ONTHEJOBTRAI

NINGREPORTAT
AMULDAI
RY
KAI
RADI
STRI
CTCO-
OPERATI
VEMI
LKPRODUCERSUNI
ONLTD.
ANAND,
GUJARAT

SUBMI
TTEDBY
Bar
iapr
iyanshuN
VISEMESTER
Di
plomai
nNut
ri
ti
onandDi
etet
ics
Pol
ytechni
cinf
oodsci
enceandhomeEconomi
csAAU

Febr
uar
y2021t
oMay2021

1
2
 ACKNOWLEDGEMENT

Market
ingManager,Kai
raDist
ri
ctCo-oper
ati
veMilkProducer
s’UnionLi
mitedfor
gi
vi
ngussuchapr esti
giousopport
unit
ytounder
gotraini
nginthi
sorgani
sati
on.We
ar
ealsothankf
ulf
orMr .MrunalDesai
,HRManagerofAmu l
Dairy,forgr
ant i
ng
t
heper
missi
ont
ocar
ryoutt
he“
Ont
hej
obt
rai
ning”i
nthecompany
.
Wear ealsov er
yt hankfult
oal l
sectioninchargeandoper atorswho
gaveusposi ti
veresponseandgui dancewhenev erweneeddur i
ngour
goldenti
meoft r
ainingperiod.Last,butnottheleast,
thetraineewould
l
iketoextendhear t
ythankstoal l
thest af
fofAmul ,Anandandal so
expresssincerethankst oparentsandf ri
endsforthei
rkindsupportfor
thecompl et
ionoft hetrai
ning.

3
 CONTENTS

S.
NO TOPI
C PAGENO.

1. ACKNOWLEDGEMENT 2-3

2. TRAI
NINGSCHEDULE 7

3. I
NTRODUCTI
ON 8-11

4. ORGANI
SATI
ON 12–13

5. THEAMULPATTERN 14

6. ORGANI
SATI
ONSTRUCTURE 15

7. CERTI
FICATI
ON 16–22
FoodSaf
etyManagementSy
stem
FSSAI
I
SO22000:
2005
I
SO9001:
2000
APEDA
8. PRODUCTRANGE 23–24

9. AMUL3RAW MI
LKRECEPTI
ONDOCK 25–36

4
 Li
stofequi
pment
’s
St
andar
disat
ioni
nALFASTUni
t
Fl
owchar
tofAl
fastuni
t
Speci
fi
cat
ionsofMi
l
kandMi
l
kPr
oduct
s
Cl
eani
ngandSani
tat
ionPr
ocedur
es
Not
es
10. L&TPOWDERPLANT 37–50

11. F–60MI
LKPOWDER/FERRUM 51-61

12. BUTTER 62-69

13. AMUL2RAW MI
LKRECEPTI
ONDOCK 70-72

14. MI
LKPOUCHPACKAGI
NGSECTI
ON 73-76

15. BUTTERMI
LK 77-78

16. AMULMASTIDAHI 79-80

17. GHEE 81-86

18. STERI
LIZEDFLAVOURMI
LK 87-94

19. QUALI
TYCONTROL 95-110

5
20. ETP 111-112

S.
NO SECTI
ON REPORTI
NGOFFI
CER
Sh.May
ankPat
el/

6
1. L&TPowder&Packi
ng Mr
s.Pi
nal
Pat
el

Sh.Gaur
angPat
el/
2. F-
60Mi
l
kPowder/Fer
rum Sh.Ket
anMeht
a

Sh.RakeshAmi
n
3. Amul
–3Mi
l
kPr
ocess

Sh.Chet
anPat
el
4. Amul
-2Mi
l
kPr
ocess

5. Mi
l
kPouch,
But
terMi
l
k&Dahi Sh.SPDeshmukh

6. But
terSect
ion Sh.Kamal
Praj
apat
i

7. St
eri
l
izedFl
avour
edMi
l
k Sh.ShubhankarMi
tr
a

8. GheeSect
ion Sh.Ranv
ij
aySi
ngh

Sh.S.
SGokul
/
9. Qual
i
tyCont
rol Sh.Dhwani
Shah/
Sh.J.
DSol
anki

7
 TRAI
NINGSCHEDULE

I
NTRODUCTI
ON
Mi l
kmaybedef inedast hewhol e, f
resh, cl
ean, l
act ealsecreti
onobt ai
ned
byt hecompl etemi lki
ngofoneormor eheal thymi lchanimal s, excluding
thatobt ainedwi t hin15day sbef oreor5day saftercal vi
ngorsuch
periodsasmaybenecessar yt or endert hemi l
kpr act i
callycol ostrum’ s-
free, andcont ainingt hemi nimum pr escr i
bedper cent ageofmi lkfatand
mi l
ksol i
dnotf at .Asanagr icultur alpr oduct, milk, alsocalleddai rymi l
k,
i
sex tract edfrom f ar m animal sdur i
ngorsoonaf terpr egnancy .Dairy
farmspr oducedabout730mi l
liont onnesofmi l
ki n2011, from 260
mi l
li
ondai r
ycows.I ndi
ai sthewor l
d'sl argestpr oducerofmi lk, andi s
thel eadi ngexpor terofski mmedmi l
kpowder ,yeti texpor tsfewot her
mi l
kpr oducts.Theev er-i
ncreasi ngr isei ndomest i
cdemandf ordai ry
product sandal argedemand- suppl ygapcoul dleadt oIndiabei nganet
i
mpor t
erofdai rypr oduct sint hef ut ure.TheUni tedSt ates,Indi a,China
andBr azi lar
et hewor l
d'slargestexpor tersofmi lkandmi lkpr oduct s.

8
ChinaandRussiaweretheworld'
slar
gesti
mporter
sofmi l
kandmil
k
productsunt
il2016whenbothcountr
iesbecameself
-suf
fi
cient
,
contri
buti
ngtoaworldwidegl
utofmilk.
Growingconsumpt ionofdai ryandot herli
v est
ockproductsi
sbr i
nging
i
mpor tantnutri
ti
onal benefi
tstolargesegment softhepopul
ati
onof
developingcountries, alt
houghmanymi ll
ionsofpeopleindeveloping
countri
esar esti
llnotabl etoaffordbet t
er-quali
tydi
etsowingtothe
highercost.Howev er,therapi
dgr owthinpr oducti
onandconsumpt i
on
ofliv
estockproduct salsopresentsri
skst ohumanandani malhealth,
theenv i
ronmentandt heeconomi cvi
abili
tyofmanypoorsmal l
holders,
butmayal soof f
eroppor tuni
ti
esforsmal l-andmedi um-scal
edairy
i
ndust r
ies.
Milkcontai
nsnumer ousnut r
ientsandi tmakesasi gni
fi
cantcont
ri
buti
on
tomeet i
ngthebody ’
sneedsf orcalcium, magnesium,sel
enium,
ri
bof l
avi
n,vi
taminB12andpant othenicacid(vi
taminB5).However,
milk
doesnotcont ai
nenoughi r
onandf oli
atetomeett heneedsofgrowing
i
nf ant
s,andthelowironcontentisoner easonanimalmilksar
enot
recommendedf orinfant
sy oungert han12mont hsol
d.
Howev er,t
heroleofmi lkanddai rypr oduct si nhumannut ri
tionhasbeen
i
ncr easi ngl
yquest i
onedi nrecenty ear s.Milki sacompl exfood
cont ainingnumer ousnut ri
ent s.Mostoft heconst ituentsinmi lkdonot
wor ki nisolati
on,butrat herint eractwi t
hot herconst i
tuents.Of ten, t
hey
arei nvolvedinmor et hanonebi ologi calprocess, somet imeswi th
conf li
ct i
nghealtheffects.Thus, whi lemi l
kconsumpt i
onisassoci ated
withar educedr i
skofNCDssuchasost eopor osisandpossi bly
color ectalcancerandt y pe2di abet es, concer nhasbeenexpr essed
aboutt hepossibleassoci ationbet weenhi ghdai ryconsumpt ionand
otherNCDssuchascar diov ascul ardi seaseandpr ostatecancer .Milkfat
prov idesagoodex ampl eoft hi s.Thet r
aditional diet–heartpar adi gm,
dev elopedi nthe1960sand1970s, hel dthatconsumpt ionoff at, and
satur atedfatinparticular,raisedl evel sofbot hchol esterolsaswhol e
andl ow- density-
li
poprot einchol ester ol,l
eadi ngt ocor onaryhear t
disease.Cur r
ently,
manynat ional andi nter
nat ional authorit
ies
recommendconsumpt ionofl ower -fatdai r
yf oods.Howev er,the
scient i
ficrati
onalebehindt hisr ecommendat ionisst il
ldebat ed.
Althoughmi l
kfrom thecowi spr ocessed, i
ti snotanengi neeredor

9
fabri
cat edfood.Itisabout87per centwaterand13per centsoli
ds.The
fatpor t
ionoft hemi l
kcont ai
nsfatsolubl
evit
amins.Thesol i
dsot her
thanf atincludeproteins,car
bohydrates,
watersolubl
ev i
tamins,and
minerals.Thesenut rientsinmil
khel pmakeitnature'
smostnear ly
perfectf ood.
Thousandsofy earsago, achancemut ationspreadinhuman
populati
onsi nEur opethatenabledtheproduct i
onoflactasein
adult
hood.Thi smut at
ionall
owedmi l
ktobeusedasanewsour ceof
nutri
ti
onwhi chcoul dsust ai
npopulati
onswhenot herfoodsourcesf ai
l
ed.
Milkisprocessedi ntoav ari
etyofproductssuchascr eam, butt
er,yogurt
,
i
cecr eam,andcheese.Moder nindustr
ialprocessesusemi l
ktopr oduce
casein,wheypr otein,l
actose,condensedmi lk,
powderedmi lk,
andmany
otherfood-additi
vesandi ndustri
alproducts.
TheU. S.federalgover
nmentdocumentDi et
aryGuidelinesforAmer i
cans,
2010r ecommendsconsumpt i
onoft hreeglassesoff at-f
reeorlow-fat
milkf oradul t
sandchildren9andol der(lessforyoungerchi l
dren)per
day .Thisr ecommendat i
onisdisputedbysomeheal t
hr esearcher
swho
callformor estudyoftheissue,gi
vent hatthereareot hersourcesfor
calcium andv i
taminD.Ther esear
cher salsoclai
mt hatt he
recommendat ionshavebeenundulyi nfl
uencedbyt heAmer i
candairy
i
ndust ry,andt hatwholemi l
kmaybebet terforhealt
hduet oits
i
ncr easedabi l
i
tytosati
atehunger.
A2008r evi
ewf oundevidencesuggest i
ngt hatconsumpti
onofmi lkis
effecti
veatpr omot i
ngmuscl egr owth.Somest udieshavesuggested
thatconjugatedl i
nolei
caci d,whichcanbef oundindairyproduct
s, i
san
effecti
vesuppl ementforr educi
ngbodyf at
.Wi t
hregardstotheclaim of
mi l
kpromot i
ngst r
ongerbones, therehasbeennoassoci ati
onbet ween
mi l
kconsumpt ionorexcesscal cium i
ntakeandar educedriskofbone
fractur
es.
I
nor dert olearnmor eaboutmi lkandmi lkproducts,
thetraineeselect
ed
Amul dair
yf orsummert r
aini
ng.Themai nreasonf orsel
ectingAmul i
s
thatitisAsia’slargestmilkproducingcompanyandt hereisnoot her
betteroptiont hanAmul .Whiterevolut
ionhelpedIndiatoemer geas
l
argestmi l
kpr oducerinthewor l
d.Thecour seoftrai
ningatAmul dair
y
wegott hechancet ocompar eourt heoreti
calknowledgewi thpracti
cal
real
iti
esspeci allywhil
ewor ki
ngi ntheprocessingsecti
onwel earned
10
manyt hi
ngssuchascommonski l
l,
senseofresponsi
bil
it
y,qual
i
typlan
ofeachproduct,cooper
ati
onandot
hersoftski
l
landalsogottolear
n
cer
tainaspectofmanagementsuchasproduct
ion,l
abourandetc.
AnandMi l
kUni onLi mi t
edorAmul i
sanI ndi
andai rycompany ,basedat
Anandi nthest ateofGuj aratFor medi n1948, itisacooper ativ
ebr and
managedbyacooper at i
vebody ,theGuj aratCo- oper ati
veMi l
kMar ket i
ng
Federat i
onLt d.( GCMMF) ,
whi cht odayi sjoi
nt l
yownedby3. 6mi ll
ion
milkpr oducer sinGuj arat.Amul spur r
edI ndia’sWhi terevol
uti
on, whi ch
madet hecount rythewor l
d'slargestpr oducerofmi lkandmi l
kpr oduct s.
Thewhi terevolut i
onwasspear headedbyTr ibhuv andasPat elundert he
guidanceofSar darPat el
.Asar esult,KairaDistrictMi l
kUnionLi mi ted
wasbor nin1946.Tr ibhuv andasbecamet hef oundi ngchairmanoft he
organizat i
onandl editunt ilhisdeat h.Hehi redDr .VargheseKur i
ent hree
yearsaf terthewhi t
er evolution.Heconv incedDr .Kur i
entostayandhel p
withthemi ssion.Kur i
en, founder -chairmanoft heGCMMFf ormor et han
30y ears( 1973–2006) ,iscr edit
edwi t
ht hesuccessofAmul '
smar ket i
ng.
Amul hasbecomet hel argestf oodbr andi nIndi aandhasv enturedi nt o
mar ketsov erseas.
Thebr andnameAmul means“ AMULYA” ,t
hiswor dderi
vedfrom the
Sanskri
tword“AMULYA”whi chmeans“ PRICELESS”.Aqualitycontr
ol
experti
nAnandhassuggest edthebr andnameAmul .Amul i
sasy mbol
ofmanyt hi
ngslikeoft hehigh-quali
typroductssoldatreasonablepri
ces,
ofthegenesisofav astcooper ati
venet work,oft
hetriumphof
i
ndigenoustechnology, oft
hemar ket
ingsav vyofafarmers’organi
sati
on.
Andhav eaprovenmodel f
ordairydev el
opmentandi sconsideredas
Indi
a’
sbestknownl ocal Br
andacr ossallcategori
es.

11
AnandPat
ter
n:-

12
13
 ORGANI
SATI
ON
Amul i
sor ganizedasacooper ati
veofcooper ati
vestherebydr i
vingthe
advant ageofscal eandunif ormi t
yi ndecisionmaki ng.Thef ounder sof
Kairauni onr eali
zedthattof ul f
ilt
hei robjectives,alargenumberof
mar ginalf armershadt obenef itf
rom t hecooper at
ive–anet wor kof
stakehol der shadt obebui lt.Andoncebui lt
,ithadt ogrowsoast odr
aw
mor er ur
al poortoundertakedai r
yf armingasameansofl iveli
hood.The
networ khadt ohaveseveral layers–t heor ganizati
onal networ kwher e
thev oiceoft heownersgov er nedal ldecisions, aphysical networ kof
suppor tser vicesandproductdel i
v eryprocessandanet workofsmal l
farmer sthatcoul ddeli
vert hebenef itofal argecooper ationi nthe
mar ketpl ace.
Amul cooper ativer egi steredon14December1946asar esponset ot he
expl oit
ationofmar ginal mi lkpr oducer sbyt rader soragent soft heonl y
exist i
ngdai ry
, t
hePol sondai ry ,inthesmal lcitydist ancest odel i
vermi l
k,
whi chof tenwentsouri nsummer ,toPol son.Thepr icesofmi lkwer e
arbitrari
lydet er mi ned.Thegov ernmenthadgi v enmonopol yr ightsto
Polsont ocol lectmi lkf rom Kai raandsuppl yittoBombayci ty
.Anger ed
byt heunf airtradepr actices, thef armer sofKai raappr oachedPat el
undert hel eader shi pofl ocal farmerl eaderTr i
bhuv andasKPat el
.He
adv isedthem t of or m acooper ative( Kair
aDi st ri
ctCo- oper ativeMi l
k
Producer s' Union)andsuppl ymi l
kdi rectl
yt otheBombayMi lkScheme
i
nst eadofPol son( whodi dt hesamebutgav et hem l owpr ices).Hesent
Mor ar j
iDesai toor gani set hef ar mer s.In1946, themi lkf armer soft he
areawentonast rikewhi chl edt otheset t
ingupoft hecooper ati
vet o
collectandpr ocessmi l
k.Mi l
kcol l
ect ionwasdecent rali
zed, asmost
producer swer emar ginal farmer swhocoul ddel i
ver ,atmost ,1–2l i
tres
ofmi l
kperday .Cooper at i
veswer efor medf oreachv il
lage, too.ByJune
1948, t
heKDCMPULhadst artedpast eurizi
ngmi lkf ort he' BombayMi l
k
Scheme' .Undert hesel fl
essl eader shi pofTr i
bhuv andasKPat el,
in1973,
Amul celebr atedi ts25t hanni v ersarywi thMor arjiDesai ,
Mani benPat el
andVar gheseKur ien.
Thecooperati
vewasfur t
herdevel
opedandmanagedbyDr .Var
ghese
Kuri
enwithH.M.Dalaya.Dalay
a'si
nnovati
onofmakingskim mi
lk
powderfrom buf
fal
omi lk(f
orthefi
rstt
imeintheworl
d)andali
ttl
elat
er,
wit
hKurien'
shelp,makingitonacommer ci
alscal
e,l
edtothefi
rst

14
moder
ndair
yofthecooper
ati
veatAnand,
whi
chwoul
dcompet
eagai
nst
est
abl
i
shedplay
ersi
n
themarket.Kuri
en'
sbrot
her-
in-
lawK.M.Phi
l
ipsensi
tizedKuri
entot
he
needsofattendi
ngtothefi
nerpoint
sofmarket
ing,
includi
ngthe
creat
ionandpopular
izat
ionofabrand.
AMUL–Meani
ngofWor
d
InSanskri
tlanguage,AmulmeansPRICELESSthati
s“amuly
a”
suggestedbyqualit
ycontr
olexper
tinAnand.Somecit
etheori
ginasan
acronymtoAnandMi l
kUnionLimi
tedthat
isAMUL.
MI
SSI
ON
GCMMFendeav ourtosat
isfythetast
eandnutri
tionr equi
rementsofthe
cust
omers,ofthewor l
dthroughexcell
enceinmar ketingbythei
r
committ
edteam.Thr oughco-operati
venetwor
king, t
heyarecommi t
ted
toof
ferqual
it
ypr oduct
sthatpr ov
idebestval
ueformoney .
VI
SION
“
Amul’
svisi
oni
stopr
ovi
demoreandmor esati
sfact
iont
othef
armer
s,
t
hei
rcust
omers,
empl
oyeesanddi
str
ibut
ors.
MOTTO
Themai nmot toofAmulistohelpfar
mers.Farmer
sarethefoundati
on
stoneofAmul .Thesyst
em worksonlyforf
armersandforconsumers
notforprofi
t.Themainaim ofAmul i
stoprovi
dequal
it
yproductstothe
consumer satmax i
mum profi
tinter
msofmoneyt othefar
mer s.
LOGO
Fourhandsshowni nlogowhichareco-rel
atedtoeachother
,fi
rsthand
i
sforfarmer,secondhandisforprocessor
,thir
dhandisformarketer
andthefourthhandisforconsumer.So,ori
ginal
lyt
hefi
rst-f
armerhand
whichisresponsi
bleforpr
oducingmilkastheslogansays“THETASTE
OFINDIA”isproven.

15
 THEAMULPATTERN
Haveasneakpeeki
ntot
her
evol
uti
oni
zi
nganduni
quet
hreet
ierpat
ter
nofAMUL
TheAmul Modelofdairydev el
opmenti
sathree-t
ieredstruct
urewit
ht he
dai
rycooper
ativ
esocietiesatthevil
l
agelev
elfederatedunderami l
k
uni
onatthedistr
ictl
evel andafeder
ati
onofmemberuni onsatthestate
l
evel
.

16
ORGANI
ZATI
ONSTRUCTURE

Chai
rmanandBOD

Managi
ngDi
rect
or

Gener
alManager

Assi
stantGener
alManager

Seni
orManager

Manager

Deput
yManager

Assi
stantManager

Seni
orExecut
ive

Execut
ive

Seni
orOf
fi
cer

Of
fi
cer
’sAssi
stant

Juni
orAssi
stant

17
 Wor
ker
s

CERTI
FICATI
ON
Foodsaf
etymanagementsy
stem
Amul hasestabli
sheddocumented,i
mplementedandmai nt
ainedan
effect
ivefoodsafetymanagementsyst
em andupdatesitwhen
necessaryinaccordancewit
htherequi
rement
softhisinter
nati
onal
standardISO22000:2005andHACCP.TheCompanyhas:
•Ensuredthatt
hefoodsafetyhazardsthatmayber easonableexpected
tooccurinrel
ati
ontoproductswithi
nt hescopeofthesy stem ar
e
i
dentif
iedeval
uatedandcontroli
nsuchmannert hatthepr oductoft
he
organi
zati
ondonotdirect
lyorindi
rectl
y,har
mt heconsumer ,
•Communi catedappropr
iateinf
ormati
ont hr
oughoutt
hef
oodchai
n
regar
dingsafetyi
ssuesrelat
edtoitsproducts,
•Communi cat
edi nf
ormati
onconcerni
ngdevel
opmentimplementati
on
andupdat i
ngoft hefoodsafet
ymanagementsystem t
hroughoutthe
organizat
iontotheextentnecessar
ytoensur
ethefoodsafetyr
equir
ed
bythisint
ernati
onal st
andar
d,
•Evaluatedperi
odicall
yandupdatewhennecessarythefoodsafet
y
managementsy st
em toensurethatt
hesystem r
efl
ectsthe
organisati
onsacti
viti
esandincor
porat
esthemostr ecenti
nfor
mationon
thefoodsaf et
yhaz ar
dssubj
ecttocontrol
.

18
FSSAI
FoodSafetyandStandar dsAuthori
tyofIndi
a( FSSAI)isanautonomous
bodyestabli
shedundert heMinist
ryofHealth&Fami l
yWel f
are,
GovernmentofIndi
at heFSSAIhasbeenest abli
shedundert heFood
Safet
yandSt andar
dsAct ,
2006whichi saconsoli
datingstatut
erel
ated
tofoodsafetyandregulati
oninIndia.FSSAIisapprovedinAmul .
FSSAIi sr esponsi blef orprot ect i
ngandpr omot ingpublichealtht hrough
ther egulati
onandsuper visionoff oodsaf ety.TheFSSAIi sheadedbya
non-execut iveChai rper son, appoi ntedbyt heCent ralGovernment ,eit
her
holdingorhashel dt heposi tionofnotbel owt her ankofSecr etarytot he
Gov ernmentofI ndi
a.FSSAIwasest ablishedbyFor merUnionHeal th
MinisterDrAnbumani Ramadoss, Gov ernmentofI ndi
aon5August2011
underFoodSaf etyandSt andar dsAct ,2006whi chwasoper ati
onalised
i
ny ear2006.TheFSSAIconsi stsofachai rperson&22member s.The
FSSAIi sr esponsi blef orset tingst andar dsforf oodsot hatthereisone
bodyt odeal wi t
handnoconf usi
oni nt hemi ndsofconsumer s, t
raders,
manuf acturers,andi nv estor s.Mi nistryofHeal th&Fami l
yWel fare,
Gov ernmentofI ndi
ai st heAdmi nistrativeMinist r
yofFoodSaf et
yand
Standar dsAut horit
yofI ndia.Thef ollowi ngaret hest at
utorypower sthat
theFSSAct ,2006gi v est ot heFoodSaf etyandSt andar dsAut horit
yof
I
ndia( FSSAI ).
1.Fr
ami
ngofr
egul
ati
onst
olaydownf
oodsaf
etyst
andar
ds.
2.Layingdowngui
del
i
nesf
oraccr
edi
tat
ionofl
abor
ator
iesf
orf
ood
test
ing.
3.Provi
dingsci
ent
if
icadv
iceandt
echni
cal
suppor
ttot
heCent
ral
Government.
4.Cont
ri
but
ingt
othedev
elopmentofi
nter
nat
ional
techni
cal
standar
ds
i
nfood.
5.Col
lecti
ngandcol
l
atingdat
aregardi
ngf
oodconsumpt
ion,
cont
ami nat
ion,
emer
gingri
sksetc.
6.Di
ssemi
nat
ingi
nfor
mat
ionandpr
omot
ingawar
enessaboutf
ood

19
saf
etyandnut
ri
ti
oni
nIndi
a.

20
I
SO22000:
2005
Thei nit
iati
onofTot al Qualit
yManagement (TQM)waybacki n1994was
towor kwi ththewel l
-knownqual i
tymanagementi nit
iati
v eswhi chhav e
provent obeef fectiveel sewher etocreat eacul tur eoft ranspar ency,
opennessandl eader shipi nt heorganisationr ealisingthatwi themer ging
compet iti
on, doi ngbusi nesswoul dbecomemor eexci t
ingy etext r
emel y
compet iti
vewhi chwoul dr equireattimenotonl yawhol esetofnew
skill
sandcompet enci esbutqui ckadapt abilit
yt ochangewi thoutmuch
stressort urbul ence.Asav eryuniquemeasur eAmul extendedal lt
he
TQM i ni
tiati
vest oi tsbusi nesspar tnerswhet heritwast hef ar mer
produceri nthev i
llageorawhol esaledistributori namet rotownori ts
mostsophi sticat edpr oductionunit.From t hest rengt hofTot alQuality
Managementi niti
at iveAmul wentont oimpl ementQual ityManagement
System ofI nter nat ional Standard.Amul hasbeent hef i
rstdai ryinIndia
togetaccr edi tedwi t
hcer tif
icati
onofI SO22000: 2005.
Theor
gani
zat
ionshal
lensuret
hef
oll
owi
ngbasi
crequi
rement
sfort
he
i
mplement
ati
onofISO22000.
•Thef oodsafetyhazardst hatmaybereasonableexpectedtooccuri
n
rel
ationtoproductwithinthescopeoft hesyst
em areidenti
fi
ed,
evaluatedandcontrol
ledinsuchamannert hattheproductofthe
organisati
ondonotdi rect
lyorindi
rect
lyharmtheconsumer s.
•Communicat
eappropr
iat
einformati
onthroughthef
oodchai
n
regar
dingt
hesaf
etyi
ssuesrel
atedtoi
tsproducts.
•Communicat
einfor
mat
ionconcer
ningdev
elopment
,impl
ement
ati
on
andupdat
ingoff
oodsaf
ety.
•Ev
aluat
eper
iodi
cal
l
yandupdat
e.
TheI
SOgaveonl
ythebasi
cdocumentsoft
hepr
erequi
sitepr
ograms
andt
hecompanyhast
owor kouti
nit
sownwayforimplementi
ngISO.

21
I
SO9001:
2000
TheI SO9000f ami l
yofqual i
t ymanagementsy stems( QMS)st andar
ds
i
sdesi gnedtohel porganisationsensur ethattheymeett heneedsof
customer sandot herst
akehol der
swhi l
emeet i
ngst atutoryand
regulatoryrequirementsrelat edtoapr oductorser vice.ISO9000deal s
withthef undament alsofqual i
tymanagementsy stems, i
ncl udingthe
sevenqual i
tymanagementpr inci
plesuponwhi chthef ami lyof
standar dsisbased, I
SO9001deal swithther equir
ement st hat
organiz at
ionswi shi
ngtomeett hestandardmustf ulfi
l.Thi r
d- part
y
certi
ficati
onbodi esprovidei ndependentconf ir
mat i
ont hator ganisat
ions
meett herequirementsofI SO9001.Ov eronemi l
li
onor gani sati
ons
worldwi deareindependent lycer t
if
ied,makingI SO9001oneoft hemost
widelyusedmanagementt ool sintheworldtoday .Howev er,theISO
certi
ficati
onpr ocesshasbeencr it
ici
sedasbei ngwast eful andnotbei ng
useful forallor
ganizati
ons.
Amul ’sprimar yvil
lagecooper ati
vesoci etiesaret hefir
st‘grassr ootlevel
’
organisationsi ntherural sectortoachi eveI SO9001: 2000cer tifi
cationin
India,perhapsi nthewor l
d.Thi shasbeenpossi blebecauseofAmul ’
s
cont i
nuedcommi tmentt oof ferconsumer sexcel l
entproduct sinthe
houseofAmul .Thef ocusont heheal t
handhy giene,housekeepi ng,
vill
agechi l
li
nguni ts,managementofv il
lagecooper ativesocieties,rapid
transportationofr awmi l
kt othedai ryplant ,
acceleratedmi l
khandl ingat
thedai r
yr eceptiondockhasr etai
nedt hef reshnessofmi lkbeing
receivedatdai ryplant.Tosust ainandr ebui l
donhi sef f
ort,tr
aining
programmesar eor ganisedf orallthest akeholdergroupsi nvolvedi nthe
‘
mi lkprocur ementchai n’namel y,milkproducer s,vi
ll
agesoci ety
personnel anddai ryplantper sonnel .Labor ator
iesareequi ppedwi t
h
state-of-
the-artequipment sandwel l
-tr
ainedpr ofessionals.

22
APEDA
GovernmentofI ndiaundert heAgr i
cult uralandPr ocessedFood
ProductsEx portDev elopmentAut hor i
tyAct ,1985hasest ablished
Agri
cultural&Pr ocessedFoodPr oduct sExpor tDev elopmentAut hor i
ty
(APEDA)i n1985t hr oughanactf ort hedev elopmentandpr omot ionof
exportofschedul edpr oduct s.Itpr ovidesf i
nanci alassistance,
i
nformat i
on,guidel inest owar dsthedev elopmentofschedul edpr oducts.
Theappl i
cationf orr egistrati
onshal lbemadewi t
hi namont hf rom the
dateofunder takingofsuchexpor tunl esst het imel imitforaf oresaid
regi
strati
onisext endedbyt heAut hor ityf orsuf f
icientcause.TheAgr i
exchangepor t
aloft heAgr i
cult
ural andPr ocessedFoodPr oduct sExpor t
DevelopmentAut hor it
y( APEDA)i sanonl i
net ool developedt oprov i
deall
rel
evantinformat iononI ndianAgr icultur alproduct st oint
er national
buyersandmar keti ntelli
gence.I tismadei ncol l
abor ationwi thUNCTAD.
Exporterscanr ecei veof fersandt r adeenqui riesonl ine,andi mpor t
ers
canmakedemandsandspeci f
icquer i
es.
APEDAi sadmi nisteredbyMi nist
ryofCommer ce,India.Amul Plantsare
certifi
edbyAgr icul
t ural
andPr ocessedFoodExpor tsDev elopment
Aut horit
y( APEDA)f orexportofdai r
ypr oductstointernat i
onalmarkets.
Guj aratCo- operati
v eMilkMar keti
ngFeder ati
on( GCMMF)whi chmar ket
s
andexpor tsdai r
ypr oductsundert hebr andof“ Amul ”hasbaggedawar d
t
h
11 t imef orex cell
entper for
mancei nexpor t
sofdai rypr oduct
sf r
om
APEDA-2008- 09,IMCRamkr ishnaBaj ajNati
onal Qual i
tyAwar d–2003,
"BestofAl l
"Raj i
vGandhi Nati
onal QualityAward-1999, The
Internati
onal Dair
yFeder ati
onMar ket
ingAwar d( 2007)f orAmul pro-
bioticice-cream launchAmul Dai r
yhasbeenr ecipientofcount l
ess
23
awar dsforit
sout standingef fort
sinprocessingandpr ov i
dingquali
ty
productstoconsumer sther ebyenhancedi ncomei ntothehandsof
dair
yf armers.Someoft heseawar dsaretheBestPr oduct i
vit
y
PerformanceAwar dsf ort hreeconsecutivey earsfrom 1985and
Sustainedproduct i
vit
yPer formanceAwar din1988- 89f rom National
Productivi
tyCounci l
,Gov ernmentofI ndi
a,IndianMer chants’Chamber
Awar d-forOutstandingPer formanceinthef ieldofR&DofFood
ProcessingIndustriesBasedonAgr i
cult
uralPr oducts-1988, againBest
Productivi
tyPerformanceAwar ds1994-99f rom Nat i
onal producti
vit
y
Counci l
,G.D.Birl
aI nternat i
onal Award-Out standingCont ri
butionto
Rural Upli
ftment, Sahkar iVikasRat naAwar d.

24
 PRODUCTRANGE
Pr
oduct
s
Fr
eshmi
l
k Amul
shakt
i(past
eur
izedst
andar
dizedmi
l
k)
Amul
T-
special(
standar
dizedhomogeni
zedmi
l
k)
Amultaaza
Amul
Gol
d(f
ull
cream mi
l
k)

Fer
ment
edPr
oduct
s Amul
Mast
iDahi
(fr
eshcur
d)
Amul
li
teDahi
Amul
But
ter
mil
k
Amul
Jeer
aBut
termi
l
k

But
ter Amul
Utt
erl
yBut
ter
ydel
i
cious
Amul
Whi
tebut
ter

25
Br
eadSpr
eads Amul
del
i
cious
Amul
li
te

Ghee Amul
Pur
eGhee
Amul
BrownGhee
Amul
CowGhee

Mi
l
kPowder
s Amul
ful
lCr
eam mi
l
kPowder(
WMP)
Amul
ski
mmedmi
l
kpowder(
SMP)
Amul
ya(
Dai
rywhi
tener
)
Amul
Spr
ay(
Inf
antmi
l
kfood)
WheyPowder

Fl
avour
edmi
l
k Badam
St
rawber
ry
Tul
si,
Ginger
,
Kadhi
Amul
Kool
caf
éAmul
kool
coco
Amulshaker
s(mango,
str
awber
ry,
saf
fron,
car
damom, r
ose)
CheeseRange Amul
Cheddarcheese
Amul
processedcheese
Cheesespr
ead
Amul
Pizza(
Mozzar
ell
a)cheese

26
 Amul
ETG(
easyt
ogr
ate)cheese
Amul
Emment
alcheese
Amul
Goudacheese
Amul
mal
aiPaneer

Chocolat
e& Amul
Mil
kchocol
ate
Confecti
oner
y
Amul
Dar
kchocol
ate
Amul
Frui
t&Nutchocol
ate
Amul
Bindazz
Amul
Chocozoo
Amul
ChocoMi
nis
Ener
gybar
Al
mondbar
Mal
tbasedpr
oduct Amul
pro(
Wheypr
otei
nmal
tbev
erage)

AMUL3RAW MI
LKRECEPTI
ONDOCK
Rawmi
l
katAmul
-3i
srecei
vedonl
ythr
oughr
oadmi
l
ktanker
scomi
ng
27
fr
om chil
l
ingcent
resandvi
l
lagechi
lli
nguni
ts.Therear
et hr
eebaysf
or
unl
oadingmil
ktanker
s.I
thasfaci
li
tyofcomputeri
zedrecepti
on.
 RecentHandl
i
ngCapaci
ty:
35LakhL/
day
PROCESSFLOW CHART

28
LI
STOFEQUI
PMENT:-

29
SR.
NO NAME CAPACI
TY NUMBER OTHER
I
NFO
1. Rawmilk 15000Lt 3
buff
ert
ank

2. Cr
eam buf
fer 15000Lt 2
t
ank

3. Bal
ancet
ank 350Lt 3

4. Cream 10000l
t/hr 1 Pl
ates-
234
pasteur
izer
(PHE)

5. Mi
l
k 30000l
t/hr 4 Pl
ates-
412
Pasteur
izer
(PHE)

6. Cream 30000l
t/hr 2 Di
scs-265
separat
or

7. Mi
l
kcl
ari
fi
er 30000l
ph 3

30
8. Chi
l
ler 30000l
ph 3

9. But
termi
lk 40000l
t 2
st
orage

10. Rawmi
l
ksi
l
o 150000l
t 4,
1

11. Past
eur
ized 150000, 5,
1
mil
ksil
o
60000l
t

12. Ri
nsemil
k 15000, 2
coll
ect
ingt
ank
2000l
t

13. Bact
ofuge 30000l
t 1 Rpm-4800-
5000

14. Sludge 5000, 1,

2
t
reatmenttank
1000l
t

31
 15. Pasteuri
zed 40000,
20000 3,
2
cream si
lo

OPERATI
ONS:-
 Asthet ankerarri
vesatt hebay,t
hesealoftheli
doft hetankeris
checkedf ori
tsintactness.Tamperedsealmayraisethedoubt sof
adult
erati
on.Forcr osscheckingofrawmi l
kquali
tysealed
samplesar ebroughti nbytanker
sfrom chi
ll
ingcentr
es.
 Labanalysttakessampleofthemilkaft
erplunging.The
temperatur
ei srecor
dedasthesampleistaken.Thenr ecepti
onl
ab
anal
ystteststhemi l
kfori
tsqual
it
y.Fir
stl
y,organolept
ictesti
s
done.
I
fthetemperatur
eofmilkisbelow10⁰Canditsacidi
tyi
slessthan
0.
136%L.A.(incaseofcream 0.085%L.
A.)andthefatandSNF
per
centmatcheswithdeli
ver
ychal l
ansentbythecentr
ewhichis

32
 automatical
l
yupdat
edbythecomputerast
heanalystmeasur
es
theseparameter
sonthei
nstr
umentswhoseterminal
sare
connectedtothemai
ncomputer
,thecomputer“
Accepts”t
hemil
k.
 Thelabanal ystsenterthepasswor dinthecomput erandgive
si
gnal “READY”f orunloadingoftankeratbay .RAM i ssel
ectedby
shi
ftin-chargefrom controlroom.Af t
erconnectingt hehosepipe
andchecki ngthatthemanhol eoftankersi
ssl i
ght l
yopen,signal
is
acceptedbyr ecepti
oni n-
char gef
rom localpanel andunloadingof
milkfrom tankerstart
s.
 Themi l
kunloadedatbayispumpedthr
oughadeaer
ator
,di
scf
il
ter
,
cent
rif
ugalpump, NRVandmassf l
owmeter(
whicharet
hen
conver
tedintokil
ogram)
.
 Thenmi l
kpassesthrought
hechil
ler(plat
etype)wherethe
temperatur
eisreducedbel
ow4⁰C, aft
ercoldclar
if
icat
ionand
fi
nall
ygetsstor
edintotheRawMi l
kSiloandtheempt iedt
ankeri
s
senttotheTankerCIPbayforcl
eaning.
 Ast her
earethreebays(RL1,
RL2,andRL3)forunl
oadingmi l
k
tankersal
lfourRMScanbeusedatat i
mei .
e.,mil
kisunloadedat
therateof3×30,000LPHinanyofthef
ourRMS.
 Milkfrom RMSi spumpedt otheFl
oatBalanceTankofPasteuri
zer
andunder goesPast euri
zati
on(78⁰
C/15sec).Meanwhil
eafter
preheati
ng,milkissepar at
edtoski
m mi l
kandcream inTr
i-
processorandadj ustedtovari
ousstandardst
oMar ketmi
lk.
 Thecr
eam i
ssentt
ocr
eam buf
fert
ank.
 TheSelfStandar
dizat
ionisdonei
nALFASTUNI Ti.
e.,Alf
aLaval
FatAnaly
singStandardi
zati
onUni
t.Thesepar
atedmi l
kisusedf
or
manufacturi
ngpowderi.e.
,WMP,Amul Spr
ay,Amulya.
 Theseparatedcream i
sfurt
herpasteuri
zedtomakeitcapabl
efor
humanconsumpt i
on.Theprocessi
ncludesheat
ingofcream at
90⁰Candt hencooli
ngtobelow10⁰C.Aftert
hati
tisstor
edin
cream si
l
o.
I
nther
ailt
ankerdispatchtoKol
kat
a,t
hemi
l
kischi
l
ledt
obel
ow
2.
5⁰Ct
hroughgly
col chil
l
er.

33
  Thet
emper
atur
emai
ntai
nedf
ort
ankerdi
spat
chi
s
Rai
ltanker
:Max1.
8⁰C
Roadt
ankerMumbai
,Pune:
Max4.
5⁰C.

STANDARDI
ZATI
ONI
NALFASTUNI
T:-

34
I
n-Li
nef
atst
andar
dizat
ionf
rom cr
eam andski
m mi
l
k(f
ull
yaut
omat
ed)TETRAALFAST
PLUS

1.Densi
tyt
ransmi
tt
er
2.Fl
owt
ransmi
tt
ers
3.Cont
rol
val
ve
4.Cont
rol
panel
5.Const
ant
-pr
essur
eval
ve
6.Change-
overv
alv
e
7.Checkv
alv
e

35
 Fl
owchar
tofAl
fastuni
t

Inonlinestandardizati
oncr eam fatcontr
olsyst
em wor ksont hebasis
ofCascadecont rol
: Acombi nati
onofaccurat
emeasur ementoft hefat
contentandr apidflowmet ering,
knownascascadecont r
ol.I
ncascade
controlaccuratefatcontentismeasur edbydensit
ytr
ansmi tt
erandf l
ow
tr
ansmi tt
ers.
I
ncascadecont
rol
,ther
ear
emai
nly3f
lowmet
ers:
1.Densit
ytr
ansmit
ter
:itsensesthedensityoff
lowi
ngf
lui
dsoi
tindi
rect
ly
helpsinmeasur
ingfl
owf orstandar
dizat
ion.
2.
Flowt
ransmi
tt
er:
accordi
ngtodensit
ymet er,
flowmeteradjust
sthe
fl
owofski
m mil
kandcream aspert
her equi
redstandar
dizedmil
k.
3.Contr
olv
alv
e: i
tist
heheartofALFASTsy
stem.I
tadj
ust
sit
sopeni
ng
accordi
ngtorequi
redfl
owformilk.

36
SPECI
FICATI
ONSOFMI
LKANDMI
LKPRODUCTS

Ty
peofmilk&mi
lk Cr
eam Fat% Fat%rat
ioor%
product F/
SNFrat
io

Tonnedmi
l
k 3.
55
42.
0
Doubl
etonnedmi
l
k 1.
60
42.
0
Mar
ketmi
l
k 4.
60
42.
0
Hi
ghf
atmi
l
k 6.
60
42.
0
Whol
emi
l
k(Gol
d) 6.
10
42.
0
Tot
alr
emi
x -
42.
0
Ski
mmi
ng 0.
05
42.
0
Whol
emi
l
kpowder 37.
50:
1F/
SNF
42.
0
Amul
yami
l
k 33.
30:
1F/
SNF
42.
0
Amul
yaspr
aymi
l
k 30.
00:
1F/
SNF
42.
0

37
Amul
Dispat
chmi
l
kinKol
kat
a,Mumbai
,pune,
etc.
…

38
 Amul
dispat
chmi
l
kbyt
rai
n

CLEANI
NGANDSANI
TIZATI
ONPROCEDURES:-
 Thi
sisdonei
ntwoway
s:
TankerCIP:compl
etesin15t
o18minbyusi
ngly
eandfr
eshwater
.
ProcessCIP:compl
etesin3t
o4hr
susingsoda–aci
d–soda.

Sodaused–sodi
um hy
droxi
de
Aci
dused–ni
tr
icaci
d
 Chemi
cal
l
ycl
eanedaf
ter6-
8hour
sofcont
inuesuse.

39
  Hygisof
tsanit
izerisadded(0.15%)int
helastst
ageofCIPf or
100%ofbacterialr
emov al
.Iti
sf oodgr
adesanit
izersof
lushingi
s
notcarr
iedout.
 Fort
hepl
atebi
ofi
lmremoval
0.2%sodi
um t
ripol
yphosphat
e(STP)
i
saddedi
ncausti
csoda.
(
STPi
sachel
ati
ngagentandbi
ndswi
thMg+i
onsandCa+i
ons.
)
 Conducti
vit
ymet eri
susedi ncontr
oll
i
ngthefl
owofaci
dandlye
asperthei
rconcentrat
ion.I
tisdoneonthebasi
sofadj
ust
ing
ampererangethatis40ms.
Roadtankersforl
ongdi
stancedi
spat
char
ehandscr
ubbedwi
tht
eepol
andIodophoreaft
erCI
P.

CI
P

NOTE:
1.Test
sdonef
orchecki
ngl
eakagei
nmi
l
kPHE:

40
 DyePenet
rat
iont
est
-thi
stesti
sdonet
ochecki
ndi
vi
dual
leakage
i
nplat
es.
Met
hod:
-
 Cl
eanwi
thcl
eaner
.
 Applypenet
rat
e(r
edcol
our
)tof
rontsi
deofpl
atet
henwai
t
for
10min.
 Appl
ydev
eloper(
whi
tecol
our
)tobacksi
deofpl
atet
henwai
tfor
10mi
n
 Pi
nkcol
ouri
fobser
vedpi
nhol
esorcr
ackspr
esenti
npl
ate.

L&TPOWDERPLANT

41
Pr
oduct Amul
Spr
ay
Name

Descr
ipt
ion I
nfantmi
l
kfood

1KgPouch/Ti n,
500gPouch/Ti
n/Ref
il
l,
200g
Pouch/Ref
il
l,
Rs10Pack,Rs5Pack
Packi
ng

Pr
oduct Amul
ya
Name

Descr
ipt
ion Dai
rywhi
tener

1KgPouch,500gPouch/Ref
il
l,
200gPouch/Ref
il
l,
100gPouch,
Rs10Pack,Rs5Pack
Packi
ng

I
NTRODUCTI
ON
TallForm Dr ier(
TFD)PowderPl ant(L&TPl ant): -LarsonandTur bo
Plantisaf ull
yautomatedTall
For m Drierplantinwhi chtwostages
dryi
ngofst andardmil
ktakesplaceinSpr ayDr yerandVi br
oFluidi
zed
BedDr ier.Thecapacit
yoftheplantis60MT/ day .Milkisrecei
vedfrom
processingsi tei
susedtomakemi l
kpowderusi ngdi ff
erentpr
ocedures.
I
nt hepl antSkimmedmi l
kpowder ,Whol emi l
kpowder ,Dair
ywhitener
(Amulya)andI nf
antmil
kfood(Amul Spray)arepr oduced.
Capaci
tyoftheplant
:60MT/day
Aver
ageproduct
ion/hr:3.
26MT
Aver
ageproduct
ion/day
:75MT

42
PROCESSFLOW CHART:-

43
44
Thewhol
epr
ocessi
sdi
vi
dedi
nthr
eest
ages:
1.
FeedPr
epar
ati
on
2.
Evapor
ati
on
3.
Dry
ing

45
FeedPr
epar
ati
on
Milkfrom mil
ksil
osfi
rstcomest othesection.Thesecti
onhast womilk
sil
oseachhav i
ng40000lit
.milkcapacit
ies.IntheDair
yWhi t
enerand
Infantmil
kfoodsugarisaddedassy r
uppr eparedinsugarDissol
vi
ng
tankshaving3000li
tcapaci
ty.Thetanksaredoubl ej
acketedforheat
ing.
Thepreparedsol
uti
onispumpedi nt
omi l
ksil
othroughi
nli
nedouble
fi
l
ter
s.Trisodi
um phosphate(
forpHadjust
ment )andVi
tamins(
A,D,B,C)
&Mineralmixt
ure(bothforAmulSprayonl
y)areaddedinthemil
ksil
o.
Ev
apor
ati
on
Heremechani calarrangementismadesucht hatmil
kinsi
detubecomes
i
ncontactwi ththest eam whichheatsthemi lkandsomeofi t
swat er
part
sabout35%i sev aporatedduri
ngthissect i
onandweget48%t ot
al
soli
ds(TS)themi l
k.Forconcentrati
onoft hemi l
k,Mult
ipl
eEffect
Evapor
ator(5ef fects)wit
hFor wardFeedModeofEv aporati
onisused.
Concentr
atedmi lkfrom ev apor
atorisgatheredinConcentr
atetanks.
Therearethreetanks.
FeedHandl
i
ngcapaci
tyoft
hecondensi
ngpl
ant–22095kg/
hr
Ev
apor
ati
oncapaci
tyoft
hepl
ant–16000kg/
hr
Ev
apor
ati
onhasf
oll
owi
ngcomponent
s:
 Bal
anceTank
 Si
xpr
e-heat
ers
 Fl
ashv
essel
.
 Di
rectcont
actTangent
ial
Swi
rlHeat
er
 Hol
dingt
ube
 Cal
andr
ia
 Vapoursepar
ator
 Vacuum sy
stem
 Ther
mocompr
essor
 De-
super
heat
ingPumps

46
  Bal
anceTank:
Mil
kfrom si
loscomestot
hebalancetank.Thel
evelandfl
owofmi
l
kis
cont
roll
edinthebal
ancet
ank.I
tscapacit
yis1250li
tre.
 Pr
e-heat
er:
Fr
om bal
ancet
ankmil
kgoesto6pr
e-heat
ersofShel
l&Tubet
ype.Her
e
mil
kisheat
edst
epbystepupt
o55⁰Cundervacuum
 Fl
ashv
essel
:
Flashvessel i
sspecial
lyconstruct
edwi t
hTangenti
ali
nletandconnect
ed
toregenerati
veheaters.Ithastwocomponent s.
Regener at
ion–Her eheatexchanget akespl
acebetweenincomingmil
k
andout goinghotmilk(90-92⁰C)
Cooling–Her epasteurizedmi l
kisfl
ashcool
ed.
 Di
rectCont
actTangent
ialSwi
rlHeat
ers:
Swirlheater
sareprovi
dedtoheatmi l
ktor equi
redpast eur
izati
on
temperatureof95⁰Cbytangent
iali
njecti
onofHi gh-Pr
essur eSteam (
8-9
kg/cm2)inanonl i
nepipi
ngsystem.Itisequippedwi t
hdesuper heat
ing
equipmentandpr ot
ect
edagainstoverpressurev i
aar eli
efvalve.
 Hol
dingTubes:
Heat
edmi
l
kishel
dinhol
dingt
ubesf
or30seconds.
 Cal
andr
ia:
Cal
andr
iaareFal
li
ngFi
l
m Shel
landTubet
ypeheatexchanger
s.Ther
e
ar
e5calandri
a.
 Vapoursepar
ator
:
Vapourwhichi spr
oducedincal
andr
iaisseparatedhereandusedto
heatthesubsequentcal
andri
a.Apartofvapourfrom t
hir
deffecti
s
recompressedinThermocompressorandv apourfr
om thefi
fthef
fect
goestothef i
rstpr
eheat
er.
Purecondensatef
rom t
hefi
rstef
fecti
spumpedbacktotheBoil
er
house.Condensat
efr
om thesecondeff
ecti
sfl
ashedi
ntothethi
rd
eff
ectandsoon.

47
  Vacuum sy
stems:
Ther
ear
etwost
agest
ogetv
acuum i
ntheent
ir
esy
stem.
 Bar
omet
ri
ccondenser
 Vacuum pumps
Noncondensablefr
om t hepr
eheater
,fl
ashv esselandcalendri
aare
routedtoBar
ometri
ccondenserf r
om whichtheyar eext
ractedwit
hthe
aidofwaterr
ingvacuum pumps.Thecool i
ngwat erfr
om thecooli
ng
towerispumpedtoBar ometr
iccondensersentbackt ocooli
ngtower
from hotwel
lusi
ngreturnwaterpump.
 Ther
moVapourRecompr
essor
:
Steam i
saddedinfir
stCalendr
iashel
lsidethroughathermo
compressorbyrecompressi
ngtheVapourf r
om thir
dCalendri
ausing
hi
ghpressuresteam.Ithel
psinsteam savi
ngs.Therearethr
eethermo
compressors.
 Desuper
heat
ingPumps:
Todesuperheatst
eam forSwir
lheaterandTher
mocompr essorast
he
super
heatedsteam l
eadstofal
lincapacit
yofcal
endr
ia.

48
  Addi
tionofBHA(f
orWMPonl y
)–BHA@ 50gpermetri
ctonof
mil
kpowderisaddedbydissol
vingBHAi
n2-
3li
nlukewarm wat
er
andisaddedtomil
kinsi
l
o.
 Addit
ionofTSP–Additi
onofbuff
eringsal
t@ 0.
2%f orSMP,
0.6%
forAmulSprayand0.
3%f oramul
ya.TSPisnotaddedtoI
MF–1
and2andWMP.
 Sugar–Wateri
stakenint
osugarvatsandheat
edto50-
60⁰C.
Requi
redquant
it
yofsugarisaddedint
osugarv
atanddi
ssolv
ed.
Sugarsol
uti
oni
spumpedt omi l
ksil
osthr
oughfi
lt
er.
 Vitami nsandmi nerals–Vi t
ami nA+Di sdissolvedinmil
kand
addedi ntosugarsol uti
on.Wat ersol
ublevi
taminsandmi neral
premi xi smixedi nlukewarm oilandaddedtov egetabl
eoilcream.
Lecithini smixedi nlukewarm oil/
gheeandheat edtoabout60-
70⁰ Cinor dertomel tlecit
hininfree-
fl
owingform andaddedi nto
veget ableoilcream mi xt
ure.
Dr
ying:
•Thecondensedmil
k(50%TS/50⁰C)from Concent
rat
emilktanki
s
pumpedtoScrapedSurf
aceHeatExchangerwherei
tisfur
ther
49
concent
rat
edandthent
otheSpr
aydr
yerwi
tht
hehel
pofahi
gh-
pressur
e
Homogenizerpump.
•Homogenizerhas3funct
ions,mainf
unct
ions,mainfunct
iont
opump
l
iqui
dupt ot
heheadofthedryer(f
if
thfl
oor
),t
or ai
sethetemper
atur
eof
condensedmil
kto70⁰
Candt opartl
yhomogenizethemilk.
•Thespr aydryeri
sofTal lFor
m desi
gnof8nozzl
esprayingat
omi
zer
,
whichconsistsofAirdispersi
ngsyst
em,El
ectr
omagnetichammer
s,
Cyclones,Fi
reexti
nguishingsyst
em andVi
brofl
uidi
zer
.
•Thedryi
ngchamberisacyl
indr
ical
v esselwit
h45⁰Cconi
cal
bot
tom.
Thedry
ingprocesspr
oceedsinaco-currentmode.

PARAMETERSOFDRYI
NGCHAMBER:
 Powderpr
oduct
ioncapaci
ty:
3000Kg/
hr
 Feedpr
essur
e:175-
190bar
 Chamberv
acuum:
12mm WC
 Dr
ierI
nletTemper
atur
e:187-
190⁰
C
 Dr
ierOut
letTemper
atur
e:91⁰
C
 Ai
rDi
sper
sionCool
i
ngTemper
atur
e:55⁰
C
Equi
pmentsy
stem wi
tht
hei
rfunct
ion:
1.
Airdi
sper
singsy
stem:
•Thesyst
em isprov
idedfordi
stur
bingairuni
for
mlyovert
hechamber
andconsi
stsofperf
orat
edsheets,i
nspecti
onwindowsandf i
nesret
urn
pumps.Cooli
ngfanprovi
dedtocool t
hehotpart
softhedispenser
.
2.
Elect
romagnet
ichammer
:
•Thepowderst ucktotheinnersi
desoft hedryerisremovedby
vi
brati
onsproducedbyt heElect
romagnet i
chammer s,whichbangsfrom
outsi
dethechamberwi thsuchaf or
cet hatthepowderstuckwithi
nfalls
ofthewall
s.Also,ther
eisuseofUl t
rasonicwav esfr
om withi
nthedrying
chambertoaidinremov alofsti
ckpowder .
•Thewav
esar
egener
atedatev
ery15secondsandl
astt
o6-
7seconds.

50
Ther
emov
alofst
uckpowderi
samustot
her
wisel
eadi
ngt
ofi
re.
3.
Fir
eext
ingui
shi
ngsy
stem:
•Itoperat
eswhenout lett
emperat
ureofthedryerexceedst
hespeci
fi
c
l
imit.Smokedet ect
orsinthepl
antsenseeven0.5ppm ofsmokeand
putsalarm on.
4.
Cycl
ones:
•Thepl
anti
sprovidedwithfourcy
clonest
or ecov
erfi
neparti
clesgoing
awaywi
thventgases.Thereisavibr
ati
ngtubebelowtheseparatort
o
conv
eythepowder.
•Also,t
hereisanairbl
owertopusht hepowderinthedir
ecti
onof
convey.Theseparat
edfines(non-
agglomer
ate)arethenconvey
edtot
he
Vibroshi
fteri
nthecool
ingstage.
•Iftheyhav
ehighermoist
urecont
ent,
theyaresentt
othespr
aydr
yer
buthalf
wayitshei
ght
,sothati
tdoesnotrecei
vetoomuchheat
.
5.
Vibr
oFl
uidi
zer
:
•Vi
broFlui
dizeri
sav i
brat
inghousi
ngwhichisdi
vi
dedi
ntot
wopar
tsby
aspeci
alperfor
atedpl
ateinasanit
arydesi
gn.
•Ai
risbl
owni ntol
owerpar
twhichiscal
l
edPlenum Chamberandt
he
powderi
sfl
uidizedi
ntheupperVi
broShi
fter
.
•I
tcompr
isesof3r
egi
ons.
I
nit
ial
heat
ingr
egi
on:
Powderheat
edt
o65⁰
C
 Dehumi
dif
iedr
egi
on:
Cool
edt
o55-
58⁰
C
 Fi
nal
Cool
i
ngRegi
on:
Cool
edt
o29-
30⁰
C
•Thevi
brat
ormountedonthelowersidepr
oducest
hev
ibr
ati
on.The
Vi
broFl
uidi
zeroper
atesatavacuum of12mm WC.
•Thef
inesf
rom cy
clonesandVi
broFl
uidi
zerpassest
hroughr
oot
s
bl
owerandfi
neret
urnnozzl
ebacktodr
y i
ngchamber.
Accessor
ies:
5.
1.Vi
broFl
uidi
zerAi
rfi
l
ter
5.
2.Vi
broFl
uidi
zerSuppl
yai
rfan
51
5.
3.Vi
broFl
uidi
zerAi
rdehumi
dif
ier
•Iti
saf i
nnedt ubeheatexchangercomprisedof2sections.Inf
ir
st
secti
onairiscooledupto8⁰ Cbychill
edwat erpassi
ngthroughfi
nned
tubes.I
nt hesecondsecti
onairisreheat
edupt o15⁰Cbycondensate
passingthroughtubes.
5.
4.Vi
broFl
uidi
zerSt
eam Ai
rheat
er
•Iti
safi
nnedtubeheatexchangerf
orheati
ngofsuppl
yheat
ingof
suppl
yai
rduri
ngproducti
onofLecit
hinat
edpowder.
6.
Div
ert
erVal
ve:
•Itisf
ordiv
ert
ingt
hepowderei
thertotheSpr
ayDryerort
othe
di
schargeendofVibr
oFl
uidi
zer
.Thisvalv
eisoper
atedwit
hapneumat
ic
actuat
or.
7.
Blowt
hroughVal
ve(
BTV)
:
•I
tisf
orf
eedi
ngpowdert
othef
inesr
etur
nduct
.
8.
Gener
ati
onofHotAi
r:
•Airfr
om surroundi
ngisusedastheheati
ngmedium todr
ythemilk.For
thi
sairisheatedtoahightemper
atur
e(10-200⁰
C0usingnatur
algasin
fi
retubeairheater
s.I
tcontai
nsPri
maril
yCOasheatingagent.
•IntheShell&Tubeheatexchangert
hefluegasinthetubesandai
ron
shel
l si
de.Ther
eshouldnotbeanyleakagebetweenthetwoasCOi s
toxi
c.

•Athi
ghtemperat
ures,
Coget
sconvert
edtoCO2,whi
chgi
vesawayheat
tot
heair
.Theventfl
uegasi
ssentbacktoat
mospher
e.
9.
ExhaustFan:
•I
tcarri
esairf
rom t
hedr
yingchambert
hroughmai
ncy
clonest
o
exhausthood.
10.
Airheat
er:
•Make:
DERTLI
,gasbur
ner
•No:
3

52
•Met
hodofheat
ingai
r:I
ndi
rectheatexchanger
•Temper
atur
eoff
urnace:
530-
540⁰
C
•Hotai
rtemper
atur
eatout
letoff
urnace:
230-
240⁰
C
11.
Stor
aget
ankf
orcondensedmi
lk:
•Make:
L&T,
Mumbai
•Capaci
ty:
10000l
•No:
2
12.PowderSi
los:
•Capaci
ty:
6T
•No:
1
PACKAGI
NGSECTI
ON:
 Manual
baggi
ng
 Aut
omat
icpackagi
ng
Manualbaggi
ng:
 Powderf
rom powdersi
ft
eri
ssendtobaggi
ngli
ne.Herei
tis
baggedmanual
lyandbagsar
esenttocol
dstor
ageviaconvey
ors.
Aut
omat
icpackagi
ng:
 Forautomati
cpackaging,powderist
akenintoPowderSilos.Each
si
lohas32000Kgcapaci ty.Wi
ththehelpofdensephasev essel
,
powderisconveyedthroughvi
brat
ingtubes,
rotar
yv al
veandr ot
ary
shi
fterandi
stakenintopackagi
ngmachi nehoppers.
 Form,Fi
l
l andSealmachinepacks50gm pouchesofAmulyaand1
Kgand½Kgpouchesf orAmul spr
ay.Manualbaggi
ngcanalsobe
donehere.Powderi
spackedi nt
obags&pouchesandt hensentt
o
col
dstoragebyconveyor.
ROVEMAPACKAGI
NGMACHI
NE:
I
tisaFor
m,Fi
l
landSeal
packagi
ngmachi
ne.
 Powdercomesi
naugerf
rom t
hehoppert
hrought
hev
ibr
ati
ngt
ube.

53
 Onthetopofauger,
onehighl
evelsensori
slocat
edwhichsense
qual
it
yofpowder.Thenpowderenter
sorstoppedaccor
dingl
yin
auger
.
 Ni
tr
ogenpi
pei
sal
sofit
tedinauger
.Powderf
lowsdownbyt
hebel
t.
Ni
tr
ogeni
s98%fi
l
ledIpack.
 Thepouchesfal
li
ntheconvey
orbeltandr
eachforconti
nuous
weighi
ngwhichi
spreset
,andther
eisonesensorl
ocatedwhich
sensesthewei
ght.
Ift
hewei ghti
sbel
owt ot
hepr esetwei
ght
,thenpouchi
spushed
outsideandother
wisepouchesmov etoCasepackert
hrought
he
conveyorbelt
.
 Therearet hr
eesensorsint hepouchf il
m side.Onei sforsensing
avail
abil
it
yoff i
l
m( i
ffi
lmisunav ail
able,machi newillbestopped).
Secondsensor ,sensesblackr ectangle(Ey emar k)ofthefil
m by
whichiscodingi spossi
ble( date,priceetc.).Thi
rdsensor
(photocel
l)al
sosensest hebl ackr ectangle,butitworksforcutti
ng
thepouches.
 Anothersensori
slocatedi
nthemachi
newhi
chsensethedoor
si
tuati
on(ifdoorwi
llbeopen,t
henmachi
newi
ll
bestopped)
.
ROVEMAPACKI
NGMACHI
NE(
500gm)
 NO:
2
 MAKE:
ROVEMA
 CAPACI
TY:
60POUCH/
Min(
500gm)
ROVEMAPACKI
NGMACHI
NE(
1kg)
 NO:
1
 Make:
Rov
ema
 Capaci
ty:
32pouch/mi
n.
ROVEMAPACKI
NGMACHI
NE(
27gm)
 NO:
1
 CAPACI
TY:
70POUCH/
Min

54
HASSI
APACKI
NGMACHI
NE(
13.
5gm)
 NO:
1
 CAPACI
TY:
80POUCH/
Min/
Head

Wei
ghtst
andar
dsf
ormi
lkpowdersect
ion:-

 Packagi
ngmat
eri
al:
pol
yest
er,
met
apol
yest
er,
ext
rudedLDPE.
 Thi
cknessofpackagi
ngmat
eri
al:

55
  1kg–100mi
crons.
 500gm –75mi
crons.
 Densi
ty–shoul
dbe0.
400gm/
cm3
SPECI
FICATI
ONOFAMULSPRAY:

CI
P(CLEANI
NGI
NPLACE)
:
Nor
mal
CIP-Af
terev
ery24hour
sofcont
inuousoper
ati
on.
Sof
twat
erf
lushi
ngi
sdoneatambi
entt
emper
atur
efor30-
35mi
n.
 Chemi
cal
cleani
ngwi
thLy
e(1.
5%)at60⁰
Cfor70mi
n.
 Hotwat
erf
lushi
ngat60⁰
Cfor35-
40mi
n.
 ExtendedCIPaft
ermaxi mum fournormalCIPcycl
es,
chemical
cl
eaningwithaci
d( 1.
5%)at60⁰Cf or40min.Fol
l
owedbyhotwat er
fl
ushingat60⁰Cfor35-40min.inaddit
iont
oabov e3steps
CI
Ptank-CI
Pti
meschedul
e:
 CIPisdoneinevery30-
40day si
ndry
ingplant.Thedeterminati
on
ofti
meofCI Pisactual
l
ydecidedbymeasuringtheinsol
ubili
ty
i
ndexofthedried,r
econst
it
utedpowder
.Ifitexceeds0.5,t
het i
me
ofCIPhasreached.

56
57
 F-
60POWDERPLANT
F-60Powderplantisoneoftheoldestplantssit
uatedinAmul-2.As
namesuggestF-meansFERRUM packagi ngmachi neand60-MTi s
capacityoft
heplant.Thi
sisathr
ee-stagedr yi
ngplantwithacapacit
yof
60MTperday .Dryi
ngsequenceinthepl antisSpraydryi
ng.St
atic
flui
dizedbeddr
yingandVi br
ofl
uidi
zedbeddr yi
ngwithco-cur
rentmode.
Itisusedformanufactur
ingofSMP( mai nl
y),WMPandAmul Spray.
F-
60Condensi
ngplanti
sa5-ef
fectpl
antwi
thacapaci
tyof14000l
tr
.of
waterev
apor
ati
onperhour
.
 Make:
APVAnhy
dro,
Denmar
k
 Modi
fi
edby
:SSP,
Far
idabad
 Ty
pe:
Fal
l
ingf
il
mver
ti
cal
tubet
ype
 No.ofPr
eheat
ers:
7
 No.OfCal
endr
ia:
7
 No.OfVapourSepar
ator
s:5
TECHNI
CALDETAI
LS:
 St
eam pr
essur
e–10Kg/
cm2
 Mi
l
kInl
etTemper
atur
e–5-
7⁰C
 LowHeatPast
eur
izat
ion-85⁰
C
 Hi
ghHeatPast
eur
izat
ion-92⁰
C
 HotWel
lTemper
atur
e-60⁰
C
EFFECT TEMPERATURE(
⁰C) VACUUM (
mm ofHg)

Fi
rst 82-
88 540

Second 78-
82 600

Thi
rd 68-
72 670
58
 Four
th 60-
64 700

Fi
ft
h 51-
56 760

•Ther
mocompr
essorst
eam pr
essur
e–8Kg/
cm2
•BaumeReadi
ng–20-
21⁰(
40%TS)
•Condensedmi
l
kout
lett
emper
atur
e-52⁰
C
•Bar
omet
ri
cCondenser
:Inl
etWat
erTemper
atur
e:35-
38⁰
C
•Out
letWat
erTemper
atur
e:40-
48⁰
C
DRYI
NGPLANTDETAI
LS:
•Make:
Nir
oat
omi
zer
,Copenhagen,
Denmar
k
•I
nst
all
edcapaci
ty:
60TPD
•Oper
ati
ngcapaci
ty:
40-
45TPD
•No.ofst
ages:
3
•No.ofcy
clones:
5
•Chamberdi
amet
er(
out
er)
:8.
8mm
•Chambercy
li
ndr
ical
hei
ght
:2.
5mm
•Chamberconi
cal
hei
ght
:7.
5mm
•Di
amet
erofconi
cal
bed:
1.1mm
•At
omi
zerMake:
Nir
oat
omi
zer
,Denmar
k
•Ty
peofAt
omi
zer
:F-
60Rot
ary
,cent
ri
fugal
spi
nni
ngdi
sc(
dia-
21cm)
•SpeedofAt
omi
zer
:15000-
24000r
pm
•Ty
peoff
eedpump:
Cent
ri
fugal
pump

59
•Feedar
rangement
:Si
ngl
eanddoubl
etubewi
thdi
str
ibut
ion
•Ai
rheat
er:
Shel
l&Tubedi
rectgasf
ir
edsi
rheat
er.

TECHNI
CALPARAMETERS:

60
PROCESSFLOW CHART(
F-60)
:

61
62
63
EQUI
PMENTS
1.Exhaustf
anmot
or
Capaci
ty:
78000m3/
hr
RPM:
1460
2.
Powderconv
eyi
ngf
an
RPM:
2390
3.Ai
rsuppl
yfan
 Capaci
ty:
28000m3/
hr
 RPM:
1410r
pm
4.Vi
brat
orsandel
ect
ri
cal
hammer
s&Acoust
icSoni
phoneSy
stem
5.Ai
rcool
i
ngsy
stem wi
thf
anandchi
l
ledwat
er.
6.Damperandhotai
rinl
etduct
.
7.Ai
rheat
er
 No:
3
 Met
hodofheat
ingai
r:I
ndi
rectheatexchanger
 Temper
atur
eoff
urnace:
530-
540⁰
C
 Hotai
rtemper
atur
eatout
letoff
urnace:
230-
240⁰
C
8.St
oraget
ankf
orcondensedmi
l
k
 Capaci
ty:
10000l
 No.
:2
9.Powdersi
l
os
 Capaci
ty:
6T
 No:
11
DRYI
NGPLANTCLEANI
NGANDMAI
NTENANCE
1.
F-60at
omi
zercanr
unsaf
elyf
or72hour
s,undernor
mal
runni
ng

64
condit
ions.Att
het
imeofat
omi
zerchangesf
oll
owi
ngj
obsar
etobe
carr
iedout.
 Changi
ngofsuct
ionai
rfi
l
ter(
wool
l
enandmusl
i
n)
 At
omi
zerf
eedl
i
nechemi
cal
cleani
ng.
 Conv
eyi
ngl
i
necl
eani
ng.
 Checki
ngoft
hef
anbel
ts,
bear
ingandel
ect
ri
cal
inst
all
ati
on.
2.Completedr
yingsy
stem i
stobedr
ycleanedev
eryaf
ter15day
sand
wetcl
eaningtobedoneonceinamonth.
3.Concentr
atechi
ll
erandpreheater
smustbechemi call
ycl
eanedatthe
ti
meofCI Pandthroughchemicalcl
eani
ngofcondensingpl
antwit
h
soda-
acid.Recommendedst r
engt
his0.8to1%for30mi n.Sani
ti
zat
ion
tobedonebyPol y
son-Dsoluti
on.
4.F-
60atomizercanrunsaf
elyf
or48-
54hoursundernor
malr
unning
condi
ti
ons.I
tiscooledandl
ubri
cat
edcont
inuousl
ywhil
ewor
king.
POWDERPACKI
NGSYSTEM:
ALBROFI
LLI
NGMACHI
NE:
 Thecontai
ner
stobef
il
ledar
efedal
ongt
heconv
eyort
osel
ectand
feedwheel
s.
 Thestarwheelspl
acethecont
aineronthel
if
tingtabl
es.Asthe
machinerot
ates,t
hetabl
esarel
ift
edbyairpressurebr
ingi
ngthe
cont
aineruptothenozzl
e(12nozzles)
 Thefil
l
eroperat
esonv acuum fi
l
li
ngprinci
ples.Whentheti
nsare
l
ift
edandcomei ncontactwit
hagasketoft hefil
l
ingnozzl
e,t
he
vacuum i
screat
edinsi
det hecontai
nerandpowderi sdr
awnfrom
thehopperi
ntothecontai
ner.
 Theproductcanbefedtoav ar
iableweightcontrol
ledbyadegr ee
ofvacuum appl
iedtothefi
ll
ingnozzleandt helengthoft henozz l
e
ri
ng.Thedegreeofvacuum isadjustedbyv acuum regulati
ngv alv
e.
I
fthelengt
hoft henozzl
eringismor eorv acuum ismor e,the
morepowderwi ll
packinthecont ai
nerandv i
cev ersa.
 Thepr
oxi
mit
ySwi
tchat
tachedt
otheconv
eyorbywhi
chempt
y

65
 cont
ainer
sisint
roducedtot
hefil
li
ngmachi
ne.I
fti
nsar
enot
comingtothemachine,i
twi
llst
opaut
omati
call
y.
 Afterfi
ll
i
ngiscompleted,f
il
ledti
nscomedownal ongwiththe
l
ifti
ngtableandthetabl
etouchesthesaf
etyswit
ch.Ifduetosome
problem,fi
ll
edti
nsarenotcomingdownal ongwit
hthelif
ti
ngtabl
e,
thenalsothemachinewill
stopautomati
call
y.
 Afterfil
l
ing, f
il
ledti
nspasst hr
ought hevi
brat
orswereshaki
ngof
thetinstakepl ace,t
oadjusttheleveloft
hepowderinsi
dethe
container.Thewei ghtofthecontai
nerischeckedmanuall
yand
ti
nsar eintroducedintotheFerrum Packi
ngMachine.
FERRUI
M PACKI
NGMACHI
NE:
I
tisf
ull
yaut
omat
icNi
tr
ogengaspacki
ngmachi
ne.
 Thetinsaredel
iveredatregulari
nter
v al
sfr
om theweighing
machineviaconvey orbel
ttoFerrum.Thein-f
eedstartakesthet
in
andsetthem atproperdistanceapartandproxi
mit
yswi tch
rel
easesalidtoeacht in.
 Theli
dtakenfrom theli
dmagazineisfedtot
het i
nviaembossing
devi
ce.Befor
eliddeli
very,
apier
cingdevi
cemakesai rchannel
int
o
thecont
ents(onlyin1KgFerrum).Theli
dissl
ightl
ycli
nkedonto
theti
natthecli
ngingstati
on.
 Aftertheti
nlidcheckpoint
, t
hetinisf
edtothev acuum rotorwi
th
thehelpofst ar
.Theli
ft
ingplateli
ft
sthecanint
ooneoft he10
vacuum chamber swheretinsareevacuat
edandf il
ledwithgas.
Afterwardsthetini
sautomat i
cal
lyseal
edinthesamechamber
andr el
easedbyt heout
letstarontotheconveyorbelt.
 Onl
yli
dfeedi
ngi
nthel
i
dmagazi
nei
stobedonemanual
l
y.
TECHNI
CALDETAI
LS:

66
PACKI
NG:
Amul
Spr
ay: ½and1KgRef
il
l
½and1KgTi
n
WMP: ½KgRef
il
l
½KgTi
n
10KgTi
n(Def
enceonl
y)
20KgBags
SMP: 20KgBags
Amul
ya: 50gr
efi
l
l
½KgRef
il
l
½KgTi
n
FLOW CHARTFORTI
NPACKI
NG

67
EQUI
PMENTS:
1.Ti
nSt
eri
l
izer
:
2.Fi
l
li
ngmachi
ne:
 Ty
pe:
Aut
omat
icVacuum Fi
l
li
ng
 Capaci
ty:
Adj
ust
abl
eupt
o180t
ins/
min.
(
Oper
ati
ngat120t
ins/
min.or60t
ins/
min.
)
3.
Doubl
eseamer
:
 Make:
Fer
rum
 Ty
pe:
Aut
omat
icGasFl
ushi
ng&Seami
ng
 ModeofOper
ati
on:
Part
ial
Seami
ngVacuum Tr
eat
ment
,Gas
Fl
ushi
ng&Complet
eSeaming
 Capaci
ty:
80Ti
ns/
min.(
Oper
ati
ngat60Ti
ns/
min.
)
68
  Mot
or:
7.5HPwi
thv
ari
abl
epul
l
eyf
orspeedadj
ust
ment
4.Vacuum pump:
FORALBRO
 Make:
Riet
schi
e
 Ty
pe:
Rot
aryv
anet
ypedr
yvacuum pump
FORFERRUM
 Make:
BuschVacuum
 Ty
pe:
Rot
aryv
anet
ypedr
yvacuum pump
 Capaci
ty:
400m3/
hr
STANDBY
 Make:
Ley
bond
 Ty
pe:
Reci
procat
ingpi
ston

69
70
 BUTTER

Pr
oductName Amul
But
ter

Descr
ipt
ion Amul
But
ter(
Madeofpur
emi
l
kFAT)

Packi
ng 100g,500g,
50g,
20g,
10gBl
i
ster
,15kgwhi
te
butt
er

PRODUCTSPECI
FICATI
ONS
Composi
ti
on Mi
l
kFAT,
Min:
80%
Moi
stur
eMi
x:16%
Sal
t,Max:
3%
Cur
d,Max:
1%

Nutr
it
ional
I
nfor
mat i
on

71
 Bestbefor
e12monthsfr
om packagi
ngwhenst
ored
Refr
iger
atedat4°
Corbel
ow
Shel
fli
fe

Stor
age At4°
Corbel
ow
condi
ti
ons

TheButtersect
ioni
slocatedi
nAmul-3whichmanufact
uresTabl
eButt
er,
WhiteButter
.Thesect
ioniscompl
etel
ycomputer
izedandisequi
pped
wit
hmostmoder ni
mportedequi
pments.
EQUI
PMENT:-

MANUFACTURI
NGPROCESS:-
•Thecr eam f
ormanuf acturi
ngBut t
erisrecei
vi
ngf r
om Amul -
3andAmul
-2processeswhilestandardizat
ionofmilk.Themilkfatwil
lbe
separatedatabove60˚ C;thecentr
ifugal
cream separat
orsinli
newi
th
milkpasteur
izerseparatethisascream.

72
•Thecr
eam t
hussepar
atedi
spasteur
izedandt
henpumpedbyposi
ti
ve
di
spl
acementpumptotheCr
eam Buff
erTankandthent
otheCr
eam Si
lo.
•Af t
erageingat8˚Cfor24hourscream ispumpedtoCr eam Chill
i
ng
Uniti
nt hebutt
ersect
ion.Therethetemperat
ureofcream isadjust
edto
therequir
edchurni
ngtemper at
ure(9-11˚
C)ofcont
inuousbut t
ermaking
machine
Wor
kingpr
inci
pleoft
heCBMM:
Pr
inci
pleTheor
y:Chur
ningorFr
othi
ng
 Pr
ocess:
Fri
tzPr
ocess
Inthi
smethod,cream chur
nsint
obutt
ergranul
esi
n1-2seconds,
churni
ngcyl
inderrot
atesat600–800rpm.Twomajorworki
ng
secti
onsar
epr ovi
ded,oneiswetandanot
heronei
sdry)
.
I
nwetworki
ngsect
ionwashingandcool
i
ngofbut
tergr
anul
esand
r
emoval
ofbutt
ermi
lktakesplace.
Indryworki
ngsecti
on,but
teri
sfurt
herworkedandreducesthe
moistur
econtentt
o13t o14%.Furt
herbut
tertr
avel
stodosing
sect
ion,whereadj
ustmentofsal
tandmoistur
ewill
behappen.
 Att
heendvacuum chamberi
spr
ovi
dedt
oreducet
heai
rcont
ent
oft
hebut
ter
.

Maj
orsect
ionoft
heCBMM

73
1.
Chur
ningsect
ion:
Thissect i
onhasahor izontalcyli
ndri
calwiththecoolingjacketand
beaterforchur ningofcr eam.Thechur ni
ngpr ocesslastsfor2t o3sec
duri
ngwhi chtheoi linwat eremul si
onoft hecream isbrokenintowat er
i
noi lemul si
onex i
stentinbut t
er.Thewat ercontentofthegr anulesand
thefatlossi nthebut termi l
kdependl ar
gelyonbeat erspeedandt he
temperat ureofcr eam att hetimeofchur ning.Thebeaterisdrivenby
powert ransmittedf rom amot orthr
oughaV- bel
t.
2.
Separ
ati
ngsect
ion:
Thissecti
onhashor i
zontal
l
yposi ti
onedcy l
inderrestingonrol
ler
sand
theothersupportedbyabear ing.Thecylinderisfit
tedwi t
hpaddles,
whichstressesthegranulessuspendedi nt hebuttermi l
ktoli
ber
ated
mostoft heirbut
termil
kcontent.Adr ai
ningsect i
oni sprovi
dedwhere
thegranulesareseparatedfrom thebutt
er milkandar ethenpassedint
o
theworkingsection.Thespeedofpaddl esi s34r pm
.
3.Kneadi
ngsect
ion:
Thekneaderconsi stsoftocontrarotati
ngaugers40to60r pm thatare
i
nmeshwi t
honeanot her
.Thef r
ontscr ewendsinperforat
eddiscsthere
are3agitat
ingbl endperscrewoper ati
ngsequenti
all
ybetweenthe
perf
orateddiscs.Spacerringsensurethedist
ancebet weenthe
perf
orateddiscs.Inthekneaderthegearunitdri
vingthescrewisdriven
byav -
beltt
hr oughamot or.
All
partsofbeat
er,
drai
ningunit,
washi
nguni
tandkneaderar
emadeup
ofhighal
loychr
omium nickel
steel
.
4.Sal
tdosi
nguni
t:
Salt
ingforadj
ustingthewatercont
entorforwatercontentorf
orsal
ti
ng
thebutt
er,waterorsaltsol
uti
oncanbeaddedt hroughanopening
i
mmedi atel
yinfrontoftheperf
orat
edplat
es.
Salti
ngiscarri
edoutbyinjecti
onof50/50sal t/waterslurr
yintobut t
er
earl
yinworkingstagetoavoidcolormottl
ei nthebutterami crofined
sal
tlessthan50mi cr
onisused.Thesal tslurr
yisloosel yf
il
tered
thr
oughwi r
egauz ebefor
einjecti
on.Theslurryismet eredtothebut t
er
makerbyposi t
ivedi
spl
acementpumps.Thedosi ngsy stem mayal sobe

74
usedforaddi
ngwat
ert
ounsal
tedorsl
i
ght
lysal
tedbut
tert
omaxi
mize
yi
eld.

PROCEDUREFORCOLOURANDSALTADDI
TION:

75
PACKAGI
NGMACHI
NESPECI
FICATI
ONS:-
1.
SIGMachi
ne
 500gm packi
ng:
-Capaci
ty-150pack/
min,
machi
nepacked60-
62
pack/
min.
2.
BENHI
LCasepackermachi
ne
 100gm packi
ng:
-capaci
ty–150pack/
min,
machi
nepacked
80pack/
min.

3.
HASSI
ABut
terTubFi
l
li
ngMachi
ne(
Bli
sterpack)

76
  10gm packi
ng:
-capaci
ty–525pack/
minut
e.
(
Mat
eri
alofpack-PVC)
4.
Tinpacki
ngmachi
ne
 400gm packi
ng:
-capaci
ty36pack/
minut
e.
Packi
ngmat
eri
alused:
 Par
chmentpaper
-useddi
rect
lyf
orwr
appi
ng.
 Car
tonusedf
orsecondar
ypacki
ng.
 Si
ngl
elami
nat
edf
oil
isusedf
orI
NDI
ANLocal
Mar
ket
.
 Doubl
elami
nat
edi
susedf
orEXPORT.
 Ti
nusedf
or400gm Ar
myPack.
 Car
dBoar
dBox-Usedf
ort
ert
iar
ypacki
ng.
 Pl
ast
icBox-Usedf
orSchool
Pack.
CLEANI
NGANDSANI
TIZATI
ON:-
 CI
Pisdoneaf
terev
ery24hr
s(usual
l
yint
hir
dshi
ft
).
 Cl
eani
ngofal
lthebutterhandl
i
ngequipmenti
stobedonel
ocal
l
y
ai
dedbyt
hebuttersecti
oninautomat
ionsyst
em.
 Bef orebeginningcl
eani
ngt hebut teraut
omat i
onsystem ensures
thatpr oducti
onisoverfatrecov er
yisempt yandrequestbutton
forCI Pispressedonallthewr appingmachi nepanel
s.The
oper atoratthewrappi
ngmachi neshallpressthepushbuttons
aftermaki ngthenecessaryswi ngbendconnect i
on.
 Thecleani
ngofthevar
iousbutt
erequi
pmentwi
l
lbegi
nwi t
h
recov
eryofbut
terfr
om theequi
pmentandfr
om t
hepi
pings.
 Cream fr
om thechur ni
ngcy l
i
nderandbutt
erfr
om thewor king
secti
onoftheCBMM i srecover
edbymelti
ngitwi
thhotwat erat
900C.thewaterisheat edinaPHEbysteam.Themi xtur
eofhot
waterandmol t
enf atispumpedt ot
herecover
edfattankf or
stor
ageuntil
furtheruse.
 Thebut
terr
emai
ningI
nthepi
pel
i
nesbet
weenbut
terpumpsand

77
 t
hewrappingmachi
neisrecoveredbypushi
ngitwithaplast
icball
“
PIG”for
cedbycompressedair.Thi
sbutt
eri
scollectedmanuall
y
t
heotherendoft
hepipel
ineneartheval
ueclust
er.
 But
terfr
om hopper
soft
hev
ari
ouswr
appi
ngmachi
nesi
smanual
l
y
col
l
ected.
 Butterint heform ofdef ormedpackagesismol teninaspecial
coldfatr ecover ytank.I
nthistankdef
ormedbut terpackagesar e
heldinaper f
or atedtubeandloweredintothehotwat erbath.After
thebut terhasmel tedouttheemptypackagingmat eri
alis
remov edandt ubesar emanual l
ycl
eanedforfurtherused.Thehot
waterf ormel t
ingt hebutteri
sgeneratedbyast eam watermi xi
ng
battery.Themi xtureofwaterandmoltenbutterispumpedt ot he
fatrecov eryt
ankf orfur
therused.
 Af
terrecover
yoff atbyv
ari
ousmeansasexpl
ainedabov
e,ahot
watercycl
eisrepeatedt
o900C.
 St
eri
li
zat
ionoftheequi
pmentwi
thhotwat
eraddedwi
thspeci
al
Ant
i-
sti
ckingchemi
cal(
Div
ochur
n)
 Mel
ti
ngofresi
dualbutt
erisdonewit
hhotwaterf
or25mi nand
mol
tenbut
teri
sdrainedint
oFatRecover
yTanDegreasi
ngisdone
f
or10min
 Di
vochur
nChemi
cal
(foodgr
adechemi
cal
):-
7Kgi
n450Lwat
er–f
orbut
termaki
ngmachi
ne&bl
endereach.
11Kgi
n450Lwat
er–f
orbut
tersi
l
o.
 Cl
eani
ngwi
thdet
ergentsol
uti
ondonef
or25mi
n.
 Ri
nsi
ng
2-
2.5ml
Hygi
sof
tin30Lwat
er.Ri
nsi
ngi
sdonef
or10mi
n.

78
PROCESSFLOWCHART:-

79
AMUL2RAW MI
LKRECEPTI
ONDOCK

80
Mi
lkpr
ocessi
ngpl
ant
 Rawmil
kist akenf
rom therawmilksi
los,
thenthemil
kis
st
andar
dizedandpasteuri
zedaccordi
ngtorequi
rement
.
I
fther
eisrequi
rementofhomogeni
zedmi
l
kthent
hemi
l
kis
homogeni
zedinhomogenizer
.
 From t
heremaini
ngmilk;cr
eam i
ssepar at
edbycream separ
ator
andstoredi
ntocr
eam sil
os.Thecream isusedf
orbutt
ermaki ng,
gheemakingandstandar
dizat
ionofmilk.
 Theskim mi l
kisalsosepar
atedandcoll
ectedinski
m mil
ksi
los.
Fort
his,thebuttermil
k(byproductofbut
ter)i
scoll
ect
edinbut
ter
mil
ksilosfrom thebutt
ersecti
on.
 Cur
dismadef
rom t
easpeci
almi
l
k,ski
m mi
l
k,ski
mmedmi
l
k

81
 powderbyaddi
ngcul
tur
e.
Mi
lkcol
l
ect
ionbycansatRMRD:
 Unl
oadi
ngofcansf
rom t
anker
s:
Iti
sdoneasFIFO(f
ir
stinfi
rstout
)method&cansar
ear
ranged
accor
dingt
othesociet
iesbythewor
kermanual
ly
.
 Loadi
ngofcans:
Cansareplacedatconv
eyormanual
l
y,mov
ingf
orwar
dtot
hewei
ghi
ng
bal
ancetank.
 Openi
ngofcans:
Li
dsofcansar
eopenmanual
l
y.
 Gr
adi
ng:
Fi
rstmi
lki
svigor
ouslyagi
tat
edbypl
ungerwhi
chmadewithstai
nless
st
eel&physi
cali
nspect
ionandor
ganol
epti
cgr
adi
ngareperf
ormedi n
mil
k.
I
f,i
ncaseofsourmi
l
ktheni
twasgener
all
yusedf
orgheemaki
ng.
 Wei
ghi
ng:
Weighi
ngi
sgener
all
ydonebydumpedcansintoweighingbalance
t
hroughanyl
onfi
l
terandt
otal
weightofi
trecor
dedautomaticall
y.
 Sampl
i
ng:
Thesampleforeachsociet
yist akenfrom t
heweighingbalancetank
i
ntoa100ml samplebott
leandmar kedfori
ndi
vidual
ly.I
twast aken
separ
atel
yfrom cowandbuf f
alo.Thef at
,SNF&pr ot
ein,
lactose,TS
werecheckedautomat
icall
ybyt hemi l
koscan(milkanal
yser).
 Dumpi
ng:
Aft
erwei
ghi
ng,mil
kiscoll
ectedi
ntodumpt ank,
from wher
eiti
s
pumpedt
hroughcent
ri
fugalpumptoprocessi
ngsecti
on.
 Washi
ngofcans:
Cansandl
idsbothar
ewashedbystrai
ghtthr
oughcanwasheri
ncl
udi
ng
4sect
iont
hatishotwat
er-l
ye-aci
d-steam.

82
  Rel
oadi
ngofcans
Washedcansanddr i
edcansarerel
oadedt
othet
rucksaccor
dingt
othe
sequenceofsoci
eti
esint
herouti
ne.

Cl
eani
ngofAMUL–2Pr
ocess

83
 MI
LKPOUCHPACKAGI
NGSECTI
ON
I
NTRODUCTI
ON:-
 Pouchpacki
ngsecti
onsituat
edi
nAmul-
2deal
swithpacki
ngof
MarketMil
k,But
ter
milkandMast
iDahi
int
opouches.
 Therear ethr
eepackingmachines.Eachmachi neconsi
stsoft
wo
i
denticalheadsforpacking;
eachheaddr awsheatsealabl
e
poly
ethy l
enesheetfrom asepar
aterollandisfedwit
hmi l
ktobe
packedf rom t
heoverheadtankbygrav i
ty.Outoft
hem two
machi nesareforpacki
ngmi l
kandot heroneforButt
ermil
kand
Masti Dahi.
VARI
ANTS:-
Fi
vet
ypesofmi
l
kar
epackedi
nthi
ssect
ion.
 St
andar
dizedPast
eur
izedmi
l
k(Amul
Shakt
i)200ml
,
500ml
Fat
=min4.
5%SNF=mi n8.5%
 Pasteuri
zedHomogenizedSt
andar
dizedmi
l
k(AmulT-
special
)500ml
,1l
i
terFat=min4.
5%SNF=mi n8.
5%
 Ful
lcr
eam mi
l
k(Amul
Gol
d)500ml
,6l
i
terFat=mi
n6%SNF=mi
n9%
 Tonnedmi
l
k(Amul
Taaz
a)300ml
,1l
i
terFat=mi
n3%SNF=mi
n
8.
5%
 Doubl
etonnedMi
l
k
Fat=mi
n1.
5%SNF=mi
n9%
 But
termi
l
kisal
sopackedi
nthi
ssect
ion(
500ml
)
Fat=mi
n1%SNF=mi
n6-
7%
Aci
dit
y=mi
n0.
2-0.
3%
EQUI
PMENTS:
-
1.
Doubl
eHeadPacki
ngMachi
ne
1.
1 Samar
panPacki
ngMachi
ne
Capaci
ty:

84
 (
1)75pouches/
min/
head(
500ml
)
(
2).
40pouches/
min/
head(
1lt
r)
Number
:4
1.
2 DeccanPacki
ngMachi
ne
Capaci
ty:
80pouches/
min/
head
Number
:1
1.
3 Ni
chr
omePacki
ngMachi
ne
Capaci
ty:
60cups/
min/
head
Number
:1
1.
4 Hor
izont
alMi
l
kSt
orageTank
Capaci
ty:
15000l
i
t.
Number
:3
Number
:2(
capaci
ty-
20,
000l
i
t)
1.
5 But
termi
l
kst
oraget
ank
Capaci
ty:
10,
000l
i
t.
2.
Crat
eWasher
 Ty
pe:
str
aightt
hrough
 Capaci
ty:
18cr
ates/mi
n
3.
Bal
ancet
ank
 Capaci
ty:
70l
i
t.
 Number
:1
4.
CIPTANK
 Capaci
ty:
2500l
i
t.
 Number
:1
CRATEWASHI
NGSECTI
ON:
 Thecr
atesr
etur
nedar
ewashedi
nacr
atewasherj
ustbel
owt
he

85
 PouchPacki
ngsect
ion.
I
tisaSt
rai
ghtTr
oughCr
ateWasherhav
ingt
wosect
ions.
1) Hotwat
erRi
nse(
5Kg/
cm2)
2) Col
dwat
erRi
nse(
4Kg/
cm2)
 Cr
atesaf
terwashi
ngar
econv
eyedt
othePouchFi
l
li
ngsect
ion
SPECI
FICATI
ONOFMI
LKPOUCH:
•Mat
eri
al:
Coext
rudedLDPE/
LLDPEQual
i
ty:
•Nat
ural
mil
kycol
our
ed,
transpar
ent
•Fi
l
m Thi
ckness:
50μm
•St
rengt
hofFi
l
m:Shoul
dnotst
ret
cheasi
l
yundernor
mal
condi
ti
on
•Fil
m shouldbestor
edatroom t
emperatur
e,RHbel
ow60%andaway
fr
om sunli
ght.I
tshoul
dbeusedinFi
rstinFir
stOr
der(FI
FO)andshoul
d
avoi
dwat ercont
aminat
ion
FLOW CHARTFORMI
LKPOUCHPACKAGI
NG:

OPERATI
ON:
 Thewhol
esy
stem i
saut
omat
ic.Themi
l
kforpacki
ngf
ir
stcomes

86
 toHori
zont
alMilkSt
orageTankandt
hent
oOv
erheadt
ankof
packi
ngmachine.
 Thepackagingmateri
almovescont i
nuouslyi
nastrip.Thefi
lm
getsfol
dedlongi
tudi
nall
y.Fi
rst
ly,ver
ti
calseal
ingoccurs,as
conti
nuouscyli
ndermovesdownwar dstransver
seheatsealsare
madebyj awswhichhavetheeffectofcl
osingthebottom of
pouch,sothatmeasuredvol
umeofmi l
kisfil
l
edintothespace
abovetheseal.
 Thepouchesaf terpackingarefil
l
edincr at
es(24packet
sper
crate)
.Thecratesarepl acedinacontinuousl
ymov i
ngconveyor
whichdirect
lygoestot hecoldroom throughahatchdoor.
Sensorsareprov i
dedalongt hepathoftheconvey
orstoavoidti
me
delay.
 Thecoldroom hasanai
rlocksystem wit
hr efr
iger
antfl
owing
throughi
t.I
tensur
esthet
emper at
ureofst oragealwaysbel
ow4⁰
C.
From her
ethepouchesar
edirectl
ydispatchedt omarket
.
 Duri
ngcontinuouspackingoper
ati
onsweightchecki
ng,seal
ing
i
ntegri
ty,
print
ingdetai
l
sandv ar
iouspackagi
ngtestsl
ikeDroptest
,
Squeezetestareconducted.
ONLI
NEQUALI
TYASSURANCE-
1)
Wei
ghtchecki
ng
2)
Pri
nti
ng
3)
Dat
echeck
4)
Dropt
est
5)
Seal
check
 Speci
fi
cat
ionofmachi
ne
1)
Temper
atur
eofhor
izont
alseal
i
ng-85º
C
2)
Temper
atur
eofv
ert
ical
seal
i
ng-40-
45º
C

87
 BUTTERMI
LK
But
ter
mil
kist
heby-pr
oductoft
hebut
terpr
ocessi
ngandi
spr
ocessed
i
nAMUL2section.

Pr
oductName Amul
Mast
iBut
ter
mil
k

Descr
ipt
ion Amul
Mast
iSpi
cedBut
ter
mil
k

1Li
terPack
Packi
ng 200ml
Pack
200ml
Premi
um But
ter
mil
k

SPECI
FICATI
ONS:-

88
FAT-0.
5%
TOTALSOLI
DS-
7%
ACI
DITY-0.
39-
.41%

PROCESSI
NGFLOWCHART

89
AMULMASTIDAHI

90
Pr
oductName Amul
Mast
iDahi

Descr
ipt
ion Curdmadefr
om Past
eur
ized
TonedMil
k

Pol
yPack-200gm,
400gm,
1kg
Packi
ng
*
PPCup-200gm,
400gm,
100gm
*
*I
nSel
ect
edmar
ket
sonl
y

FSSAISPECI
FICATI
ON

STANDARDI
ZATI
ONFORDAHI

•Manuf
act
uri
ngofDahi
–1200l
i
ter
s/day
•Aci
dit
yatt
ransf
ert
ocol
dst
orage(
0.45-
0.55%LA)
•Aci
dit
yatt
imeofdi
spat
ch(
0.80-
0.95%LA)
•Cul
tur
e–DVS(
RST744+CHN11)
(
10l
trpast
eur
izedchi
l
ledwat
er+RST744+CHN11-1packet
)

91
Fl
owChar
t

92
 GHEE
I
NTRODUCTI
ON:-
Amulhasawelll
aidoutGheeSecti
onjustbesidesprocessi
ngsect i
onof
Amul2.I
thasgotall
facil
it
iesofwhi
tebuttermelt
ing,sourCream or
cur
dchurni
ng,
GheePr ocessi
ngandStorage.
GheeismanufacturedmainlybyPr
e-Str
ati
fi
cat
ionMethodf r
om White
Butt
ermanufact
ur edinButt
ersect
ion.Whencurdisr
eceivedindai
ryor
whenfati
ssepar atedfr
om sourmil
korsourcream,i
tischurnedto
makeWhiteButter.
ThisWhi t
eBut terisheatclar
ifi
edtomakeGheef orl
ocalmarket
.The
Gheemanuf acturedfrom whit
ebut t
eri
sonl
ypr eferr
edforexpor
t
purpose.InthissectionAGMARKSpeci alGrade( RedLabel
)Gheeis
prepared.Thepr oductioncapacit
yofGheesectionis16to18TPD( Avg
producti
on8- 10TPD) .

SPECI
FICATI
ONS

93
MANUFACTURI
NGPROCESS:-
 Butt
errecei
vedfrom but
tersecti
onismelt
edat85˚
Cinanopen
Melti
ngVathavingsteam coil
sinit
sbot
tom.InWhi
tebut
terfat%
i
s83%.I ti
slef
tforabouthalfanhouri
nthevatt
osepar
atelayerof
fat
.
 Themelt
edbutt
erispumpedt oPre-
Str
ati
fi
cati
onTank.I
tis
al
lowedt
osett
lefor2hours.Thebutt
ermilksepar
atedi
sdrained
outfr
om t
hebott
om ofthetankandiscol
lect
edinaSerum tank.
 Themeltedf
atisthenpumpedtoGheeKett
lewhereiti
sheatedt
o
115-120˚Cforabout45minut
es.Gheei
sallowedtosett
lef
or1-
2
hour
sinthegheetub.
 Theniti
scl
arif
iedinaclar
if
ier
.Aft
ercl
ari
fi
cat
ionGheeisst
oredi
n
Stor
ageTanks.From t
hereiti
spumpedtoOverheadTankt
o
Packi
ngMachine.
 ThepackingTemperatur
eofGheei s40-42˚
C.Totheser
um
por
ti
onobt ai
nedduri
ngPr e-
Str
ati
fi
cati
on,chi
ll
edwateri
sadded
andchurnedtorecov
erthefat.
 GheeResi
duei
str
ansf
err
edt
ocat
tl
efeedf
act
ory
.

94
FLOW CHARTFORBROWNGHEEPREPRATI
ON

95
FLOW CHARTFORCOW GHEEPREPRATI
ON

96
GHEEPACKAGI
NGSECTI
ON:
 Gheei
spackedi
n200ml
,500ml
,and1000ml
pouchesbyghee

97
 pouchpacki
ngmachi
nehav
ingt
woheads.
 Densi
ty:
-0.
90gm/cm2
 Thi
cknessofpacki
ngmat
eri
al-100µm.
Ty
pe:
Prepac(
Pneumat
ic)
 Make:
Samar
panFabr
icat
ors,
Thane
 Capaci
ty:
13-
14pouch/mi
n
 Ai
rconsumpt
ion:
6Kg/Sq.
cm.
 Cool
i
ngwat
er:
100l
i
ter
/hrat20oC
 Gheei
sal
sopackedi
nti
ns&t
ubsi
n500ml
,1l
ts,
2lt
s,5l
tsand15
kg.
Gast
iPacki
ngMachi
ne
 Make:
Gast
iIndi
aLt
d.
 Capaci
ty:
15t
ins/mi
n.
 Fi
l
li
ngandSeami
ngMachi
ne
 Make:
Uni
tech.No–2
Fi
ll
ingandSeami
ngMachi
ne
 Make–Uni
techI
ndi
aLt
d.

98
St
andar
dsofwei
ght
:-
 Wei
ghtst
andar
dsofGheepackagi
ngat400c.

CI
Pofgheepl
ant
:
 Aft
eruseofever
ymel
ti
ngsy
stem hotwat
erof70-
75˚
Cisf
il
ledup
andfl
ushed.
 Theni
tiscleanedwith0.
2-1%oflyesolut
ionatt
emper
atur
e70˚
C
andci
rcul
ationfor30-
35mi nanddrai
ned.
 Aft
erthisthecleaningpr
ocedur
eiscar
ri
edoutwit
hhotwaterof70
-
75˚ Cwithoutlye.Thesyst
em i
swashedthi
rdt
imewit
hfresh
waterfor25-30mi n.
 Fi
nal
l
yri
nset
esti
scar
ri
edout
.
CI
POFCLARI
FIER
 Det
ergentsol
uti
on,
handbr
ushcl
eani
ngwi
thhotwat
erhav
ing

99
 t
emper
atur
eof40-
45˚
Cisusedaf
terev
eryuse.

STERI
LIZEDFLAVOURMI
LK
I
NTRODUCTI
ON
 Fl
avour
edmi
l
kisoneofthemostpr
ofi
tabl
epr
oduct
sofAmul
.The
Fl
avour
edMi
l
kSecti
onisinAmul2.

Ther
ear
e5t
ypesofst
eri
l
izedf
lav
our
edmi
l
kar
epr
oduced.
 KesarFl
avour
edMi
l
k.
 El
aichi
Flav
our
edMi
l
k.
 RoseFl
avour
edMi
l
k.
 Chocol
ateFl
avour
edMi
l
k.
 Cof
feeFl
avour
edMi
l
k
 Mi
l
kShakesofMango,
Banana,
kesar
-pi
sta&St
rawber
ry
 Packsi
ze :
200ml
glassbot
tl
es&250ml
cans.
 Shel
fli
fe :
120t
o180day
satcool
anddr
ypl
ace.
SPECI
FICATI
ONS

100
FLOW CHARTOFFLAVOUREDMI
LK
(
Rose,
Elai
chi
,Kesar
)

101
FLOW CHARTFORPROCESSI
NGOFKOOLCAFÉ

102
FLOW CHARTFORPROCESSI
NGOFKOOLKOKO
103
104
EQUI
PMENTS

105
LI
STOFADDI
TIVESFORMAKI
NGFLAVOUREDMI
LK

106
Speci
fi
cat
ions:

CLEANI
NGANDSANI
TIZATI
ON:-
CI
PforProcessv
ats,
Stor
aget
anks,
PHE,
Bul
kchi
l
ler
,Homogeni
zerand
Pi
pel
ines

107
CI
PforCanf
il
li
ngmachi
ne,
Over
headt
ank/
Bot
tl
efi
ll
ingmachi
ne

Cl
eani
ngofSt
eri
li
zer
•Allt
hesteri
li
zer
sarecleanedmanuall
yfrom i
nsi
dedaily.Condensat
e
l
inesaredismantl
ed,
brushedandcleanedwithwateronceinamont h.
Cl
eani
ngofSt
eri
li
zercr
atesandTr
oll
eys
 Al
lSteri
l
izerCr
atesar
ecl
eanedmanuall
yoncei
namonthby
br
ushingwith0.
3–0.5%Teepol
solut
ionandri
nsi
ngwi
thwat
er.
 RECORDSMAI
NTAI
NED
 Pr
oduct
ionRecor
d
 Packi
ngRegi
ster
 Fi
l
li
ngTemper
atur
eRecor
d
 Shr
inkWr
appi
ngRecor
d
 CI
PRecor
d
 Pur
chaseRecor
d

108
109