Chai Mix

Raw milk
↓
Standardization at 7% fat content
↓
Pasteurization
↓
Homogenization
↓
Transfer to UHT tank
↓
Store in UHT aseptic tank
↓
Aseptic packaging
62
NECTAR & JUICES:
Nurpur is providing three types of nectars which are apple, orange, guava and mango
nectars. These nectars are of high quality, unique tasting with high nutritive value.
Packing of all nectars in 1000ml as well as in 200ml volumes in Tetra Aseptic Packing
Process Flow Diagram of Juices & nectars on UHT flex
Ingredients
 Pulp
 Color
 Stabilizer
 Sugar
 Water
 Flavor
Process Flow Diagram of Juices & nectars
Syrup mixing
↓
Mixing of additives
↓
Lab analysis ← raw juice storage tank
↓
Standardized juice
↓
Balance tank
(UHT‐Flux)
↓
63
Pre‐heating
75ºc
↓
De‐aerator
‐0.6 Bar, 72ºc
↓
Final heating 95ºc
↓
Holding sections
(16sec)
↓
Cooling (30ºc)
↓
Storage
Process flow diagram of juices and nectars on pasteurizer
Balance tank
↓
Regeneration 1
35‐40 ºc
↓
Regeneration 2
55‐60 ºc
↓
Heating section
90 ºc
64
↓
Holding section 15 sec
↓
Regeneration 2
75 ºc
↓
Regeneration 1
50‐55 ºc
↓
Cooling section
30‐35 ºc
ASEPTIC PACKAGING
After UHT treatment products are aseptically packed in brick or slim packing by different Tetra Pak
machines.
Composition of aseptic packaging
 Paper (70 percent) – provides stiffness, strength and the efficient brick shape
 Polyethylene plastic (24 percent)
 Forms the seal on the innermost layer that makes the package liquid‐tight and a
protective coating on the exterior keep the package dry.
 Aluminum (6 percent) ‐‐ forms a barrier against light and oxygen, eliminating the need for
refrigeration and preventing spoilage without using chemical preservatives.
Benefits of Aseptic Packaging
• Convenience
Aseptic packages are portable, lightweight, and shatterproof and easily transportable
65
• Food Safety
The aseptic process and carton together ensure that the liquid food or beverage inside is free from
harmful bacteria and contaminants.
• No refrigeration required
• Long shelf life
Packaging machines
Sr No. Model No. Assigned Brick Size Capacity
1 TBA 8 A 1000 ml 1000 bricks/hr
2 TBA 19 (40V) B 250 ml 7500 bricks/hr
3 TBA 19 (20V) C 250 ml 7500 bricks/hr
4 TBA 19 (30V) D 200 ml 7500 bricks/hr
5 TBA 19 (20V) E 25 0ml 7500 bricks/hr
6 TBA 9 F 250 ml (Juices) 6000 bricks/hr
TBA = TETRA BRIK ASEPTIC
General description of working of Tetra Pak machine
 Paper coil section
In this section a reel of packaging material is fitted at the base of machine
 Shape creasing roller:
The paper is passed though bending and creasing rollers, which facilitate bending and folding of,
paper later on.
 Motor driven roller:
Motor driven rollers which ensures a smooth and safe feeding of packaging material.
 Dating section:
It prints the expiry date, machine number on the paper.
 Longitudinal seal section:
Poly strip is attached longitudinally at one end of paper by strip applicator.
66
 Aseptic chamber
Tetra Pak paper is passed through hydrogen per oxide (35%) solution so it become sterilized.
 Calendar Rollers:
Rollers which squeeze away surplus H2O2.
 Air knife section
Hot air (120‐130ċ) is applied on the paper to evaporate the hydrogen per oxide.
 Longitudinal sealing Section
Edges of packaging material are heated with hot sterile air. After the edges are heated, the
packaging material are passed through a forming ring in which LS is sealed by both edges in
packaging material being passed and forming a tubular shape.
 LS short stop element
Short stop nozzle for heating the LS at restart after a short stop.
 Filling section:
The product is introduced in packaging material. The outlet of filling pipe is under the level of
product which prevents foaming.
 Jaws section:
Sealing & cutting of paper is done according to desired shape.
 Drop Chute:
It guides the packages into the final folder. It is also used for discharging unusable packages.
 Final folder
In final folder packages are given their final shape. The top and bottom flaps are folded in and
sealed to the packages.
 Delivery section:
Properly shaped packs are thrown on conveyor.
In case of juices:
After filling of juice in pack it goes for sealing then are conveyed to straw applicator machine
where in a hot chamber plastic blows and gets molded in form of straw then glue sticker sticks the
glue on pack and straw applicator apply straw on it.
67
If there is any fault in straw application then straws are separately packed together with juice packs
while tray and shrink packing.
Tests performed in Tetra Pak Section
 Longitudinal Sealing (Ink Test)
 Transverse Sealing
 Conductivity Test
UHT LAB ANALYSIS
In UHT lab all the UHT final products are analyzed by performing different tests
ANALYSIS FOR MILK
pH
Acidity
Taste, color, smell
Fat separation
Sedimentation
ANALYSIS FOR DRINKS
pH
Acidity
Taste, color, smell
°Brix check
ANALYSIS FOR NECTARS
pH
Acidity
Taste, color, smell
°Brix check

68
ANALYSIS FOR UHT CREAM
pH
Acidity
ANALYSIS FOR FLAVOURED MILK
pH
Acidity
°Brix
TESTS PERFORMED FOR ENSURING PACKAGING SAFETY:
Three types of test are performed;
1. CONDUCTIVITY TEST
2. INK TEST
3. ZONOSCOPE TEST
4. Weight ability Tests
Why these tests are performed?
 To check abnormality in milk
 To check packaging faults
 To check leakage in pack
1. Conductivity Test:
Cut the upper horizontal side of juice pack like this;

And empty the pack in bucket or in a jar. Dry the empty juice pack completely with towel. Fill
2/3rd of another bucket with water. Take the emptied juice pack and fill water in it until all
seals are dipped in water.
69
Place it in bucket facing upward the cut portion. Connect galvanometer with two wires and
then dip one wire in bucket water and other one in pack water. If conductivity circuit
completes then needle of galvanometer shows movement indicating packaging material is
unsafe to use because of any opened pores or holes in packaging material or seal eruption.
2. Ink Test :
A special ink is made by Tetrapack company and is given to food industries using tetrapack
packages to check is seal application is perfectly done or not.
For this injection of ink is inserted in strip made of MPM material and checked if it runs smoothly
along the seal strip then seal is properly applied and sticked to packaging material.
3. Zonoscope Test:
For this test zonoscope is used and it is placed on inner seal strips facing towards light to see
whether seal is broken or not.
4. Weight ability Tests:
This test is performed to the quantity of juices and milk present in packet. If quantity of milk
or juice in a particular packet is more than required than factory will suffer a loss.
Volume Of liquid Standard Weight of liquid+packet
Nector 1000 ml 1065‐1075gm
Milk 1000 ml 1050‐1060 gm
Milk 250 ml 265‐270 gm
Drinks 250ml 258‐263gm
Flavored milk 250 ml 268‐273gm
MICRO LAB ANALYSIS
Why microbial tests are performed?
Microbial tests are performed to check microbial load in rear and front portion of milk tank,on
equipments,environment and in milk itself to avoid milk spoilage.Swab test is performed for
equipment and rear and front portion of milk tank.

70
Types of MEDIA used:
4 types of agar Medias are used i.e.
1. Mc Conkey Agar
2. Potato dextrose agar
3. Plate count agar
4.S.S agar
THESE TESTS ARE PERFORMED FOR FOLLOWIN:
1. TPC (total plate count)
2. Ecoli
3. Salmonella and shigella
4. Yeast and mould
5. Coliform
6. Environmental testification
7. Swab testification
EXPLANATION:
i. TPC: Simple agar media is used. First we sterilize all the glass ware in autoclave at 121c and 15
PSI.
MEDIA PREPARATION;
21 g /liter media is prepared in flask and then cover it with aluminum foil and sterilize it in the
autoclave at 121C and 15 PSI pressure after that in aseptic environment under laminate flow
pour the sample in Petri dish for more accuracy sample is diluted.
Dilution:
In a test tube pour 9 ml water and 1 ml sample mix it then take 1 ml sample from it and pour in
petridish and 1ml of sample in 2nd test tube containing 9ml water to form 10‾² dilutuion. And
pour 1 ml of it in petridish.Now the sterilized media is poured on them they are allowed to
solidify and then incubated.
71
INCUBATION:
Incubated at 37 ˚C for 24‐48 hr. calculate colonies by colony counter.
RESULT:
∑C/ (n +0.1n2) d
∑C=Sum of colonies
N =no of plates from lowest dilution.
N2= no of plates from high dilution.
D=dilution factor of n
ii. COLIFORM COUNT:
MEDIA: Mackonky agar is used that is of red color about 50g/L and Ph is maintained.
PROCEDURE: Prepare a media in a conical flask then cover it with aluminum foil and autoclave it
at 121˚C for 15 PSI pressure after that pour 1ml of milk sample in sterilized Petri dish and then
inoculated the media on it shake a little and allow it to solidify in aseptic condition and then
incubate for 24 ‐48 hr at 37˚C and count the choliform.
RESULT: If microbes are seen that test +ive.
iii. SALMONEELA SHAGELLA
MEDIA:
S.S agar is used. We dissolve 60g/L and ph is maintained by using 0.1 N ACID OR 0.1 N bases
PROCEDURE:
Prepare a media in a conical flask then cover it with aluminum foil and autoclave it at 121˚C for
15 PSI pressure. After that pour 1ml of milk sample in sterilized Petri dish and then inoculated
the media on it shake a little and allow it to solidify in aseptic condition 24‐48 hr and note
readings.
RESULT: If microbes are seen that test +ve.
iv. YEAST AND MOLD:
MEDIA: Potato dextrose Agar is used about 39g /L AND PH is maintained.
72
PROOCEDURE: Prepare a media in a conical flask then cover it with aluminum foil and
autoclave it at 121˚C for 15 PSI pressure. After that pour 1ml of milk sample in sterilized
Petri dish and then inoculated the media on it shake a little and allow it to solidify in
aseptic condition 24‐48 hr and note readings.
v. ENVIOMENTAL CONDITIONS: For environment test media vary if to observe coliform in
environment then Macon key agar is used and for TPC .Plate agar is used.
PROOCEDURE: Prepare a media in a conical flask then cover it with aluminum foil and
autoclave it at 121˚C for 15 PSI pressure. After that pour 1ml of milk sample in sterilized
Petri dish and then allow it to solidify then for 3min expose media to environment after
that incubate it for 24‐48 hr at 37˚C and note readings
vi. SWAB TEST:
25ml water,1cotton plug, desired media
Swab test is done to check microbiology of equipments and all the things that are in
direct contact with food.
PROCEDURE:
Auto clave 25ml water for the purpose of sterilization then make 2 inch cotton swab and
pour in water and dip it until it is socked well then take the cotton out with a sterilize holder
and rub the area to be studied about 1 foot then press cotton in water again. Now take it to
laminar flow of air then pour 1ml of this water on sterilized Petri dish and then pour media
over it. Media is selected according to organism then allow it to solidify then incubate it for
24‐48 hr at 37˚C and note readings

73
Keeping Quality Lab
In Keeping Quality Lab, check the quality of the products throughout their shelf life.
In Keeping Quality Lab:
Four samples and one reference sample of each product at normal shop temperature
condition are placed.
1 First sample is checked after one week of its production
2 Second sample is checked after one month of its production.
3 Third sample is checked at the time of its expiry.
4 Fourth sample is checked after passing half the time of its expiry date.
Incubation Lab
The dairy products like UHT and juices are checked and ensured that there is no microbial
growth in the finished products. For this purpose samples are taken from PLE Hall and
placed in the Incubation Lab at 37 oC for five days.
After five days, the samples are tested that there whether is microbial growth occurs or no
After the five days, the samples of every half an hour of production must be cutoff test its
pH and other physical tests. If the tests are negative then allow the production to sale.
If there is shortage of the product in the market and there is need to dispatch the product
early than five days, then from the stored samples, 1/2 of the packets are cut and test the
pH and perform other physical tests. If the results are negative then the product is
transferred to the distributors but they are not allowed to sale the product. The left half
samples are checked on completing the five days in the Incubation Lab by the same method
previously discussed. After confirming that the product is safe and free from
microorganisms, then allow the distributors to
74
Shelf life of products

Name of product
Shelf life of product

Orange juice

Apple nectar
270 days
Mango nectar
Flavored milk 120 days
Apple fruit drinks

Mango fruit drink
365 days
Mixed fruit drink
Plain UHT milk 90 days
UHT cream 120 days
Acidity, pH and °Brix of slim products are shown in following table.
Type of product pH acidity °Brix
Orange juice 3.78 0.46±0.02 13%
Apple nectar 3.28 0.28±0.02 13%
Mango nectar 3.74 0.18±0.02 13%
Mango drink 3.35‐3.38 0.15‐0.16 4%
Apple fruit drink 3.06 0.15 ‐0.16 4%
Mix fruit drink 3.35‐3.38 0.15‐0.16 4%
75
pH of different flavored milk are shown in following table
Types of flavored milk ph
strawberry 3.72‐3.78
mango 3.72‐3.78
chocolate 3.72‐3.78
banana 3.72 ‐3.78
ice‐cream 3.72‐3.78
Badam zafran 3.73‐3.78
CLEANING & SANITIZATION:
Cleaning in place (CIP)
CIP stands for cleaning in place. CIP is removal of milk particles and lowering the microbial load in
the production line & in the raw milk tankers by using various types of cleaning agents (acid, base &
water) and temperature.
Before the milk is stored in silos they should be cleaned, so that they can be used without any
hygienic problem. Usually after every 24 hours the silos gone through this process. Sometime if
needed they could be cleaned before 24 hours or after every production.
This process of cleaning of silos takes approximately 120 minutes.
The process includes the following steps.
1 The circuit is made for the desired silo or line.
2 Secondly hot water is circulated for 10 minutes.
3 Then caustic soda is circulated for 15 minutes.
4 In this step, hot water is again circulated for about 15 minutes.
5 In the fifth step, nitric acid is circulated for 15 minutes.
6 Finally hot water is circulated for 15 min which completes the process of CIP.
After this cleaning, the milk is stored in the silos.
Function of Various Cleaning Agents in CIP
Lye is for removal of fat residues and dissolves all the milk particles.
76
Acid for the removal of protein matter
Hot water is for the removal of residues and salt.
Acid and hot water also used for lowering microbial load.
Nitric acid also neutralizes the effect of caustic soda
Note: Caustic Soda (NaOH) and Nitric Acid (HNO3) are stored in separate tanks.
Concentrations:
The concentration of Acid and lye used for the CIP is:
1. Lye (NaOH) =1.7 ‐ 2.2 % at 80 ‐ 85°C.
2. Acid (HNO3) = 1 ‐ 1.5% at 70 ‐ 75°C.
3. Water at 80 ‐ 85°C.
Types of CIP:
Two types of CIP are done in the NOON DAIRY
1‐ Short CIP (40 min)
2‐ Long CIP (70 min)
Short CIP:
1) Milk is drained out of tanker or the pipelines and then it is washed with water for 10 min.
2) After this Lye (NaOH) solution of 1.7 ‐ 2.2 % at temperature of 80 – 85° C is circulated in the tank
or lines for 10 minutes.
3) Again tanker is washed with water for 5 min.
4) Then Nitric acid (HNO3) having a concentration of 1 ‐ 1.5% at the temperature 70 ‐ 75°C of is
circulated in the tank or lines for 10 minutes.
5) Again tanker is washed with hot water at 80 – 85° C for 5 min.
Long CIP:
1) After drainage of milk from tanker or the pipelines it is washed with water for 10 min.
2) After this Lye (NaOH) solution of 1.7 ‐ 2.2 % at temperature of 80 – 85° C is circulated in the tank
or lines for 15 minutes.
77
3) Again tanker is washed with water for 10 min.
4) Then Nitric acid (HNO3) having a concentration of 1 ‐ 1.5% at the temperature 70 ‐ 75°C of is
circulated in the tank or lines for 15 minutes.
5) Again tanker is washed with hot water at 80 – 85° C for 10 min.
TECHNICAL DATA SHEET
Plant production capacity
Reception + Dairy Processing 3,25,000 Lt/Day
UHT Packing Capacity 2,40,000 Lt/Day
Pasteurizer I 6200 Lt/Day
Pasteurizer II 7200 Lt/Day
Pasteurizer III 15000 Lt/Day
UHT Silo 1 & 2 26,500*2 Lt
UHT Silo 3 30,000 Lt
UHT Silo 4 50,000 Lt
Building Total Area
3.5‐ Acre 16 Acre
Personnel:
Male: 600
Female ‐
Total staff 600
78
2

BUILDING
Walls Beams, Bricks,
Roof RCC
Floor Acid Resistant Tiles
Windows Aluminium
Doors Aluminium
Partitions Bricks
Walkway Tiles+ Bricks
Drainage Open Drainage in Processing Area
Environment (other buildings, roads,
As described by NEQS (National Environmental
paved/unpaved surface, possible risks of
Quality Standards)
pollution, etc)
RAW MATERIALS
RAW MILK
Purchased from Self‐collection + supplier
Fat % (average) 4.5%
Protein % (average) 3‐4%
WASTE DISPOSAL
Liquid Waste is dispose in nearby sewage canal and solid waste (paper Waste) is sold.
2
3

Suggestions:
Health and safety point of view:
1) Hygiene of workers should be maintained and checked daily.
2) Sanitization of industry should be done and assessed on daily basis.
3) Industry should have its own ambulance.
4) Expert person in first aid should be present round the clock.
Behavioral point of view:
1) Wages of workers should be increased to increase their moral.
2) Appraisal must be done on workers achievement.
3) All workers should be allowed for giving innovative ideas it causes temptation for
increased work efficiency with effectiveness.
4) Workers should be ethically trained to treat each other respectfully.
5) Give no chance for backbiting.
6) Problems of workers should be shared and solved by management as when he

would work with peace of mind will give 100%.
7) Rule of everybody, anybody, somebody and nobody should not be applied, every
person should be responsible.
Improvement point of view:
1) Lab assistants should be provided with thick cotton gloves to handle the apparatus
while performing fat test.
2) Tests must be performed for every sample either raw material or final product.
3) Research and development lab should be upgraded and there must be separate lab
for testing UHT products.
3
4

4) Newly made products should be tested for their harmful effects on human health
before their launching.
5) More scientific lab equipment’s must be purchased to detect the type of adulterant
used it would help to get pure milk.
6) Don’t just go for apparent quality or doing full count of contents go for originality
means to say no masking at all.
7) Different rest rooms and changing rooms must be built separate from working
area.
8) Workers should not be allowed to do tea break in working area.
THANK YOU

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5. Milk collection system

Test Performed in Reception Lab

9. Flow diagram of pasteurization

10. Powder plant

12. Cheddar Cheese

13. UHT Section

14. UHT Lab Analysis

15. Tests For Insuring Packaging Safety

16. Keeping quality lab

17. Microbiology lab

CIP (Cleaning In Place) Section

19. Technical Data sheet

Nurpur iss committedd to supply the

NOON PA AK LIMITED is the only ddairy compan ny that undeertakes 21 rigorous quality tests to

3 Halal Cerrtified (Bu

In this, tthese departm

2. Quallity assuraance deparrtment;

In this, these departments are included

MILK RECEPTION AND

Farmer Mini Supplier Contractor

VMC VMC VMC

Reception Lab Activities

1- To check temperature of milk

Glass Thermometer, glass beaker

Thoroughly mix the sample to get representative sample.

Note the reading of thermometer.

Temperature of milk should be between 4 - 6 degrees Celsius.

The thermometer should be clean and properly calibrated.

3- Clot on boiling test:

Butyrometer, pipette (10.94mm), Butyrometer stopper, Butyrometer stand, Centrifuge

Pipette, Test Tube

Full Crream Milk

For over 30 years, Nuurpur FCMP

Types off Butter

Pasteurized & → Lab analysis

Standardized Cheese milk

Hanged in Cold Store

Types of cheese Acidity pH

Mozzarella cheese 0.90 5.10

Cheddar cheese 0.10 5.40

Process Steps of UHT plant with aseptic homogenizer:

It pumps the milk from balance tank to regeneration #1.

3) Tubular heat exchanger (THE) coil # 1:

4) Tubular heat exchanger (THE) coil # 2:

Process Flow Diagram of Chai Mix

Process Flow Diagram of Juices & nectars on UHT flex

1 TBA 8 A 1000 ml 1000 bricks/hr

2 TBA 19 (40V) B 250 ml 7500 bricks/hr

3 TBA 19 (20V) C 250 ml 7500 bricks/hr

4 TBA 19 (30V) D 200 ml 7500 bricks/hr

5 TBA 19 (20V) E 25 0ml 7500 bricks/hr

6 TBA 9 F 250 ml (Juices) 6000 bricks/hr

Type of product pH acidity °Brix

Orange juice 3.78 0.46±0.02 13%

Apple nectar 3.28 0.28±0.02 13%

Mango nectar 3.74 0.18±0.02 13%

Mango drink 3.35‐3.38 0.15‐0.16 4%

Apple fruit drink 3.06 0.15 ‐0.16 4%

Mix fruit drink 3.35‐3.38 0.15‐0.16 4%

Male: 600

2) Sanitization of industry should be done and assessed on daily basis.

3) Industry should have its own ambulance.

4) Expert person in first aid should be present round the clock.

2) Appraisal must be done on workers achievement.