Project Report on In-Plant Training at Sonai Dairy

A
Project report
On
In-Plant Training
At
SONAI DAIRY AND MILK PRODUCTS PVT. LTD.

INDAPUR.
Mr. Hrishikesh Gorakh Sutar

(Reg. No. MITU16BTFT0756)
in partial fulfilment for the requirements of the award of the degree of
BECHALOR OF TECHNOLOGY
in
(FOOD TECHNOLOGY)
Submitted to
MIT COLLEGE OF FOOD TECHNOLOGY,
MIT ART, DESIGN AND TECHNOLOGY UNIVERSITY,
LONI KALBHOR, PUNE – 412 201.
2019
CANDIDATE’S DECLARATION
I hereby declare that this project report or part thereof has
not been submitted by me or any other person to any other
University or Institute for Degree or Diploma.
Place : Pune.
Date : / /2019
Mr./Miss……………………….
CERTIFICATE
This is to certify that the In Plant training report submitted by Mr.
Hrishikesh Gorakh Sutar…” to the MIT College of Food Technology, MIT Art, Design and
Technology University, Loni Kalbhor, Dist. Pune in partial fulfillment of the requirements
for the award of the degree of BECHALOR OF TECHNOLOGY in FOOD TECHNOLOGY
is result of his/her training in Sonai dairy and milk products pvt. Ltd. Indapur. (Name of
company) from 01/07/2019 to 30/11/ 2019.
She completed the training satisfactorily and submitted report to training and placement In-
charge.
Prof. Sandip T. Gaikwad Prof. (Dr.) Vasant N.

Pawar
(In-Plant training In-charge) (Principal, MIT CFT)
Place: Pune. External Examiner

Date: / / 2019 Name:
_______________________
ACKNOWLEGDEMENT
This A cknow ledgement is about all peoples of S onai dairy w ho
cooperated and guided me at work in training.
F irstly I s incerely expres sing my gratitude tow ards the management of

S onai D airy, Mr. D. S. M ane(Chairman),Mr. V . S. Mane (C.E.D .),M r. Anil
Goel S ir(C.E.O ), Mr. B.S Avhad s ir(V .P), Mr. M. D. Shete s ir (GM PO),Mr.
Ghadge sir& Mr. A garkar Sir (HR), M r. Kudale s ir(QA) for providing us an
opportunity to undergo my one months in plant training at SONA I DAIR Y
and for allowing us to proceed our training.
I extend my gratitude toward all DPM, TO , Operators and workers for

proper guidance and helping me in training programme. I am thankful to
management staff of SONAI DA IRY AND MILK P RODU CTS LTD, Indapur.
I am express ing my gratitude to Mr. P aw ar sir D ean of M IT College of

F ood Technology, Loni-kalbhor, for giving opportunity of interns hip
programme in food sectors.
Date:
Place: Indapur.
Introduction: Sonai Dairy and Milk Products,
Indapur.
Honorable chairman Shri. Das hrathrao M ane es tablis h Indapur Dairy
and milk products ltd at 8th October 2001 under public limited act of 1965
and inaugurated at 13th may 2002 by honorable M inis ter of Agriculture
S hri. SHARAD PA WA R at mauje gokhali, sonmatha, Baramti road, Indapur
(Pune).
S hri. D ashrathrao Mane established Indapur dairy and milk products

w ith a vis ion to improve the economic conditions of milk producing farmers
of nearby areas and als o for producing quality milk and milk product along
w ith generation of employment in the taluka Indapur and nearly places
Indapur dairy has state of art manufacturing and proces sing technology
spread in the area of 45 acres in Gokhali, the dairy has well planned
infrastructure for providing necess ary facilities for efficient handling of
various activities in dairy, it has shared capital of more capital of 950 lacks
along with 2750members from co-operative milk societies and w ith
47258individual members activity involved. The dairy has an annual
turnover of over 500 cores of 2018 and has tremendous grow th opportunity
ow ing to superior quality of its product and excellent management
s trategies.
The S onai dairy has received many certification for good quality
manufacturing s tandards . Namely FSSA I, AGM ARK , ISO 9001:2008,
ISO22000 :2005,HACCP , BIS FP O . Indapur dairy and milk product ltd is
trying hard to improve the economic condition of farmer by carrying out
various beneficial programme for farmer and milk producer such as paying
extra incentive then declared rate policy of gov. by providing advantages for
personal needs , livestock loan, best cattle feed and veterinary, s ervice, thus
making it one of the most succes sful and faster growing dairy industry in
P une.
INDEX
Sr no. Department of Training Page

no.
1. HR department
2. FSMS
3. RMRD lab.
4. Process I & II
5. Milk Packaging Department
6. Butter Department
7. Ghee production & packaging Department
8. Powder Department
9. Bi-product Department
10. Product Lab.
11. Boiler section
12. Electrical
13. Maintenance department
14. Refrigeration Department
15. E.T.P. Department
16. W.T.P. Department
17. Storage department

 R.M.R.D. section (Raw Milk Reception Dock)
M ilk us ually collected from farmers is chilled in local or companies authorized
chilling centers . It is transported by companies own Tankers , it dis tributed over
large area of Maharashtra. As in map.
Rout chemist appointed by company, check Milk before collecting from
chilling center for adulteration. Then loaded chilled M ilk is transported to S onai
D airy via R oads . This journey is les s than 3-4 hr.
When Loaded tanker enters in company, is weighted, and kept on hold for
laboratory analysis, this took about 1-4 hr average. All the test mentioned below
are carried out, and decides the quality of M ilk. Adulterated milk is returned to
the chiller, or if there no adulteration and iss ues only related keeping quality,
then it is purchas ed les s prices than us ual for powder production.
After lab analysis, decis ion taken related to milk, is it suitable for
packaging or powder or butter or ghee, or byproducts . Then reception pipe
attached to the tanker, and milk pumped to res pective silos for further proces s.
There are chillers at every s tage of pumping, that maintain temperature of M ilk
below 4° C.
Currently Dairy have 25 Lakhs liter/ day production capacity, and it is

grow ing. D aily process ing is according to the orders. On an average, they process
about 15 lakhs liter milk per day.
B efore starting the reception, all the Equipment & Flooring of RM RD

are cleaned. They are then cleaned by 0.2% soda using scrubbers & then was h
w ith warm water (50°C.) and dried. Jus t before us e, the equipment, coming in
direct contact w ith milk is rinsed with potable water. Each line comprises can
w asher & centrifugal milk pump. There are manually cleaning of cans.
The main operations at RMRD are unloading of cans and tankers ,

conveying cans, s ampling, s ens ory evaluation, dumping, weighing milk, and can
loading.
 PROCESS FLOW CHART OF MILK RECEPTION
RA W MILK IN CANS
↓
TES TING , WEIG HIN G & PRICING
↓
F ILTRATIO N, CH ILLING <4°C.
↓
SAMP LING & LOADING IN TA NKERS
↓
TRAN PORTING TO DAIRY <4°C.
↓
TANK ER WEIGH ING & SAMPLIN G
↓
LA BORATORY ANA LY SIS , RESU LTS.
↓
CO NNECTIN G HOST PIP E TO TANK ER.
↓
SS FILTERS 1mm
↓
PUMP ING
↓
CH ILLING < 4°C.
↓
STORED IN SILO S FOR PROCESS
EQUIPMENT’S ON RMRD:
1. SAMPLING (FOR RMRD):
C apacity of bottles: 250 ml
Equipments : P olythene bottles , plunger, beakers. Markers.
2. AUTOMATIC WEIGHING MACHINE:

Numbers : 01
C apacity : 50 tonne.
Type : digital.
3. DUMP TANK:
Numbers : 1
C apacity : 50kl.
4. MILK PUMP:
Number : 02
M ake :Zeutech
H.P. : 7.5 & 5
C apacity : 20kl/hr
5. MILK PUMP:
Number : 02
HP : 10
C apacity : 40kl/hr.
M ake :F ristam .
6. CHILLER:
Number : 01
Type : Raw milk Chiller.
C apacity : 5000 LPH
Inlet w ater temperature : 2°C.
Outlet milk temperature : <5°C
Number of plates : 149.
M anufactured by : GEA Ecoflex pvt.ltd
P res sure : 5 bar
M ake : J ess el Engineering
RMRD LAB
FRESHNESS TEST:-
1) TEMPERATURE
2)ORGANOLEPTIC
3)ALCOHOL (65%)-------------(V/V)
4)ACIDITY
5)C.O.B-------------------------(CLOT ON BOILING)
6)M.B.R.T------(METHELENE BLUE REDUCTION TEST)
1) TEMPERATURE :-
Temperature als o less than 6°c and generally milk store at 5°C.
2) ORGANOLEPTIC TESTS :- T o check the quality of milk
i)S MELL :- Take fresh and pleas ant smell milk, rejection in cas e of any off/
foreign odor s mell.
ii) TAS TE:- Milk is tas ted by experience annalis tic, sour milk is s usceptible to
more acidity i.e. microbial action.
iii) APP ER AN CE :- take clean milk , rejection in case of fully durt and dus t
particle mixing in milk e.g soil.
3) ALCOHOL :- To check the heating stability of milk

P ROC EDU RE :-
1) Take pipette out 5ml milk s ample in tes t tube
2) Add 5ml ethyl alcohol as compare to milk
e.g :- Incoming tanker - 65%
P acking tanker / milk - 67%
P ouch packed milk - 70%

2) If curd particle are present in that tes t tube means it is pos itive and s imple
milk is negative.
4)ACIDITY :-
To check the acid percentage in raw milk is important aspect to judge heat
s tability of milk. If the acidity in milk is high that means such milk is
contaminated
because in milk the lactabacillus bacteria are found. Which is responsible for
fermentation of milk
PROCED URE :-
1)P ipette out 10 ml milk in conical flask or glass beaker
2)Add 10ml dis tilled water in that milk sample
3)Add 4 to 5 drops P henolphthalein indicator in milk s ample
4) After that take 0.1 normality N aOH (S odium hydroxide) in burette
5) Then titrate it slow ly
6) Faint pink color observe for reading
7) C alculate that reading for cheek actual acidity of milk (w ith the help of
formula )
ACID ITY = BU RRETE READIN G × 0.09
5)C.O.B(CLOT ON BOILING):- To determine the stability of milk for milk

process ing
P ROC EDU RE :-
1) Take 5 ml of milk in the test tube
2)P ut this on boiling water bath for 5 minute
3) Remove the test tube from water bath w ithout shaking
4)Note any acid s mell or precipitated particles on the sides of the tes t tube.
S ample showing precipitated particles are recorded as pos itive C.O.B test. s uch
milk is rejected on the platform.
6) MBRT TEST (METHYLENE BLUE REDUCTION TEST):-

Check the quality of the given milk s ample bas ed on the difference in
the Microbial load milk sample provided.
P ROC EDU RE:-
1)Trans fer 10 ml of milk sample in tes t tube w ith help of pipette in the
appropriately labeled tes t tube.
2)Add 1 ml of methylene blue s tain in the milk sample tes t tube
3)Tighten the tes t tube mouth with stopper. gently invert tubes at about four to
five times to ens ure proper mixing of the M ethylele Blue Stain S olution
4)Keep the test tube in the w ater bath at 37°C
5)Note the incubation time. that is ,the time elapsed for the colour to turn
whitis h
NO TE:- In case of methylene Blue Reduction Tes t all glassw are mus t be
s terilized. This test depends upon time. If the microbial load in milk s ample is
high the milk becomes turns in whitish colour in less time means that milk
quality is low . MBRT tes t is invers ely proportional to time.
ADULTERATION TESTS:-
1) DETECTION OF CANE SUGAR IN MILK:
P ROC EDU RE:
1)Take 1 ml. of milk in a tes t tube.
2) Add 1ml of resorcinol Solution and mix.
3)P lace the tube in boiling water bath for 5 min.
4)Withdraw the tube and obs erve the colour.

Appearance of deep red colour indicates pres ence of sucrose or a ketos e sugar.
In pure milk samples no such red color is developed and s ample remains white in
nature. Fructos e in cane sugar (sucrose) reacts w ith resorcinol in HCL to give
red colour.
2)DETECTION OF STARCH IN MILK:

P ROC EDU RE:
1) Take 3 ml of milk in tes t tube.
2) Boil it and cool at room temperature.
3)Add 2 to 3 drops of 1% Iodine Solution.
4)Development of Blue colour indicates pres ence of s tarch
Which dis appear when s ample is boiled and reappears on cooling
5)B lue colour indicates starch test Pos itive.
3)DETECTION OF ADED UREA IN MILK:

P ROC EDU RE:
1) Take 3ml of milk in test tube.
2)Add 3ml of DMA B (Dimethyl Amino Banzaldehyde ) solution.
3) Observe the colour change, Dark yellow colour indicates +ve test. F aint
yellow colour indicates –ve tes t.
S olution I : DMA B- take 50ml of concentrated HCl, Add 450ml of abs olute
ethanol, and add 8gm of DMA B pow der.
4) DETECTION OF SALT IN MILK:

P ROC EDU RE:
1) Take 5ml of 0.1341% AgNo3 (Silver N itrate) solution in test-tube.
2) Add 2 drops of 10% Potas sium chromate solution.

3) Shake well and add 1 ml of milk. S hake well.
4) Yellow Colour Indicates S alt test is Positive, brow n show s negative.
5) DETECTION OF NEUTRALIZER IN MILK (Soda Test) :

P ROC EDU RE:
1) Take 5 ml of milk in tes t tube.
2) Add 5 ml Absolute A lcohol shake w ell.
3) Add 3 drops of 1% rosalic Acid (Alcoholic s olution)
4) Mix ros e/Pink colour indicates pres ence of sodium carbonate
or sodium Bicarbonate.
6) DATECTION OF DETERGENT IN MILK:

P ROC EDU RE:
1) Take 5ml milk in the test tube.
2) Add 5 drops of 0.5% solution of Bromo-cresol Purple solution
3) V iolet colour indicates +ve tes t for D etergent. Grey colour indicate –ve
R es ults .
7) DETECTION OF MALTOSE IN MILK:

P ROC EDU RE:
1) Take 10 ml of milk sample.
2) Add 0.5 ml of 5% lactic acid & 0.5 ml Enzyme s olution.
3) Incubate it over w aterbath at 65°C
4) Deep the tip of D iastic s trip in s ample.
5) Change in colour of s trip indicates +ve test for Maltos e.

8) DETECTION OF FORMALIN IN MILK:
P ROC EDU RE:
1) Take 10 ml of milk in test tube.
2) Add 5 ml of conc. sulphuric acid is added on the sides of the test tube without
shaking.
3) If a violet or blue ring appears at the inters ection of the two layers, then it
shows the pres ence of formalin.
4) Note violet coloration us ually does not appear when relatively large quantities
of formaldehyde are present .
9) DETECTION OF AMMONIA IN MILK:

P ROC EDU RE:
1) Take 5 ml of milk s ample in a test tube.
2) Add 1 ml of N essler’s reagent.
3) Mix the contents of the tube thoroughly.
4) Obs erve and note the color.
5) The control milk sample gives s light grayis h colour. A t low concentration of
ammonium compounds, brow nish shade appears w hich is dis tinguishable at
0.15% followed by yellow is h colour and then orange colour development at
higher concentration
10) H 2 O 2 TEST:
P ROC EDU RE:
1) TAK E 10 ML M ilk s ample.

2) Add 10-15 drops of 1% Vanadium pentoxide solution.
3) Observe the colour change.
4) R ed colour Indicates +ve for hydrogen peroxide. No change shows absent
of it.
11) STABILITY TEST:
P ROC EDU RE:
1) Take 10 ml milk sample in test tubes .

2) Add 0.4 ml of 0.1 N HCl M ix.
3) Waterbath for 5 min at 65°C.
4) C ool it, obs erve for curdling’s .
FAT ADULTERATION TEST:

1) BR test (Butyro Refractometer)
2) FFA test ( Free Fatty acid Test)
3) RM Test (Rechert meissel)
4) MOT test (Mineral oil Test)
5) PV test (Pollesk Value)
1)B.R TEST (BUTYRO REFRACTROMETER)

A PPARA TUS : B.R. machine, water bath.
PROCED URE:
1) Clean the Pris m w ith Cotton w etted with alcohol and petroleum.
2) P lace a drop of tes t sample on the lower part of prism and lock it. Adjus t
the instrument and the condition maintain and in the procedure and note
reading.
3) If B .R. varies other than 40 to 43 the sample is pos itive.
2)FFA TEST (FREE FATTY ACID)

AI M: To determine the FF A (free fatty acid).
PROCED URE:
1) Weigh accurately about 10gm of the S ample in a previously weighed
conical flas k.
2) Add 50ml of neutral alcohal warm till the fat dis solve in alcohal .
3) Cool and add flow drops of 1% pH in indicator and titrate agains t 0.1 N
NAOH till pink colour.
CA LCUL ATI ON :
%FFA=Titrate reading X 2.28 ÷ Wt. of the sample taken
RE CORD: Record in Quality Regis tered.
3)R.M TEST (REICHERT MEISSEL)

AI M: To determine R.M . (Reichert Meis sel) valve of Ghee.
A PPARA TUS : 1) A ll RM apparatus Set.
2)Gas burner.
3)Analytical balance.
RE AGEN T: 98% G lycerol, 50%N aoH Solution, pH indicator, Filter paper

(w hattmans No-4).
PRE PAR ATI ON OF R EAGEN T:
1) Sodium hydroxide 50% N aOH (w /w ) Solution. N aOH is dissolved in an

equal w eight of water.
2)Diluted Sulphuric acid: take approximately 25ml concentrate sulphuric

acid in 1litre distilled water and dilute to 1:1 and adjust until neutralized 2ml of
the 50% NaO H solution.
PROCED URE:
1) Take 5gm ghee in R.M flas k.
2) Add 20ml glycerol.
3) Add 2ml of 50% NaOH and glas s beads.
4) Heat till it becomes clear.
5) Add 93ml of boiled distilled w ater.
6) Pour s low ly distilled w ater in four steps.
7) Add dilute sulphuric acid 50ml.
8) Then whole solution flask place at stand.
9) Heat by attach burner.
10) Take distillation flask collect 110ml marking solution.
11) P lace the flas k in the chilled water for 10-15min and filter it.
12) Take 100ml in R.M receiver and then take in conical flas k.
13) Add few drop of pH indicator.
14) Titrate against 0.1N N aOH solution and pink colour.
CA LCUL ATI ON :
R.M = (B.R-Blank)or R.M Value is >28.
4)M.O.T TEST
OBJEC T :To determination of adulteration of mineral oil in the
M ilk
PROCED URE :
1) Take 1 gm ghee s ample in flat bottom flas k/conical flas k

2) Add 25ml of prepared KOH solution/ MOT solution
3) K eep condenser on flat bottom flas k.
4) B oil 25ml distilled w ater having temperature 80°C in it
RE SUL T :If sample colour turns in milky white colour that means that sample
are adulterated from M.O .T O il If s ample colour is normal or doesn’t change
colour (as compare to ghee) that means that sample is does n’t adulterated or
negative.
5) PV TEST:
P ROC EDU RE:
1) Was h the ass embly of dis tillation in RM tes t with 15 ml Ethyl alcohol
3 times .
2) Take this 45 ml w ashed alcohol solution, add 2-3 drops of
P henopthleine indicator.
3) Titrate against 0.1 N NAOH.
4) Note titrate value as PV value.
 PROCESS SECTION
 INTRODUCTION
M ilk being highly sus ceptible to microbial deterioration, so process ing of milk
is correct way not only carries quality attributes but also ins ures hygiene and
keeping quality of milk. This is why process ing section know n as “The heart
of Dairy plant”.
The proces sing section mus t be well designed & w ell equipped with the lates t
invented Dairy equipment’s to manufactured high quality milk products
maintains acceptable s tandards permeating to safety of human health. In this
res pect SONAI Dairy has a well equipped and mechanized proces sing section
the proces sing section at SO NAI D airy is having the capacity of process
13,00,000 LPD of milk.
MAIN ACTIVITIES IN THIS SECTION
1. Chilling of milk.
2. The chilled milk goes to pasteurizer otherw is e raw milk tank storage.
3. Separation of milk into skim milk & cream
4. Pas teurization of skim milk and s torage.
5. Homogenization of milk.
6. Pas teurization of milk and s torage
7. Pas teurization of cream and storage.
8. Standardization of milk for market milk.
9. Re-chilling of s tandardization of milk for pouch filling.
PROCESS SECTION 1 :
EQUIPMENT’S SPECIFICATION:
1. MILK PASTEURIZER:
 Numbers : 2
 Type : PHE.
 C apacity : 10 K LPH.
 M ake : ID MC.
 Number of plate : 159
 Temperature at Different Sections of Pasteurizer

 C hilling –5 °C
 R egeneration- I – 45°C
 R egeneration- II – 60°C
 H eating –40°C
 Operating parameter:
 Hot w ater temperature : 78°C.
 M ilk inlet temperature : 6-10°C.
 C hilled water inlet temperature : 2.4°C.
 C hilled water outlet temperature : 4.2°C.
 S team pressure : 1.5 kg/cm2
 P asteurization temperature : 86+/- 3°C
 Holding time : 15 s ec
 F low rate : 10 KLP H.
 P asteurized chilled milk
 temperature : 34°C.
 M aximum working temperature : 110°C.
 D esign press ure : 6 kg/cm2
 R egeneration Efficiency : 90-92 %
3. HOMOGENIZER:
 Number : 02
 Type : FBF 055
 Motor power: 125HP
 P res sure :- Is t s tage : 2200-2500 ps i
 IInd stage : 400-500 psi
 A ctual capacity in absence : 10.320 K LPH Of pressure
 A ctual capacity at maximum : 10.150 K LPH
 M ake : GOMA
Operating parameter:
 M ilk inlet temperature : 60-65°C
 Working press ure : 180 bars/ 18M pa

 Installed pow er : 56.5K W
 S upply voltage : 415 VA C/50 Hz.
 P is ton diameter : 70 mm
 P umping piston stroke : 80 mm
 G ear box oil : Tels 100
 S upply minimum press ure : 2 bar Required
6. DUPLEX FILTER:
 Numbers : 01.
 M ake : ID MC .
7.DUPLEX FILTER:
 Numbers : 01.
 M ake : A lfa Laval .
8. BALANCE TANK:
 Numbers : 2
 C apacity : 200 liters
 M ake : ID MC
9. STORAGE TANK:
 Number : 08.
 Type : Horizontal.
 C apacity : 4 of 10 KL. 2 of 20 KL. 2 of 5K L.
 Agitator : Top mounted.

 M ake : M ilk max engineers, Pune.
10. SILO:
 Number : 05.
 C apacity : 2 of 30 KL, 1 of 20 KL, 2 of 23 KL.
 Type : Vertical
 Agitator : S ide mounted.
 M ake : M ilk max engineers, Pune.
11. DEODERISER:
 Number: 01
 C apacity: 20KL
 Effects : 03
 F eatures: 3 pumps , vaccum chamber, hot w ater supply, glycol cooling.
 M akers: Tetrapak pvt. Ltd.
Working: it removes volatile flavoring substances through the vaccum. That

removes water vapors which contains flavors . It concentrate milk by nearly
0.5%SNF and 0.2% fat.
12. RC unit:
 Number: 01
 Tank C apacity: 1K L
 M akers: M ilkmax engineers
 F eatures: 3 HP motor, hot water & milk supply.
 Work: it us e for standardization of milk, when milk is not as required
specifications , then its added with milk cream and milk pow der as required.
R C unit is machine which us e to mix the milk ingredients uniformly.
13. Clarifier:
 Number: 01
 C apacity: 20KLPH
 M aker: M ilkmax engineers
 Motor: 10HP
 Work: it is nearly same as cream separator, it works on centrifugal force,

clarifiers removes soil particles, s ludge, animal tiss ues from milk by
centrifugation. It is arranged betw een regeneration 1 and homogenizer.
FLOW DIAGRAM FOR PASTEURIZE AND HOMOGENIZE

MILK
Receiving raw chilled milk

↓
Float Control Balance Tank (FCBT)
↓
Regeneration Section-1 → Duplex filter
(45-60°C)
↓
Regeneration Section-2
(60-70°C)
↓→ Homogenizer (1 s t
-stage2500psi)
(2 n d
- Stage500psi)
Heating Section (86±3°C)
↓
Holding (15 sec)
↓
↓
↓
Cooling (≤8°C)
↓
Storage (4-5ᴼc)
STARTING AND SHUT DOWN OPERATION:

A) FOR PASTEURIZER:
1) The pas teurizer as w ell as line and filter are properly cleaned and fitted
w ith gas ket.
2) C heck the all valves.
3) C heck the air pres sure and steam pressure.
4) S tart the soft water in dump tank.
5) S tart the main supply to the control panel.
6) Open the w ater line in hot w ater battery and the steam line in hot w ater
B attery.
7) S tart the milk pump .

8) S tart the hot water pump.
9) S tart the cream separator.
10) Then keep the plant in auto.
11) C heck the FDV for below & above temperature.
12) The plant keeps in recirculation for the reach temperature [Set point].
13) R each that temperature the plant recirculation about 15-20 minutes on
w ater.
14) C heck the line of milk reception to pasteurizer.
15) The milk taken the pasteurizer float balance tank and attention about milk.
16) The milk inlets in balance tank then check the holding times with theH elp of
s top watch to loose the inlet holding union and outlet holding union.
17) Then s tart the chilled water supply.
18) If the homogenizer is attached to the pasteurization plant then s tart the
Homogenizer before two minutes in w ater recalculation.
19) The filters indicate the milk flow then given the press ure.
S HU T DOWN OPER ATI ON :
1) S top the milk pump into balance tank from s ilo or dump tank.
2) Open the w ater line into balance tank.
3) When flushing w ith water is over stop the separator And chilled water
supply valve.
4) M ilk line towards the s torage tank is allow ed to balance tank.
5) C IP is done after dis connecting separators.
6) F eed pump, hot water pump are stopped and s topped and steam valve toH ot
w ater battery is closed and also main steam valve is closed.
E ME RGENC Y SHU T DOWN OF PASTEURI ZER:
It may be neces sary to shut down the plant with leas t poss ible
D elay in a emergency, such as in following conditions:
1) P ower failure.
2) M echanical break down e.g. Burn out motor.
3) C omplete or partial failure of w ater s upply, break down of refrigeration

P lant.
4) F ailure of hot water and air s upply to controller.
5) F ailure of raw milk supply.
Under such condition the plant is stopped in the us ual way, but follow ing
precaution Should be taken:
A) Under heated milk from holding section should not pas s in cooling S ection.
B ) If milk flow stop, heating should be s top as soon as a possible to avoid
B urning of the milk. (close the s team valve)
In cas e of p ower failu re th e p lant is stop ped as follow s:
1) C lose the milk line from the s ilo or the dump tank to the balance tank.
2) C lose milk line from pas teurizer to s torage tank and pasteurized milk is
A llow ed to flow in the balance tank. The over flow in the balance tank is
Taken in cans .
3) S top the s team valve and chilled water valve .
PROCESS SECTION 2:
A) MILK PASTEURIZER:
 Numbers : 3
 Type : PHE.
 Capacity : 20 KLPH.
 Make : IDMC.
 Temperature at different Stages of Pasteurizer

 Chilling – 5°C
 Regeneration-I – 45°C
 Regeneration-II – 65°C
 Heating – 40°C
 Hot water temperature : 78°C.
 Milk inlet temperature : 6-10°C.
 Chilled water inlet temperature : 2.4°C.
 Chilled water outlet temperature : 4.2°C.
 Steam pressure : 1.5 kg/cm2
 Pasteurization temperature : 86+/- 3°C
 Holding time : 15 sec
 Flow rate : 10 KLPH.
 Pasteurized chilled milk
 Temperature : 34°C.
 Maximum working temperature : 110°C.
 Design pressure : 6 kg/cm2
 Regeneration Efficiency : 90-92 %
2) CREAM PASTEURIZER:
 Number : 01
 Type : PHE.
 Make : IDFC
 Operating parameter:
 Cream inlet temperature : 6-10°C.
 Steam pressure : 3 kg/cm2
 Pasteurized Chilled cream
 Temperature : 8-10°C.
 After regeneration temperature : 85°C.
 Regeneration Efficiency : 92%
3) DUPLEX FILTER:
 Numbers : 01.
 Make : IDMC.
4) DUPLEX FILTER:
 Numbers : 03.
 Make : Alfa Laval.
5) BALANCE TANK:
 Numbers : 04
 Capacity : 200 liters
 Make : IDMC
6) SILO:
 Number : 1 to 7
 Capacity : 100KL of each. Except 2nd -60KL
 Type : Vertical
 Agitator : Side mounted.
 Make : Milk max engineers, Pune.
7 )CREAM SEPRATOR :
 Number : 4
 Type : Automatic dislodging
 Capacity : 20Klph
 Make : Alfa laval
 No. disc : 360
 Milk inlet temperature : 45-50°C. [Separation temp.]
 Cream outlet temperature : 50°C.

 Skim milk outlet temperature : 50°C.
 RPM. : 4800.
 Motor KW/Hp : 40/50.
 Volt : 415.
 Ampere : 400.
 Frequency : 50 Hz.
 Separation Efficiency : 90%
 Flushing : per 12 min (25 sec req.)
 Pressure : 3 kg/ cm
 Hot water temp for dislodging: 35°C.
8) CREAM STORAGE SILOS:
 Numbers : 02
 Capacity : 20KL
 Make : IDMC
9) RC unit:
 Number: 01
 Capacity: 1000 L
 Pump: 3 HP
 Features: Hot water supply, mixing watt, tank, milk supply.
 Work: it is used for mixing of whey powder in skim milk. For powder production, protein
content should be more than 34 %, so, if skim milk doesn’t having appropriate protein
then additional whey protein is added by RC unit.
 FLOW DIAGRAM FOR MILK PROCESSING
Receiving raw chilled milk
Float Control Balance Tank (FCBT)
Regeneration Section-1 → Duplex filter
(45-60°C)
Regeneration Section-2 → Cream Separator
(60-70°C)
Heating Section (78±2°C)
Holding (15 sec)
↓
Cooling (≤4°C)
Storage (<5°C)
PROCESS FLOW FOR CREAM PASTURISATION:
Cream (40-45° C)
↓
Regeneration (65-72° C)
↓
Heating (92°±2° C)/20 Sec Hold
↓
Regeneration (65-72⁰C)
↓
Cooling (8-12° C)
↓
Cream storage Tank
(at temp. 14° C for 12 hrs for aging)
 Pasteurization gasket material is Neoprene Rubber & Nitride
 Effective pasteurization process consumes heat energy of 7500 Kcal & Cooling energy of 4
KWh For every thousand lit of milk.
 Each degree rise in temperature (Pasteurization) roughly increases load on Steam

consumption by 10% & 8% on Refrigeration.
PROCESS SECTION 03:
It is same as process section 2, includes separator, pasteurizer and silos. Its pasteurize
milk and separates cream from it.
B) MILK PASTEURIZER:
 Numbers : 02
 Type : PHE.
 Make : IDMC.
 Temperature at different Stages of Pasteurizer

 Chilling – 5°C
 Regeneration-I – 45°C
 Regeneration-II – 65°C
 Heating – 40°C
 Milk inlet temperature : 6-10°C.
 Steam pressure : 1.5 kg/cm2

 Pasteurized chilled milk
 Temperature : 34°C.
 Regeneration Efficiency : 90-92 %
DUPLEX FILTER:
 Numbers : 02.
 Make : Alfa Laval.
BALANCE TANK:
 Numbers : 02
 Capacity : 200 liters
 Make : IDMC
SILO:
 Number : 8 to 11.
 Capacity : 100KL of each.
 Type : Vertical
 Agitator: Side mounted.
 Make : Milk max engineers, Pune.
CREAM SEPRATOR:
 Number : 02
 Type : Automatic dislodging

 Capacity : 20Klph
 Make : Alfa laval
 No. disc : 360
 Milk inlet temperature : 45-50°C. [Separation temp.]
 Cream outlet temperature : 50°C.
 Skim milk outlet temperature : 50°C.
 RPM. : 4800.
 Motor KW/Hp : 40/50.
 Volt : 415.
 Ampere : 400.
 Frequency : 50 Hz.
 Separation Efficiency : 90%
 Flushing : per 12 min (25 sec req.)
 Pressure : 3 kg/ cm
 Hot water temp for dislodging: 35°C.

MILK PACKAGING SECTION
INTRODUCION:
Packing of food material is done due to following reasons:
1) To protect the product from contamination.
2) To prevent spillage losses.
3) To saves the degradation of product from oxygen & light.
4) To facilitate handling and marketing.

At SONAI Dairy packing station there are 13 packing machine out of which 6 machine are used for
200ml, 500ml & 1000ml pouch packing. 1machines are used for 5 lit. Pouch packing. The fluid
milk pouch produce in this section are sold under the brand name as: “SONAI, RAJNANDAN”
Packing of Fluid Milk: (Toned milk and Cow Milk)

Packing of liquid milk is done through from fill seal machine eight for bill seal machines are used
for packing seven of which are double headed and one is single headed machine. Milk is packed in
co-extruded multiage polyethylene milky white film, printed in high blue, dark blue, green and red
(for toned milk) dark blue, green and red (for cow milk).
MILK PACKAGING MACHINE
We take great pleasure in introducing ourselves as one of leading manufacturer of wide automatic
form, fill and seal machine under most advanced features in packing technology for various
products like free flowing liquid milk packing are available in single and double head with various
output and filling capacities. In this machine, there are two sealing section vertical(60)and
horizontal(80).
Form Fill Seal Machine:
The machine performs as follows:

1) Shaping the film into a cylindrical tube.
2) Form pack through vertical & horizontal sealing.
3) Injecting and filling the liquid into the tube.
4) Sealing and cutting the liquid pouches to a per determined length.

5) Arranging the milk pouches into the crates of accurate weight.
6) Store at cold store below 8ºC/ not more than 24 hrs.
7) Dispatch of pouches.
Starting procedure of the FFS machine

1) Start the air compressor & check the air pressure required for FFS machine. & start the chill
water supply.
2) Switch on mains from panel board & switch on packing machine.
3) Flush the machine with warm water, after completion of CIP.
4) Clean the heating electrode & change the silicon back up rubber and replace Teflon.
5) Tie the filter bag at the injection point.
6) Note down the film role & load on the FFS machine.
7) Arrange the film for forming a pouch.
8) Adjust the bag length as decided by setting of film feed „cam‟. Press the bag length using lit.
Knob which has a notch for each capacity (1000ml, 500ml, 250ml, 200ml).Pull the knob outward
for large capacity push it in for smaller capacity.
9) Rotating the knob in clockwise direction increase the length and vice-versa.
10) Select the filling quantity by pressing volume adjustment knob.
11) Check that the film is correctly overlapped length, then vertical seal electrodes. Turn on the
vertical seal switch.
12) Up to this point there is no visible movement on the machine. To check the film feed, turn on
the auto switch. The film will move downward and must be pulled below the horizontal seal jaws.
13) Check & Adjust the length of pack as required.
14) Check the strength of vertical seal adjusting the sealing temp. As necessary with the vertical
seal rheostat on the panel.
15) On horizontal seal switch and make sure that the sachet is between the jaws of seal check the
strength of seal.
16) When the sealing strength and pack cutting is done, then start the injection.
17) Check the bag length, weight of pack pouch, leakage, speed of machine and chill water
circulation.
Milk Packing Operation
1) Switch on all the switch in main panel
2) Start air compressor & air dryer unit.
3) Start machine air & cooling water, air pressure = 3-5 kg/cm2
4) Switch on the manual injection & remove the hot water
5) Put the Teflon on the injection horizontal jaw & vertical jaw checked if any problem then change
the Teflon tape & rubber strip. Shift, Date & Machine No-code is prepared & start machine.
6) Clear the milk line from the milk tank. All water through the line firstly 5-10 lit milk takes into a
can & after that switch off injection manual.
7) Main panel shows auto machine start in auto after that vertical sealing & horizontal sealing given
& injection start
8) Check the coding, weight sealing & after that fill the create with milk pouch.
9) Check the weight & bag length of milk pouch properly & mention the report After ½ hr.
10) Shift the create into cold room.
11) After completion of packing flush the line with hot water, check the Filter before 2nd shift
12) Wash machine with Teepol water
13) Machine & milk line washed with hot caustic solution
14) Log book & pouch specification report submitted to shift in charge.
15) Machine air valve & water Valve close.
16) Switch off air compressor.
Specification for packaging
Sr. no. Volume of milk weight ( gm) Bag Length Thickness

( ml) ( mm)
1 200 ml 205 – 209gm 85 +/- 5 mm 50+/-5μ
2 500 ml 518 – 522 gm 150 +/- 5 mm 50+/-5μ
3 1000 ml 1032 –1040gm 240 +/- 5 mm 60+/-5μ
4 5000 ml 5170 –5185 gm 360 +/- 5 mm 110+/-7μ
250 ml 257 –260gm 100 +/- 1 mm 50+/-5μ
Verities of Milk Packing:
Types Fat % SNF %

Sonai Rajnandan Doodh. 3.0 8.5
Sonai Lite Pasteurized Homogenized Double Toned Doodh 1.5 8.5
Sonai Pasteurized Standerdies Doodh 4.5 8.5
Sonai Pasteurized Homogenized Cow doodh 3.5 8.5
Rajnandan Homogenized Pasteurized Toned Doodh 3.0 8.5
Buffelo Milk 6.0 9.0
CIP of Packing Machine
1) After each shift CIP should be carried out.

2) Flush the milk in the packing machine tank & line. Remove the filter from injection of packing
m/c.
3) In packing machine 70 – 80 0C & 0.5 – 1.0% conc. Caustic solution CIP pass to the milk line.
4) After complete the caustic CIP flush there solution with hot water.
5) Check the presence of caustic into the hot water by using phenolphthalein as indicator.
Ethylene polymer is most important of all plastic. There are three main type LDPE, HDPE, MDPE.
They are poor barrier property of gases and aroma. The drawback of plastic can be overcome by co-
polymerization with other plastic. PE after extrusion can be converted into raps, bags, sacks and
blow molded form like bottle, jars, caps, trays, drums, etc. pre-stretched PE is also used for shrink
wrapping. SONAI DAIRY are used LDPE (low density poly ethylene). Thickness of LDPE is 55
micron.
Note:
1)Total quantity of milk pouches per day is 90,000 liter.
2)Milk is supply for selling party is Hydrabad, Parali, Nilanga, Gulbara ,Nanded, Mumbai, Pune,
Solapur, Indapur.
SPECIFICATION OF POLYETHLENE FILM TO BE USED ON POUCH
FILLING MACHINE:
 Quality : Natural or virgin clear

 Transparent, plain or printed
 Width : IS-6 M machine use film width 323+2mm
 Film Thickness: IS-6 machine use film of thickness as per std.
 Code & Code Size : The code should be of strong paper having 76 mm Inside diameter
COLD STORAGE (MILK POUCHES):

 In this section milk is storage at a cooled temperature (0 to 5)
 It is cooled by two refrigeration units mounted.
 Ammonia based refrigerants.
CRATE WASHING MACHINE:

 This machine are used to washing crate with the help of hot water, caustic soda, steam.
 Steam temperature- 70 to 75 and pressure- 3.2 kg/cm3.
 Caustic soda- 1 to 1.5 kg with 200 litre.
 Capacity –about 1000 crate per hour
 Makers: SS Engineers & Consultancy, AP.
Electronic weighing balance

 No : 6
 Make : Promote (Hercules scale)
 Capacity : Max .20kg
 Min – 20 gm
 Error-1 gram
STORAGE TANKS:
 Numbers: 06
 Capacity: 02 of 20 KL, 03 of 05 KL, 01 of 10 KL.
 Agitator: top mounted
 Features: lamp, level detector, temperature detector, manhole, agitator.
 Work: they are mounted above the packaging plant, so uniform pressure of milk supply can
be created.
FILTERS:
 Types: SS filters, Duplex Filter.
 Number: 04 of SS filters for milk. 03 of Duplex filter for Water.
CHILLER:
 Type: Plate heat exchangers SS.
 Numbers: 03
 Capacity: 02 of 20 KL, 01 of 10 KL.
 Works for cooling milk below 4 0C and store in tanks.
WATER SUPPLY:
 Types: Tank and pump.
 Work: it supply water to fillpack machine, so temperature of sealing & cutting should not
exceed.
AIR SUPPLY:
 Type: filter with compressor pump.
 Work: It supply air with constant pressure, this air used in the pneumatic valves which
controls the milk flow during filling.
CONVEYOR BELT:
 Type: crate conveyor of plastic belt.
 Work: carry empty & filled crates to store to vehicles.
BUTTER SECTION
Introduction :-
Fats are crucially important to the human diet, not just for their nutritive contribution ( Including to
the energy , fat-soluble vitamins, and essential fatty acids ) but because of their influence on mouth
feel and hence their ability to make much of our food palatable.
Milk fat is particularly valued in these role due to complex food systems become of par-amount
importance.
CONTINIOUS BUTTER MAKING MACHINE:
 No. of machine : 02
 Type of butter : Creamery butter
 Capacity : One of it having capacity of 5 MT/ Hr. and other of 3 MT/Hr.
 Features: 60 HP pump for churner, 5 HP for second press removal, 5 for 3rd screw press.
 Make : Simon Frères Cherbourg France
Process -
1) Churning cylinder:
In this the cream of 30-50% fat enter in it with high speed rotating dasher (1497 rpm} At this point,
the rapid agitation break the butter fat in a matter of second, provide the temperature and other
condition are correct. The machine of this type have an ice jacket around the churning cylinder in
order to control the churning properties. The properly churn cream drawn in working section.
2) Working section :
Where it is agitated and washes and most of buttermilk is drawn off. The butter moves into the upper
compartment.
3) Dry working section:
Where it is further work to reduce the moisture contain to 13% in case of sweet cream butter and
14% ripened cream butter.
4) Vacuum section:
Use to reduce the air contain of butter and improve its spreadability to some extent.
Operation:
1) Before operation clean the whole equipment and section.

2) If required electricity supply is available then with permission of electrical section start the
machine.
3) Before receiving the cream first insure the cream churner must be clean.
4) Before taking cream for butter making check the cream acidity, fat, temp.
5) After receiving result from lab cream taken for production.
6) By insuring cream from cream tank into in balance tank come in right way then start the
continuous butter manufacturing machine.
7) Sure for printing of batch and date on boxes.
8) Put the liner into empty boxes before taking a cream
9) Remove the loose butter, after filling 4-5 boxes test the sample for fat, acidity, and moisture set
the machine according to the lab report.
10) Then start the production.
11) Fill the empty boxes with 20 kg butter.
12) Before storing the butter in the cold room, check from lab and then pass over to cold room.
13) Note the number of boxes manufactured in the F.G. note and hand over to cold room.
14) After completing the work clean all the section.
15) Record the work in to the log sheet.
 Flowchart:
Pasteurized cream at CCP 1
92°C + 2°C for 20 sec.
↓
Cream storage tank for ageing
(temp. max 14° C for 12 hrs)
↓
Pumped to continuous butter making machine (CBMM)
↓
Churning
Butter Granulation
↓ Buttermilk
Sampling & testing
↓ ↓ chillng
Desi butter Process to powder
↓
OPRP Packaging
(polyliner bag of 20 kg, corrugated
boxes of 20 kg, BOPP tape wrapped around 1 tone)
↓
Storage below -18 0C
↓
dispatch
Nutritional Value :
 Energy : 744 kcal
 Cholesterol : 180 mg
 Energy From Fat : 738
 Total Carbohydrate : 1.0
 Total Fat : 82%
 Protein : 0.5%
 Saturated : 52%
 Trans Fat : 1.2
 Vitamins : 650
 Storages:
There are two types of cold storage, one for quick dispatch, and other for long term
storage. Smaller one is of storage capacity about 300 tones, which facilitate below -5° C
temperature. Bigger cold storage having capacity of 2000 tones of butter at a time, and
facilitate -18° C to -25° C temperature.
Butter Yield
The yield of butter from whole milk can be calculated using the following equations. (Loss and
overweight are not considered.)
kg cream = kg milk x (% fat in milk - % fat in skim milk)

% fat in cream - % fat in skim milk
kg butter = kg cream x (% fat in cream - % fat in buttermilk
% fat in butter - % fat in buttermilk
EQUIPMENTS AT BUTTER DEPARTMENT:

CREAM AGEING TANK:
 Type: SS jacketed vertical tanks.
 Numbers: 04
 C apacity: 03 of 30 KL, 01 of 20 K L.
 F eature: Water jackets , Agitator, manhole, temperature detector, level
detector.
MELTING WATT:
 Type: Hot w ater Jackets. Horizontal open tub w ith SS pipes liners.
 Number: 02
 C apacity: 5M T/Hr. each.
 Work: It melt dow n the butter coming from CBMM, removes waters from
it. And it further s ends for ghee proces sing.
BU TT ER MI LK C HI LLER :
 Type: SS P late heat exchanger.

 Number: 02
 H aving balance tank, pumps, SS filters of each.
GHEE SECTION
INTRODUCTION
Ghee is the most preferred indigenous product. It is only the best way of the
preservation of milk fat but it is also to utilize the sour milk or the curd. SONAI Dairy manufactures
the ghee under the trade name of “SONAI”. The manufacturing of the ghee from the Butter. The
sour cream from sour milk is also used for the manufacturing of the ghee. Fresh cream firstly convert
into the white butter, and then used for ghee making with the help of continuous butter making
machine.
Composition and Standards for Ghee :-
PARTICULARS PARAMETERS
Flavor and color Yellow and pleasant
Moisture 0.25 % max
Free fatty acid (as oleic acid) 0.3max.
RM value 28 min.
BR reading at 40°C 40-43
Boudouin test Negative
NUTRITIONAL IMFORMATION OF GHEE:
As per 100 gm.
Energy 897.30 Kcal
Total fat 99.70 gm.
Saturated Fat 63.50 gm.
Mono-unsaturated fatty acid 24.00 gm.
Trans Fat 3.0 gm.
Polyunsaturated fatty acid 1.6 gm.
Cholesterol 500 mg.
Vitamin A 170 mg.
Vitamin E 18 mg
Protein -
Carbohydrates -
Raw material for ghee making Creamery butter:
 Fat : 80% min.

 Curd : 1.5 % max.
 Moisture : 16%min.
 FFA : 0.3 %oleic acid max.
EQUPMENT SPECIFICATION :
Section 01:
Equipment : Storage tank

 Type : Vertical ghee storage tank
 Number : 03
 Capacity : 02 of 10 MT, 01 of 03 MT.
 Features: agitator, water jackets for temperature control, Lamp, temperature detector, level
detector.
 Heat treatment : hot water
 MFD By : Milk max engineer
Equipment: PST (pre-stratification tank)
 Number : 03
 Type: SS vertical tank.
 Capacity: 3000 lit each.
 Works: Its separates the water ghee layer by gravity on keeping for 3-4 Hrs. then lower water
is removed by bottom valve. Basically it form three layers on of ghee, emulsion and water. It
removes water by layer separation.
 MFD By : max milk engineer
Equipment: Ghee kettle/ boiler.

 Number : 04
 Capacity: 01 of 4 MT, 01 of 3 MT, 02 of 1 MT.
 Type: Steam Jacketed kettles with open top.
 Features: Steam supply, Agitator, temperature detector, bottom valve for berry removal, mid
valve for ghee removal.
Equipment : Ghee balance tank

 Number : 03
 Capacity : 50 liters of each with pump of 1.5 HP.
Equipment: Ghee Clarifier

 Number : 01
 Type : VLG-103
 Motor: 7.5 HP
 RPM : 119
 Disc no: 102
 Volt : 415
 Capacity: 1.8 KL/Hr.
 Amp : 2.1
 Hz : 50
 Maker: Tetra pack pvt. Ltd
 Work: Its removes dirt, solid parts of milk, curdling by centrifugal force. It purifies ghee.
Equipment: Ghee Settling Tank

 Numbers: 02
 Capacity: 05 MT of each.
 Features: Water Jackets for temperature control, temperature & level detector, lamp, Exhaust
valve.
 Makers: Milk max engineers, pune.
Equipment: Nylon Filter
 Numbers: 02
 Size: 120 mesh
SECTION 02:
Equipment : Ghee kettle/ boiler.

 Number : 043
 Capacity: each of 5 MT.
 Type: Steam Jacketed kettles with open top.
 Features: Steam supply, Agitator, temperature detector, bottom valve for berry removal, mid
valve for ghee removal.
Equipment: Ghee Clarifier

 Number : 01
 Type : VLG-103
 Motor: 7.5 HP
 RPM : 119
 Disc no: 102
 Volt : 415
 Capacity: 1.8 KL/Hr.
 Amp : 2.1
 Hz : 50
 Maker: Tetra pack pvt. Ltd
Equipment: Ghee Settling Tank
 Numbers: 03
 Capacity: 05 MT of each.
 Features: Water Jackets for temperature control, temperature & level detector, lamp, Exhaust
valve.
 Makers: Milk max engineers, pune.
Equipment : Nylon Filter

 Numbers: 02
 Size: 120 mesh
Equipment : Ghee balance tank

 Number : 04
 Capacity : 100 liters of each with pump of 1.5 HP.
Equipment : Storage tank

 Type : Vertical ghee storage tank
 Number : 03
 Capacity : 03 of 10 MT.
 Features: agitator, water jackets for temperature control, Lamp, temperature detector, level
detector.
 Heat treatment : hot water
 MFD By : Milk max engineer
Equipment : Berry Trolley

 Number : 03
 Capacity : more than 500 liters.
 Work: for collection of berry from kettle & move to berry press.
Equipment : Berry Press Machine

 Number : 01
 Work: Berry which is mix part of curdling, water, miscible fat & water. This contain some
quantity of ghee, so it is collected and pressed by hydraulic piston. Released fat is collected
and process again for ghee production.
FLOW CHART FOR GHEE
Pasteurize cream
↓
Continuous churning
↓
Removal of butter milk
↓
Butter melting(vat/continuous) and heating 60°C to 70°C
↓
Pre-stratification tank
↓
Cooking in ghee kettle ← ghee
At 106°C + 2°C
↓ ↑
Filtration extraction
↓
Settling Tank → ghee residue
↓
Clarification
↓
Storage tank
↓
OPRP 1 Nylon filter 120 mesh
↓
OPRP 2 Filling at temperature 40-45°C
↓
Sampling & testing
↓
Storage
↓
Dispatch
Detail Process:
I. Production of ghee is materialized looking to the seasonal Trend of demand & receipt of order
from general store. General store raised demand looking to the market trend & minimum
orders level.
II. Required quantity of melted butter is taken into the ghee kettle.
III. If there is no hurry, melted butter is taken into pre-stratification tank, allow settling for 3-4
hrs, then water layer removal is carried out.
IV. In kettle, removal of moisture is done by heating it, by steam in jacketed vessel.
V. When temperature of ghee reaches to 90°C, its stops producing foam. Then the point at there
formulation of berry began. So, start the agitator for uniform cooking of ghee .
VI. Heat till it removes nearly all moisture content of ghee. End point at which berry settles at
bottom and temperature reaches to 106°C.
VII. Stop heating, close steam valve, allow to cool to 60°C.
VIII. Drain the ghee in balance tank, it is filtered, and pumped to settling tank.
IX. It allows to settle curdling particles at bottom, and again filtered by cotton cloth.
X. Next, it is pumped to clarifiers to get clear, transparent, fine liquid ghee, which free from any
impurities. Then stored in storage tank above 45°C -50 °C.
XI. Storage tanks are held above ghee packaging section. So, uniform supply pressure can be
maintained.
XII. Its it packed by atomic packing machines, as different packages, there are different machines.
XIII. After production, it is stored in granulation room below 14°C for better texture of ghee.
Dispatch is done.
PROCESS MONITORING & MEASUREMENT
PROCESS ACTIVITY CRITERIA
Pasteurization of Heating temperature 90°C minimum

cream cooling temperature 20°C maximum.
Retention time of cream tank 24 hours maximum
Moisture content in white butter 18 % maximum
Final heating temperature of ghee 106°C-107°C
Moisture content in ghee 0.3 % MAX.
GHEE PACKAGING DONE IN SONAI:

SONAI PURE GHEE:
PET jars. Price
Quantity in ml. in Rs.
100 ml. 75/-
200ml. 125/-
500 ml. 295/-
1000 ml. 565/-
1000 ml tetrapack 550/-
5L 2700/-
15 L 8000/-
SHREE SHREE AYURVEDA:

Marketed by: S riveda Satva pvt. ltd.
F or them s onai produces ghee in tetrapack of 500ml, 1000ml.packaging

materials are chosen by marketing agency.
ARIHANT POLYPACK INDUSTRIES:

1 liter pack pouches.
BRITANIA COW GHEE:

M arketed by: Britania Dairy pvt. Ltd.
 F or them, ghee packed in tin cans of 1 liter and 500 ml.

 P ET jars of 200 ml. & 250 ml.
 P ouches are also available of 500ml. & 1 liter.
POWDER SECTION
The production of milk powder as become an increasingly important segment of the dairy
industry milk powder is the powder obtain by removal of water from milk by heat or suitable
milk, to produce solid containing 5% or less moisture.
 WMP(WH OLE MILK PO WD ER):According to the PFA Rules 1976 whole milk
powder is the product obtained from cow or buffalo milk or combination
thereof or from s tandardized milk by the removal of water. Milk pow der
should 74 contain moisture not more than 5%, fat not les s than 26%, total
acidity not more than 1.2%, standard plate count not more than 50,000/g.
coliform count not more than 90/g.
 SMP (SK IM MILK PO WD ER): A ccording to the PFA Rules 1976 whole milk
powder is the product obtained from cow or buffalo milk (the s kim milk of) or
a combination there of ,by the removal of water. M ilk pow der should contain
moisture not more than 5% ,fat not les s than 1.5% acidity not more than 1.5%
s tandard plate count not more than 50,000/g., coli form count not more
than90/g.
 DAIRY WH ITEN ER: Dairy whitener is the product obtained from cow or
buffalo milk (the s kim milk of) or a combination there of, by the removal of
w ater. M ilk powder should contain moisture not more than 5% ,fat not less
than 18%, acidity not more than 1.5% standard plate count not more than
50,000/g., coli form count not more than90/g.
Milk powder products are manufacture for the same purposes as powdered milk, viz. to reduce
bulk so as to effect storing in space, to reduce packing and transportation cost to improve the
storage life of product, to provide a product which can be utilize for many food manufacturing
operation and of which are economically attractive.
The powder plant sonai dairy with total capacity of 30 /40/50/60 tone par day.
Powder plant no.01 (30 TPD)
Effect no. 1 2 3 4 5
Temperature (°C) 80.2 74.6 70 64.6 49.2
Vacuum (mm hg) 450 510 550 600 630
Operating parameter:
Evaporator
 Feed rate : 19200 lit/hr
 Temperature flash vessel : 79 °C
 Vacuum in flash vessel : 710 mm hg
 TVR steam pressure : 10 bar
 Cooling water inlet temperature : 21.4°C
 Cooling water outlet temperature : 27°C
Dryer section:
 Capacity : 30 tones
 Nozzle pressure : 6 bar
 Heating medium : steam
 Feed rate : 19200 kg/hr
 Feed TS : 48%
 Inlet temp : 185°C
 Outlet temp : 87°C
 Water evaporation rate : 11000 kg/hr
 Chamber vacuum : -4 mm hg
 FBD vacuum : -8 mm hg
 FBD hot air temperature : 40°C
 FBD air outlet temperature : 64°C
 FBD dehumidified air temp. : 33°C
Plant no.0 2 (50TPD)
Effect no. 1 2 3 4 5 6
Temperature(°C) 71 67 65 59 55 50
Vacuum (mm hg) 450 510 540 570 600 650
Operating parameter
Evaporator
 Feed rate : 27500kg/hr
 Temperature flash vessel : 90°C
 Vaccum in flash vessel : 410 mm hg
 Cooling water inlet temperature : 31°C
Dryer section:
 Feed TS : 30%
 Inlet air temp : 200°C
 Outlet air temp : 84°C
 Water evaporation rate : kg/hr
 SFBD heating: 80-90°C
 FBD air outlet temperature : 65.5 °C
Plant no. 03 (60TPD)
Effect no. 1 2 3 4 5 6
Temperature(°C) 71 67 65 59 55 50
Vacuum (mm hg) 450 510 540 570 600 650
Operating parameter
Evaporator
 Temperature flash vessel : 90°C
 Vaccum in flash vessel : 410 mm hg
 Cooling water inlet temperature : 31°C
Dryer section:
 Feed TS : 45%
 Inlet air temp : 200°C
 Outlet air temp : 84°C
 Water evaporation rate : kg/hr
 FBD air outlet temperature : 65.5 °C
Flow diagram of powder:
Raw chill milk below 4°C

↓
Skim milk storage below 4°C
↓
Evaporator balance tank ←
↓
Pre-heating at 40 to 55°C) ↑
↓
Direct Steam injection (76°C for 30sec) → Non-
CCP 1
Conforming (conforming)
↓
Evaporation of milk
↓
OPRP
Stored in condensed tank
↓
Storage in balance tank (2hrs)
↓
Filtration (line strainer 1mm)
↓
Pumping of condensed milk
↓
Pre-heating(45 to 55°C)
↓
Atomization high pressure nozzle (150 to 200 kg\cm2)
↓
Air Supply
↓
Air Filtration
↓
Air Heating
↓
Heated Air → Drying in chamber → Air exhaust
( 180 to 190°C)
↓
←Filter Dehumidified
Hot air
← Filter Dehumidified
Cool air
↓
OP RP Fluidized bed dryer
Temp : 45-60°C for 30TPD
↓
Dried WMP, SMP or DAIRY WHITENER
70-85°C for 50TPD
↓
Metal Arrester
↓
Sifter 16 mesh
↓
Sampling and Testing
↓
Packing
↓
Metal detector
↓
Storage and Dispatch
Note: Dairy whitener is prepared with addition of sugar

(Standardization).
Start Up The Drier Unit:
1. Open the chamber door.

2. The exhaust fan.
3. Start the cooling air fan & supply fan.
4. Close the chamber door & any other “air sweep” door.
5. Start the rotary valves, the vibrating device.
6. Start the motor of instant bed, in the extent necessary for the product to be made.
7. Start the air heater; place filter cock in position of water.
8. When outlet temp form the drying chamber has increased to about 80C, start feed pump so that
water is pumped to the nozzle.
9. Control the water qty. so that specified outlet temp is kept constant.
10.Start the electric hammer.
11.When inlet temp has been obtained change over from water to product.
Operation of the plant:
When the change over from water to product made, the outlet temp must be constantly check.
The higher viscosity of the product may increase the yield of the feed pump. Due to the solids
content in the product, it will be necessary to increase the speed of the feed pump in order to
maintain the water qty to be evaporated in the drying plant. (The capacity of the spray drying
plant is a certain water evaporation kg/hr. When drying a product, the concentration of the
product only has a minor influence on the evaporation capacity of the plant.) Never let the plant
run, without addition of either water or product to the atomizer as this cause an increase of the
temp in the drying chamber & outlet ducts & the powder deposited here will then be damaged.
When the plant is in operation inlet & outlet temp are to be observed Bags of powder: The
packaging material used for powder is 4-ply paper or fiber board with an overwrap of foil
laminated to paper and with the linear.
BYPRODUCT SECTION
TYPES OF BYPRODUCTS
1) Flavoured Milk
2) Shrikhand / Amrkhand
3) Dahi
4) Lassi
5) Butter Milk
6) Paneer
Flavouredmilk :-
Flavoures milk is a sweetened Dairy drink made with milk, sugar, food colors and artificial
natural flavoring . Flavored milk is often pasteurizing using UHT.
Flavored milk flow diagram
Receiving of milk
↓
Standardization (min 4.5% fat)
↓
CCP 1 Pasteurization (72°C for 15 sec)
↓
Homogenization ( 2500 PSI)
↓
Addition of sugar (8% /100 lit)
↓
CCP 2 Filtration
↓
Addition of color (proper mixing)
↓
Addition of flavor
↓
OPRP 1
Bottle filling
↓
Capping (40 BPM)
↓
CCP 3 Sterilization (120°C for 1 h)
↓
Storage (Room temp)
TYPES OF FLAVOURED MILK :

For 40 lit milk, 2.8 Kg sugar
Flavor Color Quantity Essence Quantity
Mango Orange 26 gm Mango 24 ml
Strawberry Berry red, pink 7 gm Strawberry 24 ml
Butter scoch Lemon yellow 5 gm Butterscotch 24 ml
Badampista Apple green 13 gm Badampista 24 ml
Chocolate Chocolate color 6 ml Chocolate 32 ml
Packing 825 To 850 bottle/day (200 ml)
NUTRITIONAL VALUE:
Constituents Percentage
Fat 1.50 gm
Protein 3.30 gm
Carbohydrate 13 .00 gm
Energy 18 kcal
Mineral 0.75 gm
2) SHRIKHAND / AMRKHAND :-
Shrikhand is a semi-soft, sweetish-sour, whole milk product prepared from lactic fermented curd.
This chakka is mixed with the required amount of sugar, etc. to yield of shrikhand .
Standard Flow Diagram of Shrikhand / Amrakhand :-
Storage of milk in silo below 7°C

↓
Clarification /separation
↓
OPRP 1 Standardization
(Fat -4.5-5%SNF-9-9.5%)
↓
CCP 1 Pasteurization at 85°C for 1 min
↓
Cooling at 41°C -44°C
↓
OPRP 2 Addition of culture at 40-44°C
Incubation for 4-5 hrs at 37-41°C
↓
Inspection for texture of curd &
Testing of acidity 0.7-0.9%LA
↓
Hanging of curd for 16-20hr
↓
Whey separation
↓
Drying of chakka by hanging
Weight of chakka
↓
Addition of sugar
CCP 2
(85 % of chakka)
↓
Mixing of chakka with sugar
↓
Shredding of mixture in chakka in polisher machine
↓
Addition of ingredient
(Badam, pista, eliachi in shrikhand
(Mango pulp 17% in case of amrakhand)
↓
Mixing whole content in mixing tank
↓
Packing in to cups
↓
OPRP 3
Storage under refrigerated condition at 0-4°C
COMPOSITION
Constituent Percent
Moisture 8.5 % <= dry basis
Protein 9 % <= dry basis
Lactose with sugar 72.5>= by wt. dry basis
Lactic acid 1.4 %<=(% by weight)
PACKAGING:-
 100 gm plastic cup

 250 gm plastic cup
 500 gm plastic cup.
3) Dahl:-
Indian curd, known as dahi ,is a well known fermented milk product consumed by large section
of the population throughout the country.
Types of dahi:
1)Sour dahi
2)Sweetened dahi
Standard Flow Diagram of Dahi :-
Selection of milk
↓
Chilling (up to 4°C )
↓
Standardization (fat 3.0% and SNF 10 % )
Add of SMP and cream
↓
CCP 01 Pasteurization (90°C +/-2°C for 7 min )
↓
Homogenization (1st stage 1000 psi
2nd stage 500 psi
↓
Cooling( up to 5 °C )
↓
Testing ( quality as per )
↓
Preheating (42 °C)
↓
Culture Addition (DVS)
↓
Storage (15 min )
↓
OPRP 1 Packaging
↓
Incubating (at 42°C To 45 °C)
↓
OPRP2 2
OPRP Cooling And storage (at 5°C)
Nutritional Value :-
 Total Fat : 6 gm
 Cholesterol : Nil
 Total Carbohydrate : 27 gm
 Protein : 4 gm
 Calcium : 19%
 Vitamin A&C : Nil
4)Lassi :-
Lassi is a popular traditional dahi( yogurt ) based drink that agitated in the Indian
subcontinent .Lassi is a blend of yogurt, water sugar.
Standard Flow Diagram of Lassi :-
Fresh milk
↓
CCP 1
Pasteurization (79 °C for 20 sec )
↓
Cooled to (21 c to 22°C )
↓
OPRP 1 Inoculated with starter culture ( 0.1 to 0.15 )
↓
Inoculated for 16- 18 hr (at 21 °C to 22°C)
↓
Coagulated milk (pH 4.6 to 4.5)
↓
Stirred curd ( 1.2 lactic acid )
↓
Addition of sugar (25% of dahi )
Addition of water (10 % 0f dahi )
↓
Lassi mix
↓
Homogenization (100 kg/ cm)
↓
OPRP 2 Filling And Cooling (below 10 °C )
↓
Storage ( 4 °C )
↓
Dispatch
Composition Of Lassi :
 Water : 96.2%
 Fat : 0.8 %
 Protein : 1.29 %
 Lactose : 1.2 %
 Lactic Acid : 0.44%
 Ash : 0.4%
 Calcium : 0.6%
 Phosphorus : 0.04%
Packaging Of Lassi :
 200 ml Plastic pouch

 200 ml Plastic cup
5)Butter Milk :-
Butter milk is a liquid left behind after churning out of butter form curd . It is considered
beneficial to health as it contains probiotics microbes
Standard Flow Diagram of Butter Milk:
Receiving Milk
↓
Pre-heating of milk
↓
CCP 1 Filtration Or Clarification
↓
Boiling
↓
Cooling
↓
Addition of previous dry curd
↓
Incubation (16 to 20hr)
↓
Coagulation
↓
Cutting
↓
Separation of butter → Butter Milk
↓
OPRP 1 Storage (5 to 10 °C ) → Packaging
↓
Dispatch
Nutrient Composition Of Butter Milk:

 Moisture : 97.6 gm
 Protein : 0.8 gm
 Fat : 1.1 gm
 CHO : 0.5 gm
 Calcium : 30 gm
 Iron : 0.1 gm
6)Paneer :-
Paneer is the most common Indian from of cheese. It is an unaged acid set non- melting unsalted
cottage cheese.
Standard Flow Diagram of Paneer :
Receiving of buffalo milk

↓
Filtration
↓
Standardization of Milk
↓
Heating to 90°C
↓
Cooling to 70°C
↓
Addition of coagulant (2%citric acid solution )
↓
Draining
↓
Hooping
↓
Pressing (3kg per cm2 for 15 minute )
↓
Cutting into small blocks (6×6)
↓
Dipping in chilled water (5 – 6 °C)
↓
Packaging
↓
Storage at 5°C
↓
Dispatch
Nutrient Composition of Paneer :

 Moisture : 57.1 gm
 Protein : 18.3 gm
 Fat : 20.8 gm
 CHO : 1.2
 Calcium : 208 mg
Packaging:
 250 gm plastic pouch
 500 gm plastic pouch
QUALITY CONTROL LAB
Quality:
ISO defines, “Quality is the totality of features and characteristics of a product or service to bear
on its ability to satisfy the stated or implied needs.”
Quality control:
It is responsible for checking final product with respect to that whether it is meeting with
standard or not. It does nothing to improve quality of products.
Quality Assurance:
All those planned and systematic action necessary to provide adequate confidence that a product
or service will satisfy given requirements for quality.
1) SKIM MILK
a) Acidity
b) Fat
c) SNF
2) CREAM
a) Fat
b) Acidity
3) BUTTER
a) Moisture
b) Fat
c) RM (Richerd meichel value)
d) FFA
e) Curd
4) GHEE
a) Fat
b) FFA
C) RM
d) Moisture
5) SKIM MILK POWDER

a) Protein content
b) Bulk density
c) Acidity
d) solubility
TEST FOR SKIM MILK
A) Detection of Fat by Gerber Method:
 Principle:
Gerber sulphuric acid demulsify the fat and where as iso - amyl alcohol reduce the interfacial
tension between the two layer.
 Reagents:
1) Gerber Acid – Automatic tilt measuring bottle (10 ml)
Specific gravity: 1.815 – 1.820 at 20° C.
2) Iso - amyl alcohol -- Automatic tilt measuring bottle (1 ml)
Density: 0.803 – 0.805 gm / ml at 27 ° C.
It should be free from fatty matter.
 Procedure:
1) Take 10 ml Gerber sulphuric acid in butyrometer (0 –10 % scale)
2) Pipette out 10.75 ml milk .transfer it carefully into the butyrometer without disturbing
the acid.
3) Add 1 ml Iso- amyl alcohol & make up volume with distilled water.
4) Centrifuge at 1100-1200 RPM for 5 min.
5) Take the reading after adjusting the fat column.
Result: In % fat
B) Detection of SNF:
Apparatus :
1. Zeal lactometer.
2. Lactometer jar.
3. Thermometer.
Procedure:
1. Take appropriate milk sample & warm upto 45 to 50 º C.
2. Cool the sample at 21 º C.
3. Wash the lactometer & jar with little quantity of milk.
4. Take sample in jar having temperature 21 º C. upto top brim of jar.
5. Insert the lactometer into jar.
6. Take column reading of lactometer as “Lactometer reading”.
7. According to corrected factor reading table note the corrected lactometer reading (CLR).
8. The reading of zeal lactometer at 21 º C. is the “CLR”.
Formula:
SNF % = CLR/4 + 0.21 × Fat % + 0.36.
C) Acidity of Skim milk:
Apparatus:
1. 10 ml pipette
2. 100 ml conical flask.
3. Burette with stand.
Reagents:
Phenolphthalein indictor
0.1N NaOH
Procedure:
1. Take 10 ml Skim milk &10 ml of dist. Water in a 100 ml conical flask
2. Add 1 ml (4-5 drops) of phenolphthalein indicator.
3. Titrate it against with the 0.1 N NaOH till a faint pink color is observed.
Formula:
Titratable Acidity: 9 A× N % L.A.
W
A – No. of ml of NaOH required
N – Normality of NaOH.(0.1 N)
W – No. Of ml of sample taken
TESTS FOR SMP
A) Protein by Kjeldahl method
Principle:
The protein content is determined from the organic nitrogen content by Kjaldhl method.
The nitrogen compound are converted into ammonium sulphate by boiling with sulphuric acid.
The ammonium sulphate is formed is decomposed with an alkali (NaOH) and the ammonia
liberated is absorbed in excess of standard solution of acid and then back titrated with standard
alkali
Apparatus:
a) Kjeldahl flask 500 or 800 ml capacity. Kjeldahl distillation apparatus, same digestion Flask
fitted with rubber stopper through.
b) which passes lower end of efficient rubber bulb or trap to prevent mechanical carry over of
NaOH during distillation
c) conical flask of 250 ml capacity
d) Burette 50 ml, Pipette 10 ml , 2 ml.
e) Measuring cylinder
f) Gas burner
REAGENT:
a) Concentrated sulphuric acid of 98% by weight and nitrogen free
b) Copper sulphate
c) Pottasiumsulphate
d) Standard sulphuric acid 0.1 N

e) Sodium hydroxide solution 50%( dissolve in 500 gm of NaOH into 1000ml distilled water)
f) Standard sodium hydroxide solution 0.1N
g) Methylene red indicator dissolve 0.5 gm of methyl red in 100 ml of 95% alcohol.
h) Sucrose.
PROCEDURE:
a) Weight accurately about 1 gm SMP and transfer to a kjedahl flask taking care to see that no
portion of sample cling to the neck of flask.
b) Add around 10 gm of digestion mixture containing copper sulphate (0.2 gm ) and potassium
sulphate (9.8 gm) and 25 ml of conc. Sulphuric acid
c) Now mix content properly.
d) Place the flask in an inclined position on the stand in the digestion chamber for digestion.
e) Heat the flask gently at low heat until frothing cases and the mixture boil steadily at a
moderate rate.
f) During heating rotate the flask several time continue heating about an hour until the colour of
digestion mixture is pale blue.
g) Cool the digest and add slowly 200 ml water add anti bumping glass bead and swirl the flask.
h) Now connect the flask with distillation apparatus incorporating an efficient flask head to
condenser.
i) To condenser fit a delivery tube which dip just below the surface of the standard acid
containing in a conical flask.
j) Now start the flame be make low digestion flask and carefully pour 50 % NAOH solution to
make the content strongly alkaline before mixing acid and alkaline layer.
k) Boil the content until 150 ml of distillate have distilled in receiver flask.
l) Add 5 drops of methylene red indicator and titrate against the 0.1 N( NaOH) solution.
m) carry out blank titration with same quantity of sucrose
CALCULATION :-
% protein = 0.8934×(V-B)/W×96.5
B=volume standard NaOH solution required for titration blank
V=volume of standard NaOH required for titration of sample
W=weight of in gram of prepared sample taken for test
B) BULK DENSITY
Principle:
1. Take a20 gm of powder sample in measuring cylinder.
2. Place in bulk testing machine.
3. Take 20 stock of it.
4. Observe bulk powder collect at upper level.
Calculation:
Bulk density= sample weight/reading
General standard for SMP is 0.50 -0.70 gm/ml
C) ASH:
Apparatus:
1) Silica crucible
2) Muffle furnace
3)Weighing balance
4)Desiccators
Procedure:
1. Take a empty weight of silica crucible and record as W.
2. Add a 3gm of powder sample in it and record it weigh as W2.

3. Warm the powder sample over necked flame.
4. Then keep silica crucible in muffle furnace at550⁰c for 5 hr.
5. After take out silica crucible, cool it in desiccators to room temperature , and weight it.
6. Repeat the process of heating, cooling, weighing. For final reading.
D) MOISTURE:
Apparatus:
Automatic moisture meter
Spatula
Procedure:
1. Take 5 gm of sample.
2. Spread on a dish uniformly in moisture meter.
3. Close the lead.
4. Wait for result.
E) SEDIMENT TEST:
Apparatus:
Magnetic stirrer , Beaker 250 ml
Procedure:
1. Take 100 ml distilled water in beaker.
2. Then add 10 gm of powder sample.
3. Put the magnet piece in the beaker.
4. Then place on automatic stirrer machine for 5 min.
5. Check the sediment at bottom of beaker.
F) ACIDITY
Apparatus:
1)10ml pipette
2)100 conical flask.
3)Burette with stand.
Reagents:
Phenolphthalein indictor
0.1N NaOH
Procedure:
1)Take 1gm powder sample10 ml water in a 100 ml conical flask.
2)Add 1 ml (4-5 drops) of phenolphthalein indicator.
Titrate it against with the 0.1 N NaOH till a faint pink color is observed.
Formula:
Titratable Acidity = 9 A× N % L.A.
W
A – No. of ml of NaOH required
N – Normality of NaOH.
W – No. Of ml of sample taken
G) ALCOHOL
Principle :
The alcohol test determine the susceptibility of milk to coagulation due to developed acidity .salt
unbalance or high albumin content. This test is of important in evaporated milk plant to detect
milk which has a tendency to curdle during sterilization process. it also detect abnormal milk
such as colostrums, stripper milk and high in salt content.
Reagent:
Ethyl alcohol. Of 68% by weight of 75% by volume (density-0.8675 gm/ml)
Apparatus:
Test tube, pipette
Procedure:
1. Take 1 g powder sample in beaker add 10 ml of distilled water mix it properly.
2. Take 5 ml above milk prepared in test tube
3. Add 5ml of 68% alcohol for raw or 70% for past. skim Milk
4. Observe the any flex formation

TESTS FOR BUTTER
A) FREE FATTY ACID:
Procedure:
1. Take a 10 gm butter sample in a conical flask.
2. In measuring cylinder take 50 ml ethyl alcohol ,in this add a 2-3 drop of phenolphthalein
indicator and titrate against 0.1 N NaOH
3. Then add above ethyl alcohol into conical flask and it heat until the clear solution is obtain.
4. Then titrate against 0.1 N NaOH and record the reading
Calculation:
FFA =(burette reading ×2.82)/10 gm sample.
B) RM
Principle:
The material is saponified by with glycerol, sodium hydroxide solution and then split by
treatment with dilute sulphuric acid.
The volatile acid immediately steam distilled . The soluble volatile acid in the distilled are
filtered out and estimated by titration with std. NaOH solution.
Procedure:
1. Take a 10 gm butter sample then melt it then take 5 gm ghee sample in conical flask.
2. To this add a 20 gm glyceraldehyde and mix it well.
3. Then to this add 2 ml 50% NaOH.
4. Heat whole mix until clear solution form.
5. Then add 93 ml distilled water boil water and add 50 ml 1 normal H2SO4.
6. The above preparation fit distillation plant.
7. Collect 100 ml distilate.
8. Which titrate against 0.1 normal HCL, using phenolphthalein as indicator.
C) MOISTURE / FAT:
Apparatus:
Hot plate
Moisture dish
Spatula
Holder
Procedure:
1. Take empty weight of moisture dish.
2. Take weight of dish with 10 gm butter sample.
3. Put on hot plate for 5 min (still brawn particle appear at bottom of plate).
4. Then cool the dish and weight it.
Calculation:
Moisture % = Weight of dish with sample - Weight of cooled dish × 100
10 gm Sample
FAT (%) = Moisture + curd-100
D) CURD :
Apparatus:
1) 100 ml beaker
2) Hot plate
3) Spatula
4) Holder
Procedure:
1) Take empty weight of beaker.
2) To this add 10 gm of butter sample.
3) Then put it on hot plate up-to brawn particle appear at bottom of beaker
4) Cool it drain the upper layer of fat in other beaker
5) Give the 3 washing with petroleum ether of 40 ml each washing.
6) Drain the petroleum ether
7) Dry it in oven 10-15 min .cool and weight it
Formula:
Curd (%) = empty wt. of beaker – cool wet of beaker × 100 ÷ 10 gm of sample
TEST FOR GHEE :-
A) RM VALUE
Principle :
The material is saponified by with glycerol, sodium hydroxide solution and then split by
treatment with dilute sulphuric acid.
The volatile acid immediately steam distilled. The soluble volatile acid in the distilled are filtered
out and estimated by titration with std. NaOH solution.
Procedure :
1) Take a 5 gm ghee sample in conical flask.
2) To this add a 20 gm glyceraldehyde and mix it well.
3) Then to this add 2 ml 50% NaOH .
4) Heat whole mix until clear solution form.
5) Then add 93 ml distilled water boil water and add 50 ml 1 normal H2SO4.
6) The above preparation filt distillation plant
7) Collect 100 ml distilate.
8) Which titrate against 0.1 normal HCL, using phenolphthalein as indicator.
RM= (burette reading-blank reading) ×5.5/sample weight
B) FREE FATTY ACID:
Procedure:
1. Take a 10 gm ghee sample in a conical flask.
2. In measuring cylinder take 50 ml ethyl alcohol ,in this add a 2-3 drop of phenolphthalein
indicator and titrate against 0.1 N NaOH
3. Then add above ethyl alcohol into conical flask and it heat until the clear solution is obtain.
4. Then titrate against 0.1 N NaOH and record the reading
Calculation:
FFA =burette redings×2.82/10 gm sample
MICROBIAL TESTS FOR DIFFERENT PRODUCTS
1. STANDARD PLATE COUNT

i. Done for raw milk, pasteurized milk in the silos, horizontal milk storage tanks (HMST) and
pouches, butter, SMP, by-product etc.
ii. Select the dilutions so that the count comes in the range of 30-300 colonies/plate.
iii. Label the petri- plates and transfer 1 ml of each diluent into the respective plate.
iv. Pour 15 ml of the agar media at a temperature of 42 - 44 oC.
v. Allow the agar to solidify.
vi. Incubate the plate in the inverted position at 37 °C for 48 hours.
vii. Observe the colonies and tabulate the results.
viii. The count should not exceed 30,000/ml of pasteurized milk (BIS).
2.COLIFORM COUNT
i. Select the dilutions (dilution done by Serial Dilution Technique) so that the count of colonies
is in range of 30-300 per plate.
ii. Pour Violet Red Bile Agar (VRBA) at 42-44 oC and mix the contents.
iii. Keep the petri - dish undisturbed and allow it to solidify.
iv. Pour another layer of agar on the already solidified agar in order to facilitate microaerophilic
condition conducive for coliform growth.
v. Invert the plates and incubate at 37 °C for 24-48 hours.
vi. Count the number of colonies.
vii. Record the observation and tabulate it.
viii. Interpret the result for judging the quality of product and degree of sanitation maintained
during production, post process handling and storage.
3.YEAST AND MOLD COUNT

After preparing the dilutions and pipetting in the petri-plates, PDA (potato dextrose agar) is
poured in the petri- plates after adjusting its pH to 3.5.
Invert and incubate the plates at 21-25 °C for 5 days.
4.SWAB TEST
i. Take 25ml buffer and swab in a swab beaker / test tube.
ii. Autoclave to sterilize.
iii. Swab from 9 squares of 10*10 sq. cm area.
iv. Make first dilution.
v. Plate in SPCA (37°C for 48 hrs).
vi. Count = No. of colonies * 25
BOILER SECTION
Boiler section possesses a great significance in dairy industry. Steam is the main heat energy
source for the completion of each & every operation being done in a dairy plant. At Sonai Dairy,
there are two fire tube boiler having capacity 2 KL/hr each and new boiler having 3KL/hr
capacity. For steam production coal is used, as heating media. Which is highly economical than
other.
In fire tube boiler, hot gases passed through the tubes & steam in the shell.
SPECIFICATION
 Number : 02
 Capacity : 12.5 tones / hr
 Type : Vertical water tube
 Heating surface : 533 square cm
 Maker : Phadtare engineering walchandnagar
 Max pressure : 24 Kg/sq. cm
 Designed temperature : 216oC to 219oC
 Furnace type : Dumping Grate
 Operated on : Bagus
 Capacity : 200-250 tone steam/day
 Safety valve pressure : 25 Kg/cm2
 Cleaning : 2 month
 Open test : 11 month
 Water specification for use in boiler :
 Boiler feed water hardness 4 PPM
 PH of feed water 7.5 TO 9
 PH of boiler water 11.0
 TDS Less than 300 ppm
 Boiler Mounting:
o Safety Valve
o Water Level Indicator
o Fusible Plug
Safety Valve:
Spring loaded safety valve -2 boiler is designed for a certain maximum operation pressure, if this
pressure is exceeded, there is a danger of an explosion. This danger is so great that it necessitate
equipping boiler with safety valve to machine the boiler pressure within design limit. spring
loaded safety valve is hot affected by vibration.
Water level indicator:

The most satisfactory water level indicator is the glass tube water gauge. it makes the water
level in the boiler visible from the boiler room floor. The gauge is a gal s tube the lower end of
which communicates with the water space of the boiler & the upper and with the steam space.
Fusible plug:
The crown of the furnace of boiler is fitted with a plug held in position by fusible metal or alloy.
This plug under normal condition is covered with water in the boiler which keeps the temp. of
the fusible metal below its melting point. Melting point of the fusible metal is 232 ° C, when the
water level in the boiler falls low enough to uncover the top of the plug, the fusible metal quickly
metal the plug drops out & the opening so made allows the steam to rush into the furnace. The
stream this pats out the fire or gives warning that the crown of furnace is in danger of being
overheated.
Steam pressure gauge:

Boiler has a steam pressure gauge to show or read the pressure of stream in the boiler. The
stream pressure read in kg/cm 2 or lb/sq in above pressure.
Feed check value:

A value is placed at the boiler end of this feed pipe to control or regulate the flow of water into
boiler.
Blow of cock:
Purpose of discharging the loose mud & sediment deposited from the feed water at the lowest
point to which water circulates stream boiler accessories.
1) To increase the efficiency
2) To help smooth working of boiler plant. Feed water pump:
Use to deliver feed water to the boiler. it is required to supply a quantity of water at least equal
the converted into stream & used by plant.
Injection:
The injection is a device to lift & force water into a boiler which is operating under pressure
operates are the principal of stream expanding through a valve imparting its velocity energy to a
mass of water.
Pressure reducing valves:

Function in to maintaining a constant reduced pressure on its delivery side.
MAINTENANCE AND SERVICE
Two types of maintenance are followed:
a. Preventive maintenance
b. Breakdown maintenance
Maintenance plan at sonai dairy
FOR PROCESS OPERATION

i. Capacity checking per 6 month.
ii. Milk past. Heating/ chilling checking per 6 month.
iii. Milk chiller capacity checking per 6 month.
iv. CIP PHE washing/capacity checking per 6 month.
v. Separator service checking per 3 month.
vi. Homogenizer service checking per 3 month.
vii. Butter churn service capacity checking per 6 month.
viii. Ghee kettle service capacity per 3 month.
C) BOILER SECTION
1) Boiler passing per year.
2) Softener washing /capacity checking per 3 month.
3) Stock gas per year.
4) PRS service checking per 6 month.
5) Steam leakage checking per month.
D) ELECTRIC SECTION
1) Electrician inspection per year
2) Remove grass near transformer per 6 month
3) Water OHT washing per 6 month
4) Water under ground washing tank per 3 month
5) DG set servicing per month
6) Tube lighting checking per 3 month
7) Insect killer light per month
8) Water leakage checking per month
9) Electrical panel washing per 3 month
E) PACKING SECTION
1) Air compressor servicing per 3 month
2) Packing machine service per month
3) Packing machine local CIP per month
4) Crate washing servicing per month
5) Air leakage checking per month
F) REFRIGERATION SECTION
1) Ammonia compressor serving per year
2) Cooling tower servicing per year
3) Condenser servicing per 3 month
4) Condenser tank filter washing per 3 month
5) Oil purging:
 Accumulator Daily
 IBT Month
 Condenser Month
 Oil Separator 15 Days
6) Ammonia leakage checking per Month
G)ETP SECTION
1) Inlet Outlet sample checking per month
2) Remove sludge per year
H)MAINTAINCE& SERVICE
1) Oil painting per 6 month
2) Tem. Indicator Calibration per 6 month
3) Fire Articulator refilling per year
4) Press. Vessel hydraulic testing per 6 month
5) Vacuum cleaner service per 6 month
6) Wash basin service per 6 month
REFRIGERATION SECTION
Ammonia Refrigeration System
Cooling is one of the important operations frequently performed in many section of Dairy plant.
To produce cooling medium a well- equipped refrigeration section is essential for any dairy
plant. Sonai Dairy has the Refrigeration plant, having the capacity 515 TR. Chilled water from
IBT is use in RMRD section, Processing section, Butter section, , Air compression.
REFRIGERATION SYSTEM AT SONAI DAIRY
There 2 Refrigeration plant

1) Old plant
2) New plant
OLD PLANT
Compressor:
 No. : 02
 Type : Reciprocating
 Refrigerant : Ammonia
 Piston : 3
 Capacity : 20 Tones
 Make : Kirlsoker
NEW PLANT
Compressor:
 Number : 03
 Type : Reciprocating
 Refrigerant : Ammonia
 Piston : 03
 Capacity : 100 TR
 Make : Kirloskar
Tube chamber [Oil separator]:

 Number : 06
 Make : Kirloskar
Condenser:
 Number : 02/02
 Capacity : 200/100 TR
 Make :kirloskar.
 Insulation material for liquid &vapour pipe line : Thermacole
 Insulation material for hot gas pipe line : Fiber glass wool.
CIP SECTION
PROCEDURE OF MANUAL CLEANING,DOCK CIP CLEANING AND

SANITIZATION:
1) Ensure the tank / Equipment is empty in which CIP is to be carried out.
2) CIP tanks are prepared with acid / alkali solution, strength of solution is 0.5 to 1.0%.
3) Equipment is rinsed with water till water comes clear.
4) Alkali solution is circulated for 20 minutes at 70°C to 80°C temperatures.
5) Equipment is rinsed with water till it comes free from alkaline residues.
6) Acid solution is circulated for 20 minutes at 60°C to 70°C temperatures.
7) Equipment is rinsed with water for 10 minutes.
8) Circulated alkali solution for 10 minute and maintain temperature at 70°C to 80°C.
9) Finally rinse the equipment with hot water till return water comes free from alkaline residues
& temperature of return water more than 80°C.
10) When the CIP is being carried out for pasteurizer Ensure that the FDV and diversion line is
cleaned every times.
11) Ensure visual cleaning wherever possible.
FREQUENCY:
Sr No Equipment Frequency
1 Pasteurizer (4KL) Once in a Shift
2 Pasteurizer (10 KL) Once in a Shift
5 Silo Once in a Week
6 Buttermilk Silo Once in a Week
7 Milk Line Once in a Week
8 Milk Chiller Once in a Week
ALKALI CIP :-
1) Ensure the tank / Equipment is empty in which CIP is to be carried out.

2) CIP tanks are prepared with acid / alkali solution, strength of solution is 0.5 to 1.0%.
3) Equipment is rinsed with water till water comes clear.
4) Alkali solution is circulated for 20 minutes at 70°C to 80°C Temperature.
5) Equipment is rinsed with water till it comes free from alkaline residues.
6) Hot water used for final rinsed is maintained at temperature 80°C or Above.
MANUAL CLEANING :-
1) Rinse the equipment or vat surface with warm water.

2) Manually scrubbing of equipment surface with nylon brush by applying liquid detergent
solution. [Prepare approximately 0.5 % strength].
3) Rinse the surface with warm water.
PROCESS MONITORING & MEASUREMENT:
 Strength of alkali & acid solution - 0.5 % to 1.0 %

 Heating temperature of cleaning solution Alkali - 70°C to 80°C
 Acid - 60°C to 70°C
 Concentration - 100 ppm for equipment
 50 ppm for hand washing
Cleaning Agents Storage tank:
 Caustic - 2000 Lit

 Nitric acid - 1000 Lit
 Hot water - 1000 Lit
Water Softening Plant:

Introduction:
Soft water bears a lot of importance to the dairy industries. The basic principle of this plant is ion
exchange process in which resin is used as an ion exchange material. Calcium & magnesium ion
of hard water is exchange for sodium ions of resins. This process continues till the ion exchange
material contains no more sodium. Regeneration of the resin is carried out by sodium chloride
solution (brine) treatment.
Flow diagram of water softening plant
Water
↓
Hard water (300ppm)
↓
Pump to cylindrical vertical tank
↓
Water passes through pressure sand filter
↓
Activated carbon filter (to remove smell oil grease)
↓
Ions exchanger (reduce hardness )
↓
Chlorination 2ppm(15%)
↓
Storage tank
↓
Reverse osmosis
↓
Degasser
↓
Cylinder of cation( total hardness remove)
↓
Cylinder of anion (to maintain total dissolve solid)
↓
Out
EFFLUENT TREATMENT PLANT (ETP)
Introduction:
The effluent treatment plant (ETP) of "Sonai Dairy" is the Ist of its kind in the dairy
sector, based on "UASB" process i.e. Up flow Anaerobic Sludge Blanket. This process
developed in "Netherland" result in saving of about 50 % in term of power saved as compared to
the conventional process. Utilization of biogas generated in UASB system gives saving in terms
of fuel consumption amounts to 30 % of the recurring cost as compared to the conventional
process.
The decomposition of organic matter in UASB feeds to three-phase separation in
affluent wastewater.
a) sludge
b) clear effluent
c) Gas (ethane) generated.
Biogas collected in gas holder
Excessive sludge is periodically removed from bottom of UASB clear effluent is drowning out
from the top of UASB.
Environment & Safety
· Effluent Treatment plant of 6000/day UASB

· Treated Water from ETP is used as Gardening Samples are tested by External agencies
M/s Envision Enviro Engineers, Baramati on regular basis
· Entire water is chlorinated on line with Sodium Hypochlorite and maintained potable water
standard. Water samples are tested by external Laboratory M/s Micro Chem ,pune
REQUIRMENTS OF ETP PLANT:
1.EQUILIZER:
well developed drainage system which flow effluent form different section of dairy
plant. The drainage hole consists of
(i) Invert bucket: to prevent the odour
(ii)Sieves
(iii) Net. Maintain the ph7
2. OIL TRAP
USE: To remove the visible material like polyethylene & any material other than dairy effluent.
3. PUMP SUMP USE:
Through which the proper amount of effluent given to buffer tank at appropriate amount
4. BUFFER TANK:
USE: For equalization of effluent for further processing. It is also called as equalizer tank Solid
Waste.
5. BIODIGESTER:
Here the decomposition of organic matter takes place & effluent divided into three layer
I) sludge
ii) clear effluent
iii) Gas (methane)
6. AERATOR:
USE: incorporation of air.
7. CLARRIFIR:
USE: To remove fatty material from clear effluent remains after treatment
8. SLUDGE DRYING BED
USE: Drying of sludge
9. TREATED WATER STORAGE TANK:
USE: Treated Water used for gardenin

Anaerobic Digester system provided for getting Bio-Gas from waste of production section.
· Generated bio-gas (95 % methane 5 % other.)
· Development of Green belt in and around factory by External Agencies, A co-operative
society of Anand farmers.
· Various types of plants and lawns are developed to improve environment
· Lawn – In front of Raw milk receiving Dock, Around ETP plant, In front of Office building &
near Canteen area are planted.
ADVANTAGES:
• No moving apparatus therefore has leas maintenance
• Recovery of valuable products such as Fatty material.
• UASB system treating 1000 m3 /day waste water having COD of 2000 kg/day can produce
• approximately 830 cubic meter of methane gas.

Project Report on In-Plant Training at Sonai Dairy

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A

SONAI DAIRY AND MILK PRODUCTS PVT. LTD.

Mr. Hrishikesh Gorakh Sutar

in partial fulfilment for the requirements of the award of the degree of

Prof. Sandip T. Gaikwad Prof. (Dr.) Vasant N.

Place: Pune. External Examiner

F irstly I s incerely expres sing my gratitude tow ards the management of

I extend my gratitude toward all DPM, TO , Operators and workers for

I am express ing my gratitude to Mr. P aw ar sir D ean of M IT College of

S hri. D ashrathrao Mane established Indapur dairy and milk products

Sr no. Department of Training Page

5. Milk Packaging Department

7. Ghee production & packaging Department

10. Product Lab.

11. Boiler section

13. Maintenance department

14. Refrigeration Department

15. E.T.P. Department

16. W.T.P. Department

17. Storage department

Currently Dairy have 25 Lakhs liter/ day production capacity, and it is

B efore starting the reception, all the Equipment & Flooring of RM RD

The main operations at RMRD are unloading of cans and tankers ,

2. AUTOMATIC WEIGHING MACHINE:

2) ORGANOLEPTIC TESTS :- T o check the quality of milk

3) ALCOHOL :- To check the heating stability of milk

1) Take pipette out 5ml milk s ample in tes t tube

2) Add 5ml ethyl alcohol as compare to milk

e.g :- Incoming tanker - 65%

P acking tanker / milk - 67%

P ouch packed milk - 70%

1)P ipette out 10 ml milk in conical flask or glass beaker

2)Add 10ml dis tilled water in that milk sample

3)Add 4 to 5 drops P henolphthalein indicator in milk s ample

4) After that take 0.1 normality N aOH (S odium hydroxide) in burette

5) Then titrate it slow ly

6) Faint pink color observe for reading

ACID ITY = BU RRETE READIN G × 0.09

5)C.O.B(CLOT ON BOILING):- To determine the stability of milk for milk

6) MBRT TEST (METHYLENE BLUE REDUCTION TEST):-

P ROC EDU RE:-

2)Add 1 ml of methylene blue s tain in the milk sample tes t tube

4)Keep the test tube in the w ater bath at 37°C

1)Take 1 ml. of milk in a tes t tube.

2) Add 1ml of resorcinol Solution and mix.

3)P lace the tube in boiling water bath for 5 min.

4)Withdraw the tube and obs erve the colour.

2)DETECTION OF STARCH IN MILK:

1) Take 3 ml of milk in tes t tube.

2) Boil it and cool at room temperature.

3)Add 2 to 3 drops of 1% Iodine Solution.

4)Development of Blue colour indicates pres ence of s tarch

Which dis appear when s ample is boiled and reappears on cooling

5)B lue colour indicates starch test Pos itive.

3)DETECTION OF ADED UREA IN MILK:

1) Take 3ml of milk in test tube.

2)Add 3ml of DMA B (Dimethyl Amino Banzaldehyde ) solution.

4) DETECTION OF SALT IN MILK:

1) Take 5ml of 0.1341% AgNo3 (Silver N itrate) solution in test-tube.

2) Add 2 drops of 10% Potas sium chromate solution.

4) Yellow Colour Indicates S alt test is Positive, brow n show s negative.

5) DETECTION OF NEUTRALIZER IN MILK (Soda Test) :

1) Take 5 ml of milk in tes t tube.