INTERNSHIP REPORT

MADURAI DISTRICT COOPERATIVE MILK

PRODUCER UNION LTD (AAVIN INDUSTRY)

Submitted By

M.PAVITHRA (2022530029)

P.SWETHA (2022530039)
Partial fulfillment for award and degree of

MASTRER OF SCIENCE

IN

MICROBIOLOGY

ALAGAPPA UNIVERSITY

[Re – Accredited with ‘A+’ Grade by NAAC (CGPA: 3.64) in third cycle]

KARAIKUDI-630 003

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MADURAI DISTRICT COOPERATIVE MILK PROCEDURE

UNION LTD (AAVIN INDUSTRY)

TITLE: REPORT ON INTERNSHIP AT MADURAI DISTRICT

COOPERATIVE MILK PRODUCER UNION LTD (AAVIN)

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 INDEX
S.NO TITLE PAGE NO

1. INTRODUCTION 5

2. QUALITY CONTROL 6

3. DIFFERENT KINDS OF TESTS 6

4. BY PRODUCTS OF MILK 9

5. EFFULENT TREATMENT 14

6. CIP-CLEAN IN PLACE 16

7. CONCLUSION 18

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ABOUT

The Dairy Development Department was established in Tamil Nadu in the year 1957 to oversee
and regulate milk production and commercial distribution in the state .The Dairy Development
Department took over control of the milk cooperatives. It was replaced by the Tamil Nadu
Cooperative Milk Producers Federation Limited in the year 1981.

On February 1, 1981; the commercial activities of the cooperative were handed over to Tamil
Nadu co-operative Milk producers’ federation Limited which sold milk and milk products under the
trademark “aavin”. Tamil Nadu is one of the leading states in India in milk production with about
14.5 million litres per day.

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 INTRODUCTION

As part of microbiology activities one has undergo particular training in an

organization. Institutional training is a very good opportunity for every student. Under
this system, ALAGAPPA UNIVERSITY has asked the students to undergo
institutional training to get practical experience in processing milk and its products.By
this training, the student can improve their talent, knowledge, skills and self
confidence. Through this training practical and technical knowledge are improved. It
helps to increase the self confidence of the students and it also helps in getting the
employment opportunities. Training is aimed at improving the behaviour and
performance of person training is closely related with education, essentially Consisting
of practical knowledge

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 QUALITY CONTROL

MILK TESTING AND QUALITY CONTROL

Milk quality control is the use of approved tests to ensure the application of approved
practices, standards and regulations concerning the milk and milk products. The test are designed to
ensure that milk products meet accepted standards for “chemical and purity as well as levels of
different micro-organisms’’.

Sampling:
1. The sampling procedure differs according to the purpose for which the sample is collected and the
tests are to be carried out.
2. The sample should be truly representative of the bulk.
3. Since milk fat is of lower density that the other milk constituents, it tends to rise to the surface.
4. Thorough mixing of milk is essential to ensure are preservative sample of the entire batch.
5. Milk churns easily at 26.5-29.5’C and agitation around this temperature should be avoided.
6. Preserve the sample with 0.1ml of formation (the liquid containing 40% of formaldehyde) for
every 25ml of milk or 0.06 gm potassium dichromate per 100 ml.

Sampling From Storage Tanks and Road Milk Tankers:

Mix the milk thoroughly using a large plunger or mechanical agitator. In case of a
plunger being used, insert the clean plunger through the man-hole and move it forward, backward,
downward and each time bring to the surface. Transfer 100-250ml of the mixed milk with a suitable
dipper to a sample bottle.

DIFFERENT KINDS OF TESTS:

A. ORGANOLEPTIC TESTS:

The appearance of the surface of the milk and the lid is observed and inspected right
away after disposing of the lid of the incoming milk can. Any strange coloration of the milk, seen
dirt and particles, changes in viscosity etc. are determined. Any strange odour if noticed by way of
inhalation of air status above the milk inside the upper part of the milk can also determined.

B. LACTOMETER TEST:

If the milk appears during organoleptic inspections to be too thin and watery and its
colour is “blue thin” it is suspected that milk contains added water. Lactometer test serves as a quick

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method for determination of adulteration of milk by adding water. The lactometer test is based on
the fact that the specific gravity of whole milk, skim milk and water differ from each other.

C. FAT TEST:

GERBER METHOD:

The Gerber method is a primary and historic chemical test to determine the fat content
of substances, most commonly milk and cream. The Gerber method is the primary testing method in
Europe and much of the world. But, we are following the Babcock test primarily similar to the
Gerber method. It was developed and patented by Dr. Nikklaus Gerber of Switzerland in 1891.

Procedure:

➢For performing this test we should take 10ml 90% of sulphuric acid and 10.75ml of milk sample
that may be raw milk or any other milk.

➢Then, add 1ml of amyl alcohol and shake it up and down.

➢ Centrifuge it by setting 1300 rpm.

➢ The appearance of the golden yellow proofs that the fat content is separated.

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D. METHYLENE BLUE DYE REDUCTION TEST:

Methylene blue dye reduction test, commonly known as the MBRT test is used as a
quick method to assess the microbiological quality of raw and pasteurized milk. This test is based on
the fact that the blue color of the dye solution added to the milk get decolorized when the oxygen
present in the milk get exhausted due to microbial activity. The sooner the decolourization, more
inferior is the bacteriological quality of milk assumed to be. This test is widely used at the dairy
reception dock, processing units and milk chilling centres where it is followed as
acceptance/rejection criteria for the raw and processed milk.

PROCEDURE:

The test has to be done under sterile conditions. Take 10ml milk sample in a sterile
MBRT test tube. Add 1ml MBRT dye solution (dye concentration 0.005%). Stopper the tubes with a
sterilized rubber stopper and carefully place them in a test tube stand dipped in a serological water
bath maintained at 37 ± 1°c. Record this time as the beginning of the incubation period.
Decolorization is considered complete when only a faint blue ring (about 5 mm) persists at the top.

E. FAT (MILKO TESTER MRTHOD):

PROCEDURE:

• After de-airing and zero check, the milk-o-tester is ready for use. The first result after zero check
should not be used, as it will be too low. Therefore, measure the first sample twice and record the
second result only.

• Make sure that the MEAS switch is set to the correct calibration (I & II) for the sample to be
measured.

• Turn the warm sample upside down a few times and take off the cap of the bottle. Place the sample
under the milk intake tube so that tip of the tube dips about 5mm in milk.

• Press the MILK IN button all the away.

•Remove the sample without touching the milk intake tube and place a lean mix beaker under the
milk intake tube so that it fits into the side of the instrument. When the beaker is positioned correctly
the tube will be off-center to improve mixing.

•Press the MILK OUT button all the way to discharge milk and diluents into the mix beaker.

•Move the mix beaker to the mix intake tube and place it so that it rests in the notch.

•Operate the pump handle up and down 3 times with steady motion.

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BY-PRODUCTS OF MILK:

1. Butter 2. Ghee 3. Skim Milk Powder 4.Paneer

5. Yogurt 6. Curd 7. Ice-Cream 8. Milk Peda

9. Flavoured Milk

BUTTER
• Conical Butter churner is either batch method or continuous method. Churner is made of
stainless steel (SS). The equipment mainly comprises of the barrel, the workers, and the drive all
assembled to a one unit. Similarly vacuum arrangements are also provided for sucking the cream into
the churn and for quick efficient incorporation of moisture and also butter.

• This also reduces the air pockets in the butter. Inside of metal churn is should be rough to prevent
sticking of butter to the metal.

PROCESSED BUTTER:

• Table butter
• Fat (82%)-Moisture (16-17%)-Curd (1.5%)
• Fat 80%) - Moisture (16-17%)-Buttermilk (1.0%) and Salt (3.0%)

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BUTTER PACKING MACHINE:

➢The packing machine is of complicated mechanism working on a motor and a vacuum pump. The
butter to be packed is fed manually into the hopper, which has twin screw conveyors into a mould on
a rotating head, which helps in the continuous supply of butter.

➢ The vacuum pump helps in parchment paper movement. 500g blocks are wrapped in parchment
paper. This is packed manually in cartons.

➢ Major portion of butter manufactured by CBM is used for bulk packing i.e., 20kg cooking butter
in CBM cartons. This is used for melting purpose.

GHEE
PRODUCTION OF GHEE:

Ghee is clarified butter fat obtained from cow or buffalo milk. The process of clarification of butter
into ghee consists of removing all possible moisture with simultaneous coagulation and denaturation
of the solids not fat constant application of heat.

COMPOSITION:

• Fat - 99-99.5% Moisture -0.3% Unsaponifiable - traces (charred casein, salt of copper, iron) Butter
meant for ghee manufacture is first taken in to melting vats of 1000L capacity each.
• Here a hot water tank is maintained at the side of the vat where raw water gets mixed with the
steam and generated hot water is circulated through coils provided inside the vat. Here butter is
melted to a temperature of 80- 90°C and gets converted into butter oil.

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• The melted butter forms 3layer with at the bottom. After allowing it to stand for sometimes
buttermilk is drained out and the melted fat is pumped in to the ghee kettle. The melted fat in the
ghee kettle (ghee boiler) is heated to 105-120°C in order to make ghee.
• Agitator is also provided in the ghee kettle to avoid settling of ghee. A separate kettle, settling tank
is maintained for sour ghee preparation. After the ghee is cooled to about 40°C then it is packed.
• Generally ghee is packed in 1000ml, 500ml and 200ml pet jars. About 5 MT of ghee is packed
every day. Prior to filling, samples are send for Agmark quality testing in the lab. Then only Agmark
labelling is done.
• Here, special grade AGMARK GHEE is produced. Ghee contains not more than 0.2% moisture
and 0.2-0.4% FFA. And acidity is also checked. Samples are taken from sour ghee are tested, sold
separately to second grade quality.

SKIM MILK POWDER

Whole (full cream) milk contains, typically, about 87% water and skim milk contains
about 91% water. During milk powder manufacture this water is removed by boiling the milk under
reduced pressure at low temperature in a process known as evaporation. The resulting concentrated
milk is then sprayed in a fine mist into hot air to remove further moisture and to form a powder.
Approximately 13 kg of whole milk powder (WMP) or 9 kg of skim milk powder (SMP) can be
made from 100l/case of whole milk.

EVAPORATION:

The evaporator the preheated milk is concentrated in stages or "effects" from around 9.0%
total solids content for skim milk and 13% for whole milk, up to 45- 52% total solids. This is

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achieved by boiling the milk under a vacuum at temperatures below 72 °C in a falling film on the
inside of vertical tubes, and removing the water as vapour.

This vapour, which may be mechanically or thermally compressed, is then used to heat the milk in
the next effect of the evaporator which may be operated at a lower pressure and temperature than the
preceding effect. Modern plants may have up to seven effects for maximum energy efficiency. More
than 85% of the water in the milk may be removed in the evaporator. Evaporators are extremely
noisy because of the large quantity of water vapour travelling at very high speeds inside the tubes.

SPRAY DRYING:

Spray drying involves atomizing the milk concentrate from the evaporator into fine droplets. This is
done inside a large drying chamber in a flow of hot air (up to 200 °C) using either a spinning disk
atomizer or a series of high-pressure nozzles. The milk droplets The concentrate may be heated prior
to atomization to reduce its viscosity and to increase the energy available for drying. Much of the
remaining water is evaporated in the drying chamber, leaving a fine powder with around 6%
moisture content with a mean particle size typically of <0.1 mm diameter. Final or "secondary"
drying takes place in a fluid bed, or in a series of such beds, in which hot air is blown through a layer
of fluidized powder removing water to give product with a moisture content of 2-4%.

PANEER
PROCEDURE:

➢ Raw milk with fat content 4.5-5.0 was heated to 90°C and further cooled down to 85°C.

➢ For coagulation, citric acid (2%), which was prepared and maintained at temperature of 85°C was
mixed with the milk at this temperature.

➢ Stirring is preferred till the separation of whey.

➢ Remove all the whey produce in this process and collect the coagulated mass in the hoops lined
with muslin cloth and its temperature must maintained above 63°C during draining

➢ The filled hoops were further pressed for about less than 20 minutes. Then it is immersed in
pasteurized chilled water maintained at 4–7°C for around 2 Hours.

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➢ Dipping of paneer pieces helps to improve the texture of paneer along with Cooling. Further, the
paneer pieces were placed on the perforated tray to allow lose water to drain. Finally it is packed
under a vacuum packing machine for air Removing and stored under refrigerator.

YOGURT
Yogurt processing begins with modification of the incoming milk composition. This
process typically involves reducing the fat content and increasing the total solids in the milk. A
standardizing clarifier and/or a separator (centrifuge) are used to separate fat from milk and reduce
the fat content. Alternatively, milk fat can be added to skim milk to obtain the desired fat level.
Depending on the type of yogurt, the final fat content ranges from 1% to 10%. The final fat content
affects yogurt consistency and viscosity. The milk fat content also affects the fermentation rate. From
the separator, the milk is placed in a storage tank. It is then tested for fat and solids content.

The solids content of the milk is then increased to around 16%, with 11%– 14% of that
being solids-non-fat (SNF). SNF components include lactose, protein, and minerals. SNF in yogurt
typically ranges from 9% to 16%. Traditionally, either some water is evaporated off of the milk to
increase the solids content, or concentrated milk, milk powder, whey protein concentrate, or casein
powder is added to accomplish that objective.

CURD
PROCEDURE:

➢ The skim milk or the cow milk is mixed with skim milk powder and boiled at 90° C and then
cooled at 40°C.

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➢ Then culture addition in inoculation tank takes place and the curd is ready for packing.

➢ Keep the package for incubation for nearly 4–5 hours at 40°C and store it in 4°C.

EFFLUENT TREATMENT PLANT OF AAVIN

The Effluent treatment plant studies show that how the Aavin industry is recycling the waste water
for further use. Some of the water in the balancing tank is utilized by the cowin directly by some
process. Effluent from the collection tank comes to the equalization tank in waste water treatment.
The main function is to act as a buffer. To collect the incoming raw effluent that comes at widely
fluctuating rates and position to the rest of the ETP at a steady flow rate. During the peak hours, ETP
comes at a high flow rate. The equalization tank stores this effluent and let sit out during the noon
peak time when there is no/little incoming effluent. The inlet pipe of equalization tank carries filtered
effluent from cooling tower. The raw effluent in the industry includes the washing out of some
instrument, milk pockets, milk, and soon

•100%deliveranceasperlocalpollutionboardguidelines.
•Upto28%lesserrunningcost.
•Upto32%lesserinitialinvestment.

ETP TREATMENT METHODOLOGY:

ETP process is either batch flow type or continues flow type.

EPT TREATMENT TYPE:

Effluent treatment plant are further categorized into chemical treatment, biological treatment,
combination of chemical & biological treatment.

ETP CHEMICALS

•Urea/DAP

•Anticipant liquid/powder

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•Sodium Bicarbonates for pH treatment

•Chlorine

•Alum

•Silica

•Ferrous sulphate etc.

ETP/WASTE WATER TREATMENT STAGES

Stage 1:

Preliminary effluent treatment of waste water involves processes like

•Effluent screening process.

•Oil & grease removal process.

•pH correction process.

Stage 2:

Primary treatment of waste water involves processes like

•Chemical treatment process.

•Coagulation & flocculation treatment process for color, suspended solids & associated organic
matter.

•Oil, grease & fat removal process.

•Inorganic treatment process for removal of hardness etc, from waste water

Stage 3:

Secondary treatment of waste water involves processes like

•Biological treatment process for treatment of dissolved & suspended organic impurities.

•Commonly using secondary treatment process & types are Activated sludge, Extended Aeration,
MBB, SAFF, MBR, UASB, Anaerobic filter, anaerobic digester process etc.

Stage 4:

Tertiary treatment of waste water involves processe like

•Depth filtration, Ultra filtration, Resin column set processes for polishing the effluent
contamination.

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•Tertiary treatment also involve advanced treatment like tertiary MBR, Ozonation, UVetcfor removal
of traces of organic compounds, turbidity, virus, SDI etc.

Stage 5:

Waste water recycling is one of the most challenging & critical treatment stage mainly for removal
of inorganic compounds in waste water. It involves processes like RO, NF, EDI for further treating
the ETP treated water & removing most of the inorganic compounds & making it reusable

(CIP) CLEAN-IN-PLACE

Clean-in-place (CIP) is a method of cleaning the interior surface of pipes, vessels, process
equipment, filters and associated fittings, without disassembly. Closed systems were disassembled
and cleaned manually. The advent of CIP was a boon to industries that needed frequent internal
cleaning of their processes. Industries that relyeavily on CIP are those requiring high levels of
hygiene , and include:

•dairy,

•beverage,

•brewing,

•processed foods,

•pharmaceutical, and

•Cosmetics.

The benefit to industries that use CIP is that the cleaning is faster, less labour-intensive and more
repeatable, and posesless of a chemical exposure risk. CIP started as a manual practice involving a
balance tank, centrifugal pump, and connection to the system being cleaned. Since the 1950s, CIP
has evolved to include fully automated systems with programmable logic controllers, multiple
balance tanks, sensors, valves, heat exchangers, data acquisition and specially designed spray nozzle
systems. Simple, manually operated CIP systems can still be found in use today

PROCEDURE

•Rinse (soft water)

•Caustic soda

•Rinse

•Acid

•Rinse

•Lye

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•Rinse

•Hot water

•Final rinse

Acid concentrated solution tank

•Quantity: 1 No.

•Capacity: 15 KL

•Construction: As per bidders’ design

•Insulation: 50 mm thick mineral wool

•Cladding: The tank is complete with air vent, perforated filter, and manhole, level

Switches along with re-circulation pump for agitation.

Lye concentrated solution tank

•Quantity: 1No

•Capacity: 15KL

•Construction: as per bidders’ design

•The tank is complete with air vent, manhole, perforated filter and levels witches along with
recirculation pump for agitation

Concentrated solution unloading pump

•Quantity: 2Nos.

•Capacity: As required one each shall be used for unloading of acid/lye concentrated solution into the
Acid/Lye solution tank respectively from tanker.

Hot water tank

•Quantity: 1No

•Capacity: 8KL

•Construction: as per bidders’ design Insulation: 50 mm thick mineral wool

•Cladding: The insulated tank is complete with air vent, manhole, per forated tube and level switches

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 CONCLUSION
As a Microbiology student this internship training programme is very much useful for us to
know about the milk processing. It also helps in experiencing various functions of machines
involve in processing of milk & it’s by products. It clearly explains us about how it reaches
the consumers from milk producers involving various processing techniques. Because of this
Aavin milk products quality, taste, cost of availability it has great demand among people in
Madurai.

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