Professional Documents
Culture Documents
Parag Report
Parag Report
Submitted to - Submitted by -
Mr GN Sahu Sparsh Tiwari
( In charge of Quality Assurance) ( Khwaja Moinuddin
Chishti Language University)
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DECLARATION
2
ACKNOWLEDGEMENT
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S. No Topic
2. About Parag
4. Plant Layout
5. Milk Processing
6. Products at Parag
9. Conclusion
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DAIRY INDUSTRY AT PRESENT
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ABOUT PARAG
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Parag has recently set up a new plant in Lucknow which is just seven
months old and happens to be set up with Asia's latest technology for
the dairy industry. The plant is fully mechanized with very minimal
manual work.
Everything is controlled by computers. Lab’s are equipped with
'Milkoscan' by Indie FOSS for checking the milk composition and
adulterants and the"Refractometer' by ATAGO to check the Butyro-
Refractometer (B.R.) reading of ghee. Chemicals used are of
Analytical Grade and Laboratory Grade. All instruments Used in labs
are calibrated with high precision. They are sent for testing at a
NABL.
The working staff at Parag is also very welcoming and friendly. They
maintain complete transparency while working and work with
dedication. These are huge variety of products produced at Parag with
a high demand in the market. All the products are of very good quality
and seems to meet all the parameters required at any time.
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About The Plant
The other plants are situated in 5 different cities in the state, which
are:
1. Raebareli
2. Hardoi
3. LakhimpurKhiri
4. Sitapur
5. Unnao
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The Plant Building consists of 2 floors
1. The Ground Floor
2. The First Floor
The ground floor consists of a Milk Reception Unit and Tanker Bay, 7
Silos for pasteurized and raw milk storage, an Alcove room which
connects us to the gate of the silos at the back of it for the purpose of
transferring milk to it. It also consists of a Reception/Dock Lab, CIP
Room, Rinse and RCM Room, Control Room/Office, Paneer
Processing Room, Crate Washing Area, Packaging section, Incubation
Room, Buffer Room and Blast Room. There are several storage room
like Cold store, the most important storage unit, then we have
Packaging material storage and Khoya and Panner storage room.
Milk Reception Unit/Tanker Bay: The milk reception line includes
intake liquid milk for further processing in a milk processing plant.
The primary function is to eliminate air, measure the quantity,
pumping and cooling before storing and further processing.
Silo Foundation: The silo foundation consists of a total 7 silos.
Thecapacity of each silo is 60000 litres, 3 silos are allocated for raw
milk storage known as'Raw Milk Storage Tanks' (RMST's) whereas 4
are allocated for pasteurized milk storage known as 'Pasteurized Milk
Storage Tank' (PMST's).
Alcove Room: The alcove room connects us to opening gate of silos
which are situated at the back of them.
Reception/Dock Lab: This lab, as he name suggests is situated right
beside the tanker bay. Raw milk is tested in the lab before unloading
of milk in order to check for any adulteration, fat percentage and SNF
percentage. All types of milk testing are performed in the dock lab.
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Cleaning-in-Place(CIP) Room: The room consists of 5 silos,
consisting of lye tank, acid tank, hot water, recuperation tank and a
fresh water tank.
Paneer Processing Room: The processing of paneer takes place in
this area. The processing step such as heating of milk, acidifying of
milk, curd separation and pressing of curd takes place in this room.
Crate Washing Area: This section is specific to washing of milk
crates in a machine designed especially for the washing of crates. It is
situated right before the packaging section and is connected to the
packaging section through conveyor belt.
Packaging Section: This is an essential part of any food plant. Filling
of Milk, mattha, chaach and dahi takes place in this section. The area
consists of different kinds of machines for filling and packaging of
various products.
Incubation Room: The incubation room is essential for dahi
preparation.The room maintains a temperature of 40-42 degrees
Celsius for dahi preparation. Filled dahi cups and polypacks are
brought to this room after filling for the purpose of incubation.
Blast Room: Dahi is kept in this room for the purpose of setting of
curd. The temperature of this room is maintained below 4 degrees
Celsius. Dahi is kept in this for minimum 4-6 hours before dispatch.
Cold Store: All finished goods except butter are stored in this room
before dispatch. The temperature of this room is set below 4 degrees
Celsius.
Packaging Material Storage Room: This room is used for the
storage of all kinds of packaging material for milk and other dairy
products. Each packaging material has been given a series number.
The costing of packaging material used is calculated with the help of
the series number. The first floor consists of the plant office, Quality
control and assurance lab, incubation room, Laminar Air Flow Unit
(LAFU), Process Hall, Control Room, Curd processing room, Butter
Processing room, Butter packing room, Butter deep room, Ghee
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processing room, Ghee packing room, Ghee storage room, Horizontal
Milk storage Tank (HMST room), Khoa processing room, packing
storage room.
Plant Office: The quality control in charge/ the factory manager sits
in this office.
Quality Control and Assurance Lab (QC/QA lab): This lab is
involved with all kinds of testing of various milk products such as
dahi, mattha, chaach, shrikhand, peda, paneer, etc. The lab is equipped
with advance machinery to perform the most efficient testing. The
incubation room and the LAFU is also attached to the QC/QA lab for
the purpose if performing microbiocidal testing on milk products.
Process Hall: This hall is equipped with pasteurizers, homogenizers
and cream separators for milk processing. This is controlled by the
control unit in the control room.
Curd Processing Room: This is the curd processing room, where the
milk is standardized, heated and inoculated with culture for curd
processing. The filling of hand is also done in this area whereas the
cups are filled downstairs in the packing area.
Ghee Processing Room: Ghee is processed from the white butter
processed in the plant and then packed and stored into the storage
room.
Butter Processing Room: Butter is processed with the cream
separated from milk. There is an entire unit set for butter production
including churns, chillers, butter packing machine and then the
produced butter is stored in the deep freezer at -18 degrees Celsius.
Horizontal Milk Storage Tank (HMST room): There are 4
horizontal milk storage tanks which store standardized, pasteurized
market milk ready for filling in packing and dispatch. The purpose of
the horizontal tanks is efficient filling of milk into packs as the milk is
moved downstairs which is aided by the gravitational force.
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Khoa Processing Room: Milk is heated through steam produced in
the boiler house and the heated to a concentration appropriated for
khoa making.Milk for kheer is also produced in this room.
Composition of Milk
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PROTEINS 3.40% 3.80%
LACTOSE 4.50% 4.50%
ASH 0.70% 0.078%
Milk Processing
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• To ensure economics in production.
Products At Parag
Parag offers a wide range of products, from the very basic milk to rich
Indian delicacies like GulabJamuns and Milk cakes. Each product is
produced with high quality standardized raw material. There is a
standard operating procedure (SOP) for the production of each
product which has been certified by ISO 22000:2005, It is also
certified by HACCAP.
PRODUCTS
S.No. Names Of Product
1. Full Cream Milk
2. Standardized Milk
3. Toned Milk
4. Skimmed Milk
5. Sweet Dish
6. Plain Dahi
7. Poly pack Dahi
8. Chhach
9. Mattha
10. Chenna Kheer
11. Shrikhand
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12. Patisa
13. Milk cake
14. Rasgulla
15. Besan Laddu
Full Cream Milk: Full cream milk contains 6 % fat and 9% Solid-
Not-Fat (SNF) which is the highest amount of fat and SNF found in
market milk. This standard is set by the Food Safety Standards
Association of India (FSSAI). The milk procured from the villages
has an average of5.2-5.4% fat and 8.20-8.50% SF, hence we need to
add milk solids and fat to the procured milk in order to reach the
desired standard. FCM milk is sold in an orange colour packaging.
There are 4 types of packaging sizes available in the market, that is:
• 170ml poly pack
• 500ml poly pack 1 litre poly pack a
• 5 litre poly pack
Standardized Milk: Standardized milk contains 4.5% fat and 8.50%
Solid-Not Fat (SNF). This milk is processed by Parag especially for
the 'Indian Army' It is daily supplied only to the cantonment of the
city. Parag produces 9000 litres of standardized milk every day. The
packaging colour of this type of milk is green and this comes in only
one size that is the 500 mlpoly pack.
Toned Milk: Toned milk is standardized to 3% fat and 8.50% solid-
not-fat (SNF). Toned milk is fortified with vitamin A and vitamin D.
This variant of milk is packed in a blue colour poly packed due to
high demand, there are 5 different types ofpackaging sizes available
for toned milk, that are:
• 105ml poly pack
• 180 poly pack 500ml poly pack
• 1 litre poly pack.
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• 5 litres poly pack
Skimmed Milk: Skimmed milk is stripped off of all the fat in milk
and contain from 0-0.5% fat only. The Solid-Not Fat (SNF) in this
type of milk is 8.70% which is 0.20% higher thatstandardized and
toned milk. This type of milk is preferred by people looking for low
fat options in their diet, people trying to lose weight and even heart
patients. This type of milk comes with purple packaging and is sold
only in one size of packaging that is 500ml poly pack.
Dahi: Dahi is the product obtained from pasteurized or boiled milk by
souring, natural or otherwise,by a harmless lactic acid or other
bacterial culture. Dahi may contain added cane sugar. Dahi shall have
the same minimum per cent of milk fat and milk solids-not-fat as the
milk from which it is prepared. The shelf life of dah is around 7 days.
Parag produces 2 types of Dahi.
1. Sweetened Dahi
2. Plain Dahi.
It is produced with pasteurized and homogenized milk. The minimum
amount of fat in milk used in dahi preparation should be around 3.2-
3.6% with solid-not-fat (SNF) around 11%.
The reason behind a higher percentage of SN in milk is that is aids in
well setting of the curd. In order to increase the SNF of the milk we
add skimmed milk powder to the milk. The organized sector for dahi
market is around 23-24% and rest of the market falls under the
unorganized sector, with the NCR region being an exception. The
organized market.
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COMPLETE MILK TESTING: DOCKLAB
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• After 5 minutes the centrifuge opens automatically, we can see
the results.
We can adjust the level of fat using a lock stopper key for after taking
down the fat reading, we calculate the SN with the help the case of
noting the.
After taking down the fat reading, we calculate the SF with the help
of the followingreading:
Formula:
SNF% = CLR/4+ fat% *0.2 +0.29
Where, CLR=Clear Lactometer Reading
Procedure:
• Take 9 ml milk in a beaker using a pipette. Add 1 ml
phenolphthalein to the milk.
• Take NaoH in a pipette and start titrating the milk.
• Make sure to titrate with dry hands for proper dripping of the
NaOH from the pipette.Stopimmediately when the colour of the
milk changes to baby pink. Note the amount of NaoH consumed
for titration of milk, take reading for the same formula used for
the calculation of acidity of milk:9*N* weight of the sample
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Where,
N = Normality of NaoH
V = Volume of NaoH consumed
MILKOSCAN
Milkoscan FT1 is dedicated to liquid dairy production. It allows you
to control and standardize liquid dairy products while simultaneously
screening for abnormalities. It works on the FTIR spectroscopy
technology. It is connected to a computer to display the results of
testing.
Parameters for Testing
• Fat Protein Lactose
• Total solids
• SNF
• FPD
• Total acidity
• Density-FFA
• Citric acids
• Casein
• Urea
• Sucrose
• Glucose
• Fructose
• Galactose
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Testing of Moisture Percentage, Curd Percentage and Fat
percentage of White Butter:
Materials required:
• White butter sample
• Beaker
•Glass covered weighing balance
• Spatula
• Hot Plate
• Desiccator
• Petroleum ether
• Hot air oven
Procedure:
1. Moisture Percentage of Butter
• Take a beaker and measure the empty weight of the beaker on a
weighing scale.
• Note down the weight of empty beaker i.e. WI.
• Now press tare and take 10.0000 grams of butter in the beaker.
Add the weight of empty beaker and the weight of the sample.
Mark this as W2.
• Set the hot plate to 40 degrees and heat the butter till the butter
turns dark golden brown and curd granules start to separate.
• Once this is done, put the beaker in the desiccator for it to cool
down.
• Weight the beaker again and note down the weight. This weight
is less and indicates loss of moisture. This is W3.
• Calculation of moisture percentage (W2-W/Weight of sample)
*100
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2. Curd Percentage of Butter
• Take the dark brown butter or ghee and wash the sample with
petroleum ether.
• First washing involves using 30 ml of petroleum ether. Carefully
pour the petroleum spirit all over the circumference of the
beaker in order to wash all fat from the walls.
• Let it rest for a few seconds and let the curd the settle down,
then drain all the liquid.
• Repeat this process 2 more times with using 15ml petroleum
ether each time.
• After 3 washings, the curd will be mostly free of fat and will
begin to look moisture free.
• Now we will put the beaker in the hot air oven for 25-30
minutes and let it dry.
• After drying the curd, we will let it cool down in the desiccator
for 20 to 25 minutes.
• After cooling the beaker, we will now weigh the beaker again.
Mark it as W4 Take reading.
• Note the difference between this weight and the weight of empty
beaker.
Materials Required:
•Sample
• Parchment Paper
• Weighing Scale
• Aluminium petri dish
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• Spatula
• Mixing rod
• Dry sand
• Hot air oven
Procedure:
• Weigh 2 grams sample with the help of weighing scale Note
down weight of sand + weight of dish + weight of mixing rod +
lid. This is WI.
• Add sample and note down the weight again, this is W2-
Rupture the sample in the petri dish along with sand with the
help of mixing rod. Make sure the sample has been ruptured and
mixed evenly with the sand.
• Transfer the petri dish to the hot air oven for 2 hours at 102
degrees Celsius
• After 2 hours remove the dish from the oven and transfer in to
the desiccator for 25-30 mins for cooling down
• After cooling, weigh the dish again and notice the difference in
temperature, this isW3
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Methylene Blue Reduction Test (MBRT)
Procedure:
• Note down the fat percentage of milk.
• Take 2 petri dish for each sample and weigh them to note down the
weight of empty dish, mark this as 'A'.
• Add 5 ml milk sample to each dish.
• Weigh the petri dishes again and calculate the weight of sample of milk.
• Keep the petri dishes above the water bath at 100 degrees Celsius for the
water evaporate from the milk. Keep the dishes like this for 30 minutes or
until a dry layer to form on the surface of the milk.
• After this, remove the dished from the water bath and transfer them to the
hot air oven for at least 2 hours.
• Remove the petri dish from the oven and put it in the desiccator for 30
minutes
• Weigh the dish again, this weight is 'B'.
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Calculation of total solids in milk:
B-A weigh of total solids in milk 'C'
Percentage of TS in milk = C/weight of sample
Sugar Test: Take 3 ml milk and add 5 ml sugar solution. Mix and
immense the test tube in boiling water for 5 minutes. If the solution
turns blood red, then it means it is positive for sugar.
Soda Tests: Take 2 ml milk sample and add 2 ml soda solution to it.
Mix the solution and observe change in colour. If the colour change is
pink, test is negative and if the colour change is brick red, test is
positive.
Urea Test: 2 mi milk sample and 2 mi urea test solution. Mix and boil
and cool to observe colour. If the change in colour is brick red then it
is positive. If white then it is negative.
Salt Test: Take 5 ml milk sample and add few drops of potassium
dichromate and 5 ml of silver nitrate. Mix and observe colour change.
If the colour change is yellow then the test is positive, else if brown
then the test is negative.
Starch Test: Take 3ml of milk sample in test tube and add 5 drops of
iodine solution, mix it and observe change in colour. Result- If blue in
colour, then test is positive, if brown or yellow then test is negative.
Formalin Test: 5ml of milk sample in test tube + 1% FeC13 0.5ml,
mix it, pour H.SO, from side of test tube & observe colour. Result- If
violet in colour, then test is positive: if yellow then test is negative.
Glucose test: 1ml of milk sample in test tube + 1ml barford (reagent
A), heat for 3 min in boiling water, now cool in tap water+ 1ml
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phosphomobilic acid (reagent), mix it, & observe colour. Result- If
dark blue in colour, then test is positive, if light blue then test is
negative.
Mineral oil test: 50ml of milk sample in test tube centrifuge for 15
min, remove cream layer, convert it into ghee + 1ml ghee in a flask &
22ml alcoholic KOH slowly into it, heat it +25ml distilled water, mix
it observe colour. Result- If turbidity is their then test is positive; if
transparent then testis negative.
CONCLUSION
* The great cooperation and guidance of the staff of the plant towards
its trainees has made it possible for me to grasp better
practicalknowledge of the dairy industry.
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