Milk Collection and Dairy Development

For year 2020

Submitted by:

Ali Hasan 16-Arid-3413

Ali Saadullah 16-Arid-3415

Muhammad Abrar 16-Arid-3418

Muhammad Faisal 16-Arid-3419

Sohail Abbas 16-Arid-3422

Session (2016-2020)

Internship Report Malmo Foods (PVT) Ltd Lahore

A project report submitted in partial fulfillment Of the

requirements for the degree of

BS (Hon’s) Dairy Technology

Department of Food and nutritional sciences

PIR MEHR ALI SHAH Arid Agriculture University Rawalpindi

Sub Campus
To Whom It May Concern

It is certified that students of BS Hons Dairy Technology, Pir

Maher Ali Shah Arid Agriculture University Rawalpindi Sab-Campus Khushab
have completed their Internship training program in Malmo Foods (Pvt) Ltd, from
24th February to 7thJuly 2020.
I found them very honest, hardworking, regular and obedient. He did his
job with great interest.

I wish him every success in his life and a prosperous future.

Regards:
Akhtar Ali (QAM)
Asad Hameed
Mudasir Farooq (Lab Supervisor)
Mudasir Hussain (RO Incharge)

Malmo Foods (Pvt) Ltd

Lahore

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 Acknowledgment:

We surrender ourselves before ALMIGHTY ALLAH who created

this universe and blessed him with good health, high morale,
intellectual efficiency and capabilities to complete this project.
Without the special blessings of Allah, it wouldn’t have been a
possible issue.

With the special reverence to the teacher of the world, the lamp of
piousness, HOLY PROPHET MUHAMMAD (Peace Be Upon
Him) who enabled the mankind to think and to recognize creator.
The man who led the mankind from the clouds of darkness and evil
to the developed world of today’s era.

No Acknowledgement could ever be completed without paying

homage to Parents, family and loved ones. We are quite indebt able
to our family for not only supporting him financially but also
morally and socially that helped made a contended man.

May Allah Almighty Bless him.

Dedication:
This piece of our work is dedicated to Almighty Allah, the caliph of all the Prophets, the sun
of pious, the obligor of whole humanity Hazrat Muhammad (S.A.W.). our Parents who
themselves suffered to make him prosper, our all teachers specially (Dr. Muhammad Abid, Dr.
Muhammad Kamran, Dr. Muhammad Nadeem, Dr. Anees ur rehman, Dr. Muhammad Ajmal,
Mr.Haji Muhammad Ehsan) who equipped him with knowledge and our sweet friends whose
words have always been a source of strength for him. We are also thankful to the administration
and staff of Malmo foods for their corporation.

No# Topic Name Page

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 No
01 Introduction 05

02 Introduction Of Malmo Foods

03 History

04 Certification

05 Mission 07

06 Malmo Food Products 08

07 Milk Procurement Department 10

08 Collection Center’s Of Malmo 11

09 Milk SamplingFresh Milk Testing 11

10 Fresh / Pasteurized / UHT Milk Tests 13

11 Milk Parameters Of Malmo Food 24

12 Powder Milk Tests 25

13 Powder Milk Parameters Of Malmo Food 29

14 Butter/Ghee Lab Tests 29

15 Ice Cream Lab Tests 31

16 Cheese Lab Tests 31

17 31

18 32

19 34

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 20 34

21 35

22 UHT Section 39

23 Milk 42

24 Cheese Section 47

25 Ice Cream Section 53

26 Juice Section 55

27 KHOA Section 58

28 Ghee Section 59

29 Butter Section 61

30 63

31 Tetra PAK 67

32 68

33 69

34 71

35 72

Introduction:-
As a part of bachelor’s studies in sustainable development I did a internship (24 fab to
7 July). This report covers the exercises and obligations that I performed amid my temporary
position at Malmo Foods (Pvt.) Limited. Malmo Foods is the National Company with a
consuming enthusiasm to go up against the universal market. The report begins with the

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presentation of the organization, at that point the mission and the vision of the association and its
structure covering every one of the offices.

Dairy:

A dairy is a facility for the extraction and processing of animal milk mostly from
cows or goats, but also from buffalo, sheep or camels for human consumption.

Technology:

The Science and the application of scientific, economic as well as sociological knowledge
and legal rules for the production of Raw material and their further processing into semi finished
and finished products.

Dairy technology:

Defined as, combination of theoretical and practical knowledge based on a

scientific background and control of process for the treatment and conversion of milk
into milk products.

Process technology:

Deals with the conversion of raw material into

finished products.

Introduction of Malmo Foods:

Malmo Foods is managed by a board

of Directors who have vested the control of the company operations with the Chief Executive
(CE). The CE is nominated as a person with overall responsibility for all matters relating to
quality. CE is supported by a number functional heads of departments, including a full time
Management representative, responsible for maintenance of the ISO 9001 quality
management systems.
History:

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  Malmo Foods was incorporated in 1999s an organization. The Head Office & Plant
is situated at 2-km Defense road, Off Raiwind Road Lahore
 In 2000, it also started production of butter and ghee for its Malmo Outlets with
brand name "Malmo Butter". At start two types of powder were produced, SKIM
Milk Powder & FULL CREAM Milk Powder.
 Later in 2001, Malmo Foods launched VEGETABLE FAT FILLED Milk Powder
first time in Pakistan, which attracted many multinational companies.
 Commercial production of dry milk powder was started in 2000.
 In year 2004, company lunched UHT packed milk and Desi Ghee in Tins. Malmo
Foods decided to implement the concept of TQM. As an initial step, the
management opted to acquire ISO 9000 certification.
 In 2004, Malmo Foods installed UHT & Tetra Pak and launched its product with
brand name "VANIA Milk" pack size of 250ml. Malmo Foods has its distribution
network in all major cities of Punjab, kpk and Baluchistan. Major customers of
Malmo Foods Powder Products are Asian Foods (Mayfair), Pakistan Army and
many Pharmaceutical companies.
 In 2008 start the production of Malmo Apple, Mango, Guava and pomegranate
 In 2012 start the production of Malmo drinking water
 In 2015 Malmo powder milk and pasteurized milk started.
 In 2016 Malmo UHT tetra pack milk and Malmo tetra pack flavor started.
 In 2017 Malmo start the production of non dairy whipped cream and Malmo cheese
(Mozzarella and Cheddar cheese).
 In 2019 Malmo lunched the Continuous Butter making Machine (CBM).
Certifications:

Our wide range of pure dairy products has a significant impact on the
improvement of health of people. Dairy brands of Malmo Foods play a major role in the
nutritional building of human body. These instant and full of taste products help you
growing faster and healthier.
Malmo Foods products are certified from.

 Members of Sedex

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  Halal certification
 ISO-9001
 Food Safety certification -22000

Some of our certificates are placed

Mission:

“To continuously exceed our customer expectation for quality products and services”
Our goal is to offer top quality brands and innovative packaging to meet the individual needs of
consumer all over the country, whenever, wherever and however.

At Malmo Foods, our research makes it possible for everyone to enjoy better food
for a better life. Good Food is the primary source of Good Health throughout life.

Vision:

Excellence in food and especially in Dairy products.

Malmo Diaries Products:

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 Our wide range of pure dairy products has a significant impact on the
improvement of health of people. Dairy brands of Malmo Foods play a major role in the
nutritional building of human body. These instant and full of taste products help you growing
faster and healthier.

1) Malmo Pasteurized Milk

2) Malmo Milk UHT tetra pack

o Malmo Strawberry Flavored milk
o Malmo RUS Milk (Banana flavored)
o Malmo RUS Milk (BADAM ZAFRAN flavored)
o Malmo RUS Milk (KHAJOOR Flavored)

3) Malmo UHT Milk

4) Dairy Fresh milk

5) Tea whiteners
 Vania (Liquid Tea whitener)
 Every Time (Liquid Tea Whitener)

6) Instant Milk Powder

*IFCMP (Instant full cream milk powder)
*ISMP (Instant skim milk powder)
*VFFMP (Vegetable fat filled milk powder)

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 7) Malmo Butter

8) Malmo Desi Ghee

9) Malmo KHOA

10) Malmo Cheese

 Malmo Cheddar cheese
 Malmo Mozzarella cheese
11) Pasteurized Cream

12) Wiped Cream

13) Malmo Drinking Water

14) Malmo Fruit Rus (juices)

 Apple Drink
 Pomegranate
 Mango
 Guava

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 15) Malmo Ice Cream
 Malmo Kulfa
 Malmo Pista
 Malmo Strawberry
 Malmo Mango
 Malmo Vanilla
 Malmo Chocolate
 Malmo Coconut
 Malmo coffee

Milk Procurement Department:

Milk is defined as "clear lacteal secretion of healthy animals after and
before fifteen days of calving" Generally, the gross composition of milk is Water 87.7%,
Lctose4.9%, Fats 3.4%, Proteins 3.3%, Minerals 0.7%. However its composition varies from
species to species. In Pakistan, cows and buffaloes are the prime sources of milk.
Dairy department deals with the reception, processing & production of UHT milk and various
milk products.

Milk Reception:

Here milk from the Milk Collection Centers is received, tested and forwarded to the
Standardization Section. This department is responsible for all operations, involving the
collection of milk from the tankers to testing the milk as per requirement. There are few fixed
procedures that are to be followed before receiving milk.

The milk received through tankers is first properly weighed on a weighing bridge. The
weight shown on the scale is actually the truck weight (or “tare “weight) plus the weight of milk.
The cumulative weight is noted. The tare weight of each tanker is already in the data and that is
subtracted from the cumulative weight and we get the actual weight of the milk. After the milk is
pumped out, the tanker is again weighed so as to counter check the tare weight of the tanker. If
there is any significant change, appropriate action is taken.

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The tankers coming to the factory are in two capacities

 12,000 liters

 20,000 liters

The most critical parameter in the milk reception area is the CIP of the tankers
entrusted for the purpose. For the said purpose, all the tankers irrespective of the capacities are
sent for CIP at the specified station. Dairy department deals in the milk reception, its processing
& production of UHT milk and various milk products.

Collection Centers:

There are three Self collection centers.

 Chichawatni
 Abdul Hakeem
 Arif Wala

Milk Sampling:

Quality Sample:

This sample is taken from each portion of the tanker and is taken before receiving
the Fresh milk. On quality sample, the following tests are performed to check the quality of the
milk.

“Milk Quality Tests”

Four types of fresh milk testing.

1. Organoleptic test.

2. Quantitative tests.

1. L.R

2. Fat%

3. SNF%

3. Qualitative tests.

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 1. Temp 0C

2. COB

3. APT

4. Acidity

5. pH

6. Salt

7. Protein %

8. Whey Protein %

9. Antibiotic

10. Aflatoxin

11. DRT

4. Adulteration tests.

1. Glucose

2. Sugar

3. Detergents

4. Starch

5. Urea

6. Formalin

Fresh Milk Analysis in Milk Reception Lab

1. Organoleptic test.

Principle:

To check the suitability of milk for further processing.

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Materials:

Water bath, Thermometer, Beaker 500ml.

Method:

 Heat sample to 35-40 0C.

 Stir it; examine it for color, taste, and smell.
 Normal milk has a slightly sweet pleasant taste, white in color with no objectionable
odor.
2. Quantitative tests.
1. Determination of Fat % By Gerber Method:

Principle:

Milk and sulphuric acid added to Gerber butyrometer. The butyrometer is

shaken manually during which acid digest the milk protein. A small quantity of
ISO amyl alcohol is also added to enhance fat separation during centrifugation.
The butyrometer is graduated to give reading of fat contents.

Safety Precaution:

Wear normal laboratory protective equipment to protect against accidental

release of sulphuric acid. Never mouth pipette the acid and amyl alcohol

Materials:

Milk sample, butyrometer, Automatic measurer, sulphuric acid 90-91 %, Iso-amyl

alcohol, Gerber machine 1280rpm,

Method:

 Take butyrometer and add 10ml sulphuric acid 90-91 % at 20 oc.

 Now added 10.94ml milk sample with pipette.
 Then added 1ml Isoamyl alcohol.

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  Close the stopper and shake well and placed in the Gerber machine having 1280rpm for 3
minutes and another butyrometer is also placed in front of it to create balance.
 After 3 minutes the butyrometer is taken out and fat % is noted.
2. Lactometer Reading for SNF Calculation in Fresh Milk sample:

Purpose:

Determination of SNF %/ Total solid % in Fresh Milk sample.

Materials:

Lactometer (20 0C), Measuring cylinder 250/500 ml, Thermometer, Beaker.

Method:

 Warm the sample of milk to 40°C then cool down to 20°C and then pour in cylinder.
 Gently lower the lactometer in cylinder.
 Note the reading when lactometer comes in rest. This is called lactometer reading (LR).
Then specific gravity is calculated by the following formula
 Then SNF% calculate as follows

SNF% = LR/4 + (0.22xFat) +0.72

3. Paneer test

Purpose

To check the water activity of milk

Procedure

 Take 250ml of milk sample in beaker

 Add 10 ml of H2SO4 (sulphuric acid)
 Give aging time about 1 to 2 hour
 If water activity is low then milk is good.

3. Qualitative tests.

1. APT Test for Fresh Milk sample:

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Purpose:

Check the stability of fresh milk

Materials:

Milk sample, Test tube, pipette, Apt Solution 60 %.

Method:

 Take 3ml milk in test tube with pipette.

 Add 3ml 60 % ethanol in it.
 Shake it well.
 Check precipitates.
 If precipitates are formed then test is positive otherwise negative.

2. COB Test for Fresh Milk sample:

Principle:

Heating of milk to boiling point.

Materials:

Milk sample, Test tube, pipette, Burner.

Method:

 Take 3ml milk in test tube with pipette.

 Now heat it on burner up to boiling point
 If clot formation occurs then test is positive otherwise negative

3. Determination of Acidity for Fresh Milk sample:

Principle:

Formation of light pink color in the presence of indicator when titrated against the 0 .1N
NaOH.

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Materials:

Milk Sample, Beaker, Pipette,, phenolphthalein, 0.1N NaOH.

Method:

 Take 10ml milk sample in beaker with pipette.

 Add 2-3 drops of phenolphthalein in it.
 Now titrate with 0.1N NaOH solution.
 Note light pink color is appeared.
 Note reading on equipment.
Acidity% (as lactic acid) = burette reading×0.009×100/volume of sample taken.

Acidity%= Reading×0.1 (Malmo Foods)

4. Determination of pH in Fresh Milk sample:

Materials:

Milk sample, Pipette, Beaker, pH meter, KCL3, Buffer 4,7 and 10, Thermometer.

Method:

 Milk sample temperature is adjusted at 20 0c and buffer 4,7 and 10 are calibrated.
 Wash the electrode of pH meter with distilled water before use.
 Dip the electrode of pH meter in milk sample and note the pH of milk sample on pH
meter.
 KCL3 is a storage solution for pH meter electrode.
5. Determination of Salt in Fresh Milk sample:

Purpose:

Determination of (NaCl) Salt % in Fresh Milk sample.

Materials:

Burette, Pipette, Dropper Bottle, Beaker.

Method:

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  Take 9ml of well mixed sample in a 100ml glass beaker.
 Add 3~4 drops of Potassium Chromate indicator.
 Tare the burette reading before titration and make sure that it is at “0”.
 Titrate the sample against 0.1N Silver Nitrate (AgNO3) solution.
 Stop titration when light brown color appears.
 Note the reading of AgNO3 used from burette.
 Calculate the Salt percentage as follows:
Salt%= readingx0.065x8.52 / SNF %
6. Determination of Protein % in Fresh Milk sample:

Principle:

Milk sample is neutralized with NaOH using phenolphthalein for the release of
ammonia and back titration using formalin solution.

Materials:

Milk sample, Titration Flask, pipette, Titration Apparatus, NaOH .1 N, dropper for 1 %
phenolphthalein, Formaldehyde 35% 2ml.

Method:

 Take 10 ml thoroughly mixed sample in titration flask and add 3 drops of 1 %

phenolphthalein as indicator.
 Now neutralized it with .1 N NaOH to get light pink color.
 Now add 2ml 35 % formaldehyde solution and wait for 5 minutes.
 Neutralize it again with .1N NaOH and note the volume V1.
 Take 2ml formalin and add 10ml distilled water in titration flask.
 Neutralize with .1 N NaOH using phenolphthalein as indicator.
 Note the volume V2
Protein % = (V1 –V2) x 1.94
7. Detection of Whey Protein in Fresh Milk sample:

Purpose:

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 To check the Whey Protein % of Total Protein % in liquid milk

Materials:

Glass Beaker, Glass Cylinder, Pipette 10 ml, Pipette 2.0 ml, Thermometer, Water Bath,
Filter Paper. Formaldehyde Solution Min. 35%, N/10 NaOH Solution, phenolphthalein Solution
(as indicator), Citric Acid 99.5 %.

Method:

 Perform Protein Test as per QCL/STM/053 and save (V1 = Final Reading X 1.94)
 Thoroughly mix the Milk Sample with the help of Thermometer.
 Take 50ml milk sample in a clean dry 100ml glass beaker.
 Heat the sample up to 60 ~ 65 °C in water bath and add 0.5gm Citric Acid to get whey
content.
 Filter the whey content with the help of filter paper in a clean dry glass cylinder.
 Take 10ml filtrate in a glass beaker and add 2~3 drops of Phenolphthalein indicator.
 Titrate it against N/10 NaOH solution till light pink end point.
 Add 2ml Formaldehyde in this sample and stay for 5 minutes.
 After 5 minutes, again titrate the content with N/10 NaOH till light pink colour end point
and note the reading as V2
 Take 2ml of Formaldehyde in glass beaker and add few drops of distilled water.
 Add 2~3 drops of Phenolphthalein indicator and titrate against N/10 NaOH till light pink
end point.
 Note this reading as V3.
 Calculate the Whey Protein % as per given formula:

Final Reading = V2 – V3
Whey Protein % (of Total Protein %) = (Final Reading X 1.94 X 100)

V1
8. Antibiotic Test for Fresh Milk sample:

Principle:

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 To detect Beta lactam & tetracycline drugs this test is used. Twin sensor equipment is
used for this purpose. This test also determines oxytocin in milk.

Materials:

Milk sample, Twin sensor, Micro well, twin sensor chip, and Micro pipette.

Twin Sensor BT

(ß-lactam + Tetracycline detection)

Test procedure:

 Add milk (200μl) to the reagent micro well and homogenize with the pipette.
 Place the micro well onto the heater block for 3 min.
 Add dipstick to micro well and incubate it for another 3 min.
 Take out the dipstick and interpret the color intensities.

Reading the results

Comparing the intensity of the «TEST» lines with that of the «CTRL» line allows a

Visual interpretation of the results.

 When the «TEST» lines - either bottom ß-lactam or top tetracycline - are more visible
than the «CTRL» line, the sample is considered to be NEGATIVE and contains a lower
antibioticconcentration than the Detection Limits.

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  When the «TEST» lines are as visible as the «CTRL» line or less visible than the
«CTRL» line, the sample is considered to be POSITIVE and contains an antibiotic
concentration that is equal to or higher than the Detection Limits.
 No «TEST» line indicates a HIGHLY POSITIVE sample for both ß-lactam and
 Tetracycline compounds. When hesitating, you should regard the sample as positive and
confirm by having a second interpretation four (4) minutes later.
9. Aflatoxin Test for Fresh Milk sample:

Purpose:

To detect aflatoxin this test is used. Twin sensor equipment is used for this purpose.

Materials:

Milk sample, Twin sensor, Micro well, twin sensor chip, and Micro pipette.

Twin Sensor

Test procedure:

 Add milk (200μl) to the reagent micro well and homogenize with the pipette.
 Place the micro well onto the heater block for 3 min.
 Add dipstick to micro well and incubate it for another 3 min.
 Take out the dipstick and interpret the color intensities.

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Reading the results

Comparing the intensity of the «TEST» lines with that of the «CTRL» line allows

10. Dye reduction test of Fresh Milk sample:

Principle:

Estimation of quality or shelf life in milk is determined through Methylene blue activity.

Materials

Milk sample 9 ml, 1ml Pipette, Methylene blue Reagent, water bath 40 0c.

Method:

 Take 9ml milk sample in test tube with the help of pipette.
 Now add 1 ml Methylene blue in it.
 Mix it well, it will become blue colored then place it in 40 0c water bath.
 Check result after every 30 minutes.
 If it is pure white milky in less time it means that milk sample has less shelf life.
 If it takes longer time to become white milky it indicates that milk sample has more shelf
life and of good quality.
5. Adulteration tests.

1. Detection of Glucose in Fresh Milk sample:

Principle:

To check the presence of Glucose in liquid milk.

Materials:

Milk sample, Test tube, pipette, Barford’s reagent, water bath 100 0c

Method:

 Take 5ml of milk in test tube with the help of pipette.

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  Now add 5ml Barford’s reagent.
 Mix it well and place in water bath 100 0c for minute.
 And note the result by comparing the color change with evaluation chart.
 If color is greenish then it is positive and if color is blue then negative.
2. Detection of sugar in Fresh Milk sample

Principle:

This method is based on visual comparison of test sample with a blank sample by
heating them in presence of HCL after addition of alpha naphthol.

Materials:

Milk sample, Test tube, pipette, water bath 100 0c & chilled water bath, Alpha
naphthol, HCL 37%.

Method:

 Take 0.5 ml milk in test tube with the help of pipette.

 Now add 3 drop of alpha naphthol with dropper.
 Then add 3ml 37% HCL.
 Mix it well and place it in water bath 100 0c for 10 seconds
 Blue or violet is positive light blank color is negative.
3. Detection of detergent in Fresh Milk sample:

Principle:

Formation of dark pink coloration suddenly by reaction of ethyl alcohol and rosalic acid.

Materials:

Milk sample, Test tube, pipette, 95 % ethanol, Rosalic acid.

Method:

 Take 5 ml milk sample in test tube with the help of pipette.

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  Now add 5 ml ethanol.
 Add 3-5 drops of Rosalic acid and shake well
 Formation of pink color after 15-45 minutes indication of detergents.
4. Detection of Starch in Fresh Milk sample:

Principle:

Color of starch in milk by mean of iodine. It is added to increase density.

Materials:

Milk sample, Test tube, pipette, Iodine solution

Method:

 Take 3ml composite sample with pipette on Petri dish.

 Now add 2-3 drops of iodine in it.
 And check the color from the base of the Petri dish.
 If black spots are appeared then test is positive otherwise negative.
5. Detection of Urea in Fresh Milk sample:

Principle:

Formation of pink coloration of the phenol red indicator due to reaction of urea with
urease enzyme in the solution.

Materials:

Milk sample, Test tube, pipette, Urease solution, Phenol red indicator, Water bath 40 oc,
Evaluation chart.

Method:

 Take 5ml milk in test tube with pipette.

 Now add 5ml urease solution (2g urease powder, 3g dipottasium hydrogen phosphate and
make the volume up to 1000ml).
 Mix them and place it in water bath of 40 0c for 15 minutes.

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  After it add 1-2 drops of phenol red and note the result by comparing it with evaluation
chart.
 Dark pink color indicates test is positive.
 Orange or yellow color indicates test is negative
6. Detection of Formalin in Fresh Milk sample:

Principle:

Sulphuric acid containing traces of ferric chloride give purple color with formalin present
in sample.

Materials:

Milk sample, Test tube, pipette, 90 % Sulphuric acid with traces of ferric chloride.

Method:

 Take 2ml 90 % sulphuric acid in test tube with the help of auto measurer and add 2 ml
milk sample in it.
 After about 1 minute formation of violet or blue ring at junction of milk and acid indicate
the presence of formalin in milk sample.
 If color is brown then test is negative.
Raw Milk Parameters

Parameters Norms
Organoleptic Clean flavor, no off odor, no off taste
APT - ve
COB -ve
Acidity 1.1-1.5
Ph 6.60-6.85
Salt 0.18-0.23
SNF 7.5 to 8.5
Protein > 2.75
Glucose -ve
Sugar -ve

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 Starch -ve
LR 25 to 32
Formalin -ve
Urea -ve
Antibiotics -ve
Temperature <8 0c
Fat 4.35%
Total solid 12.45%
Detergents -ve
Antibiotics -ve
Aflatoxin -ve
Parameters of flavor milk / tea whiteners/ cream

Parameters Norms
LR(flavor) 45 to 50
Fat (flavor) 3.5%
Fat (cream) 46 to 52%
Fat (whitener) 3.5%
LR 15s
Milk Powder lab tests.

1) Organoleptic
2) Moisture
3) Fat%
4) Acidity
5) Ph
6) Wettability
7) Bulk density
8) Protein
1. Determination of Moisture in milk powder

Purpose

To check the moisture content in milk powder

Procedure

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  Take 2.5 g of milk powder
 Tear and remove moisture from moisture analyzer plate
 Place the sample in moisture analyzer at 110°c temperature
 Reading is appeared on screen.
2. Determination of fat% of milk powder

Purpose

Determine the fat% of milk powder

Procedure

 Take 2.5 g of milk sample of milk powder

 Take a butyerometer of 35%
 Add 10 ml of sulphuric acid with help of pipette.
 Add 10ml of water in butyrometer and add the sample in butyrometer.
 Add 2ml of isomayal alcohol.
 Put stopper on it and shake well until all milk is dissolve in it
 Place the butyrometer in centrifuge machine for 10 minute at 65°c temp and 1100rpm.
 Note the reading of butyrometer.
3. Wettability of powder milk

Purpose

To check the intensity of milk powder.

Procedure

 Take 10ml of powder milk sample

 Take 100ml of water in 250 ml beaker
 Add the milk sample in beaker and note the time until powder is dissolved in water.
4. Bulk density of milk powder

Purpose

To check the solidity of powder milk.

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Procedure

 Take 35g of milk powder sample

 Put into 100ml of plastic cylinder
 And tapping 100 time and note the reading on cylinder

Calculation

Density = g/c

5. Determination of acidity in milk powder

Principle.

Formation of light pink color in the presence of indicator when titrated against the 0 .1N
NaOH.

Procedure.

 Make a solution of powder milk if full cream powder then take 13g of powder sample
and 87g of water and if skim milk powder then take a 10g of powder in 90 g of water
 Mix the sample well until no clots are appeared
 Take 17.6 ml of sample from solution with help of pipette in beaker
 Add 3 drops of phenolphthalein
 Titrate with NaOH 0.1 solution until the light pink color is not appeared
 Note the reading

Calculation

Reading / 20

6. Determination of protein in powder milk

Principle

Milk sample is neutralized with NaOH using phenolphthalein for the release of
ammonia and back titration using formalin solution.

Procedure

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  Take 10 ml thoroughly mixed sample in titration flask and add 3 drops of 1 %
phenolphthalein as indicator.
 Now neutralized it with .1 N NaOH to get light pink color.
 Now add 2ml formaldehyde solution and wait for 5 minutes.
 Neutralize it again with .1N NaOH and note the volume V1.
 Take 2ml formalin and add 10ml distilled water in titration flask.
 Neutralize with .1 N NaOH using phenolphthalein as indicator.
 Note the volume V2.
Calculation

Final reading =V1- v2

Protein% = final reading×1.94×100/9
7. Determination of ph in powder milk

Materials:
Milk sample, Pipette, Beaker, pH meter, KCL3, Buffer 4 and 7, Thermometer.
Method:

 Milk sample temperature is adjusted at 20 0c and buffer 4 and 7 are calibrated.

 Wash the electrode of pH meter with distilled water before use.
 Dip the electrode of pH meter in powder milk sample solution and note the pH of powder
milk sample on pH meter.
 KCL3 is a storage solution for pH meter electrode.
Parameters of full cream milk powder.

Parameters Norms
Organoleptic Creamy white color. no objective able odor,
Fat% 25 to 32%
Moisture 2 to 3%
Wettability 20sec
Solubility 1.25ml

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Butter / Ghee lab tests.

1) Organoleptic
2) Moisture
3) Fat%
4) Free Fatty Acid ( FFA)
1. Determination of Moisture in Butter / Ghee.

Purpose

To check the moisture content in Butter / Ghee

Procedure

 Take 2.5 g of Butter/ Ghee sample.

 Tear and remove moisture from moisture analyzer plate.
 Place the sample in moisture analyzer plate at 155°c temperature.
 Moisture Reading is appeared on screen.
2. Determination of fat% in Butter / Ghee

Purpose

Determine the fat% of butter

Procedure

 Take 5 g Butter / Ghee sample.

 Take a butyerometer of 90%.
 Add 10 ml of sulphuric acid with help of pipette.
 Add 2ml of isomayal alcohol.
 Add about 10ml of water in butyrometer and mix the sample in butyrometer.
 Put stopper on it and shake well until all milk is dissolve in it.
 Place the butyrometer in centrifuge machine for 10 minute at 65°c temp and 1100rpm.
 Note the reading of butyrometer.
3. Determination of Free Fatty Acid

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Procedure

 50 ml of ethanol in flask
 Add 1 ml or 10 drops of phenolphthalein
 Titrate with NaOH 0.1N solution
 Take 56.40 ml of ghee sample
 Add into flask and mix well
 Titrate with NaOH 0.1N solution until brick red color is not appeared.

Calculation

Ffa % = final reading × 2.82 / wt of sample

Butter / Ghee parameters.

Parameters Norms
Fat % 80 to 88%
Moisture 16 to 18%
Ash .2 %
R.M value Max 26
FFA% 0.30 %
Ice cream lab tests.

1. Organoleptic
2. Fat %
3. SNF %
4. PH

Parameters of ice cream

Parameters Norms
Fat % 8 to 14%
SNF% Not less than 10.1
Total solids 36 to 40%

Cheese lab tests.

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 1) Fat
2) Moisture
3) PH

Parameters of cheese.

Parameters Norms
Fat % 45 to 55%
PH 52 to 60%
Moisture 5.90%
Juice lab tests.

1. Brix
2. Acidity
3. PH
a Brix of juice
 Take brix meter
 Put 1 to 2 drops of juice
 Turn the brix meter towards light
 Note the brix of juice
b PH of juice

Materials:

Milk sample, Pipette, Beaker, pH meter, KCL3, Buffer 4,7and 10, Thermometer.

Method:

 Milk sample temperature is adjusted at 20 0c and buffer 4, 7and 10 are calibrated.

 Wash the electrode of pH meter with distilled water before use.
 Dip the electrode of pH meter in juice sample and note the pH of juice sample on pH
meter.
 KCL3 is a storage solution for pH meter electrode.
Juice standard in Malmo foods.

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 Parameters Norms
PH 2.5 to 4%
Brix 10 to 13
Acidity 0,25 to 0.28
Water lab tests.
1. Hardness of water
2. Ca hardness
3. Mg hardness
4. Nitrate content material of water
5. Sulphate content of water:
6. TDS
1. Hardness of water:
 Take 25 ml sample of water in a beaker.
 Add 2ml ammonia buffer in it. Add 2-3 drops of Erichrome black T (0.2%).
 Titrate with EDTA (zero.01N).
 End factor is light blue color.
Hardness=ml of titrant used/ml of pattern taken×1000 ppm OR
Hardness = ml of titrant used× 40
2. Ca hardness:
 Take 25 ml sample of water.
 Add 2ml ammonia buffer in it. Stay for 3-5 mints.
 Add 2- 3 drops of murex ide (0.5%).
 Titrate with EDTA, till mild crimson cease point.
3. Mg hardness:

Total hardness-Ca hardness= x (Mg hardness) = x×978

4. Nitrate content material of water:

 Took sample in a take a look at tube.
 Insert 1 nitrate take a look at strip in check tube and be aware the time.

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  After 60 seconds took out strip from pattern and in shape the coloration with the
reference coloration scale at the box.
 And note the result in ppm and mg/l of a pattern according with the matching field.
5. Sulphate content of water:
 Took sample in a take a look at tube.
 Insert 1 sulphate test strip in check tube and note the time.
 After 120 seconds took out strip the form pattern and suit the coloration with the
reference shade scale on the box.
 And observe the result in ppm and mg/l of a sample according with the matching field

Parameters of Drinking water.

Parameters Norms
PH 6.5 to 8.5
TDS 170 to 200ppm
Nitrites 1.0ppm
Chlorides 200ppm

TH 200PPM

Tests for CIP.

 Acid (nitric acid)

 Lye (sodium hydro oxide)
 PH of water

ACID

 Used nitric acid for CIP

 Take 1ml of acid sample
 Add 2 to 3 drops of phenolphthalein indicator
 Titrate with NaOH 0.1N solution until light pink color is not appeared
 Note the reading

Calculation

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 = Reading × 0.63

STANDARD IS 1 to 1.5

Lye

 Used sodium hydro oxide for CIP

 Take 1ml of lye sample
 Add 2 to 3 drops of phenolphthalein
 Titrate with sulphuric acid H2SO4 until color is dispersed or not appeared.

Calculation

= reading × 0.4

Standard is 1.5 to 2.0

Incubation Lab:

Purpose is check to shelf life and quality of products.

 Incubation time (01day, 3days, 5days)

 Shelf life (12 weeks)

Purpose is check to shelf life of finish good products.

 Organoleptic
 pH
 Fat separation
 Sedimentation
Pasteurization Section

The founder of this procedure is Louis Pasteur; in which heat treatment is given to
the milk in order to inactivate the enzymes and destroy the pathogenic microorganisms & it also
produce whitening in the milk. The shelf life of the milk is increased up to 7-8 days after
pasteurization.

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 The following steps take place in the process of pasteurization:

i) Reception of raw milk

From the formers and collection center milk is received comes through three
filters that totally removed all sediments, sand particle, straws from the milk the
temperature of milk is 7 to 10 °c and transferred towards silos.
ii) Balance tank:
From the silo milk comes in the tank through a bag filter. 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.

iii) Regeneration No. 1

From balance tank milk goes to regeneration No 1, where the temperature of the milk
is raised up to 35-40ºC by regeneration method. In regeneration No1 the milk & the hot milk
coming after pasteurization has counter flow.

iv) Regeneration No 2

Then milk goes to regeneration No. 2. It is also a part of plate heat exchanger
(PHE) in which milk is heated up to 55-65ºC. the capacity of PHE is 8000 t0 12000 /hour

v) Separator

From regeneration No. 2 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 from milk
(Sludge). Separator works at 6000-7000 rpm & it has porous stacked plates.

Pressure of separator is about 50 to 200bar and capacity of milk in one hour is

14000 to 15000 liter

vi) Deodorizer:

From separator milk goes to deodorizer. As the name indicates it deodorize the
bad smell of milk. It is steel tank (5 feet long) and divided into two parts by a thin steel plate.

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The lower portion of deodorizer contains cold plate having chilled water line, which cools the
central plate. Milk falls on the cold surface; the bad odor vapors rise upward and these are
sucked out by a vacuum pump and released out after condensation along with water.

vii) 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 (1
µm)

viii) Heating section:

In the heating section temperature of milk is increased to 75-80ºC with help

of hot water.
ix) Flow Diversion Valve:
If temperature of milk is less than 75ºC, it will not go towards holding tubes, it is
delivered back to balance tank by flow diversion valve for reproducing.

x) Holding Tubes:

Here milk stays for 15-20 sec at 75-80ºC, so that enzymes like phosphatase,
peroxidase, lipase etc. are inactivated ad microbes are killed.

xi) Regeneration No 2:

Pasteurized milk moves back in regeneration No 2 to warm the cold milk of balance
tank. So in this way energy is conserved. Here temperature of milk drops to 55-60ºC.

xii) Regeneration No 1:

Pasteurized milk heated the incoming cool milk to save the energy. Here the
temperature of milk drops 35-40ºC.

xiii) Cooling section:

In cooling section the temperature of the milk drops to 4-6ºC by coming in contact
with chilled water.

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 Equipment Capacity

Silo (1,2) 75,000L

Tank milk 22,000L

P (1,2,3,4)

Tank(chilled cream) 8,000L

p (5)

Tank (hot cream) 12,000L

p (6,7)

Total milk received 2,00,000L

Balance tank 500L

Flow Diagram for Pasteurization Plant

Raw milk tank Homogenizer
Triblender Filter
storage

Feed Pump
Pump Tank p3 Heating
section

Bag Filter Holding Tube

Balance Tank

Flow
Product Pump Diversion

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Balance Tank

Cream Pasteurizer R1 Pasteurizer

Pasteurizer

Pasteurizer
Pasteurizer R1
Separator

Cooling Section
Hot cream
P(5,6,7) Deodorizer
Shifted to
silo 1, 2,
and P
1,2,3,4
UHT SECTION

Definition:

A sterilization process is defined as a UHT (Ultra High Temperature) process. If the

product is heat-treated in a continuous flow at a temperature of not less than 135ºC for few sec
followed by Aseptic Packaging.

Process Steps:

i) Balance Tank:

From silos after standardization milk to the balance tank which controls the quantity
of incoming milk.

ii) Pump:

It pumps the milk from balance tank to regeneration no.1

iii) Regeneration Coil #1:

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 It is a part of Stabilizer (it is a long drum shaped unit in which spiral shaped tubes
(double jacketed) are present. In this section temperature of milk is raised to 70ºC by outgoing
sterilized milk)

iv) Homogenizer# 1:

Here the homogenization is done to break the fat clamps that formed during
pasteurization and storage under a pressure of 200-210 bar.

v) Regeneration Coil #2:

Here the temperature of the milk is raised up to 120ºC by outgoing UHT milk.

vi) Heating Section:

Milk is heated to 135-140ºC by indirect action of steam.

vii) Holding Tubes:

Here the milk will stay for 2-3 seconds.

viii) Regeneration Coil # 2:

From holding tubes milk comes into regeneration no 2 coil, where it is cooled to
120ºC by coming cold milk.

ix) Homogenizer # 2:

It is done at 40 bar. Here the fat is uniformly distributed in the milk.

x) Regeneration Coil # 1:

Milk is cooled to 80ºC by coming milk entering in the UHT plant from silo tank.

xi) Chilling Section:

Milk in this section is cooled to 24-30ºC with the help of cold water.

xii) Aseptic Tank Storage (ATS Tanks):

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 Theses tanks are used to store the UHT milk if t is not delivered to Tetra Pack.
Milk can stay there for 24 hrs. capacity of Aseptic tank is 15,000L

xiii) Aseptic Filling:

It is done by Tetra Pak

xiv) Aseptic Packaging:

Packaging of a sterile packaging material under sterile conditions.

NOTE:

 UHT plant capacity is 13000L/Hr

 AIR operating valve used in UHT plant
 Load cells in UHT plant shows us the volume of aseptic filling
 Whole plant pressure is 3-4.5bar
 Pressure of steam in UHT is 14bars
 In ATS pressure is 1.10 bar

UHT Flow Diagram

Pasteurize milk storage

Pump

Balance Tank

Product Pump

Regenerator 1

Homogenizer Pressure stage 1

Regenerator 2

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 Sterilizer

Holding Tube

Regenerator

Homogenizer stage 2

Regenerator 2

Cooler

Aseptic Filler Aseptic Storage

Advantages of UHT

Long shelf life:

Greater than 6 months, without refrigeration can be expected.

Packaging Size:

Processing conditions are independent of container size, thus allowing for the filing of
large containers for food-service.

Cheaper Packing:

Both cost of package and storage and transportation costs; laminated packing allows
for use of extensive graphics.

Difficulties with UHT

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Sterility:

Complexity of equipment and plan re needed to maintain sterile atmosphere between

processing and packing; higher skilled operation; sterility must be maintained through aseptic
packing.

Particle Size:

With larger particles there is a danger of overcooking of surface and need to transport
material-both limits particle size.

Equipment:

There is a lack of equipment for particulate sterilization, due especially to setting of

solid and thus over processing.

Powder Plant

Milk Powder:

Powder milk is a manufactured dairy product made by evaporating milk to

dryness. One purpose of drying milk is to preserve it, milk powder has a far longer shelf life than
liquid milk and does not need to be refrigerated due to its low moisture content.

Another purpose is to reduce its bulk for economy of transpiration. Powdered milk and dairy
products include such items as dry whole milk, non-fat dry milk, dry butter milk and dry dairy
blends.

Spray Dryer:

A spray dryer is a device used in spray drying. It takes a liquid steam and
separates the solute or suspension as a solid and then solvent into vapor. The solid is usually
collected in a drum of a cyclone.

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The liquid input stream is spray through a nozzle into a hot vapor steam and vaporized. Solids
forms as moisture quickly leaves the droplets. A nozzle is usually used to make the droplets as
small as possible, maximizing heat transfer and the rate of water vaporization. Spray dryers can
dry a product very quickly compared to other methods of drying. They also turn a solution into a
dried powder.

Principle:
Pasteurized  milk is first concentrated in an evaporator to approximately 50
percent milk solids. The resulting concentrated milk is then sprayed into a heated chamber where
the water almost instantly evaporates, leaving fine particles of powdered milk solids.
Alternatively, the milk can be dried by drum drying. Total milk is used for powder milk is about
1,50,000 to 20,00,000.in production 20,000 to 22,000 milk used in one batch and produced
about 90 bags per batch. A batch contain about 2 to 3 hour of time.
Powder plant consist of
 Evaporator
 Dryer
 Condenser
1. Evaporator:
Two types of evaporator is used in Malmo industry.
1) 3 effect evaporator (capacity 5000L)
2) 6 effect evaporator (10,000 to 20,000 capacity)

 Concentrated products come from storage tank into the pre heater by pump where milk
heats and goes to heater where all dust particles in milk separated.
 There are three pre-heaters attached to the triple effect evaporators. Temperature of 1st,
2nd and 3rd pre-heater is 30°C, 35°C and 40°C respectively.
 From filters, milk comes into the header by high pressure pump which have pressure 200-
210 bars

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 2. Condenser
There is also a condenser on powder plant for the purpose of conserving to make a
powder.
3. Drying Milk in Spray Dryer:

The plant specially designed for the drying of skim milk and is prepared for
additional equipment for whole milk production. The plant consists of a spray dryer in
connection with a fluid bed. There is a two stage drying process. Major part of the moisture is
removed in first stage of spray dryer and remaining part of the moisture is removed in second of
fluid bed dryer.

 Hot air can be produced by steam radiator, air is sucked by blower, when this normal air
is sucked with the steam at 180-190 Celsius temperature, then air obtains this temperature
and hot air is introduced the main chamber along with the panel header which sprayed
into the main chamberat 200-210bars.
 Header has three nozzles which are sprayed on the milk into the main chamber.
 When milk and air comes in chamber, there I co-current flow I chamber hot air absorb
the moisture or moisture evaporated because hot air tract with droplets of milk.
 Powder comes in cone. In chamber provided with pneumatic hammers an electronic to
prevent powder deposits on the surface inside the chamber.
 The fine particles come into the cyclones number one and dust particles go out by
exhaust fan. And particles of proper shape and size come into cone.
 In chamber temperature is 85-95℃, and vacuum is -5 to -8. From con milk comes on
fluid bed portion where first give the lecithin spray on it and hot air to remove moisture
by vibrio heating fan and here remaining moisture is removed. In vibrated bed, vacuum is
-10 to -15.
 After heating, for cooling power, goes into cooling section where give cool air from
Vibro cooling fan milk cool and temperature will become 35℃
 From fluid vibrated bed fine particles which are not proper comes into the cyclone
number 2 and very light particles exhaust by fan.

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  From cyclones number 1 and number 2, powder comes into cyclone number 3 by rotary
valve operating and by shoots. When this fine particle comes into this cyclone then by
shoots and rotary valve operating it goes to the main chamber where it is processed again.
 At temperature 35 Celsius of powder, it is taken out by sieve and packed in pouches
which is 1k and bags which are 25kg.

Powder packaging machine

There is likewise a packaging system on powder plant made by china, which %

the 1 kg Malmo milk powder and different in bulk quantity in 25 kg.

Rotary Valve:

Transfer powder from one blade to another without disturbing the vacuum and
it is also called Air located instrument.

Milk powder Flow Diagram

Balance Tank Of Condense Milk Pre Heaters

Filters

High Pressure Pump

Spray through nozzles

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 Drying in hot air chamber Vibro Heating fan

Fluidized bed drying 02 Vibro cooling Fan

Sieving

Packing in poly and paper bags

Cheese Section

Cheese:
Cheese  is a dairy product derived from milk that is produced in a wide range of
flavors, textures, and forms by coagulation of the milk protein casein. It comprises proteins
and fat from milk, usually the milk of cows, buffalo, goats, or sheep.
During production, the milk is usually acidified, and adding the
enzyme rennet causes coagulation. The solids are separated and pressed into final form. Some
cheeses have molds the outer layer, or throughout. Most cheeses melt at cooking temperature.
Cheese is a good source of calcium and protein, but it can also be high in
saturated fats and sodium.

Pasteurization

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 For cheese formation, raw milk is taken on the base of protein ratio. Then
Pasteurization is done to remove the extra fat. Pasteurization is done at 50℃ then chill at 10-
12℃

1. Cheese vat

Then Pasteurization milk is pure into a vat (Its capacity is 2000L) which is heated
at 35℃.It is double jacket contain water steam circulates in the double jacket.

2. Milk Culturing and Clotting

There is such thing as “good” bacteria. In this part of the process, this “good”
bacteria (otherwise known as a starter culture) is mixed into the milk, which gets the actual
cheese forming process going. Next, the milk is clotted using a coagulant, which causes the milk
to curdle up and take shape. In Malmo bulk culture is use in the powder form and gives it 15-20
mints. They take 5 L milk and then mix one g of culture and give stay time to the culture that
should be overnight.

Then take 2000L milk in cheese vat and then add one kg of yoghurt to form cheese. They also
add CaCl2 (200g).After adding CaCl2 give 15-20 mints later add rennet 20-22g ( dissolve in
water) mix it for 5 mints. Then leave it for 1hr but continuously check it.

Objective of CaCl2:

In Pakistan the milk quality is low so protein ratio also low. So the coagulum is not
form properly form. By adding CaCl2 the formation of CaCl2 is correctly done.

3. Cutting the Cheese

Once the milk begins to solidify into curds, it is sliced away from the whey (or
liquid) and cut into small pieces.

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 4. Cooking & Stirring

The cooking and stirring process continues until the curds have reached the preferred
temperature (40-41℃) and hardness rise the 1℃ temp in every 5 mint. Once this is complete, the
whey is drained away, leaving the solidified curd.

5. Cheddaring process

Cut into blocked and changed the side (to remove excess remaining water from the
blocks by changing the sides).it takes 1 hour to complete the process.

Objective:

 To remove the whey completely

 Culture growth is good
 Holes formed un curd are removed.

6. Milling:

When whey is removed completely milling is done. Salt added in curd. About
2 to 2.5 kg salt is added in 1 vat.

7. Pressing:

Mold pressing is done. Overnight pressing with 3 to 4 bar pressure.

Objective:

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  To remove whey completely otherwise mold growth takes place that ultimately produces
bitter taste during aging process.
 Muslin cloth added with blocks so that molded cheese doesn't flow outside

8. Aging:

Muslin cloth removed and polythene bags wrapped around the blocks. Then it
place in cold storage for 24 hours at 3 to 4℃ its purpose is to dry the surface after
pressing. After that potassium-sorbate is sprayed (10 percent solution is prepared to
spray) then it is packed again place in cold storage for 24 hours so surface become
compact and dry.

9. Ripening:

Ripening process is done for minimum 2 months i.e. it is placed in cold storage
for 2 months. Its purpose is to produce the flavor, cheesy aroma and required texture.
20kg polythene bags are used to wrap the blocks. During ripening culture growth takes
place, protein structure breakdown and amino-acids units are formed. The breakdown
produces softness.

10. Cheese Kettle:

Before kettle cheese is passed out through machine and converted into very
small cheese particles then it is pressed in blocked formed and put into kettle. The inner
temperature of kettle is about 75-80℃ in kettle tape water is added which purpose is to
stop the thickness of cheese and produce soft texture. Kettle is doubled jacket in between
steam flows. Agitator moves in kettle to homogenize. Three types of emulsifying salts are
added in kettle that are antifungal and give shelf life.

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  Tri-Sodium Sitrate
 Di-sodium phosphate
 Potassium Sorbate

11. Molding, packaging and storage:

Melted cheese is put in mold trays then to cold storage overnight for
hardening purpose. Then it is packed in polythene bags and it is done under vacuum.
Again it is stored in cold storage. Storage temp. Is about -18℃.

Flow Diagram Of Cheese Processing

Raw milk received

Pasteurizer 50℃

Standardization

Bulk culture added

Calcium chloride 200gm

Mixing

Add rennet 20 to 22gm

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 Coagulum cutting

Cooking

Whey separation

Chaddaring process

Milling

2 to 2.5 kg salt added

Overnight pressing

Ripening (minimum 2 months)

Kettle process 77-85℃

Cooling overnight

Emulsifying salts added

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Ice-cream section

1. Mixing:
All the ingredients mix together. Powdered milk is added other ingredients
include water (60℃) sugar, fresh cream (40 percent fat), Khoya, chocolate, Kulfa, coco
powder and glucose added according to taste. Mix temp should 80℃.

2. Homogenization:
Homogenization done at 100 to 120 bar pressure. It takes 30 minutes for 500 kg
mix. In homogenization tank agitator attached helps in homogenization. Purpose is to get
well mixed paste.

3. Aging tank:
Mix is shifted in aging tank. Aging takes 6 to 8 hours. Chiller tank is
connected with it for cooling purpose. After aging flavors added. Mixed well so that no
bitter taste produced.

4. Continuous freezer:
Mix is shifted in continuous freezer at-4 to -7℃ temp. Dasher has blades that
cut ice-cream and air is incorporated through compressor that produces softness in it.
Cooling tower is attached with freezer I which cool water in and warm out.

5. Fruit filler:
Fruits are added according to flavor and taste. Almond crunch, chocolate and
coco powder added at this stage. Different nuts and pista added also.

6. Packaging:
Packaging done according to requirement i.e. in cups, packs, boxes.

7. Cold storage:
Packed ice-cream is placed in cold storage at -20℃ to -22℃

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 Flow Diagram of Ice-cream section

Boiler tank

Mix prepared (80℃)

Homogenizer

Plate cooler

Aging tank

Continuous freezer

Cooling tower

Fruit filler

Packaging

Blast room (-30℃)

Cold storage

Juice Section

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Juice:

Juice is the liquid that is naturally contained in a fruit or vegetable tissue. Juice is
prepared by mechanically squeezing or macerating fresh fruit flesh without the application of
heat solvent.

Juice is a very healthy food. It consists of water, fruit sugar, fruit acid and minerals.
Depending on the particular type, juice contains different vitamin concentrations. Due to its high
water content, juice is very susceptible to micro-organisms and must be processed very carefully
and hygienically

In Malmo foods mango, apple, pomegranate, guava.

Juice process:

. The brix of juice is 12 For manufacturing of juice required pulp about 800kg, sugar 22 bags,
color 2.5g and flavor about litter in one batch about 10,000 litter.

juice machine consist of three portions:

 Two tanks
 Tri blenders
 Pulp suckers
Tanks

One tank is use for mixing purpose and other is use for storage. In the tank rotating
bowls are present which homogenize the recipe.
Tri blenders
Before making the batch recipe is blend in tri blenders at the high speed

Plate heat exchanger

Plate heat exchanger pasteurizes the juice at 98°c and cooling at 30°c and its
regeneration process.
Process line
 First we make batch in tanker B. Fill both A, B with hot water.

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  For batch we take this water small quantity in tri blander bye pump and some ingredients
and sugar pour in it. Then bland the ingredients. Then this mixture go to the tank B and
A.
 A motor attach with agitator in both tank who mix or agitate the solution thoroughly.
 Batch is ready.
 When process start, juice witch is in tank A and B comes into the filter by pumps where it
filter all dust particle remove here.
 After filter juice goes into the balance tank by feed pump. From balance tank feed pump
juice and transfer to the PHE (plate heat exchanger).
 In PHE juice comes in section where temperature is 60-65℃ this portion is regeneration
section. In this section juice heat, temperature raise.
 After this section juice comes to the other section where the temperature of juice become
85℃ it is also regeneration section.
 Juice heat more in regeneration section ,now it comes in more heating section , the
temperature of this section is 95℃ in this section temperature of juice is more because in
this section one aide of plate is more hot water circulate and one juice.
 After this section juice goes to holding tube , in holding tube juice stay 16 sec to 20 sec in
tube and comes back to the regeneration section where it transfer heat of incoming juice
and self-temperature of juice down and incoming juice temperature increase.
 Then after this section the juice comes into the booster pump where one bar pressure is
apply.
 Then juice comes into the other regeneration section (60-65℃) where it transfers the heat
to the incoming juice and self-temperature down.
 Juice comes into the PHE section 4.this is cooling section. In this section one aide cold
water circulate and one side juice which comes into the regeneration section.
 In cold section temperature will become 30℃
 After this section juice goes to for packaging in packaging room bye pipe lines, juice
pack in tetra pack pouches.
 At the end CIP of this plant.

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 Flow chart of Juice plant

Flavors Reception of raw Color

material

Water Stabilizer

Mixing of ingredients

Sugar Others

Tank A and B Filters

Balance tank Feed pump

Regeneration 1

Regeneration 2

Heating section

Holding tubes FDV

Packing

Regeneration 2

Booster pump
Cooling section
Regeneration 1

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Khoya section
For production of Khoya milk is received on Fat and LR base. Milk is
received in raw form i.e. no pasteurized milk. It is cooled in chiller before use. Steel pans used to
heat the milk on very high temp. Milk becomes concentrated on this high temp. Processed Khoya
is layered in trays to cool down at ambient temp. And then packed in polythene bags and stored
in cool storage at

-18℃

Flow chart of Khoya production

Raw Milk

Panning

Heating (160℃ for 50 to

60 minutes).

Continous Stirring

Khoya

Cooling and Packaging

Storage

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Ghee Section

Ghee is clarified milk fat prepared chiefly from cow or buffalo milk. The term
clarifies means to make clear a liquid or something liquefied bye remaining unwanted solid
matter or impurities.

Taste aroma and texture:

The taste of ghee is surprisingly different from that of butter its aroma is best
described as nutty and it has the unique property of carrying and enhancing the flavor of
practically any that one briefly fries with it.

The texture colour or taste of ghee depends on the source of milk from which the
butter was made and extent of boiling.

Ghee manufacturing process:

 Fill ghee melters to about 800-900kgs with butter.

 Open steam valve of melter's pressure at 1-1.5 bar .steam temperature at 100 to 110°c for
3 to 4 hours.
 Remove lassie and sludge from the bottom of the melters.
 If moisture is 0.3%, then close the steam valve.
 Open raw water valve of the melters to cool down the ghee to room temperature for. 1
hour.
 Filter out ghee carefully into clean and dry plastic cans and covers the lids.
 Then pack of ghee in 1kg tin and pouches.
 At the end, CIP occurs.

Flow Chart of Ghee production

Butter

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 Steam (200℃ for 30
minutes)

Melted butter

30-45 minutes stay time

Butter milk drained out

Ghee filter

Steam (above 200℃ for 2-3

hours)

Ghee obtained with 99.5% fat

Packaging and storage (-20℃)

Butter section
Butter is clarified milk fat prepared chiefly from cow or buffalo milk. The term
clarifies means to make clear a liquid or something liquefied bye remaining unwanted solid
matter or impurities.

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 For the production of butter separate the cream from the milk. Pasteurize
chilled or fresh cream is used for production of butter. Acceptable butter fat% is about 82% and
moisture is about 14 to 16%.

Process line.
 Cream is processed by continuous butter making machine (CBM).
 In butter section pasteurize cream come through the line in CBM.
 The temperature of cream when come into CBM is about 5 to 6°c. And the fat% of cream
is about 35 to 40%.
 When cream come to in 1st churner at temperature 8 to 10°c butter granules are formed at
centrifugation of 1000 to 2000 rpm.
 Water is sprinkle on butter churner to low the temperature.in 2 nd churner butter whey
separate from butter.
 Then butter is packed into 1 kg tin and named as Malmo butter and bulk amount Into 16
kg carton.
 Total capacity of CBM machine is 2100kg in one hour.
 For salted butter add 15 kg salt in 1000kg cream
 The packaging of salted butter is 200g pouch.

Flow Chart Of Butter Section

Cream (above 40% fat)

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 CBM Machine

Butter milk drained out

Butter (82 to 84% fat)

Washing with cold water

Butter pressure

Water removed out

Packaging and storage (-18 to -20℃)

RO Water Filtration
1. Raw water source:

Underground water is source of this water filtration system. Turbine and

pumps used to pull water in tank. Then it moved further for filtration purpose.

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 2. Filter Assembly:

Cartridge water assembly used to filter water. Three filters with 5µsize are
used. Purpose is to remove the suspended particles and un-dissolved particles.

3. Sand Filter:

Sand layers of different particle size are used in this filter. Granular gypsum is
used in layers through which water moves. 4-5 layers of sand are used. Top and bottom layer of
large size to move water with ease.

4. Activated Carbon filter:

Activated carbon is used. It helps to remove odor and unpleasant smell.

5. Filter Assembly:

Again water is passed out through another filter assembly. Here 5 filters with
1-3µ size are used. Here ultra filtration done.

6. High pressure Pump:

Water is passed through high pressure pump 2-3 bar pressure. The inlet and
outlet pressure is same i.e. water enter and leave with same pressure. Greater the pressure less
will be the TDS. Then it will inject water in RO.

7. Anti scaling:

Anti-scale dosing is done and its purpose is to remove un-dissolved

minerals i.e. no sticking of minerals with walls of filters. Water after passing out this stage is
called as "permeate water"

8. Pneumatic Dosing:

Mineral dosing is done. Ozone is also used for dosing along minerals. Mostly
Calcium, Magnesium and sodium are added as minerals. Mineral dosing is done to balance the
minerals level in water. Moreover, ozone dosing done. Ozone acts as antimicrobial. It takes 2.5
to 3 hours to complete the ozone reaction with water.

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 9. Storage tank:

Water is stored in storage tank. Here water stayed for 13 minutes until the
minerals and ozone get dissolve in water completely. Then water is passed to final storage tank
through feed pumps with 1.5 to 2 bar pressure.

10. U.V lamps:

Water is passed through U.V lamp assembly. After passing through this all the
microbes killed.

11. Auto washer and filling:

Bottles are washed inside and outside with hot water pressure. Then filling is
done. Balance tank check the level of filled water in bottles. Then bottle is passed through
conveyer. Cap is pressed and then bottle passed through UV screen and then sealed.

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 Flow Chart of RO Water Filtration

Raw water line

Raw water storage tank

Cartridge water
assembly (5µ)

Sand filter

Activated carbon filter

Pressure Vessel

Filter assembly (1-3µ)

Anti-scaling

Pneumatic dosing in
storage tank

Mineral dosing
Ozonation

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 Final Storage tank

UV lamp and cartridge assembly

Auto washer

Balance Tank and Filling

Conveyer

Caper and cap presser

Screening

Sealing

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Tetra pack:
In this segment UHT produce are packed aseptically in sterile packing materials in aseptic
environment with the assist of Machine provided by using tetra pack. And packing cloth is
likewise provided with the help of tetra Pack Company
1. Paper coil section:
In this section a reel of packaging material is fitted at the base of machine
2. Shape creasing curler:
The paper is surpassed although bending and creasing rollers, which facilitate
bending and folding making of paper in a while.
3. Dating section:
It prints the expiry date, machine quantity on the paper.
4. Longitudinal seal section:
Poly strip is attached longitudinally at one end of paper.
5. Filling phase:
The favored level of milk is crammed in tubular Tetra Pak paper.
6. Jaws segment:
Sealing & reducing of paper is done according to favored shape.
7. Delivery section:
Properly shaped packs are thrown on conveyor

PLE Section:
In PLE section one shrink wrap machine is present that main purpose is
packaging. the capacity of the machine is 30 trays. The measurement of tray is necessary weight,
width and height must be checked and then passed through the further process
In PLE section packaging of products are started and ready for the dispatching.

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Ware House
Capacity of warehouse is 12 lots. Warehouse is beneath the deliver chain
department. All the goods after packing are transferred to the warehouse from they're loaded on
the motors & transported to the marketplace.
Its functions is to generate
 Daily stock Release Report
 Order Sheet
 Loading Slip

Fork Lifter

is use for transferring the goods from one place to another

Utility Section:

utility section consists of two main things

1- Boiler
2- Chiller
Boiler:
2 tube boilers are used in industry. Wood gas, and furnace oil are used as fuel
Chiller:
chiller consists of
 Compressor
 Oil separator
 Condenser
Compressor:
A gas compressor is a mechanical tool that increases the strain of a fuel by
lowering its volume .The suction pressure of the compressor is 55-60 psi. A gas compressor is a
mechanical device that increases the pressure of a gas by reducing its volume. An air compressor
is a specific type of gas compressor. Compressors are similar to pump: both increase the pressure

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on a fluid and both can transport the fluid through a pipe. As gases are compressible, the
compressor also reduces the volume of a gas. Liquids are relatively incompressible; while some
can be compressed, the main action of a pump is to pressurize and transport liquids.
Oil separator:
Oil separator is used to separate the oil from the refrigerant. Globe valve is used
to separate the oil from refrigerant.
Condenser:

Condenser is used to condense the gas by lowering its temperature.

Evaporated type condenser is used in industry.

CIP (Clean in place) section:

Definitions:

CIP is removal of milk particles and lowering the microbial load in the production
line & in the raw milk tanker by using various types of cleaning agent (acid, base & water).

Functions of various cleaning agents in CIP:

 Lye for removal of fat residues.

 Acid for the removal of protein matter and snf .
 Hot water for the removal of residues and salt.
 Acid and hot water also used for lowering microbial load.
 High concentration of acid or lye cause of corrosion.
Concentrations:

Concentration of acid and lye used for the CIP is:

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 Lye (NaOH) = 1.7-2.2% at 80 -85℃
Acid (HNO3) =1-1.5% at 70-75℃
Water at 80-85℃
CIP Steps:
 Water rinsing
 Alkali rinsing
 Acid rinsing
 Water rinsing
Types:

 Two types of CIP are done.

 Short CIP (40min)
 Long CIP (70min)
Short CIP:

 Milk is drained out of tanker or the pipelines and then it is washed with warm water at
temperature 80 to 85°c for 10 min.
 After this lye (NaOH) solution of 1.7-2.2 % at temperature of 80- 85℃ is circulated in
the tank or lines for 10 minutes.
 Again tanker is washed with water for 5 min.
 Then Nitric acid having a concentration of 1-1.5% at the temperature 70-75℃ of is
circulated in the tank or lines for 10 minutes.
 Then washed with tab water that PH is equal to 7,0 to 7,5%
Long CIP:

 Milk is drained out of tanker or the pipeline and then it is washed with warm water for 5
minutes.
 After this lye (NaOH) solution of 1.7-2.2% at temperature of 80- 85℃ is circulated in the
tank or lines for 15 minutes.
 Again tanker is washed with water for 10 min.
 Then Nitric acid having a concentration of 1-1.5% at the temperature 70-75℃ of is
circulated in the tank or lines for 15 minutes.

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  Again tanker is washed with hot water at 80 -85℃ for 10 minutes.
 H2O2 is also circulating for 10 minutes in case of ATS tank.

SWOT Analysis:

Strengths

The strengths are:

 The Thickest Milk 

 Taste
 Nutritious
 Hygienic
 Packaging
Weaknesses

The weaknesses are:

 Focus Shifted from Main Product to other products

 Lack of Research & Development
Opportunities

The Opportunities are:

 Target market has big profit margins.

 Bright scope of dairy products.
Threats:

The threats are

 Big competitors
 Inefficient labor
 Disease animals
 Availability of natural milk

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Conclusions:

This internship proved to be very helpful for us. we got a lot of knowledge and also the
practical aspect of life. It was our first experience, which was obviously very tough, but it will be
very beneficial for us in our coming future .During internship I have learnt the basic knowledge
about dairy technology. we gain a knowledge about the production line. we learn how to perform
a milk and other milk products test. The procedure of making different product. And at last
thanks to our all teachers, friends and the staff of Malmo.

THANK YOU 

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