Visit Report – Gokul Dudh Utpadak

Sangh, Kolhapur
Name:- Nilesh dipak m ahadye Roll No: 35

Prof. N M Qureshi Date: 25/4/22 Time: 11:00 am

Introduction
Kolhapur Zilla Sahakari Dudh Utpadak Sangh Ltd. well known with its
popular brand ‘Gokul’ is an Operation Flood cooperative dairy project established on
16th March 1963. Since then, achieved many land marks in Milk Procurement,
Extension, Animal Health, Breeding, Milk Processing, Product making and Marketing. At
present Gokul has modern 15 Lakh Litres/day capacity dairy plant, satellite dairy at
Udgaon, tal. Shirol and 4 owned chilling centres having 6.50 Lakh Litres/day milk
handling capacity with modern Packing Unit at Navi Mumbai.

For milk production enhancement in milk shed we have presently 46 Mobile veterinary
routes, 406 Cluster A. I. Centres, A state of the art new 450 MT/day capacity Cattle
Feed Plant with popular ‘Mahalaxmi’ brand is operational at Kagal- Hatkanangale
Five Star MIDC. The old cattle feed plant with 200 MT/day capacity plant is
simultaneously operational. With the assistance of NDDB Gokul started Total Milk Ration
(TMR) project of 50 MT/Day capacity. The TMR plant is operational from 07 December
2018.

Total turnover for the year 2003-04 is Rs. 435 crores and net profit Rs. 4.09 crores,
shares capital of sangh is Rs. 32.68 crores. Reserve Fund is Rs. 8.09 crores and other
funds are Rs. 19.13 crores.
The product range –
The Dudh Sangh products are very popular in the market. Branded “Gokul”, they include White
Butter, Table Butter, Shrikhand and Ghee. Besides, of course, Skimmed Milk Powder which is IS-
Part I and Part II Extra Grade. This is on its way to capture the global market.

Quality management and iso 9002 –

Under guidance and assistance from NDDB and FAO, Gokul implemented a quality
management system in order to improve the quality of the plant and its output, not only
the national standards but also to compete at international levels. Quality management
system accelerated business in following ways.
1. Achieving and sustaining quality of products and gain in customer satisfaction.
2. Lower operation cost and improved productivity and profitability.
3. Enhance market share and image. To give the best services and products to the
satisfaction of their esteemed customers, they practiced quality management from its
evolution and in short period from now they are going for ISO- 9002, an
international accreditation for system certification along with HACCP to assure food
safety of our customers and organization. Looking at all these achievements it would
seem the Dudhsangh would be content enough. However, resting on laurels isn’t what
the Dudh Sangh believes in. Far from it, ifs already looking much ahead into the future.
Expansion in every activity is what the Dudhsangh is looking forward to. Because in
spite of achieving so much, the Dudhsangh still feels that the best is yet to come. This
feeling has arisen from their firm faith and practice of an age old saying which goes
this way, - “Start with what you are, with what you have, get something out of it and
never be satisfied”. ‘DR. VERGIS KURIEN’ pioneer of White Revolution practiced this
concept with lot of confidence, this concept was further made flowing success by Ms.
Amrita Patel by implementing it nationwide.

Gokul Setup -

Automation at Gokul –
We went through different sections in the factory. The production process was
advance and automated to maximize the production of the facility. There were different
sections in the plant divided for different products and processes. We went through
different sections like collection centre, storage sections, packing section, freezing
section.
Conveyors move raw materials and finished products through a dairy plant. After filling,
packages might travel to secondary packaging stations, to freezers, to warehouses
and to pallets. The type of conveying system that is best for your plant depends upon
what you make.
Whenever question of material handling comes, thought must be given to available
material handling devices, such as, cart, trolleys, fork lift truck, conveyors, etc. All these
devices save labour and time. Not only efficiency is achieved but delays are also
curtailed. Out of all these for constant and organized movement of the product from
one point to other conveyers are the best. Other devices are good for small operations.
Conveyors should be properly laid out, timed and provided with convenient shut off
switches. They should be so located that they do not block passages. Automatic
controls for speed control and stopping in the event of a pile- up are desirable. The
length of conveyor between two pieces of equipment is important and serves as a
storage to aid in synchronizing the speed of the two machines. This storage function
gives the operator a brief period in which to correct minor difficulties with a machine
without stopping the entire line.
All complete chain conveyor systems may consist of one or more power units
depending upon the size of the plant and the complexity of the package handling flow
in plant.

Above floor chain conveyors have an open type steel welded or bolted frame. The
chain is pulled along in the hardened steel chain tracks mounted in this frame – usually
foot above the floor. The return chains run in channels mounted in the frame below the
carrying chains. The standard chain height for an above-floor conveyor in most plants is
between 18 and 22 inches. This is because the top of the case is generally 30 to 36
inches off the floor, which is the most convenient working height for most washer and
filler operators. This type of conveyor is used to convey single cases and cans. The
conveyor frame has side rails that extend up above the top of the chain to keep the
case and can on the conveyor.

Chain Conveyor
The in-floor type conveyor is a double chain conveyor imbedded in the floor. The in-
floor type conveyors cost same as above floor type conveyors except that installation
cost is slightly higher because of the necessity of supplying in floor pits for drives and
take up units. Also cost of additional work required to imbed the conveyor in the floor
flush with floor level. The frame consists of a steel plate 1/8 to 3/16 inch thick, formed
with channels for the carrying and return chains, so that the overall width of frame is
about 16 inches. The conveyor frame is embedded in the floor. The two carrying chains
are usually ½ inch above the floor level. The return chain travel is between and below
the carrying chains.
 Milk Filling in Bottles using Chain Conveyor

Plant Layout

Collection
centre –
In this centre the collection of milk takes places. Milk from different place is collected
and brought in the plant using big capacity milk containers from collection centres
around the city. Then that collected milk is then transferred to pasteurization centre and
to storage units through pipes.
A conveyor assembly is used to carry those milk containers and once they are empty,
they are carried through the same transfer line ahead where they are washed and then
returned to the trucks in which they are brought.

Storage centre –
Milk storage is done in large containers in which pasteurisation also takes place.
The collected milk from the containers is carried through pipes to the containers where
through different automation techniques its temperature is controlled, its fat
percentage is checked and the process of pasteurisation takes place.

Packing Sections –
This section is a highly automated section in which different automation techniques like
transfer line, packing machines are used which for packing of milk bags (final product).
In this firstly, the milk is brought through pipes to this section, then the milk bags roll is
attached to the machine on which the packing takes places. The roll goes upward in
direction in which the bag like structure is made and then transferred further onto next
machine where milk is packed where it is vertically poured in the bag and then the bag
sealed as per the specifications after which it is cut and then falls into the downward
collection tank where an employee checks the packaging and the weight of the bag and
sends it further.
After the milk is packed it send through trays where these trays are brought through
transfer line and filled by the worker there as they collect the bags from collection tank
again inspection is done at this stage for any leakage in the bag. Then these trays are
filled with bags and send again to dispatch section through the same transfer line which
goes back to dispatch section through a different way.

Dispatch Section –
In this section the last process of dispatching the finished milk bags that are filled in
the tray and some other products are then filled into the truck manually by workers and a
inspection of quantity is done where the quantity of the dispatch is checked and the
trucks are then send to there delivery locations.

Freezing Section –
We also went to freezing zone where their different products which need freezing like
butter, shrikhand etc are kept. It is basically a storage unit for these products but the
required temperature is maintained in this facility which about -16°C is maintained.
These products later go through trucks thar are also have a freezing temperature set.