INDUSTRIAL REPORT ON

S.K Dairy Pvt Ltd.

A tour report submitted in partial fulfillment of the requirement for the
completion of Bachelor degree in Food Technology

By
Ranjan Karki
B. Tech (Food) Fourth
year

Department of Food Science and Technology

National College of Food Science and Technology
Institute of Science and Technology
Tribhuvan University, Nepal
2022

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The industrial visit take part as an important role in B.Tech Food. The main objective of this
program is to know how dairy products are manufactured and its practices in the context of
Nepal.
This report is written in order to give the information about the dairy products . It also contains
information about the industry, product.
In January 2023, we the student of NCFST had visited the factory of S.K dairy Pvt Ltd . I take
help from some sites to prepare this report by fulfilling the requirements. I am very thankful to
our teacher and college department for giving this opportunity to do this project. I hope that this
report will adequately meet it’s aim.

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Contents
INTRODUCTION...........................................................................................................................4
GENERAL INTRODUCTION.......................................................................................................4
OBJECTIVE....................................................................................................................................4
PRODUCTION................................................................................................................................5
1. Standard and Whole Milk.....................................................................................................5
Manufacturing procedure.....................................................................................................5
Packaging materials and type of container.........................................................................6
2. 2. Cream................................................................................................................................6
3.Butter.........................................................................................................................................7
Manufacturing procedure.....................................................................................................7
4.Ghee..........................................................................................................................................8
Manufacture procedure.........................................................................................................8
4.Yoghurt.....................................................................................................................................9
Manufacture procedure.........................................................................................................9
5.Paneer......................................................................................................................................10
Manufacture
procedure…………………………………………………………………..10
6.Fresh milk...............................................................................................................................11
Manufacture procedyre.......................................................................................................11
QUALITY CONTROL..................................................................................................................12
Standard milk production line....................................................................................................12
CONCLUSION:........................................................................................................................14

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INTRODUCTION

GENERAL INTRODUCTION

S.K dairy Pvt Ltd company is located in Nepalgunj-22, bake-5.It is initiated for the economic
advancement of the poor farming communities, has flourished mostly in western side of Nepal.
With the sate-of-art infrastructure comprising of fully modern dairy plants.
At S.K Pvt Ltd ,They are uncompromising about a strict adherence to quality of milk & milk
products, hygiene and sanitation of the plants. Pledge to uphold the grand tradition set by
predecessors and to endorse the trust and faith placed in us by their valued customers.
S.K dairy follow a strict adherence to quality of milk & milk products, hygiene and sanitation of
the plants. Milk is collected through the farmers owned, Milk producers Cooperative Societies
(MPCS).It has been playing a special role in contributing to uplift the economic status of rural
farmers. Thus dairy has been recognized as an effective tool for poverty elimination

OBJECTIVE

The main objectives of the company are as follows.

To provide a guaranteed market for milk to the rural milk producing farmers with fair price.
To supply pasteurized milk and milk products to urban consumers.
To develop organized milk collection system to meet increasing demand for the pasteurized milk
and milk products.
To develop organized marketing system for milk and milk products in urban areas.
To uplift the economic status of rural milk producers by providing remunerative prices for the
products.

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PRODUCTION
1. Standard and Whole Milk
Type Fat% SNF%

Standard milk 3 8

Whole milk 5 8

The fat content in milk is adjusted either by skimming the milk in cream separator or adding
skimmed milk powder in correct proportion.
Manufacturing procedure
Receiving and collecting at collecting center

Transportation by transport tankers

Receive at factory sampling (fat, SNF, COB, MBRT

and adulteration test)

Filtration and cooling

Warming (40°C)

Cream separation cream

Homogenization (at 2000-2500 psi) and standardization

Pasteurization (72-74°C for 15 sec)

Cooling (4°C)

Packaging

Cooling storage (4°C) marketing

Fig- Flowchart of Standard Milk manufacture

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Packaging materials and type of container
Milk is filled in plastic pouches made up of three layer co-extruded films of LDPE and LLDPE.
The roll of plastic film is formed, filled and sealed in the filling machine. It is sterilized by
means of UV light coming from UV lamp fitted in the machine itself.
A pouch of filled milk weighing 505 – 515 gm. is accepted. The packets are packed in polythene
crates (20 packets per crate).

2. 2. Cream

Cream is that portion of milk, enriched to a varying degree with milk fat, which rises to top of
milk when it is standing, or is separated from it by means of centrifugal separator. During the
separation of whole milk, two streams are produced: the fat-depleted stream, skim milk and the
fat-rich stream, the cream. This usually comes off the separator with fat contents in the 35-45%
range. Cream is used for further processing in the dairy industry for the production of ice cream
or butter, or can be sold to other food processing industries.
Manufacturing procedure

Milk reception
Sampling Testing
Preheating to 40°C

Cream separation
Skim milk
Cream (40-60% fat)

*
Cream pasteurization: 90-95°C for 15sec

Vacuum de-aeration (0.4 bars)

Cream ageing (12-24 hrs)

Cooling to 20°C

Immediate storage at 10-20°C

*Critical Control Point

Fig: Flowchart of cream manufacture

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3.Butter

Butter is a fat concentrate that is obtained by churning cream, gathering fat into a compact mass
and then working it. There are several types of butter but they are usually divided into (i) sweet
cream butter, and (ii) cultured or sour cream butter. Butter can also be classified as salted,
unsalted and extra salted. Butter should contain not less than 80% fat, not more than 16%
moisture, 2% salt and 1% curd. Plain butter does not contain salt. In the dairy it is permitted to
use a natural, yellow color called annatto.
For the preparation of butter, cream of very good quality is needed. Laboratory testing must be
done to see if the cream is fit for use in butter making. If the acidity is very high, it must be
neutralized with calculated amounts of sodium bicarbonate (or calcium hydroxide). The acidity
(as lactic acid) should not be more than 0.25-0.3%.
Manufacturing procedure
1. Plain Butter
Milk reception Sampling Testing

Cream separation (centrifugal)

Cream (35-50 % fat)

Pasteurization, 82-88°C, 25s

Cooling (5-10ºC)

Churning* (9-11C, 45-75 min)

Test moisture content and work** again

Packaging and storage (-10 to -20ºC)

Plain Butter

Fig: Flowchart of plain butter manufacture

In the preceding figure, the terms in *, **, and *** refer to:

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Churning = agitation of the cream to separate the butter granules and buttermilk. Churning is
done until the butter granules come together in the form of lump. The churning temperature is
controlled by spraying chilled water over the churn.
Break water = in the hot climate, temperature of butter or cream increases during churning. To
keep the temperature down, some cold water is added. This water is called break water.
Working = after the butter has lumped together and buttermilk has been drained, the butter is
further pressed to remove the moisture. This is called working.

4.Ghee

Ghee may be defined as the pure clarified fat derived solely from cow or buffalo milk or from
cooking butter or from cream to which no coloring matter is added. Ghee should consist of large
milk fat crystals floating on liquid fat, giving the product a coarse appearance the color of ghee
depend on the type of milk and the production method. Ghee from cow milk has yellowish-
orange color; whereas ghee from buffalo milk has a whitish, pale cream color with a greenish
tinge.
Ghee can be produced by several methods, some of which are creamery butter method, direct
cream method, pre-stratification method, etc.
Manufacture procedure

Receiving Butter

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Melting in Steam jacketed vats (80 c)

Ghee stratification

Draining off the separated water layer by opening the valve

Boiling the separated fat in the ghee boiler to a temperature 110ºC

Filtration

Clarification

Storage in ghee storage tank

Filling at 450c

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 Crystallization and cold storage

Fig: flowchart of ghee manufacture by creamery butter method

4.Yoghurt

Yoghurt is a fermented milk product. Yoghurt is the product obtained from pasteurized or boiled
milk by souring, natural or by a harmless lactic acid or other bacterial culture. It may contain
additional cane sugar. It should contain same percentage of fat and solid-not-fat as the milk from
which it is prepared. Two microorganism, Lactobacillus bulgaricus and Streptococcus
thermophillus growing together symbiotically, are responsible for the lactic fermentation of
yoghurt.
Special sweet yoghurt: fat-4%, SNF-8%, sugar-4% and SMP-2%
Manufacture procedure

Milk reception

Filtration

Batch Pasteurizer Vat

Heating to 40°C: by steam

Addition of Sugar and SMP: 4% sugar & 2% SMP

Agitation

Homogenization at 55-65°C: 2000-2500 Psi

Heating to 85-90°C for 30 min

Cooling to 42-45°C

Addition of culture: DVS culture 1 packet /500L milk

Agitation for 10 min

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 Filling

Incubation at 45-470C for 2-3hrs

Observation for setting of yoghurt

Yoghurt

Store at 5-8°C

Fig. Flowchart for yoghurt production

5.Paneer

Paneer refers to the milk solids obtained by acid coagulation of pasteurized whole milk and
subsequent drainage of whey. Commonly used acids are lactic or acetic acid.
Moisture : 52-55%
SNF : 18-23%
Fat : 25-27%
Manufacture procedure

Citric acid and Calcium lactate receiving of milk (Fat > 5%)

Mixing with hot water Heating unto 90 C

Holding at 75 C

Clotting

Hold for 5 min

Filter through muslin cloth

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 Frame and press

Dip into ice water

Cutting Packaging material

Vacuum packing

Cold store

Dispatch
Fig: flowchart of paneer manufacturing
6.Fresh milk

Fresh milk is the sterilized flavored milk produced by the addition of sugar, flavor and color to
the pasteurized milk. Fresh milk requires 9 % of SNF and 3% of fat in 500 L of milk. 6 kg sugar
is added per 100 L milk.
Manufacturing procedure
Receiving pasteurized milk Receiving/Recollecting Bottle

Test (COB, Alcohol) Dipping in chemical solution for whole night

Cooling at 5 C Brushing outside and inside of the bottle

Addition of sugar, color and flavor *Machine sanitizing

Mixing in cooling vat by agitation finally cleaning with clean water and store facing
downward

Transfer in the milk reservoir Inspection of the empty bottles

Filling in bottles and Crowning

Inspection

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*Sterilization (121oC, 20 min) Steam Boiler

Cooling near room temperature

Labeling storage distribution

QUALITY CONTROL
Standard milk production line
Milk samples are drawn and sent to the lab to check for fat and SNF content before and after
standardization and the errors corrected or adjusted.
The pipelines, vats and tanks are cleaned in place (CIP) after processing each lot.
Filled milk pouches are frequently checked for any fault, such as proper sealing, sufficient
weight, any leakages etc.
The packaging film roll is UV treated before being formed to sterilize the packaging materials.
Pasteurizing and cooling time and temperature are checked frequently
Records are kept for each parameter.
Butter production line

Separated cream is sent to the lab to check for its fat%.

Churning temperature and time are also controlled.

Working speed and time are also controlled.

Moisture content in butter is determined in the laboratory and necessary measures are taken.
Organoleptic test of butter milk is done for its suitability to be mixed for standard milk
production, a sample is sent to the lab for its fat, SNF content, COB and acidity test.

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Lab quality control
After receiving milk, COB, acidity and alcohol test is done before accepting for pasteurization.
Temperature, SNF and fat content are also checked. Any adulteration (salt, sugar, soda) is also
tested. Only after passing those tests, milk is accepted.
Microbial tests such as TPC, coliform count of milk before and after pasteurization and filling
are periodically done. Swab tests, pipelines, vats, PHE etc. are also periodically done. Necessary
remedial and corrective instructions are then given to the operators. MBRT test is also
periodically performed in milk.
Microbial test of water (UV treated) is also done (TPC, coliform count) and necessary corrective
measures suggested.
SNF, Fat, moisture content of products are checked, from which the processing section can take
corrective action if needed.
Lab also checks the compliance of packaging materials, chemicals and other required materials
with the specifications. Records of the result are kept which can later be used to review the
quality products.

Tests on Finished Products

Pouch Milk: Fat Test, SNF ,Phosphates Test, Methylene Blue Reduction Test(MBRT), Total
Plate Count (TPC), Coliform Count (CC)
Fresh Milk: Sensory Evaluation, Coliform Count (CC), Fat
Cream: Fat, CC
Ghee: Sensory, FFA, Moisture Content (MC), Adulteration, acid value, peroxide value
Butter: Fat, MC, Pouch Weight, CC, Yeast And Mold Count (Y & M)
Yoghurt: fat, total solid, acidity, sensory
Paneer: moisture, fat, acidity

Tests on Raw Materials

Milk: COB, Acidity, pH, fat, Lactometer reading (at 27oC), SNF, and Adulteration tests (soda,
sugar, salt, starch, glucose)
Water: Total Plate Count, Coliform count

CONCLUSION:
My site visit to S.K Dairy Pvt. Ltd. was very beneficial. I learned about manufacture process
of different dairy products listed above and their challenges. It was an excellent opportunity to

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experience industrial visit. The products of the company have big market in different places
of Nepal.

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