Internsip Damul Final Report-1

UNIVERSITY OF AGRICULTURAL SCIENCES, DHARWAD.
COLLEGE OF COMMUNITY SCIENCE, DHARWAD.

B-TECH FOOD TECHNOLOGY
INTERNSHIP REPORT ON
“OVERVIEW OF A DAIRY PLANT”
Undertaken at
DHARWAD CO-OPERATIVE MILK UNION LIMITED, DHARWAD
(Duration 13.12.2022 to 31.03.2023)
SUBMITTED BY
GAGANA MAGANUR (UGS19BFT188)
SHASHIMOHAN A M (UGS19BFT207)
B. Tech Food Technology
UNIVERSITY OF AGRICULTURAL SCIENCES, DHARWAD
COLLEGE OF COMMUNITY SCIENCE, DHARWAD
DHRWAD-580005
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CERTIFICATE
This is to certify that the in-plant training report entitled “Overview of dairy plant” carried out in Dharwad Milk
Union Limited, submitted by Gagana Maganur (UGS10BFT188) & Shashimhoan A M (UGS19BFT207) to the
Industry and also to the University Of Agricultural Sciences, College of Community Sciences, Dharwad in partial full
fillngthe requirements of the course SPR 405 (0+20) in pursuring the B. Tech. (Food Technology) to the university of
agricultural sciences, Dharwad during the period of in-plant training at Dharwad milk Union Limited (KMF)
Dharawd Manager
2022-2023 Dharwad Milk Union Limited (KMF)
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DECLARATION
We Mrs. Gagana Maganur, Mr. Shashimohan A M hereby declare that the training and report undergone at Dharwad
Milk Union Limited (DAMUL).So we hereby declare that this internship report is based on “overview of dairy plant”.
It has been prepared under the guidance of Dr. Archana Lamdande, Assistant Professor, Dept. Food Processing
and Technology.
This report has been submitted in partial fulfilment of the requirement for the award of degree in B.Tech (Food
Technology) to the UAS Dharwad, college of community science Dharwad and not been submitted to any
institution, board or university and previously formed the basis for the award of any degree, diploma or any similar
titles.
Date:
Place: Dharwad
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ACKNOWLEDGEMENT
“A grateful heart is a beginning of greatness. It is an expression of humbleness. It is the foundation for the
department of such virtues as prayer, faith, courage, contentment, happiness, love and well being”
We express our utmost gratitude to Dr. Yashoda Hegde (Dean), College of Community Sciences
Dharwad for her encouragement. Dr.Hemalatha S, HOD, Department of Food Processing and
Technology ,College of Community Sciences Dharwad, whose guidance, induced concentration, timely
suggestions & encouragement helped me to complete this project successfully.
We take the opportunity to express our heartfelt felling to the Management and Staff of Dharwad milk
Union Limited (DAMUL) for their guidance, support, for cooperating and providing us elite facilities for
academic purpose. We are obliges for the positive learning environment we have been provided with.
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CONTENT
SI NO TOPIC
01 INTRODUCTION
1.1 MILK AND MILK PRODUCTS
1.2 DAIRY INDUSTRY IN INDIA
1.3 KARNATAKA MILK FEDERATION
1.4 DHARWAD MILK UNION LIMITED, DHARWAD
02 OBJECTIVES, MISSION & VISION OF KMF& DAMUL
03 OBJECTIVES & SCOPE OF STUDY
04 FUNCTIONAL DEPARTMENT
4.1 PROCESSING,PACKAGING AND RECEPTION DEPARTMENT
05 PRODUCTION DEPARTMENT
06 QUALITY CONTROL DEPARTMENT
07 ENGINEERING DEPARTMENT
08 MARKETING DEPARTMENT
09 SWOT ANALYSIS & METHODOLOGY OF THE STUDY
10 CONCLUSION
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CHAPTER 1
INTRODUCTION
1.1 MILK AND MILK PRODUCTS
Milk is a white liquid food produced by the mammary glands of mammals. It is the primary source of nutrition. Milk
contains many nutrients, including protein and lactose. Immune factors and immune-modulating components in milk
contribute to milk immunity. Early-lactation milk, which is called colostrum, contains antibodies that strengthen
the immune system, and thus reduces the risk of many diseases.
Milk is a n emulsion or collied of butterfat globules within a water-based fluid that contains dissolved
carbohydrates and protein aggregates with minerals. Because it is produced as a food source for the young, all of its
contents provide benefits for growth. The principal requirements are energy (lipids, lactose, and protein), biosynthesis
of non-essential amino acids supplied by proteins (essential amino acids and amino groups), essential fatty acids,
vitamins and inorganic elements, and water.
Dairy products or milk products, also known as lacticinia, are food products made from (or containing) milk. The
most common dairy animals are cow, buffalo, Goat, and sheep. A facility that produces dairy products is known as
a dairy. Dairy products are consumed worldwide to varying degrees. Some people avoid some or all dairy products
either because of lactose intolerance, veganism, or other health reasons or beliefs.
Milk is produced after optional homogenization or pasteurization, in several grades after standardization of the fat
level, and possible addition of the bacteria Streptococcus lactis and Leuconostoc citrovorum. Milk can be broken
down into several different categories based on type of product produced, including cream, butter, cheese, infant
formula, and yogurt. Milk varies in fat content. Skim milk is milk with zero fat, while whole milk products contain fat.
Milk is an ingredient in many confectioneries. Milk can be added to chocolate to produce milk chocolate. The milk
products are condensed milk, flavored Milk, skimmed milk Evaporated milk, powdered milk, khoa, pedha, lassi,
butter milk, tonned milk, double tonned milk, Cheese, butter, ghee, cream, fermented products (yogurt, curd) ice
cream etc.,
1.2 DAIRY INDUSTRY IN INDIA

Dairy in India was once a largely subsistence-oriented occupation intended to produce milk for home consumption. In
1919, a dairy animal census was conducted for the first time by British colonial officials. A report authored in 1937
indicated a sub-optimal rate of milk consumption in the country. It estimated a per captia intake of 200g per day
(inclusive of all dairy products)
In the 1920s, modern milk processing and marketing technologies were introduced in India. The National Dairy
Development Board (NDDA) was founded in 1965. It launched Operation Flood in 1969-70, a programme aimed at
modernizing and developing the dairy sector using co-operatives. During this period, dairy co-operatives emerged as a
dominant force, as a result of the exploitative nature of private milk plants and vendors. Co-operatives were based on
the “Anand model” – a three-tier organizational structure comprising (1) village-level co-operative societies (the
primary producers), (2) district-level co-operative producers’ unions which collected the milk and operated processing
plants, and (3) state-level federations for marketing. This model was evolved in Anand, Gujarat, having begun there in
1946, and came to adopted all over the country.
India is ranked 1st in milk production contributing 24% of gobal milk production. Milk production in the country has
grown at a compound annual growth rate of about 6.2%to reach 209.96 Mn Tonnes in 2020-21 from 146.31 Mn
Tonnes in 2014-15. Export of dairy products recorded a growth of 19.45% as its export rose to $471 Mn in FY 2022-
2023 till now (April - December 2022) from $395Mn in April – December 2021 of last fiscal year.
Dairy is one of the biggest agri-business in India and a significant contributor to Indian economy. It is the largest
single agricultural commodity with ~4 per cent share in economy. India is the largest producer of milk globally with a
~188 million MT production in 2019-20. Indian dairy industry has grown at ~12 per cent during last 5 years, with
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value-added products driving market growth. It is a significant contributor to farmers’ income as approximately 70
million farmers are directly involved in dairying.
1.3 KARNATAKA MILK FEDERATION
Karnataka Cooperative Milk Producers' Federation Limited (KMF) is the Apex Body for the dairy co-operative
movement in Karnataka. It is the second largest dairy co-operative amongst the dairy cooperatives in the country. In
South India it stands first in terms of procurement as well as sales. One of the core functions of the Federation is
marketing of Milk and Milk Products. The Brand "Nandini" is the household name for Pure and Fresh milk and milk
products. KMF has 16 Milk Unions covering all the districts of the State which procure milk from Primary Dairy
Cooperative Societies (DCS) and distribute milk to the consumers in various Towns/Cities/Rural markets in
Karnataka. The first of the dairy co-operatives that make up KMF started in 1955 in Kudige, Kodagu District. KMF
was founded in 1974 as Karnataka Dairy Development Corporation (KDDC) to implement a dairy development
project run by the World Bank. In 1984 the organisation was renamed KMF.
Karnataka Dairy Development Cooperation (KDDC), the first ever World Bank/ International Development Agency
funded Dairy Development Program in the country started in Karnataka on co-operative lines with the organisation of
Village Level Dairy Co-operatives in 1974. The AMUL pattern of dairy co-operatives started functioning in
Karnataka from 1974-75 with the financial assistance from World Bank/IDA, Operation Flood II & III. The Anand
Pattern three tier organisation structure – Dairy Cooperative Societies at the village level, District Milk Unions at the
District level to take care of the procurement, processing and marketing of milk and provide technical input services
for enhancing milk production at producers level and Federation at the state level to co-ordinate the growth of the
sector in the State, are resolutely and harmoniously working hand-in-hand in creating self-sustaining rural economy
based on cooperative dairying. KMF is one of the few federations in the country, who have converted dairying from a
subsidiary occupation into an industry.
At the end of the march 1998, the network of 8023 Dairy Co-operative Societies (DCS) have been established which
are spread over 166 taluks of the total 175 taluks in all 27 districts of Karnataka. There are 13
THE GROWTH PROCESS

KEY ITEMS
1976-
UNIT 77 2018-19 2019-20 2020-21
Dairy Co-operatives
Nos 416 16059 16071 16789
DCS Registered
DCS Functioning Nos 14512 14493 14864
Women DCS Nos 4122 4239 4547

Registered
Women DCS Nos 3777 3868 4079
Functioning
STEP Registered Nos 2374 2474 2585
STEP Functioning Nos 2199 2299 2375

Membership Nos 37000 24.74 24.75 Lakhs 25.71 Lakhs
Lakhs
Ann.Avg. Milk LKPD 0.50 74.80 75.61 78.73
Procurement
Peak Procurement LKPD 84.44 84.44(June'18) 88.30(July'20)
(June'18)
Avg.Milk Sales LLPD 95050 35.47 35.57 35.59
Avg.Curd sales LKPD 6.28 6.18 5.14
Avg.Good life sales LLPD 5.28 6.01 6.80
Daily Payment to Rs.Crores 0.09 18.28 18.12 21.41

Farmers
Dairy Co-operatives
Nos 416 16059 16071 16789
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KMF has 14 milk unions throughout the Karnataka State which procure milk from Primary Dairy Cooperative
Societies (DCS) and distribute milk to the consumers in various urban and rural markets in Karnataka State with 1,500
members.
There are 14 Milk Unions in Karnataka
1. Bengaluru Milk Union

2. Haveri Milk Union
3. Bekagavi Milk Union
4. Vijapura Milk Union
5. Chamrajnagar Milk Union
6. D.K Milk Union
7. Dharwad Milk Union
8. Hassan Milk Union
9. Kalaburgi Milk Union
10. Kolar Milk Union
11. Mandya Milk Union
12. Mysuru Milk Union
13. Shivamogga Milk Union
14. Tumakuru Milk Union
15. Chikkaballapura Milk Union
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1.4 DHARWAD MILK UNION LIMITED
1.4.1 ESTABLISHMENT:
Dharwad Co-operative milk producers Union Ltd.,(DAMUL) has been registered under Karnataka Co-
operative Act on 3rd March 1986 covering Dharwad, Haveri, Gadag and Uttara Kannada Districts. DAMUL has 995
number of Functional DCSs covering 28 taluks, of which DAMUL has infrastructure to handle 2.10 lakh litres of
milk, produce 10 tons of milk powder, 9 tons of Butter and 4 tons of ghee per day. It is located in the spacious 25
acres of land, located in Lakamanahalli Industrial area, adjacent to the National Highway-4. It is patterned the AMUL
Milk Dairy, Anand, Gujarat.
1.4.2 HISTORY:
A group of experienced officers, appointed by the Karnataka Milk Federation surveyed the whole of Dharwad, Haveri,
Gadag, and Uttara Kannada Districts. Further they found out there as a need for a Milk Dairy. They traveled the surrounding
villages, educated the villagers about Milk and Milk products and the benefits they would get from the Milk Dairy. It has Chilling
Centres at Haveri - 20 TLPD, Hirekerur - 20 TLPD, Gadag(Mallasandra)- 20 TLPD, Sirsi - 20 TLPD, Rona - 10
TLPD & Kumta - 2 TLPD with total capacity of 92 TLPD. There are 18 Bulk Milk Coolers and 351 Automatic Milk
Collection units in the union. The union procures on an Average of 2.34 lakh kgs/day of milk,sells 0.96 lakh
litres/day and 0.09 litres/day of curd. Further in 1988, the Raipur Dairy and Chilling Center, setup in 1968, also cameunder the
union. In 1989, the training center, which was controlled by KMF, came under Dharwad Milk Union.
Excellence: Known for quality Dharwad peda, Kuduke Mosaru(set curds in earthern pot) and 10g butter chiplets.
1.4.3 DHARWAD DISTRICT CO-OPERATIVE MILK PRODUCERS SOCIETIES UNION LIMITED:
Further in 1988, the Raipur Dairy and Chilling Center, setup in 1968, alsocame under the union. In 1989, the training
center, which was controlled by KMF, came under Dharwad Milk Union.DMU was Rs.7 Crores Projects of which
Government has Rs.2 Crore of share capital and authorized capital of DMU is Rs.5 crore. DMU formed 551 milk
producer’s co-operative societies in Dharwad, Gadag, Haveri and Uttar Kannada districts. The prediction capacity of
DMU is 2 lack litres of milk per day and also has the capacity to produce 12 tons of milk powder, 10 tonnes of butter,
and 6 tonnes of ghee per day.DMU is collecting 70thousand litres of milk per day from its societies and sells 60
thousand litres of milk per day and the remaining milk is used for producing milk products.
A) Product/service profile: - Milk and milk products
B) Area of operation – Regional
C) Ownership pattern.
DAMUl builds and runs under the co-operative institutions such as
 District Co-operative Society.(DCS)

 National Dairy Development Board.(NDDB)
D) Competitors Of Information.
DMU has various competitors in the milk products market such as
 Krishna
 Arokya
 Spurthi
 Datta
 Bharath Dairy
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 Dodla milk
E) INFRASTRUCTURAL FACILITIES.
Infrastructural facilities of DMU are as follows.
 Security facilities.
 Canteen facilities.
 Shifts facilities-3shifts per day.
 Heat allowance
 Cold allowance
Nandini pasteurized toned milk, nandini double toned milk,

nandini homogenized cow’s pure milk, shubam pasteurized
KMF standardize milk, samrudhi pasteurized full cream milk, special
toned milk, shubham gold milk, homogenized toned milk,
goodlife, nandini slim, goodlife UHT long life milk, nandini
curd, yoghurt, buttermilk, sweet lassi, flavored shrikhand,
panner, cheese flavored milk,salted butter, unsalted butter, ghee,
skimmed milk powder, ice cream, frozen dessert, badam burfi,
cashew burfi, besan laddu, kunda, milk peda, jamun,rasgolla,
nandini chocolates etc.,
Homogenized toned milk, Homogenized cow milk, Shubham

DHARWAD MILK UNION LTD milk, Buffalo milk, Curd, Sweet lassi, Masala majjige, Panner,
Ghee, Unsalted butter, Dharwad peda, Milk peda, Mysore pak,
Green gram laddu, Khoa and Skimmed milk powder.
F) INPUT REQUIRED PER DAY
 Milk Procurement up to 70000 liters

 5 to 6 lakhs liters pf water
 10,000 units of electricity
 4 to 5 tons of coal
 Generator in case of electricity failure and manpower
G) ACHIEVEMENTS OR AWARDS
DMU has got ENERGY SAVING award for the production activities
H) FUTURE GROWTH AND PROSPECTUS

 Procuring and selling 1 lack litters per day.
 Preparing for ISO-9001 certification
 Marketing quality improvement.
 Developing HACCP-hazards Analysis and Critical Control Points.
 Getting export Grade milk powder
I) PRODUCT PROFILE OF KMF AND DHARWAD MILK UNION LTD (DAMUL)
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CHAPTER 2
OBJECTIVES, VISION AND MISSION OF KMF
2.1 OBJECTIVES
KMF is a Cooperative Apex Body in the State of Karnataka representing organizations of milk producers' and
implementing all round dairy development activities to achieve the following objectives:
 To ensure assured and remunerative market round the year for the milk produced by the farmer members.
 To make available quality milk and other premier dairy products to urban consumers.
 To build & develop village level institutions as cooperative model units to manage the dairy activities.
 To ensure provision of inputs for milk production, processing facilities and dissemination of know how.
 To facilitate rural development by providing opportunities for self employment at village level, preventing
migration to urban areas, introducing cash economy and opportunity for a sustained income.
2.2 VISION
 To march forward with a missionary zeal which will make KMF a trailblazer of exemplary performance and
achievements beckoning other Milk Federations in the country in pursuit of total emulation of its good deeds?
 To ensure prosperity of the rural Milk producers who are ultimate owners of the Federation.
 To promote producer oriented viable cooperative society to impart an impetus to the rural income, dairy
productivity and rural employment.
 To bridge the gap between price of milk procurement and sale price.
 To develop business acumen in marketing and trading disciplines so as to serve consumers with quality milk,
give a fillip to the income of milk producers.
 To compete with MNCs and Private Dairies with better quality of milk and milk products and in the process
sustain invincibility of cooperatives.
2.3 MISSION
Heralding economic, social and cultural prosperity in the lives of our milk producer members by promoting vibrant,
self-sustaining and holistic cooperative dairy development in Karnataka State.
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CHAPTER 3
OBJECTIVE AND SCOPE OF THE STUDY
3.1 OBJECTIVE
The principle objectives of the study is to get interrelate the theoretical aspects with practical things that are moving in
industry, and studying the organization as a whole. Some important objectives of the study are:
 To get the practical exposure in the corporate world.
 To have a proper balance between the theory and practical knowledge.
 To study Origin, Growth, Vision, Mission, and Status of the Organization.
 To study the functional departments exist in the organization.
 To evaluate the effectiveness of the organization.
 To study the problem areas in the organization.
 To provide some valuable suggestion to improve the efficiency in the organization
3.2 SCOPE
The study helps to get an overall idea regarding the various departments in theorganization and overall function
of organization. This organization study mainly focuses on organizational setup, overall performance,
departmental performance etc. Apart from this
 To get a practical vision of the organization apart from the theory which have been learned in the class
 To understand the actual working condition
 To get in touch with the industrial and organizational environment
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CHAPTER 4
FUNCTIONAL DEPARTMENTS
FUNCTIONAL DEPARTMENTS
1. Processing, Packaging and milk reception Department

2. Production Department
3. Quality control Department
4. Engineering Department
5. Marketing, Storage and Technical Department
4.1 PROCESSING, PACKAGING AND MILK RECEPTION DEPARTMENT
Milk is highly perishable product has to process immediately to avoid spoilage milk with respect to its flavor, texture
and taste. Milk contains all the nutrients required by the neonate (new born) and has thus been recognized as perhaps
nature's ultimate food; furthermore, it is also a rich source of protective agents, enzymes and growth factors. Milk
constituents are divided mainly into three groups namely—fat soluble, water soluble, solid-not-fat (SNF). The
constituents other than water are called total solids (TS). Total solids minus butterfat are known as solid not fat. All the
constituents except fat are known as milk serum.
The relative ease with which milk can be converted into a wide variety of products makes it extremely useful base
material. In some cases, milk undergoes relatively limited processing, consisting of heat treatment to decrease
the bacterial shelf life of the product and homogenization to increase the physical shelf life through fat separation.
Milk has a high nutritional value but it is an excellent medium for microbial growth. Milk is heated for a variety of
reasons. The main reasons are: to remove, the pathogenic organisms; to increase shelf-life up to a period of six
months; to help subsequent Processing.
FLOW CHART OF MILK PROCESSING
Receipt of raw milk cans
Loading to the conveyor and

Opening the can lid
Screening of cans for Rejects and Discards

Organoleptic evaluation
Can washing Dumpling pre

and can sterilization filtering and weighing
Can dispatch QC Check
Releasing into the

Dump tank and filtration
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Chilling receipt of raw chilled
milk in tanker
Storage in raw tanker washing

chilled milk silo & despatch
QC check
Addition & mixing Standardization

of SMP & cream
Addition of Vitamin A & D in balance

tank
Homogenization HTST Pasteurization

74-80˚ C for 15 Sec
Storage in
Pasteurization milk silo’s
Receiving crates Re-chilling of milk to

Less than 4˚C
Washing through Packing in sachets Received coded packing

Crates washer (Feeding of films to FFS) material and visual
Inspection
Sachets collection
In crates Batch date coding
Transferring to the cold

Storage manually LDPE Films
Loading milk crates to

Distribution vehicles Store
Dispatch
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4.1.1 STEPS INVOLVED IN MILK PROCESSING:
1. Milk Reception Dock

Two methods of raw milk collection
a. Cans from co-operatives societies
b. Milk tankers from different Union and Chilling center
Milk reception collects the milk from the co-operatives. The Raw milk comes in va ns c ont a i ni ng m i l k
c a ns enter input dock. The cans go one by one t hrough a m a c hi ne ry t ra c k or c onve yors,
workers check the cans, and writes the num be r of l i t e rs of m i l k contained in the cans. The buffalo milk
is collected and packed separately.
L a rge quantity of raw milk is delivered t o da i ry pl a nt i n m i l k t a nke rs, from di ffe re nt c hi l l i ng
c e nt e rs. The tankers are insulated & ma i nt a i ne d a t l ow t e m pe ra t ure t o pre se rve t he ra w m i l k;
t he re by, the tanker provide facility to pre se rve m i l k t o proc ure i t from l onge r di st a nc e t o pl a nt
wi t hout any harm to milk. The tank outlet valve is then opened so that milk is transferred to raw milk silo. The
quantity of milk carried by tanker is weighed by weighing the tanker. The tanker is weighed on platform scale before
& after emptying, every day for every lot. A food grade hose pipe employed to provide a flexible coupling to the
tanker for unloading. Sampling is done before transferring milk for processing.
The reception is divided in to three phases.
1) Weighing chilling
2) Unloading
3) Prepare to unload
Preparing to unload normally involves inspecting for off flavour, appearance and for quality. Screening of cans
for organoleptic evaluation.
a. Can cleaning
Can cleaning is done by mechanically (straight through or tunnel type), in this type, empty can and lid in inverted
position enter into the tunnel at one end of the conveyor and comes out at the other end. After getting cleaned, rinsed,
sterilized and dried in straight-up position. The main operations involved are: pre-rinsing with clean water, steam
sterilization, detergent solution washing, hot water rinsing and hot air drying. All these operations are carried out in
quick succession and the process is continuous.
b. Cleaning Of Truck Tankers: -
After unloading the milk, rinse the inner barrel of tanker with tap water. Wash with hot water using
detergent as cleaning solution, use nylon brushes for scrubbing the inner walls manually. Dismantle the
manhole, valve, and gasket & clean with detergent thoroughly. Then rinse with hot water until the detergent
solution is removed up completely. Rinse with tap water. If tanker is used for loading of pasteurized milk,
use sanitizers. Record the tanker no & name of the person who wash the tanker, in the tanker cleaning
register.
2. Testing:
Testing mainly concern with the quality check up of each milk collected from co-operative societies. The
Quality control department takes the sample of the milk and its analysis the fat and divides it, like fat and SNF
(Solid Not Fat)
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•Fat percentage: Gerber method/ Electronic milko tester method/ Fatomatic method
•SNF: Lactometer reading at 27°C is noted
3. Chilling:
To maintain the quality of milk received in dairy or chilling center, it is to be chilled. It is the process of cooling the
milk below 4ºC to suppress the bacterial activity, so that the shelf life is extended upto12-18 hrs and facilitates further
processing of the milk. The chiller consist of stainless plate chiller. Chilling is done by flowing milk from one side and
chilled from other side of the plates (counter current) resulting in the cooling of milk and it stored in silos. After
receiving milk from tanker (chilling center) it was washed and dispatch.
4. Storage of raw milk:

The milk is stored in chilled raw milk silo and it was pumped through a filter and stored till standardization.
5. Standardization of milk:
It is the process of adjusting the fat content ; These process facilitates raising or lowering of fat content of the milk. It
is carried out by skimmed milk/milk powder depending on the initial fat/SNF content of milk in the storage tank. And
also addition of vitamin A and vitamin D in balance tank. Standardization is done on raw milk. DHAMULtd markets
has four types of milk.. Homogenized toned milk, Homogenized cow milk, shubham milk, Buffalo milk.
6. Pasteurization:
Pasteurization is a process where milk is heated to high temperature to less than 100 °C and cooled instantly, to
destroy all pathogenic microorganism. It is the process of heating the milk to 72°C/15 sec holding and immediately
cooling to 4-5 °C or below. The purpose is to render the milk safe for human consumption by destructing some of
the pathogenic microorganisms.
Pasteurizer is cleaned by circulating hot water throughout. Raw milk is pumped to the balance tanks,
water is then flushed in the pasteurizers. The pasteurized milk is pumped to the cleaned silos and then sent to QC
check before packaging . Packing is done in 500m l and 1000ml and stored in cold storage at 4-5 °C. Temperatures
must be maintained throughout the heating and cooling processing. Mixing of water and milk must be avoided.
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7. Separation of milk:
The pipeline connection for separator are changed, water is circulated in the separation line. The separator was started
to pick up the speed. After attaining the desired speed, milk is allowed to separate. Adjust the percentage of fat in milk
by operating the screw of the separator to the required percentage. Then when the desired quantity of milk is
separated, run water into the entire quantity of milk flushes out.
8. Homogenization:
Homogenization is the process in which size of the fat globules in the milk are broken down into smaller and uniform size
of fat particles of 1-2μ. This prevents the cream formation. It also ensures that the milk fat is evenly distributed. Chilled
milk cannot be sent to the homogenizer since the fat will be in solid state and difficult to homogenize hence the milk
sent to pasteuizer it should have a temperature of around 60 °C. Partially heated milk from the pasteurizer is forced
towards a small passage with high pressure in an adjustable valve by multiple cylinder pistons pumps; the shearing
effect causes the fat globules to break down. Then it is sent back to refrigeration.
The pipeline connections for homogenizer are changed, and water is circulated in the homogenizer line. Take
the milk from the pasteurizer and set the pressure in the homogenizer at 2500 psi in the first stage and 500 psi in the
second stage. Then when the desired quantity of milk is homogenized, run water into the system until the entire
quantity of milk flushes out to check the efficiency of the homogenizer, continuous samples are drawn then it is sent
back to refrigeration.
9. Pasteurization and Separation of cream

Pasteurizer is cleaned by circulating hot water throughout. (The heating and chilling temperature are determined to be
85˚-90˚C and 6˚C to 8˚C temperatures respectively). The milk in bulk is taken to the cream separator. Here, the cream
is separated. The cream is passed through cream Pasteurization Unit. Then the cream is sent to butter section .The
milk with no fat is for skimmed milk. This skim milk is pumped back to Pasteurization Unit and heated to 72˚C using
steam and chilled to 4˚C using chilled water and stored silos. This skimmed milk is sent to powder section. The
pasteurize cream is mixed in portion to pasteurized milk.
Pasteurizer is cleaned by circulating hot water throughout. Raw milk is pumped to the balance tanks, water
is then flushed in the pasteurizers. The pasteurized cream is then pumped to the cleaned cream tanks. The
temperatures must be maintained throughout the heating and cooling processing. Mixing of water and cream must be
avoided.
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10. Packing and cold storage:
After, the process milk is packed with the help of packing machine (FFS machine). Packed milk packets are stored at
4-5°C till its delivery to milk delivery trucks.
11. Dispatch:
Packet milk is stored in a crates and distributed to the dealers through organized tendered contract vehicle and distributed to Nandini
parlour.
12. Cleaning of crates:

Cleaning of crates is done by mechanically (straight through), in this type, empty crates are enter into the tunnel at one
end of the conveyor and comes out at the other end. After getting cleaned, rinsed, sterilized and dried in straight-up
position. The main operations involved are: pre-rinsing with clean water, steam sterilization, detergent solution
washing, hot water rinsing. All these operations are carried out in quick succession and the process is continuous
18
13. Cleaning in place (CIP):
CIP is an automated process which is done for cleaning and sterilizing of the pasteurizing and homogenizer
equipment. Chemicals used are caustic soda (NaOH) and nitric acid (HNO3).
 Cleaning of milk silos and tank:

Rinse the milk tanks with water after removing entire quantity of milk. Flush with hot water.
Circulate alkali solution for 30 min. Maintain the temperature of alkali solution at 70-75 C and alkali
solution strength to 0.5-0.6%.Flush the alkali solution after 30 min. by hot water. Circulate hot water about
80C for 5 min. Flush with cold water to reduce the temperature of milk tanks to ambient temperature then
rinse the tanks with sanitizers for pasteurized milk silos and cream tanks. Allow the milk after confirming
the milk temperature. Cleaning should be carried out as per the cleaning schedules.
 Cleaning of milk and cream pasteurizer:

 Caustic CIP:
Water rinse for 10min.Add 0.8% of caustic soda. Circulate for 30min/80-85 0C then drain the caustic and
flush with water for 10min.Circulate hot water [80-850C] for 10min.
 Acid CIP:
Water rinse for 10min. Add 0.8% of caustic soda. Circulate for 30min/80-85 0C. Intermediate rinse for
10min then add 0.5% HNO3 and circulate for 30min at 60-650C. Drain acid solution and flush with water for
10min and circulate hot water [80-850C] for 10min.
CIP TANKS
STORAGE TYPE CAPACITY

Acid tank 3000 litres
Lye tank 3000 litres

Hot water tank 3000 litres
Recuperation tank 4000 litres
4.1.2 Curd processing:
Curd is also known Dahi is a well-known fermented milk product consumed by a large population in the world. It is
obtained by coagulating milk in a process called curdling. Harmless mesophilic microbes are added to pasteurized
milk. It may contain additional sugar and it should have the same percentage of fat and SNF as the milk from which it
is prepared from. The inoculum is added at a temperature of 32˚ – 37˚ C. These convert lactose into lactic acid, which
imparts the sour taste to curd. In many cases it has been said that curd is more beneficial than milk. The acidity of curd
increase with increase in time till a certain value.
The horizontal milk storage tank (HMST) is cleaned and hot water is circulated in the plate heat exchanger. The
quantity of homogenized curd milk having 6% fat & 10% SNF. Milk is pasteurized at a temperature of 90˚ C for 12-
15 minutes and cooled down to 35– 40˚C and stored. The culture at 1-2 % is added to the milk just before packing.
The packaging is done in 200 or 500 gm sachets and 5kg bucket .The curds is then incubated for 4-6 hours and then
sent to cold storage for dispatch. Shelf life of curd is 3 days.
19
Nutritional information of curd per 100g:
Energy, kcal 56
Total fat, g 3.0
Total carbohydrate, g 3.9
Protein, g 3.3
Minerals, g 0.7
Vitamin A, µg 35
20
4.1.3 Sweet Lassi
Collection of curd from the SS tank and cold store room (conversion of sugar into sugar syrup by using pasteurized
water) .Adding sugar syrup and flavors to the curd, and also addition of pasteurized water and milk. Mixing uniformly
and packed and store in cold store room and dispatch. It is made from fresh curd. The refreshing drink available in 200
ml pouches
Nutritional information of sweet lassi per 100g
Energy, Kcal 80
Total carbohydrates, g 15
of which sugars (lactose),g 15
Proteins, g 1.7
Total fats, g 1.4
Minerals, g 0.4
Calcium, mg 60
Vitamin A, µg 18
4.1.4 Masala buttermilk
Nandini Masala butter milk is a refreshing health drink. It is made from quality curds mixing with pasteurized chilled
water and is blended and filter with fresh green chillies, green coriander leaves, asafetida and fresh ginger. Adding salt
and mixing uniformly, packed it and store and dispatch. It is available in 200 ml packs. In buttermilk, the ratio of curd
and water is 1:2 and the percentage of spices is 0.5%.
Nutritional information/100ml of buttermilk;

Energy, Kcal 19
Total Carbohydrates, g 1.3
Sugars (Lactose), g 1.3
Proteins, g 1.1
Total Fat, g 1.0
Minerals, g 0.5
Calcium, mg 40
Sodium, mg 275
Vitamin A, µg 12
4.1.5 Packing Machine
Packing machine is called as Form Fill Seal (FFS) machine.
WORKING AND OPERATION:

These machines work on the principle of Form-fill-seal (FFS) machines. Form-fill-seal machines are machines
that form the package, fill it with a wet or dry product and seal it closed. Most FFS systems are flexible film to form
the primary package, such as bag or pouch. Plastic films are used and are supplied in the form of a roll. The liquid
milk going in the machines is based on an electronic time based digital circuit. The filling machines consist of a
constant level tank with a float valve is maintained at a constant head of liquid to be filled. After the requisite is
received, the dispensing valve opens to allow the flow of liquid for a particular pre-set time. Time of flow is adjusted
according to the liquid density.
21
Step 1: Forming
The initial step is forming the bag. Depending on the package type, it is taken from a stack or a roll. The film roll is
placed in the given space at the back of the machine in the film carrier. The film is brought into the forming collar with the
support guide rollers provided at the back and also the film is brought at the top ‘where it goes through a protecting area
where it undergoes UV radiation treatment for sterilization. Then plain film sheet is formed as tube in vertical sealing section.
The film is worked outside the forming tube and is folded longitudinally and sealed to make a flat vertical tube. The
package is sealed with a horizontal seal at the top and bottom of the bag.
Step 2: Filling
The next step in the process is filling, which is accomplished by interfacing a filling machine. The machine is
programmed for filling, so this step is completely automated. The pre-measure product is dispensed from the machine
into the bag. Then, the film is sealed.
Step 3: Sealing
In many of these machines, a sealing bar seals the top of the package with a horizontal sealing bar. If necessary, the
package will then be moved on to the final sealing process.
 Vertical sealing: The formed tube is sealed on the overlap using a sealer called vertical electrode equipped with
a pulse heat band. After sealing it is cooled through cooling water supply arranged in the vertical basket. The
machine is equipped with motor and gear box for length adjustments of the film. The gear box pulls down the tube
through nip Toilers after that the horizontal seal-will take place.
 Horizontal sealing: The sealing is also with a sealer called horizontal electrode, equipped with a pulse heated
band it is mounted by the same part which controls the vertical sealing. Immediately milk will fill to the required
quantity. In this way, we can adjust the quantity and also the length of the sachet as per our requirement. Each
machine has two head switch capacity of 35 packets/min' each(70 packets/min for the machine). hi high speed
packing machine also there are two heads of capacity 70 packets/min (140 packets/min for the machine). Then it is
transferred to cold storage through crate conveyors.
22
23
4.1.5 PRODUCT PROFILE OF MILK
1. Homogenized toned milk (HTM):

Nandini homogenized toned milk is pure milk containing 3.1% fat & 8.5% SNF. This is homogenized & pasteurized.
So fat content is lesser as compared to HCM and naturally rich in nutrients. It is available in 500ml & 1 litre.
2. Homogenized cow milk (HCM) : Nandini homogenized milk containing 3.6% fat & 8.5 SNF. This is
homogenized & pasteurized. It is easy to digest.
3.Shubham milk: A pure pasteurized standardized milk having 4.6% fat &8.5% SNF. Processed with all the
goodness of healthy milk for healthy growth in children.
4. Buffalo milk: It has 6% fat & 9% SNF and high protein, which gives it a rich & creamy texture. Perfect for
producing butter, cream, & yoghurt. Available in 500ml.
5. Curd: Raw milk is heated to 90˚C and allowed to cool to 30˚C. Later culture is added to it and packed; the curd is
formed in the packet itself. It is stored and packed in 200gms, 500gms and 5 litres bucket.
PRODUCT DETAIL
FAT SNF MRP/ UNIT
SI NO PRODUCT CONTENT CONTENT
(%) (%)
500ml /20rs
01 Homogenized toned milk 3.1 8.5
1ltrs/ 40rs
250 ml/11rs
02 Homogenized cow milk 3.6 8.5
500ml/20rs
500ml/21 rsrs
03 Shubham milk 4.6 8.5
1 ltrs/41rs
04 Buffalo milk 6 9 500ml/
05 Curd milk 3 10 -
24
1. Homogenized Tned milk 2. Homogenized pasteurized cow milk
3. Shubham milk 4. Sweet Lassi
5. curd 6. Masala buttermilk
4.1.6 PROCESSING SECTION EQUIPMENTS
NUMBER OF
SI NO EQUIPMENTS CAPACITY
EQUIPMENT
25
01 Raw chilled milk silos 30,000 liters 03
30,000 liters 05
02 Pasteurized milk silo
03 Milk pasteurizer 20000 LPH 02
04 Cream separator 20000 LPH 02
Cream pasteurizer
05 4000LPH 01
06 Homogenizer 150 bar, 1000 ltrs 02
07 Cream ripening tank 30,000 LPH 03
08 Curd pasteurizer 5000 LPH 01
 *LPH: liter per hour
Chapter 5
PRODUCTION DEPARTMENT
Milk is a valuable nutritious food that has a short shelf-life and requires careful handling. Milk is highly perishable
because it is an excellent medium for the growth of microorganisms – particularly bacterial pathogens – that can cause
spoilage and diseases in consumers. Milk processing allows the preservation of milk for days, weeks or months and
helps to reduce food-borne illness.
26
The usable life of milk can be extended for several days through techniques such as cooling (which is the factor most
likely to influence the quality of raw milk) or fermentation. Pasteurization is a heat treatment process that extends the
usable life of milk and reduces the numbers of possible pathogenic microorganisms to levels at which they do not
represent a significant health hazard. Milk can be processed further to convert it into high-value, concentrated and
easily transportable dairy products with long shelf-lives, such as panner, peda, butter, cheese and ghee etc.,
Processing of dairy products gives small-scale dairy producers higher cash incomes than selling raw milk and offers
better opportunities to reach regional and urban markets. Milk processing can also help to deal with seasonal
fluctuations in milk supply. The transformation of raw milk into processed milk and products can benefit entire
communities by generating off-farm jobs in milk collection, transportation, processing and marketing .
In DAMUL production department has 8 products. Which are made by milk and other ingredients.
1. Khoa
2. Dharwad Peda
3. Milk Peda
4. Mysore Pak
5. Green Gram Laddu
6. Panner
7. Unsalted & Salted Butter
8. Ghee
5.2.1 KHOA:
Khoa is used as the base for a wide variety of Indian sweets. Khoa is made by pasteurized milk (4.5% fat &
8.5%SNF) which undergoes QC check. Pouring the milk into khoa pan and the gradual evaporation of its water
content leaves only the milk solids with continuous stirring at the temperature 80-95˚C. Continue mixing, heating until
it becomes thick.
In DHAMUL , the khoa pan vat capacity of 120L is used for stirring the milk during boiling and also to scrap the milk
film forming on the surface during boiling. A rapid stirring and scrapping is carried out through out boiling to
facilitate quick and rapid evaporation of water from milk and also to prevent scorching of milk film on surface. Due to
continuous evaporation of water, the milk progressively thickens. The heating is continued till the milk thickens
considerably and at this stage heating is reduced and speed of stirring and scraping is increased to obtain good quality
product. If the milk is subjected to high heat treatment with less stirring and scraping at this stage it results in dark
colored khoa that does not fetch a good price in the market as white/ cream colored khoa is preferred for sweets
making. There are 5 khoa pan vat which are used for production of khoa, Dharwad peda & White Peda which are done
by batches, and it takes 2 ½ hours for 1 batch. Packing with MAP. After it will be dispatch.
A stainless steel double jacketed, steam heated pan or kettle is used to provide greater control on the heating process
and to ensure a non smoky heating. milk is brought to boil in the kettle. During boiling, bottom and the surfaces of the
kettle are scraped and milk is stirred vigorously by a stainless steel stirrer to avoid burning of milk solids. About 2
kg/cm2 pressure is used for boiling milk. When the milk attains a rabri stage, slow heating is necessary at this stage to
prevent burning of solids on the surface, discoloration of the product, development of burnt flavour and hard body and
coarse texture. The rate of stirring should be increased during last stages to obtain good quality product. As soon as
the product shows signs of leaving the sides of the kettle and accumulates in the centre in a pat form, heating is
stopped.
Nutritional information per 100g
Energy, kcal 377
Carbohydrates, g 25.5
Fat,g 23.0
27
Saturated fat, g 15.0
Trans fat, g 0.6
Cholesterol, mg 70
Protein, g 17.1
Calcium, mg 770
Vitamin A, µg 262
FLOW CHART
Collection of raw chilled Milk (4.5% fat &8.5%SNF)
QC Check
Pouring the milk into Khoa Pan
Evaporation with continuous stirring (90-95˚C)
Transferring the Khoa into SS tray
Allow for cooling at room temperature for 10-12 hrs
Packing
Dispatch
5.2.2 PEDA:
There are several varieties of peda and their methods of manufacture also vary from region to region. Depending on
the consumer requirements. There are two types of peda i.e., white peda (milk peda) and brown peda (Dharwad
peda). Peda is made from pure milk, sugar and can be stored at room temperature. Available in 250g pack containing
10 pieces each
28
Different methods are used for the preparation of peda, depending on the type and scale of production. This method is
identical to that of burfi preparation wherein a mixture of khoa and sugar is heated at low fire with sufficient working
and kneading till desired texture is attained. Peda is normally made into round balls of about 20-25g size by rolling
between the palms. Nandini peda is a sweet condiment which is prepared out of the following main ingredients: Khoa,
sugar, pasteurized milk..
The following modifications in method of preparation of peda are made to meet special requirements. Sugar is added
when 20% moisture evaporate or before condensing of milk to develop more burnt and caramelized taste, grainy
texture. (This method is used in Kuttch district of Gujarat. Khoa and sugar are cooked with or without ghee for a long
time to obtain completely brown color peda of long keeping quality. This method is adopted in Mathura and Dharwad
districts.) For getting a white product, sugar is added to khoa and mixture heated at relatively slow heat. Packing with
MAP. After it will be dispatch
Milk peda Dharwad peda
FLOW CHART 100g %RDA

Energy, kcal 449 2.2
Collection of raw chilled Milk (4.5% fat Carbohydrates, g 58.0
&8.5%SNF) Total sugar, g 58.0
Added sugar,g 41.0 8.2
Energy, kcal 433 Total Fat, g 18.3 2.7
Carbohydrates 55 Saturated Fat, g (not 12.0 5.4
Total sugars, g 55 more than)
Added Sugar, g 34 Trans fat, g 0.0 0.0
Cholesterol, mg 55.0
Total fat, G 17.6
Protein, g 13.0 2.4
Saturated Fat 11.4 Calcium, mg 488 4.9
Trans Fat, g 0 Sodium, mg 203 1.0
Cholesterol, mg 53
Protein, g 13.7 QC Check
Calcium, mg 514
Sodium, mg 204
Vitamin A, µg 150 Pouring the milk into Khoa Pan
Evaporation with continuous stirring (90-95˚C)
Transferring the Khoa into SS tray
Allow for cooling at room temperature for 10-12 hrs
Ball making for Dharwad peda, (dusting with sugar)
Shaping for milk peda
29
Packing
Dispatch
Sugar crystallization
Receipt of sugar in HDPE bags
QC inspection
Addition of sugar in semisolid stage for peda making
Preparatation of saturated solution
Vigorous stirring & boiling
Crystallization
Cooling & sieving
Sugar in dust from
5.2.3 MYSORE PAK:
Karnataka’s traditional sweet made from pure ghee. The texture of this sweet is similar to fudge. It is made of
generous amounts of ghee, sugar and gram flour. Collection of sachet milk (4.6% fat &8.5% SNF ). Then pouring the
milk into Mysore pak vat 250 L, adding sugar and continuous stirring it heating upto 90- 95˚C for 30 min till it
reaches semisolid. Then adding ghee and also adding Bengal gram flour to it & mixing uniformly. Again add the ghee
and heat and stir it uniformly at 90-95˚C still it reaches doughly state & golden yellow color, drain excess ghee from
the product and transfer it into stainless steel trays allow it cool at room temperature and cut into rectangle and
packing with MAP. After it will be dispatch.
30
100g %RDA
Carbohydrates, g 47
Total sugar, g 40
Added sugar,g 37.5 19
Total Fat, g 46 17
Saturated Fat, g (not more than) 30 34
Trans fat, g 0.0 0.0
Cholesterol, mg 136
Protein, g 3.7 1.7
Calcium, mg 22 0.6
Sodium, mg 16 0.2
FLOW CHART
Collection of sachet milk (4.6% fat & 8.5% SNF)
QC check
Pouring the Milk into Mysore pak vat
Addition of sugar
Continuous stirring
Heating 90-95˚C /30 min till it reaches semisolid
Addition of Bengal gram flour
Continuous stirring at 90-95˚C
Addition of ghee
Heating and stirring at 90-95˚C still it reaches doughly state & golden yellow color
31
Drain excess Ghee from product
Transfer to SS trays and allow for cooling to room temperature
Cutting
Packing
Shrink wrapping
Dispatch
5.2.4 GREEN GRAM LADDU:
Green gram is rich in nutrients, particularly protein. First green gram flour is roasted with ghee, adding sugar powder
to it and adding elachi,cashew & pista and kneading it and making laddu. Packing with MAP. After it will be dispatch.
Nutritional information per 100 g
100g %RDA
Total sugar, g 42.6
Added sugar,g 39.5 26.9
Total Fat, g 40.6 20.6
Saturated Fat, g (not more than) 12.4 19.2
Trans fat, g 0.0 0.0
Cholesterol, mg 53.2
Protein, g 10.7 6.7
Calcium, mg 60 2.0
Sodium, mg 77.5 1.3
FLOW CHART
Receiving of Green Gram Dhal
Wet Cleaning
Roasting of Green Gram Dhal

32
Grinding into powder form
Roasting of Powder with step by step & cooling for 10 min
Addition of sugar powder, Ghee, Cashew, Elachi and pista
Mixing & kneading
Making balls of required size
Packing
Dispatch
5.2.5 PANEER:
Paneer is Indian cheese which is made by acid coagulating whole milk at high heat. It is also known as cottage
cheese or farmer’s cheese. It is unaged and non-melting fresh cheese. It is used in a variety of dishes the
main essentials needed to make paneer is heated milk, milk breaker or milk protein coagulant such as lemon juice,
vinegar or any other good acids.
Paneer is made by standardization of milk having 4% fat &8.5%SNF. Milk is filled in paneer vat (1200 liters). Heat
the milk upto 90-95˚C for 15 sec with continuous agitation mixing. Cooling it when it reaches to 85˚C . add glacical
acetic acid (1%) leave it for 10- 20 sec for coagulation. removing of whey from paneer. Take out paneer from water
and fill in the paneer to the hooks and place to drain the excess whey from it. Pressing it 2-3 kgs/cm 2 and maintain for
40 min. collect the paneer blocks in SS vat and dipping in pasteurized chilled water for 2 to 3 hours at 4-5˚C. After
cutting of paneer blocks with SS knife as per requirements and packing with vacuum sealing and storage at < 4˚C after
it will be dispatch.
Nutritional information/100 ml paneer:
Energy, kcal 297

Fat, g 22.7
Trans fat, g 0.57
Protein, g 18.6
Vitamin A, µg 260
FLOW CHART
33
Receipt of raw chilled milk
Standardization of milk (4% fat & 8.5% SNF)
QC check
Heating to 90-95˚C
Cooling at 80-85˚C/ 20 min
Addition of Glacial Acetic Acid to from coagulate (1%)
Holding coagulate for 4-5 min
Draining of whey
Collect the solids and hooping
Pressing at 2-3 Kgs/cm2 & maintain for 40 min
Collect the Paneer Blocks in SS vat
Dipping in pasteurized chilled water for 2-3 hr at 4-5˚ C
QC check
Cutting of paneer blocks with SS knife as per requirements
Packing and vacuum sealing
34
Storage at < 4˚C
Dispatch
5.2.6 BUTTER
Butter is made by churning of pasteurized cream, to separate from other constituents. The liquid portions i.e., “butter
milk” will return back to raw milk and is reprocessed if COB is negative and the cream is further processed into
butter. Butter consists of 80% fat, Curd 1.5%, Salt 3%, Moisture 16%, small percentage of lactose and protein, the
remaining is water in the form of minute droplets dispersed throughout the butterfat. The butter is produced by
continuous butter making machine and packed manually. The capacity of butter production is approximately 8-10 tons
per day. The butter is produced by fresh cream after the minimum ageing period of 5 hours. The fat % of cream butter
is maintained around 38-42% for butter production in the continuous butter-making machine. There are 2 types of
butter (a) Salted Butter (b) Unsalted Butter.
PACKAGING:
1. Bulk packaging: 25 kg package using LDPE film as liners. 3ply cardboard is used for packing of butter. Usually
unsalted butter is used.
2. Retail packaging:10g, 100g, 500g, using packing machines in which the quantity can be adjusted accordingly.
3. Packaging material: Parchment paper is used as inside surface material and it is covered by paper box line
with polythene thin layer, both unsalted and salted butter are prepared.
Butter is composed of ingredients: Fat 80%, Curd 1.5%, Salt 3%, Moisture 16%. It is a dairy product which contains
up to 80% butterfat which is solid when chilled, at room temperature and liquids when warmed. It is made by
churning fresh or fermented cream or milk to separate the butterfat from the buttermilk
This process leaves approximately 18 liters of skim milk and buttermilk, which at one time were disposed of as animal
feed or waste. Commercial butter is 80-82% milk fat, 16-17% water, 1-2% milk solids other than fat, Curd 1.5%,
Moisture 16%. It may contain salt, added directly to the butter in concentrations of 3%. Unsalted butter is often
referred to as “sweet butter”.
Although there are over 120 different compounds that contribute to the butter’s unique flavor, the five primary factors
responsible for butter’s flavors include: fatty acids, lactones, methyl ketones, diacetyl and dimethyl sulfide.
Chemically butter fat consists essentially of a mixture of triglycerides, particularly those derived from fatty acids, such
as palmitic, oleic, myristic and stearic acids.
FLOW CHART OF SALTED BUTTER
Collection of pasteurized cream (38-42% Fat)
QC Check
Aging for 12 hr at 8-11˚C
35
Churning and working of cream in CBMM
Dosing of saturated brine solution
Receipt of butter
QC check
Collection and hardening of butter in trolleys for 12h
Packing
Storage in deep freeze (-18 to -22˚C)
Dispatch
FLOW CHART OF UNSALTED BUTTER
Collection of sweet butter milk and storage in BM Tank
Receipt of sweet butter milk to Dump Tank
Chilling and storage in Raw chilled milk silo
Collect Pasteurized cream
QC Check
Aging for 12 hr at 8-11˚C
Churning and working of cream in CBMM
36
Receipt of butter
QC check
Collection and hardening of butter in trolleys for 12h
Packing
Storage in deep freeze (-18 to -22˚C)
Dispatch
Energy, kcal 745

Fat, g 82.5
Trans fat, g 2.1
Cholesterol, mg 250
Protein, g 0.5
Carbohydrate, g 0
Vitamin A, µg 940
5.2.7 GHEE
Ghee is made by creamy butter method i.e., initially the cream is converted to butter through continuous butter making
machines and then this butter is melted and heated to make ghee. Ghee is made by melting butter (80˚C) over
medium-low heat until simmering. Removing of butter milk the water in the butter slowly evaporates, the milk solids
sink to the bottom of the pan. After all the water has evaporated (the butter will stop making a sputtering sound), it’s
removed from the heat, and poured through a cheesecloth-lined strainer to remove the milk solids. The leftover is
pure butterfat (clarified butter).The absence of milk solids leaves ghee with a much higher smoke point, which makes
it a lot easier to cook with over high heat. Since the milk solids are slightly toasted when making ghee, it has a more
golden color than regular clarified butter and it is a bit deeper in flavor.
STORAGE:
Pour ghee into heatproof jar and it will last quite a while. It doesn’t go rancid as quickly as regular butter, so it is okay to
leave it out at room temperature, away from light and heat, for about 9 months. To extend its life, store it in a fridge, where it
37
can last for up to a year. Like coconut oil, it will harden in the fridge, but soften up relatively quickly when left out on the
counter for 5-10 minutes.
Energy, kcal 897

Total carbohydrates 99.7
Cholesterol, mg 300
Protein, g 0
Saturated Fat, g 59.2
Vitamin A 700
FLOW CHART
Collection of Butter in Trolleys
Transferring to Butter Melting Vat Draining of Curd Particles
Transferring to Ghee Boilers
Boiling of Melted Butter to 118 to 121˚C/ 10-15 Min
Cooling
Clarification
Storage of Ghee in Storage Tank & Granulation
QC Check
Packing
Dispatch
38
 YIELD OF THE PRODUCT
SI NO PRODUCT YIELD
1 Khoa 20-25 kg /120 ltrs
2 Peda 18-20 kg/80ltrs
3 Mysore pak 15kg
4 Green gram laddu 20kg

18-20%
5 Paneer (180 -200kg per batch
1200ltrs) depends upon fat
1-2 ton
6 Butter
Depends upon fat content
1 ton
7 Ghee
Depends upon fat content
 PRODUCTION
SI NO PRODUCT PRODUCTION
1 Khoa 1-1.5 tons/month
2 Peda 180-280 kg/day
3 Mysore pak 50-80kg/day
4 Green gram laddu 150kg/week
5 Paneer 1-1.5tons/day
6 Butter 1-2 tons/day
7 Ghee 1 ton/day
Product availability and price
SI NO PRODUCT MRP/UNIT
200 g/90rs
1 kg/ 350rs
01 Khoa
Bulk
100g/50rs
02 Dharwad Peda 250g/ 125 rs
39
100g/60rs
03 Milk Peda
250g /140rs
04 Mysore Pak 250g/160rs
05 Green Gram Laddu 200g/100rs
10g/
06 Butter 100g/
500g/255rs
200g/90
500g/190
07 Paneer
1kg/ 370rs
Bulk
200ml/135rs
500ml/305rs
08 Ghee 1ltrs/610
15kg/10,200rs
40
SPECIFICATION OF THE PRODUCTS
1. SPECIFICATION FOR PEDA
SI NO PARAMETERS KMF STANDARDS

It shall have uniform granular texture & consistency.
The surface should not be dry & nor should be
1 Appearance & colour sandy. The co;our of the product shall conform
declared type and designation. It shall be free from
discoloration, rancidity and bitterness.
It shall have characteristics flavor.it shall be free
2 Odour & flavor
from objectionable flavor and odours.
3 Moisture,% Max. 15.0
4 Fat,(on dry basis),% Min.12.5
5 Acidity,% as lactic acid Max. 0.35
6 Lactose, percent by weight Min. 12.0
7 Sucrose, percent by weight Min. 40.0
8 Total plate count ,/g Max. 30,000

9 Yeast & mould /g Max. 10
2. SPECIFICATION FOR MYSORE PAK
It shall have uniform granular texture & consistency.

1 Appearance & colour The surface should not be dry & nor should be dry. It
shall be in golden yellow colour
It shall have pleasant characteristics flavor. It shall be

2 Odour & flavor
free from objectionable flavors & odors
3 Moisture, percent by mass Max. 6.0
4 Fat,(on dry basis), percent by mass Min. 40

Acidity of extracted fat (as oleic
5 Max.1.0
acid), percent by mass
6 Total plate count ,/g Max. 5000
7 Yeast & mould /g Max. 50
8 Coliform count/ g Max.10
41
3. SPECIFICATION FOR PANEER
It shall be free from signs of fat or water

seepage or both and mouldinees. It shall be
1 Appearance & colour white to pale yellow. No extraneous colour
shall be added.
It shall have pleasant curdy flavor. It shall be

2 Odour & flavor
free from objectionable
It shall have a uniform smooth texture, firm
3 Texture & consistency cohesive and spongy body. It shall be free
from coarseness
4 Moisture, percent by mass Mot more than 70.0
Fat,(on dry basis), percent by

5 Not less than 50.0
mass
Acidity as lactic acid, percent
6 Max. 0.50
by mass
7 Total plate count ,/g Max. 3,00,000
8 Coliform count/ g Max. 50
9 E.coli/g Less than 10
10 Salmonella/g Absent
Staph aureus/g
11 Max.50
(co agulase positive)
12 Listeria monocytogenes Absent
13 Yeast & mould Max.150
42
4. SPECIFICATION FOR PASTEURISED SALTED/TABLE BUTTER
Sall be free from vegetable oil and fat,

animal body fat, mineral oil,added
flavor, wax and extraneous matter. It
shall have the characteristic smell
agreeable taste. It shall be clean,
1 General characteristics
pleasant and free from objectionable
odour and rancidity. The colour of the
butter shall be uniform and without
any streakiness, mottling or signs of
curd particles.
2 Moisture, percent by mass Max.16.0
3 Curd, percent by mass Max.1.0
4 Fat, percent by mass Min.80.0
5 Acidity (as lactic acid), percent by mass Max 0.15
6 Coomon salt, percent by mass Max 2.5
7 Total plate count/g Max. 10000
8 Coliform count/g Max.10
9 E.coli/g Absent
10 Salmonella/25g Absent
Staph aureus
11 max.10
(co agulase positive)/g
12 Listeria monocytogenes/g Absent
13 Yeast & mould/g Max.20
43
5. SPECIFICATION FOR PASTEURISED UNSALTED BUTTER
It shall be clean, smooth, firm and of

uniform colour and or no signs of curd
particles, the flavor and aroma of butter
shall be pleasant and free from
objectionable odour and rancidity. It
1 General characteristics
Sall be free from vegetable oil and fat,
animal body fat, mineral oil,added
flavor, wax and extraneous matter. It
shall have the characteristic smell
agreeable taste
2 Moisture, percent by mass Max. 16.0
3 Curd, percent by mass Max. 1.5
4 Fat, percent by mass Min. 82.0
Acidity (as lactic acid), percent by

5 Max. 0.06
mass
6 Total plate count/g Max. 10000
7 Coliform count/g Max.10
8 E.coli/g Absent
9 Salmonella/25g Absent
Staph aureus
10 Max. 10
(co agulase positive)/g
11 Listeria monocytogenes/g Absent
12 Yeast & mould/g Max.20
44
6. SPECIFICATION FOR GHEE SPECIAL GRADE
The ghee shall be pure, clarified milk fat

only and shall have the natural, sweet,
pleasant odour, agreeable taste and free
1 General from rancid or other objectionable
flavor, the ghee shall be clear,
transparent and free from sediment or
foreign coloring matter.
The solid phase shall be well defined

2 Texture
granular structures,
White or golden yellowish and shall be

3 Colour
uniform throughout
4 Moisture % Not more than 0.3
5 Free fatty acid as oleic acid,% Max. 0.6
6 Butyro refractometer reading at 40˚ 40.0 - 43.0
7 Reichert meissl value Not less than 28.0
8 Polenske value 1.0 – 2.0
9 Baudouin test Negative
45
PRODUCTION EQUIPMENTS
SI NO EQUIPMENTS CAPACITY MANUFACTURER
1 Khoa pan vat 120 ltrs R.M.P
2 Mysore pak vat 250 ltrs R.M.P
3 Panner vat 1200 ltrs R.M.P
4 CBMM 1500kg/ hr Tecnal
5 Cream balance tank 120 ltrs Pornpe moineau
6 Butter melting vat 2 ton R.M.P
7 Ghee settling tank 2500 ltrs VULCAN- LAVAL
Unitech engineering Ltd

8 Ghee boiling tank 1500 ltrs
Pvt
9 Vacuum packaging (Weight 5 kg) Sevana
46
Packaging
47
PRODUCTS PACKET
1. khoa 2.Dharwad Peda
3. Milk Peda 4. Mysore pak
5.. Green Gram Laddu 6. Paneer
48
7. Ghee
8. Butter
49
Chapter 6
QUALITY CONTROL
Quality control and quality assurance department are the heart of the dairy plant without which a dairy cannot exist. It
follows certain principles, measures, etc. which controls the production activity in a plant. After getting confirmation
from quality control department, the product is further packed and sold. This section assures for the safety of milk and
milk products manufactures in that particular dairy.
The major activity conducted by Quality Control department is:
 Checking the quality of incoming raw milk.

 Checking and microbial analysis of incoming raw milk.
 Checking the quality of milk at processing and after processing stage.
 Conducting the tests to confirm quality of the products.
 Checking the sterility of working surface.
 Checking the suitability of water use in dairy industry, etc.,
DAMUL has two quality control labs
1. One is in the root where minimal tests can be done, that is checking CLR, Fat , adulterations & other platform tests
2. Another one is main lab, which also has microbial lab facilities where all types of quality control activities takes
place.
Various tests performed in quality control laboratory
Products Tests
Raw milk Alcohol test, COB, CLR, Acidity, Fat, SNF, MBRT,
SPC, Coli forms, Temperature.
Processed milk Acidity, Fat, SNF, Phosphatase test, MBRT, SPC, Coli
form , E-coli , Temperature.
Cream Titratable acidity, fat, Temperature ℃
Buttermilk Acidity, Temperature ℃, Fat% , SNF
Ghee Moisture, FFA, B.R. reading, R.M.VALUE & P.V,
Temperature.
Butter Moisture, acidity, fat, curd content, yeast &mold, SPC,
Coliform , E-coli , Temperature.
Skim milk powder Moisture, TS, Total ash, TA, Fat, Bulk density, Wet
ability, SPC, Coli forms, yeast and mold count, E-coli
sensory evaluation
Curd Acidity, body & texture, sensory evaluation,
Temperature. Coli forms, yeast and mold count, E-coli
Sweets Moisture, fat, microbial load.
50
PLATFORM TESTS
Objectives:
For examination of milk by adopting rapid test for acceptance / rejection of incoming milk. Platform tests include the
tests for judging the quality of the raw milk.
1. Organoleptic Evaluation
Examine the given sample of milk and record your observations on following aspects.
2. Odour / Smell:
 It can be judged within few seconds.

 Remove the lid of can hold it inverted and raised to the nose and inhale the smell.
 Record the odour / smell as normal or abnormal.
 Milk should be free from any off flavour like feed, fishy, barny etc.
3. General Appearance:
Note whether the milk is clear or any visible dirt or foreign matter has gained entrance in milk. If so describe its
nature for detecting the amount of dirt, in the milk, conduct the sediment test if necessary.
4. Consistency:
Record the consistency of milk as normal, watery, thick, ropy, and slimy.
5. Colour:
Observe the colour of milk as white, light yellow; record whether colour of milk is normal or abnormal. (Abnormal
colour are reddish, bloody, bluish etc.)
6.1 MILK
6.1.1 CLR(Corrected Lactometer Reading at 27°C)
It is done to check the density of milk(both raw and pasteurized milk) using Lactometer
Principle: It works on the Archimedesprinciple,it measures the relative density of milk with respect to water.
Procedure:
 First heat the milk until it reaches 40°C then cool it upto 27°C .
 Mix the sample of milk well. Pour it into a dry cylinder which enables the lactometer to float without touching
the sides.
 Let the lactometer into the cylinder. Take the reading from the lactometer as soon as it becomes stationary.
Note the lactometer reading (CLR) if any deviation in temperature correction facto should be considered.
51
6.1.2 Titratable acidity of milk
The titratable acidity test is employed to ascertain if milk is of such a high acidity as to reduce its keeping quality and
heat stability.
Principle:
Natural acidity in milk is due to its constituents, such as casein, albumin, citrate, phosphate and carbon dioxide. This
acidity can be measured by titrating milk against a standard alkali using as indicator like phenolphthalein and is
expressed in term of lactic acid.
Procedure:
 Fill the burette with N/10 NaOH solution.

 Transfer 10 ml milk with the pipette in conical flask.
 Add equal quantity of distilled water.
 Add 3-4 drops of phenolphthalein indicator solution.
 Take the initially reading of the alkali in the burette at the lowest point of meniscus.
 Rapidly titrate the contents with N/10 NaOH solution continue to add alkali drop by the drop till change to
pink colour which remains constant for 10 to 15 seconds.
 Note down the final burette reading.
Calculation:
Acidity=Burette reading×9×0.1
6.1.3 FT1 Test:
FT1 analyses the main product components in milk as well as screening for milk abnormalities that is adulterant in
milk– all at once.
Principle: analyses the product using FT-Infrared technology, assessing milk constituents, using absorption at
different wavelengths in the infrared spectrum to detect the presence of specific parameters in milk like Fat, SNF and
Protein.
52
Detection of adultrants in milk
Targeted adulterant Detection limit of FT 1 As per FSSAI Norms

Ammonium sulphate 0.09 0.09
Detergent 0.15 0.15
Glucose 0.15 0.10
Maltose 0.25 0.30
Melamine 0.10 -
Salt 0.27 0.02
Sodium bicarbonate 0.07 0.1(Na2Co3:NaOH)
0.2(NaHCo3)
Sodium citrate 0.09 -
Sorbitol 0.15 -
Starch 0.30 0.02
Sucrose 0.12 0.10
Urea 0.05 0.20
Vegetable oil 0.36 -
Formaldehyde 0.10 0.10
Maltodextrin 0.11 0.30
6.1 4 MRBT (Methylene Blue Reagent Test) :
To determine the shelf life of milk under room temperature.
Principle:
The methylene blue reduction test is based on the fact that the colour imparted to milk by the addition of a dye such as
methylene blue will disappear more or less quickly. The removal of the oxygen from milk and the formation of
reducing substances during bacterial metabolism causes the colour to disappear. The agencies responsible for the
oxygen consumption are the bacteria. Though certain species of bacteria have considerably more influence than
others, it is generally assumed that the greater the number of bacteria in milk, the quicker will the oxygen be
consumed, and in turn the sooner will the colour disappear. Thus, the time of reduction is taken as a measure of the
number of organisms in milk although actually it is likely that it is more truly a measure of the total metabolic
reactions proceeding at the cell surface of the bacteria.
Procedure
 Take 1ml of methylene blue indicator in 15×150mm test tube as per the number of sample
 Add 10ml of milk sample to it, immediately close test tube with sterile rubber cork to avoid cross
contamination.
 Keep all the test tube to hot water bath at 37°C.
53
 Observe for colour change after few hours.
Result
Change in colour from light yellow to milk white shows the spoilage of milk, time must be note down which indicates
the shelf life of that milk.
6.1.5 Fat Analysis (Using Gerber method)
Apparatus required
 Butyrometer 10% scale (0-10% scale with 0.1% mark)

 10ml automatic measure for sulphuric acid
 10.75 ml pipette for milk
 1ml automatic measure for amyl alcohol
 Stoppers for butyrometer
 Gerber Centrifuge (1200-1500 +/- 70 RPM) Water bath (65 +2°C)
 Butyrometer stand
 Lock Stopper Key
Reagents:
 Sulphuric Reagents: acid (Specific Gravity 1.807 to 1.812 gm/ml at 27 C) corresponding to a concentration of
90 to 91% by mass which is normally called as Gerber Sulphuric Acid.
 Iso amyl alcohol (Specific Gravity 0.810 to 0.812 gm/ml at 27°C) conforming to grade I of IS:360:1964 of
clear and colorless liquid shall distil berne 30 to 132°C
Procedure:
 Take calibrated Butyrometer.

 Pour 10ml of 90% con. Sulphuric acid into that butyrometer.
 Slowly add 10.75ml milk sample using pipette.
 Add 1 ml of iso amyl alcohol to it.
 Close the butyrometer by stopper.
 Mix well.
 Heat if required.
54
 Keep it in Gerber machine at 1500 RPM for 5 min.
 Adjust the fat column within the scale on butyrometer and take the reading.
6.1.6 Determination of Ash Content
Principle:
Milk contains soluble substances containing salts like the phosphate , citrate , Sulphate , chlorides and bicarbonates of
calcium , Magnesium , potassium ,sodium etc…heating of milk at higher temperature decomposes organic matter and
soluble inorganic salts are left behind in the form of ash.
Procedure:
 Heat the dish in order to remove any moisture from it. Cool in a desiccators to room temperature and weigh it
accurately.
 Weigh 10gm of milk in the weighed dish.
 Evaporate the sample to dryness on water bath, avoid spilling and spurting of milk by using thin glass rod
drawn to a point and remove any particle adhering to the rod into the dish. Ignite the sample.
 Keep the ignited sample in a muffle furnace at temperature of 550-600°C until the ash is free from carbon
(white precipitate).
 Cool in desiccators to room temperature weigh quickly and accurately.
Observation:
Weight of empty dish = Wg.
Weight of dish with milk=W1g.
Weight of dish after ashing=W2g
Weight of milk taken =W1-Wg.
Weight of ash =W2-Wg.
Calculations:
Percentage of ash = (W2-W)/(W1-W)*100
6.1.7 Clot on boiling test
It is done to check the developed acidity /Spoilage of milk & to check weather the milk is fit for processing or not.
Principle:
The organoleptic tests of determining the quality of the milk is not very reliable. Milk of highly developed acidity
clots on boiling.
Procedure
 Take 5ml of milk sample in a sterile test tube.

 Heat that test tube using Bunsen burner on direct flame.
 Observe whether the milk clot after it starts boiling
Results
If milk gets clot after boiling it indicates milk gets spoiled due to excess of acidity.
55
6.1.8 Alcohol test
To determine the heat stability of milk
Principle:
The alcohol determines the susceptibility of the milk to coagulation due to developed acidity, salt imbalance or high
albumin content.
Procedure:
 Take 5ml of milk sample in a test tube.

 Add 5ml of ethyl alcohol (70% alcohol).
 Mix well.
Results
If clot occur then it is positive for alcohol which is undesirable, if milk is clear then it is negative for alcohol.
6.9 ADULTERATION TEST FOR MILK
1.UREA TEST:
Procedure:
 Take 2 ml of milk
 Add 2 ml of urea reagent and mix well (Dimethyl amino benzaldehyde) 1.6 g of dissolved in 100 ml of water
 Add 10 ml of con HCL solution
56
Observation:
As indicated in the above chart if thick yellow colour appears then it is adulterated with urea.
2. STARCH AND CEREAL FLOURS TEST:
Procedure:
 Boil 5 ml of well-mixed milk and cool it.
 Add a few drops of starch reagent.
Observation:
As indicated in the above chart if purple colour appears then it is positive to starch adulteration.
3. SUGAR:
Procedure:
 Take 1 ml of milk,
 Add 1 ml 0f sugar reagent (RESORCINOL AR C6H602 ) add 6 ml +35 ml of hydrochloric acid
 Place in a boiling water bath for 3-5 minutes .
Observation:
As indicated in the above chart if brick red colour appears then that milk is adulterated with sugar.
4. SALT TEST:
Procedure:
 Take 5 ml salt reagent -1 (Agno3 –0.1 N )
 Add a few drops of salt reagent 2 = 10 % potassium chromate ( red colour develops )
 Add 1 ml of milk and mix well
Observation:
As indicated in the above chart if thick yellow colour appears then it is positive for Salt adulteration.
5. NEUTRALIZERS TEST:
Procedure:
 Take 2ml of milk Add 2 ml
 Neutralizer reagent and mix well
Observation:
As indicated in the above chart if thick pink colour appears then it is positive for neutralizer adulteration.
6.2. GHEE
6.2.1 Free fatty acid (FFA) Test
It is done to determine the acidity of Ghee (ie-> Oleic acid)
Procedure:
 Take 50ml of spirit and 10g Ghee in a separate 250ml conical flasks.
 Titrate conical flask containing spirit by adding 2-3drops of phenolphthalein indicator against 0.1N NaOH sol.
In a burette.
 Heat both conical flask.
 Mix both solutions in a single conical flask.
 After it reaches ~65°C add few drops of phenolphthalein indicator to it and titrate against 0.1N NaOH sol. In a
burette.
57
 Take burette reading.
Calculation:
Burette reading ×2.82
FFA= ------------------------------
Sample taken
6.3 PANEER
6.3.1 Moisture Estimation:
Procedure:
 Take a sterile dry dish plate and weigh it.

 Take ~3g of paneer sample in that dish plate.
 Keep it in a Hot air oven under 100°C for 3hrs.
Calculation:
Take the readings after 3hrs and calculate the difference in weight
6.3.2 Acidity
Procedure:
Take 1g of paneer sample in a small beaker.
 Add 10ml warm water to that beaker.

 Add 2-3 drops of phenolphthalein indicator to it.
 And titrate against 0.1N NaOH sol. In a burette.
Calculation:
Burette reading ×9×0.1
Acidity= -----------------------------------
Sample taken
6.3.3 Fat
Procedure:
 Weigh 1.690g of sample in a small beaker

 Add 10ml of hot water to that beaker
 Take 10ml of Sulphuric acid in a Butyrometer
 Add the above prepared sample to it
 Add 1ml of iso amyl alcohol to that mixture
 Close it with stopper
 Mix well
 Heat In a hot water if required
 Keep it in a Gerber machine at 1500 RPM for 5min
58
 Adjust the fat column within the scale on butyrometer and take the reading.
Observation:
Observe for fat concentration.
6.4 WATER SAMPLE TEST
4 Water Samples are taken:
 DM-Demineralised water.
 SW-Soft water.
 BF-Boiler feed water.
 BDW-Boiler blowdown water.
6.4.1 Hardness test:
To check concentration of CaCO3 in water sample
Procedure:
 Take 50ml of all water sample in a beakers

 Add 2ml of ammonium solution to all beaker
 Then add 2 drops of Ericher indicator to all beaker
 Titrate individual beakers against 0.02N EDTA Sol. In a Burette
Observation:
Observe for the colour change during titration and note down the burette value.
Calculation:
Burette reading×20
6.4.2 Alkalinity Test
It is done to determine the concentration of carbonate and bi-carbonate in water sample.
Procedure:
 Take 10ml of all four water sample in separate beakers.

 Add 2-3 drops of 1% methylene orange indicator to all beakers.
 Titrate all beakers against 0.1N HClin a burette.
Observation:
Calculation:
Burette reading×100
6.4.3 Caustic alkalinity test
To determine the NaOH concentration in water sample. And it is done only for DM and BDW sample
Procedure:
59
 Take 10ml of water sample in a beaker.
 Add 2-3 drops of phenolphthalein indicator.
 Titrate against 0.1NHCl in a burette.
Observation:
6.5 Packaging materials test:
Milk and milk products are classified in several categories and require a different types of container and level of
protection depending on the conservation techniques used and the shelf life expected. Packaging is a technique of
using the most appropriate containers and components to protect, carry, identify and merchandise any product. It
constitutes an important link between the manufacturer and ultimate consumer for the safe delivery of the product
through different stages of production, storage, transport, distribution and marketing.
Though great efforts have been made in producing high grade processed milks or manufactured dairy products, unless
they are delivered in a fresh, sound and suitable form to the consumer, they are likely to be rejected, thus causing
enormous wastage. The loss can be offset to a great extent by adequate protective packaging to withstand the hazards
of climatic changes, transportation, handling etc.
General requirements in packaging
6.5.1 Width:
The width of the film shall be 324+/- 2mm for films other than 6 litres.
The width of the film shall be 595+/- 2mm for 6 litres.
Volume of milk packets Thickness (in micron) Pouch length (in mm) Yield(packets per Kg)
250 ml 41-47 110 ~680
500 ml 43-49 150 ~480
1ltr 52-58 230 ~560
6.5.2 Drop test: Sixteen samples of filled pouches shall be taken randomly from the filling line. The temperature of
the pouches must be maintained within 4° C of the filling temperature of the milk. Sample pouches shall be dropped
from an appropriate height on flat surface.
Each one of the samples are dropped in the following order: on the flat side, on the opposite side, on flat longer edge,
on opposite longer edge. The samples will be deemed to have passed the test if not more than four pouches burst out
of 20.
6.5.3 Test for ink adhesion: The printed film is immersed in milk for 12 hours at a temperature of 8°C. The film must
be then be removed from the milk and wiped dry with a cloth. The printed surface isthen rubbed gently with a tissue
paper. The milk should not affect the film is a way to reduce the printed matter not readable after the test.
6.5.4 Leak test: The milk pouches made from the film when filled with milk at about 8°C and sealedshall not show
any leakage when subjected to uniformly distributed load of 2.5 kg for 200ml and 250 ml pouch, 5kg for 500 ml, 10
kg for 1 liter pouch and 30 kg for 6 liter pouch in flat position for 10 minutes with sealed side on top.5.
6.5.5 Random weight test: The milk is taken randomly from machines and weighed. The measured weight must fall
within the range and if it differs the flow must be varied to suit the range of weights.
Volume of packets Acceptable weight range
60
250ml 255-260
500ml 515-520
1L 1030-1035
6.6 MICROBIOLOGY
Microbial analysis is classified into three areas
1. Low risk area- Analysis done once in a month.
2. Medium risk area- Analysis done once in 15 days.
3. High risk area- Analysis done weekly for every products.
Various tests performed in Microbial laboratory are
6.6.1 MBRT (Methylene Blue Reagent Test) and Phospatase test
The methylene blue reduction test is based on the fact that the color imparted to milk by the addition of a dye
like methylene blue will disappear more or less quickly. The removal of the oxygen from milk and the formation of
reducing substances during bacterial metabolism cause the color to disappear. The agents responsible for the oxygen
consumption are the bacteria. Though, certain species of bacteria have considerably more influence than others, it is
generally assumed that the greater the number of bacteria in milk, the quicker will the oxygen be consumed, and in
turn the color will disappear. Thus, the time of reduction is taken as a measure of the number of microorganisms in
milk. Although, it is likely that it is more truly a measure of the total metabolic reactions proceeding at the cell surface
of the bacteria. The test is useful in assessing the bacteriological quality of milk by determination of the time taken for
the reduction of methylene blue in milk indicated by its colour change.
Principle:
Oxidation reduction potential of a substrate may be defined generally as the chemical process in which the substrate
either loses or gains electrons. When an element or compound loses electrons the substrate is said to be oxidized,
while a substrate that gains electrons becomes reduced.
Milk, as it exists in the udder has a sufficiently low redox potential to reduce the methylene blue immediately. The
processes like milking, cooling, dumping etc. raise the oxidation reduction potential of milk to +0.3V, because of the
incorporation of atmospheric oxygen. At this particular O-R potential, methylene blue is in oxidized state. When
bacterial cells multiply in milk these, consume dissolved oxygen and as more and more oxygen is used and gets
depleted, the dye starts acting as electron acceptor instead of oxygen. As the oxidation reduction potential decreases
61
from + 0.06 to � 0.01 V, methylene blue gets reduced. One atom of hydrogen is taken up by the double bonded
nitrogen of the dye that converts it into colourless state. The greater is the number of microorganisms in milk, the
greater is the metabolic activity and the faster is the reduction of methylene blue.
Procedure
 Take 1ml of methylene blue indicator in 15×160mm testube as per the number of sample.
 Add 10ml of milk sample to it, immediately close testube with sterile rubber cork to avoid cross
contamination.
 Keep all the testube to hot water bath at 37°C.
 Observe for colour change after few hours
Result
Change colour from blue to white shows the pasteurization of milk whether it pasteurize or not, time must be noted
down.
6.6.1 Phosphatase test:
Pasteurisation is an essential process in the production of milk which is safe and free from pathogens. Alkaline
Phosphatase is an enzyme which is naturally present in milk, but is destroyed at a temperature just near to the
pasteurization temperature. Alkaline Phosphatase test is used to indicate whether milk has been adequately pasteurised
or whether it has been contaminated with raw milk after pasteurisation. This test is based on the principle that the
alkaline phosphatase enzyme in raw milk liberates phenol from a disodium para-nitro phenyl phosphate and forms a
yellow coloured complex at alkaline pH (Scharer, 1943). The intensity of yellow colour produced is proportional to
the activity of the enzyme. The colour intensity is measured by direct comparison with standard colour discs in a
Lovibond comparator. The test is not applicable to sour milk and milk preserved with chemical preservatives.
Apparatus required
1. Water-Bath -maintained at 37±l⁰C, thermostatically controlled.
2. Comparator - with special discs of standard colour glasses calibrated in µg p-nitrophenol per ml milk, and 2 x 25
mm cells.
3. Test Tubes - of size 16 x 1.50 mm and rubber stoppers to fit.
4. Pipettes - 1, 5, and 10 ml.
5. Filter Paper - Whatman No. 2 or equivalent.
6. Litmus Paper
Reagants
1. Sodium Carbonate-Bicarbonate Buffer - Dissolve 3.5 g of anhydrous sodium carbonate and 1.5 g of sodium
bicarbonate in one litre of distilled water.
2. Buffer Substrate - Dissolve 1.5 g of disodium p-nitrophenyl phosphate in one litre of sodium carbonate-
bicarbonate buffer. This solution is stable if stored in a refrigerator at 4°C or less for one month but a colour control
test should be carried out on such stored solutions
Procedure
62
1. Pipette 5 ml of buffer substrate into a clean, dry test tube followed by 1 ml of the milk to be tested. Stopper the
tube, mix by inversion and place in the water-bath
2. At the same time place in the water-bath a control tube containing 5 ml of the buffer substrate and 1 ml of boiled
milk of the same kind as that under test that is pasteurized homogenized, low fat.
3. After 2 hours, remove the tubes from the bath, invert each and read the colour developed using the comparator
and special disc, the tube containing the boiled milk control being placed on the left of the stand and the tube
containing the sample under test on the right. Record readings which lie between two standard colour discs by adding
a plus (+) or minus (-) sign to the figure of the nearest standard.
NOTE - If artificial light is needed when taking these readings, an approved ‘day light’ source of illumination must be
used.
Result
Change in colour from light yellow to milk white shows the spoilage of milk, time must be note down which indicates
the shelf life of that milk.
6.5.2 STANDARD PLATE COUNT METHOD-It is a technique called the ‘standard plate count’ to estimate the
population density of microorganisms in a media by plating a small and dilute portion of the sample and counting the
number of microorganism colonies.
There are pour plate, Streak plate and Spread plate method are done to determine the bacteria, yeast, mold and
coliform.
Pour plate method
The pour plate method is a microbiological laboratory technique for isolating and counting the viable microorganisms
present in a liquid sample, which is added along with or before molten agar medium prior to its solidification.
Objectives of Pour Plate Technique
 To isolate the microorganisms from the sample

 To calculate viable microbial load by counting colony formation unit (CFU) per mL
 To isolate the pure culture of microorganisms from a mixed population
 To isolate microorganisms in discrete colonies in order to study colony characters
Principle of Pour Plate Method

63
The pour Plate Method is based on the fact that when an agar medium mixed with microorganisms is incubated, each
of the viable microorganisms will multiply forming a separate colony. In this method, a certain volume, usually 1 mL,
of the serially diluted liquid sample is mixed properly with approximately 15 mL of specific molten agar medium of
about 40 – 45°C (less than 50°C) in a Petri plate. The medium is allowed to solidify and is incubated, usually at 37°C
for 24 – 48 hours. Following the incubation, the viable microorganisms in the sample will grow into visible colonies
on the surface of and within the medium. The visible colonies can be counted and CFU/mL can be calculated using
the following formula;
Number of colonies × Dilution factor

Total count (CFU/g sample) =
weight of the sample
Requirements for Pour Plate Method
 Liquid Specimen (or suspension of the solid sample)
For the pour plate, the sample must be either liquid or in suspension form. The solid sample must be suspended in a
suitable solvent that doesn’t influence the growth of any microorganisms or react with any material of the media.
 Suitable Solid Culture Media
Specific culture media is used for the isolation and differentiation of suspected (or specific) bacteria. The culture
medium is a solid agar medium that is melted and is at a temperature of 40 – 45°C.
 Petri Plates
Sterile Petri plates are used. They must be labeled before pouring samples or media.
 Test-tubes
Test tubes are needed for serial dilution during sample preparation. The tubes must be sterile.
 Sterile Distilled Water (or Sterile Broth)
Either distilled water or broth can be used for serial dilution. They are also used for dissolving the solid or semi-solid
sample.
 Micropipette (or Graduated Pipette)
A micropipette of 0-200µL or 1 mL capacity is required for measuring the sample during serial dilution and sample
inoculation.
 Other Laboratory Facilities
Procedure of Pour Plate Method
The general procedure for performing the pour plate method can be summarized as follows:
a. Arrange all the requirements, put on the PPE, sterilize the work surface, and set up the laboratory types of
equipment.
b. Sample preparation:
If the sample is in liquid form, serially dilute it to make the microbial load to the range of 20 – 300 CFU/mL. (Prior
pilot test may give exact value. You can prepare serial dilution up to 10-10 and use different dilutions.)
If the sample is in solid or semisolid form, dissolve it in sterile distilled water or sterile broth, or any other solvent.
(Generally, 1 gm sample is mixed with 9 ml of solvent to get the concentration of 10-1 gm/mL.)
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c. Media preparation:
Which we will discuss in detail in next slides
d. Arrange sterile Petri plates. Label at the edge of the bottom of the plate with the dilution factor, date, name,
sample ID, and other required information.
e. Inoculation:
Is the process of introducing microbes into a culture media so that it reproduces there.
f. Close the lid of the Petri plate. Allow the media to completely solidify.
g. Incubate the plate in an inverted position under suitable incubation conditions (mostly for 24 hours at 37°C).
Applications of Pour Plate Technique
 Used to isolate and enumerate viable bacteria and fungi (calculate CFU/ml) from suspensions or liquid
samples.
 Used in food and pharmaceutical industries to isolate microorganisms and calculate CFUs from raw materials
and products, like water, beverages, foodstuff, tissue samples, etc. This will help in quality control to ensure
whether the product is safe to consume or not.
 Used to isolate and enumerate microorganisms from soil to study soil microflora.
 Used to generate growth curves while studying microbial metabolisms and biochemical features, and the
effects of environmental factors on microbial growth.
 Used in getting discretely isolated colonies for obtaining pure culture and studying biochemical characters.
 Used in separating pure culture from mixed cultures.
Advantages of Pour Plate Technique
 It is easy to perform and doesn’t require extra tools or materials for inoculation.
 Don’t require previously solidified agar medium.
 Don’t have a risk of gouging during inoculation as like in streaking and spreading.
 Even a very low microbial load can be detected.
 Along with the isolation of microorganisms, their isolated colonies can be obtained. The number of CFU/mL
can be calculated as well.
 It can use any type of specimen like clinical or environmental samples, liquid or solid (it can be dissolved).
 It is suitable for isolating facultative and anaerobic microorganisms. Aerobes can also be isolated by this
method.
READY MEDIA USED IN PLATE COUNT METHOD
I. Plate count agar(PCA) media-For Bacteria
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Plate count agar (PCA) is a bacteriological substrate used for the determination of the total number of live, aerobic
bacteria in a sample. It is not a selective medium. The amount of bacteria is expressed as colony-forming units per
gram (CFU/g), in solid samples and per ml (CFU/ml) in liquid samples.
Principle of Plate Count Agar (PCA)
Plate Count Agar is also called Tryptone Glucose Yeast Agar or Casein-Peptone Dextrose Yeast Agar. The medium
contains an enzymatic digest of casein that provides amino acids, nitrogen, carbon, vitamins, and minerals for the
growth of the organism. Yeast extract primarily supplies the B-complex vitamins. Glucose is a fermentable
carbohydrate and provides an energy source for the growth of bacteria. Agar is the solidifying agent.
Composition of Plate Count Agar (PCA)
Ingredients(in Gms/L)
 Enzymatic Digest of Casein/tryptone-5.0

 Yeast Extract-2.5
 Glucose-1.0
 Agar-15.0
Preparation of Plate Count Agar (PCA)
 Suspend 23.5 grams in 1000 ml distilled water.

 Heat to boiling to dissolve the medium completely.
 Sterilize by autoclaving at 15 lbs pressure (121°C) for 15 minutes.
 Cool to 45-50°C.
 Mix well and pour into sterile Petri plates.
Uses of Plate Count Agar (PCA)
 Plate Count Agar is used for the enumeration of bacteria in food, water and other materials of sanitary
importance.
 It is also suitable for enumerating bacterial count of sterile rooms.
II. PDA(Potato Dextrose Agar) media- For Yeast and moulds
It is used for the cultivation, isolation and enumeration of yeasts and molds from foodstuffs and other materials. This
culture medium complies with the recommendations of the American Public Health Association for food (1992) and
the United States Pharmacopeia.
Principle of Potato Dextrose Agar (PDA)
Potato Dextrose Agar (PDA) contains dextrose as a carbohydrate source which serves as a growth stimulant and
potato infusion that provides a nutrient base for luxuriant growth of most fungi. Agar is added as the solidifying
agent. A specified amount of sterile tartaric acid (10%) may be incorporated to lower the pH of the medium to 3.5 so
that bacterial growth is inhibited.
Composition of Potato Dextrose Agar (PDA)
Ingredients(in Gms/L)
 Potatoes, infusion from-200.0

 Dextrose-20.0
 Agar-15.0
 Final pH ( at 25°C) 5.6±0.2
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Preparation of Potato Dextrose Agar (PDA)
 Suspend 39 grams in 1000 ml distilled water. Heat to boiling to dissolve the medium completely.
 Sterilize by autoclaving at 15 lbs pressure (121°C) for 15 minutes. Mix well before dispensing.
 In specific work, when pH 3.5 is required, the medium should be acidified with sterile 10% tartaric acid.
 The amount of acid required for 100 ml. of sterile, cooled medium is approximately 1ml.
 Do not heat the medium after addition of the acid.
Uses of PDA
 It is used for the detection of yeasts and molds in dairy products and prepared foods.
 It may also be used for the cultivation of yeasts and molds from clinical specimens.
 PDA with TA (Tartaric Acid) is recommended for the microbial examination of food and dairy products.
 PDA with Chlortetracycline is recommended for the microbial enumeration of yeast and mold from
cosmetics.
 PDA with Chloramphenicol is recommended for the selective cultivation of fungi from mixed samples.
III. VRBA(Violet Red Bile Agar) – For Coliform
Coliforms refer to all aerobic and facultative anaerobic, gram-negative, non-spore-forming rod-shaped bacteria that
ferment lactose with gas and acid formation within 48 hours at 35°C. Procedures to detect, enumerate, and
presumptively identify coliforms are used in testing foods and dairy products. One method for performing the
presumptive test for coliforms uses Violet Red Bile Agar (VRBA). Violet Red Bile Agar (VRBA) is a selective
medium used to detect and enumerate lactose-fermenting coliform microorganisms.
Principle of Violet Red Bile Agar (VRBA)
 It relies on the use of the selective inhibitory components crystal violet and bile salts and the indicator system
lactose and neutral red.
 Crystal violet and bile salts inhibit growth primarily of the Gram-positive accompanying bacterial flora.
 Degradation of lactose to acid is indicated by the pH indicator neutral red, which changes its color to red, and
by precipitation of bile acids.
 Thus, the growth of many unwanted organisms is suppressed, while tentative identification of sought bacteria
can be made.
 Organisms that rapidly attack lactose produce purple colonies surrounded by purple haloes. Non-fermenters or
late lactose fermenters produce pale colonies with greenish zones.
Composition of Violet Red Bile Agar (VRBA)
Ingredients(in Gms/litre)
 Peptic digest of animal tissue-7.000

 Yeast extract-3.000
 Sodium chloride-5.000
 Bile salts mixture-1.500
 Lactose-10.00
 Neutral red-0.030
 Crystal violet-0.002
 Agar-15.00
 Final pH (at 25°C): 7.4±0.2
Preparation and Method of Use of VRBA
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 Heat with stirring to boiling to dissolve the medium completely.
 Note: DO NOT AUTOCLAVE.
 Cool to 45°C and pour into sterile Petri plates containing the inoculum.
 Transfer a 1 mL aliquot of the test sample to a petri dish.
 Add 10 mL of Violet Red Bile Agar (at 48°C) and swirl to mix.
 Allow medium to solidify before incubating at 35°C for 18 – 24 hours; use 32°C for dairy products.
 Examine for purple-red colonies, 0.5 mm in diameter (or larger), surrounded by a zone of precipitated bile
acids.
 Continue with confirmatory testing of typical organism’s colonies.
Uses of Violet Red Bile Agar (VRBA)
VRBA is used for the isolation, detection, and enumeration of coli-aero genes bacteria in water, milk, and other dairy
food products and also from clinical samples.
IV. EMB(Eosin Methylene Blue) agar media – For Water and Milk powder
Eosin Methylene Blue (EMB) agar is a differential microbiological medium, which slightly inhibits the growth of
Gram-positive bacteria and provides a color indicator distinguishing between organisms that ferment lactose (e.g., E.
coli) and those that do not (e.g., Salmonella, Shigella).
Composition of EMB Agar
Ingredients(in Gms/liter)
 Peptic digest of animal tissue-10.000

 Dipotassium phosphate-2.000
 Lactose-5.000
 Sucrose-5.000
 Eosin – Y-0.400
 Methylene blue-0.065
 Agar-13.500
 Final pH (at 25°C): 7.2±0.2
Preparation and Method of Use of EMB Agar

 Mix until the suspension is uniform. Heat to boiling to dissolve the medium completely.
 Sterilize by autoclaving at 15 lbs pressure (121°C) for 15 minutes. AVOID OVERHEATING.
 Cool to 45-50°C and shake the medium in order to oxidize the methylene blue (i.e. to restore its blue color)
and to suspend the flocculent precipitate.
 Pour into sterile Petri plates.
 Allow plates to warm to room temperature.
 The agar surface should be dry before inoculating.
 Inoculate and streak the specimen as soon as possible after collection.
 If the specimen to be cultured is on a swab, roll the swab over a small area of the agar surface and streak for
isolation with a sterile loop.
 Incubate plates aerobically at 35-37°C for 18-24 hours and protect from light.
 Examine plates for colonial morphology. If negative after 24 hours, reincubate an additional 24 hours.
Uses of EMB Agar
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 EMB Agar (Eosin Methylene Blue Agar) is recommended for the isolation and differentiation of gram
negative enteric bacteria from clinical and nonclinical specimens.
 It is useful in differentiating gram positive and gram-negative bacteria.
 It helps in the isolation and differentiation of enteric bacilli and gram-negative bacilli.
 It is used in testing the quality of water, especially in determining if the water is contaminated by harmful
microorganisms.
 It differentiates microorganisms in the colon-typhoid-dysentery group.
 EMB media assists in visual distinction Escherichia coli, other nonpathogenic lactose-fermenting enteric
gram-negative rods, and the Salmonella and Shigella genera.
 It also helps in the isolation and differentiation of lactose fermenting and non-lactose fermenting enteric
bacilli.
6.5.3 Air Count/Sampling – especially it done to check the presence of bacteria, yeast and moulds in the working
environment. If enough microbial count occurs then that working area is not fit for production activity.
Air sampling is carried out to ensure that workplace or environmental air is meeting regulatory standards and to help
Occupational Hygiene and Health & Safety professionals assess employee exposure to airborne hazards.
Two methods of air sampling-Active and Passive
a) In active monitoring, a microbial air sampler is used to force air into, or onto its collection medium (e.g., Petri
Dish with nutrient agar based test media) over a specified period of time. The collected culture can then be
incubated and analyzed (ie., count bacterial and/or fungal, colony forming units (CFU), and identify if
required).
b) In passive monitoring, settle plates (Petri dishes) are opened and exposed to the air for specified periods of
time to determine what microbiological particles may be present in the environment, as they may settle out of
the ambient air, and onto the media surface of the Petri Dish.. These plates are then incubated and analyzed.
6.5.4 Swab method - is a practical analysis method used in the detection of microorganisms regarding personnel
hygiene and sanitation, surface control, environments and food.
a) Hand Swab test-Hands of workers must be clean to produce a quality product, hence frequently swab test is done
for hands to check the microbial load.
b) Apron Swab test – Similar to the hand swab apron swab is taken and check for microbial load in order to ensure
proper sterility in the working area and to ensure personal safety who are working in the lab.
c) Equipment swab test –It is done to determine the microbial load present in the equipment’s used in laboratory.
Example like Milk Cans, Paneer Vat, Utensils are rinsed in water and that water is tested for microbial load.
6.5.5 Pesticides test
Milk and dairy products present considerable socioeconomic importance but are also a regular pesticide residue
contamination source, which is considered a worldwide public health concern and a major international trade issue.
To detection of pesticide, pesticide kit is used (carbaryl rapid test)
6.5.6 Aflatoxin test–The main fungi that produce aflatoxins are Aspergillus flavus and Aspergillus parasiticus, which
are abundant in warm and humid regions of the world.
Aflatoxin M1 found in milk of dairy cattle is the metabolite of Aflatoxin B1 that occurs in feed materials.
Approximately 0.3 to 6.2 per cent of Aflatoxin B1 is converted into Aflatoxin M1 and excreted in milk of dairy
animals.
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To detect the aflatoxin in milk, aflatoxin kit is used.
6.5.7 Antibiotic test
Different analytical methods have been developed to examine the drug residues in milk, divided into screening tests
and confirmatory tests. Screening methods are qualitative-based methods like thin layer chromatography and
microbial inhibition test usually used to detect residues. In contrast, confirmatory methods are costly and require more
time and trained personnel. To detect the antibiotics in milk, antibiotic kit is used (ProGnosis and Delvotest ®)
6.6 Curd propagation
Starter propagation is the most important operation of the quality control unit of dairy plant as the quality of starter is
having a direct bearing on the quality of finished product. The main aim of propagation is to maintain pure cultures
and activate cultures without any loss of viability . The culture organisms are preserved in small quantities known
as‘stock cultures’. Fermentation process of any cultured dairy product relies on the ‘purity’ and ‘activity’ of the
starter culture.
An active starter must have the following characteristics
1. Must be active
2. Must contain maximum number of viable organisms
3. Must be free from contaminants
To obtain the above qualities of culture
1. The inoculum (Inoculation) is carried out under aseptic conditions
2. Growth is initiated in a sterile medium.
The dairy product manufacturers need to inoculate the culture into milk or other suitable substrate. Number of steps
are to be followed during propagation of starter culture for ready to use. They can be seen from the following:
I. Stock culture: can be obtained from
1.Research establishments
a.WDCM - The World Directory of collection of cultures of microorganisms.
Situated at the National Institute of Genetics, Shizuoka, Japan
http:// wdcm.nig.ac.jp
b. NCDC - National Collection of dairy Culture- NDRI ,Karnal.
c. ATCC -American Type Culture Collection
P.O Box 1549,Manassa, VA 20108, USA
Web: http:// www.atcc.org.
d.ECCO - European Culture Collections Organization
e.NCFB - National Collection of Food Bacteria-UK
f.NCIM - National Collection of Industrial Microorganisms- Pune
g.NIZO - Netherlands Dairy Research Institute
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2. Educational Colleges
3. Cultural stock Organizations
4. Commercial manufacturers
a. Chr.Hansen laboratoriam-Harsholm, Denmark. Specialized in DVS (Direct vat Set) cultures and ready
set cultures. In India- ESDEE chemocrats, 46 White Hall, 143 A, Kranti Marg, Mumbai-400 036
b. Wisby laboratoriam - Tonder , denmark.Specialized in DIP (Direct-in-product) cultures for direct

inoculation of milk.In India- Food & Pharma specialities, D-22, Nizamuddin East, New Delhi
c. Gist-brocades- Delft, TheNeteherlands- In Australia & USA
II.Mother culture - (first inoculation): allcultures will originate from this preparation.
III.Intermediate culture (feeder) –is used in preparation of larger volumes of prepared starter.
IV.Bulk starter culture - this stage is used in dairy product production.
Scale up system of propagation
Stock and mother cultures are propagated in laboratory and feeder and bulk cultures in the starter room of the dairy
plant.
Starter propagation steps
Different stages of starter propagation are

1. Selection of milk
2. Treatment of milk
3. Inoculation
4. Incubation
5. Cooling of starters
 Selection of milk
 Milk is a good medium for the propagation of starters because it gives better and milder flavour,better
viscosity. The milk meant for the starter propagation should be of high quality.
 Milk of first grade should be used
 Milk of abnormal quality i.e. mastitis milk or colostrums milk or late lactation milk should not be used
 Milk should be free from antibiotic residues
 Milk should be free from bacteriophage
 Milk should not contain residues of detergents and sanitizers
 Milks should have a low bacterial load
 Milk should have high SNF content
 Milk should have clean flavour and odour
 Milk of above characteristics is difficult to obtain and hence the NFDM (SMP) is used for the propagation of
starters as it avoids daily variations. Flavour and odour defects are easy to detect if skim milk is used for the
starter propagation.Skim milk with a total solids content of 10-11 % is desirable for the propagation of
starters.
 Treatment of milk
Milk is usually subjected to heat treatment before using for the inoculation of starters.
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 The purpose of heat treatment is
 To inactivate harmful organisms and bacteriophage in milk

 To inactivate the natural germicidal properties of milk such as immunoglobulin, LP system, lactoferrin and
lysozyme.
 To reduce the oxidation reduction potential of milk by driving out the dissolved oxygen
 To denature the proteins to make available the nitrogenous compounds for the bacteria and also formation
of SH compounds which in small concentration act as stimulants for the growth of starters.
 To improve the viscosity of the finished culture due to denaturation of whey proteins by improving their
water retention properties to minimize the wheying off.
 A heat treatment of milk to 90°C for 1 hour or boiling/steaming for 30 min is usually preferred. Autoclaving
at 121°C for 15 min is also followed but this may result in the formation of curd with soft and sloppy body
and texture. It may also give rise to scorched flavour making the curd difficult to judge. Tyndalization of
reconstituted skim milk is the best.
 Tyndalization
a. First day the reconstituted skim milk is autoclaved at 110°C under 10 lbs pressure for 10 minutes. The milk
samples are kept at room temperature so that the spores which escaped the heat treatment may geminate and
cause curdling of milk if they are present in large number.
b.On the second day the samples are examined for any curdling. The curdled samples are discarded and the
other samples are steamed for 30 minutes.
c. After steaming the milk samples are kept at room temperature.
d. On the third day the samples are again examined for any curdling. The curdled samples are discarded and
the other samples are again steamed for 30 minutes.
e. The samples so sterilized are either kept at room temperature or in refrigerator till they are used.
 Inoculation
Inoculation is preferred with sterilized equipment. Inoculation has to be carried out in separate rooms with UV
lamp designated for this purpose or by using Laminar flow system. Freeze dried ampoule is sterilized with
alcohol and liquid culture tubes are shown to flames.
The amounts of inoculums depend on the activity of starter, temperature of incubation and time of incubation.
Normally 0.5% to 2.0% is used subject to variations depending upon the situation. Possibilities of external
contamination are minimized as far as possible by working quickly.
 Incubation
Incubation temperature depends on the amount of inoculum and on the type of starter culture. For the
mesophilic organisms the temperature is 21-22°C for 14-16 hours and for the thermophilic organisms it is 41-
43°C for 3 -4 hours. Change in temperature may affect the composition of starters in mixed population.
 Cooling
After incubation the culture is cooled to stop further development. Refrigeration appears to give
appropriatecooling effect.
The drawbacks in traditional method of propagation is
 Time consuming
 Requires skilled operators
 May lead to contamination by bacteriophage.
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6.6 Packaging materials test:
Milk and milk products are classified in several categories and require a different types of container and level of
protection depending on the conservation techniques used and the shelf life expected. Packaging is a technique of
using the most appropriate containers and components to protect, carry, identify and merchandise any product. It
constitutes an important link between the manufacturer and ultimate consumer for the safe delivery of the product
through different stages of production, storage, transport, distribution and marketing.
Though great efforts have been made in producing high grade processed milks or manufactured dairy products, unless
they are delivered in a fresh, sound and suitable form to the consumer, they are likely to be rejected, thus causing
enormous wastage. The loss can be offset to a great extent by adequate protective packaging to withstand the hazards
of climatic changes, transportation, handling etc.
General requirements in packaging
6.6.1 Width:
The width of the film shall be 324+/- 2mm for films other than 6 litres.
The width of the film shall be 595+/- 2mm for 6 litres.
Volume of milk packets Thickness (in micron) Pouch length (in mm) Yield(packets per Kg)
250 ml 41-47 110 ~680
500 ml 43-49 150 ~480
1ltr 52-58 230 ~560
6.6.2 Drop test: Sixteen samples of filled pouches shall be taken randomly from the filling line. The temperature of
the pouches must be maintained within 4° C of the filling temperature of the milk. Sample pouches shall be dropped
from an appropriate height on flat surface.
Each one of the samples are dropped in the following order: on the flat side, on the opposite side, on flat longer edge,
on opposite longer edge. The samples will be deemed to have passed the test if not more than four pouches burst out
of 20.
6.6.3 Test for ink adhesion: The printed film is immersed in milk for 12 hours at a temperature of 8°C. The film must
be then be removed from the milk and wiped dry with a cloth. The printed surface isthen rubbed gently with a tissue
paper. The milk should not affect the film is a way to reduce the printed matter not readable after the test.
6.6.4 Leak test: The milk pouches made from the film when filled with milk at about 8°C and sealedshall not show
any leakage when subjected to uniformly distributed load of 2.5 kg for 200ml and 250 ml pouch, 5kg for 500 ml, 10
kg for 1 liter pouch and 30 kg for 6 liter pouch in flat position for 10 minutes with sealed side on top.5.
6.5.5 Random weight test: The milk is taken randomly from machines and weighed. The measured weight must fall
within the range and if it differs the flow must be varied to suit the range of weights.
Volume of packets Acceptable weight range

250ml 255-260
500ml 515-520
1L 1030-1035
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Chapter 7
ENGINEERING DEPARTMENT 👨‍🔧
Safety instruction for electrical section:
 Always wear leather shoes while attending electrical works.

 Use properly insulated tools.
 Ensure switch of the electrical main while attending electrical maintenance works.
 Use fuse puller for removing fuses.
 Use hand gloves during GOS and transformation operation at HT yard.
 Switch off main during electrical hazards.
 Use fire extinguishers during electrical hazards.
 Don’t wear ornaments and fancy items during working hour.
Maintenance Steps:
 Keep dirt out of engine.

 Maintain lubricating film on all bearings.
 Regulate the engine fuel.
 Control operating temperature.
 Prevent over speeding.
7.1 REFRIGERATION SECTION
INTRODUCTION:
Refrigeration is ‘Heart’ of the dairy industry because milk is safe by cooling for long time. Refrigeration system is
based on Heat transfer method.
“Refrigeration may be defined as an art of producing & maintaining the temperature in a space below atmospheric
temperature.”
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PARTS OF THE REFRIGERATION SYSTEM:
Compressor: it’s the heart of the refrigeration system. It compresses the vapour refrigerant of lowpressure and
temperature to high pressure and temperature.
Condenser: vapour refrigerant is converted into liquid refrigerant.
Receiver: stores excess refrigerant.
Economizer: used for sub-cooling purpose.
Expansion valve: releases the refrigerant at low temperature and low pressure.
7.1.1 COMPRESSOR-KC 9
The compressor is the “heart” of a refrigerator. It circulates the refrigerant throughout the system and adds pressure to
the warm part of the circuit, and makes the refrigerant hot.
a. Suction
It is always cold, where liquid ammonia pass through it
b. Discharge
Compressed hot refrigerant pass through this discharge chamber
a. Oil separator
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It is used for lubrication
d. Kirlosker-215 HP02
It is the energy source to run the compressor
7.1.2 IBT (Ice Bank Tank)
In an ice bank tank, the refrigeration system is used to build ice (or iced water) which is stored and used later to cool
the milk.
a. Ammonium coil
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Contain ammonium refrigerant in it
b. Surge drum(accumulator)
It helps is balanced flow of refrigerant
c. Expansion valve
If helps in controlled flow of refrigerant
d. Agitator motor
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It helps in constant agitation
7.1.3 CONDENSOR
The condenser removes heat from the hot refrigerant vapor gas vapor until it condenses into a saturated liquid state.
After condensing, the refrigerant is a high-pressure, low-temperature liquid
a. Receiver
Receiver is a storage vessel designed to hold excess refrigerant which is not in circulation.
b. Condenser Fan
It is the chamber where condensation takes place
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c. Condenser motor 10HP
It provides energy to the flow water to the condenser.
7.2 BOILER
 It is used to produce the steam to run the plant

 Only DM(Demineralised) water is used in the boiler to avoid corrosion- Separate set up is commissioned
toconvert normal water into DM water.
 Conductivity of DM water-40ppm
 Fuel used-Coal+sand(Currently operational) , CNG(Not yet operational)
 FBC(Fluidized bed combustion) Technology is used in Coal combustion boiler.
 Number of boilers-2
 Capacity-2 to 8 ton/hr
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 Heating surface area of coal boiler-183m2
 Boiler pressure-17. 5Kgcm2
 Ash is collected separately an disposed safely.
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7.3 EFFLUENT TREATMENT PLANT (ETP)
WASTE WATER TREATMENT
7.3.1 Grip chamber-where oil(like fat, Colestral, etc.,)and water gets separated here.
7.3.2 Collection tank-The collection tank collects the effluent water from the screening chamber, stores and then
pumps it to the equalization tank.
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7.3.3 Equalization Tank- EQ tanks are used in many industrial applications to reduce the peaks and flows in
wastewater discharges from the production area as well as the pollutant loadings
7.3.4 Aeration Tank(primary and secondary tank) – Bacterial growth takes place here. An activated sludge process
where air is added into the water to encourage microbial growth. The microbes in the water feed on the organic
material and form flocs that then settle out.
7.3.5 Cycling Tank-Further sludge settlement takes place here.
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7.3.6 Primary treated Water tank-Water from cycling tank collected here, which is not yet ready to use.
7.3.7 Carbon tank- A filter with granular activated carbon (GAC) is a proven option to remove certain chemicals,
particularly organic chemicals, from water. GAC filters also can be used to remove chemicals that give objectionable
odours or tastes to water.
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7.3.8 UF(Ultra Filtration) Tank- UF can remove most organic molecules and viruses, as well as a range of salts. It
has gained popularity because it produces a stable water quality no matter the source water, has a compact physical
footprint, removes 90-100% of pathogens.
7.3.9 Final Treated water-used for
 Gardening.
 Agriculture.
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 Washing, etc.,
7.3.10 SLUDGE UTILIZATION
After drying the sludge it is used as a fertilizer directly or mixed with other fertilizer in Agriculture.
85
Chapter 8
MARKETING DEPARTMENT
Marketing
Marketing refers to activities a company undertakes to promote the buying or selling of the products or services.
Marketing process:
The marketing process is very useful for the dairy industry. It is a process that helps the dairy industry in analyzing the
opportunities in the market, selecting the target markets, developing the marketing mix, and management of the
marketing efforts.
FLOW CHART
Marketing manger
Deputy manger
Assistant manager
Marketing office
Marketing superiendent Marketing accountants
Market supervisor Market clerks
Steps of the marketing process-
1. Analysis of the opportunity in the market: A producer or an organization needs to analyze the opportunities.
These opportunities are related to the needs and wants of the customers. When these are not properly satisfied by the
competitors in the market. While initiating the marketing process, a company should focus on the opportunities that
would be beneficial in the long run. For this purpose, the company gets help from the marketing information system to
get useful information from the market.
2. Selection of the target market: Selecting the target customer is the most important step in the marketing process.
As it is obvious that the company cannot satisfy the whole market. Therefore, it must divide the whole market into
different segments. Like segmenting, targeting, and positioning. Then choose the best meets.
86
3. Development of the marketing mix: The marketing mix is the set of tactical marketing tools that the firm blends
to produce the response it wants from the target market. Besides, The marketing mix is composed of the following
four P’s.
 Product – Any offering of goods or services to the market.

 Price – The customers paid money to obtain the product.
 Place – The efforts which ensure the availability of the product in the market to customers.
 Promotion – The efforts by which the company ensures the sale of products to customers through the better
provision of information about the advantages of the product
 Cost involved promotion
 Without cost promotion:
4. Management of marketing efforts: The development marketing program is actually the action phase. It is a
suitable marketing mix is set for a target market. However, The management of marketing efforts has core four
functions. They are-
 Analysis of the Market

 Marketing Planning,
 Market Implementation,
 Marketing control.
Based on these steps, we divide the firm and food products marketing process below-
 Dairy farm products:
1. Analysis of the opportunity in the market:
Firm products mean milk that may be pasteurized or not. In the past time, Goals collects milk and used to visit
households every morning with their milk containers to sell fresh milk. And the household used to buy from them. But
over the last two to three decades, things have changed a lot.
Because customers demand have been changed. Now, They become more conscious about their health and taking
hygiene food. The market analysis found that several industrial processors have emerged. They collect, process, and
sell milk and milk products in packaged form with the promise of hygiene and quality.
2. Selection of the target market:
The selection of the target market for the firm product is not so diversified. People of all regions and ages consumed
liquid milk.
3. Development of the marketing mix:
The product is milk which is an offer to the customer. Price setting of milk is almost the same in all the industries.
Companies buy milk from producers at $5. Then process it and distribute it to the wholesaler at $3-4. Wholesaler
gives it to retailers at 65-70tk. Finally, customers get at $5. Products are available to the customers. They found their
favorite brands’ milk at their onvenient place. After that, Companies do promotional activities for their product. But
it’s not a huge one.
4. Management of marketing efforts:
Management of marketing efforts is maintained by the organizations properly.
 The farm marketing problem:
1. Free-rider problem
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2. Cost-price squeeze
3. Superior bargaining power of the buyer
4. Changing food market price efficiency
5. Profit gap between farm and food sectors
 Dairy food products:
1. Analysis opportunities of the market:
Dairy food products have different types of the product line. Like- cheese, curd, sweets, ice cream, chocolates, ghee,
etc. this product market needs to be analyzed. Knowing the customer’s needs, demand, and want, firms try to fulfill
their satisfaction.
2. Selection of the target market:
Food products need to be segmented, targeted, and positioned. At present, The demand for cheese and chocolates are
not the same. At different ages, people have different types of food. Like, young peoples and children like to have ice-
creams and chocolates. Some regions’ people are fond of cheese while others are not.
3. Development of the Marketing mix:
Products are different. That’s why the price is different from each other. But, the organization always is ensured the
availability of products.
4. Management of marketing efforts:
The organizations properly are maintained the management of marketing efforts.
Total collection of milk is 1.5 L from Dharwad, Gadag and uttara Kannada. Which is processed and distributed to the
dealers? And The ksheera bhagya scheme was launched on 1 august 2013 by the Karnataka state government. This
scheme is implemented by the ministry of education and the ministry of women and children in Karnataka as part of
this scheme, the government provides free milk to schools and courtyard shelter children. Total marketing of milk and
milk product is 415 crores.
STARAGETIES OF THE MARKETING DEPARTMENT:

 Visit to all roots of individual points by going in a root distribution vehicle for contact with all agents.
 Aims to conduct 5 Consumer Awareness Program and various Seminars.
 Aims at conducting agents‟ meetings.
 Aims at setting 10 Exclusive NANDINI Milk Parlors.
 Aiming to set up new sales promotional and advertisement activities.
 Women association programs.
 Joining with other programs.
STRATEGY IMPLEMENTATION SYSTEM:
 Marketing strategy like sales promotional and advertisementactivities of DMU are as follows.
 Press advertisements
 Hoardings
 Wall paintings
 Rental for KSRTC Buses
 Leaf lets
 Banners
 Vehicles paintings and own hoarding paintings
 Pole ads and Flute boards
88
 Rate display boards
 Milk carry bags
 Calendar and greetings
 Exhibition, drawing and consumer mela.
In 2022-23 target to market
SI NO PRODUCT QUANTITY (kg or liter)
01 Milk 118002/ day
02 Curd 14301/day
03 Sweet lassi, Ltrs 856/day
04 Butter milk 1432/day
05 Peda 289/month
06 Ghee 1223/ month
07 Panner 1134/ month
08 Mysore pak 143/month
09 Khoa 240/month
10 Butter 1032/month
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Chapter 9
SWOT ANALYSIS AND METHODOLOGY OF THE STUDY
SWOT ANALYSIS
 Strength:
 NANDINI is a strong brand image in south India.
 An ISO HACCP certified company.
 Automated computerized plant.
 Supply chain management.
 Maintain uniform quality.
 Company has good relationship with customer.
 Low operation cost.
 Weakness
 Lack of effective media advertising.
 Promotion is based on seniority.
 High man power over head.
 External interference from state federation.
 Opportunities
 DAMUL can maintain and improve the quality to build customer confidence.
 Exsisting breed nandini can be used to expand product line.
 DAMUL can also export its product to near countries.
 Exsisting infrastructure can be used to meet considering demand in future.
 Threats
 Using market share because of price change.
 Very attractive commission for agent from rural.
 Entitling MNCs into dairy industry with cheap milk and milk products may create different competitors.
 External political interference may create unfavourable circumstance .
Methodology of the study
The required information and data was assimilated trough two sources:
1. Primary Data :
 By observing the various departments of the organization

 By interacting with various employees in the organization
2. Secondary Data:
 From company website

 Internet
 Books
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Chapter 10
CONCLUSION
It was an exciting experience to us working with DAMUL Dharwad. From this project we learnt about milk
and milk product, processing production packaging, quality control check, working refrigeration unit, how
the boiler are using in milk industry, how they utilize the waste water and how they treat the waste water, the
marketing tactics used by Dharwad Milk Union Limited Dharwad.
Dharwad Milk Union Limited Dharwad is reputed organization which comes under Karnataka Milk
Federation. DAMUL has developed innovated milk product and marketing in Karnataka and Overall India.
And also competing with many milk and milk product industry. Dharwad is functioning well for the social
as well as economical up-liftment of rural population.
After liberalization, many foreign companies have entered into Indian market, so, DAMUL (KMF) should
strengthen all of resources to face their competitors and adopting itself to changing scenario. The Nandini is
house hold name in Karnataka and other neighbor states. So, all efforts should be continued to build upon
the important asset.
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UNIVERSITY OF AGRICULTURAL SCIENCES, DHARWAD.

COLLEGE OF COMMUNITY SCIENCE, DHARWAD.

DHARWAD CO-OPERATIVE MILK UNION LIMITED, DHARWAD

(Duration 13.12.2022 to 31.03.2023)

GAGANA MAGANUR (UGS19BFT188)

B. Tech Food Technology

UNIVERSITY OF AGRICULTURAL SCIENCES, DHARWAD

COLLEGE OF COMMUNITY SCIENCE, DHARWAD

2022-2023 Dharwad Milk Union Limited (KMF)

suggestions & encouragement helped me to complete this project successfully.

1.1 MILK AND MILK PRODUCTS

1.2 DAIRY INDUSTRY IN INDIA

1.3 KARNATAKA MILK FEDERATION

1.4 DHARWAD MILK UNION LIMITED, DHARWAD

02 OBJECTIVES, MISSION & VISION OF KMF& DAMUL

03 OBJECTIVES & SCOPE OF STUDY

4.1 PROCESSING,PACKAGING AND RECEPTION DEPARTMENT

06 QUALITY CONTROL DEPARTMENT

09 SWOT ANALYSIS & METHODOLOGY OF THE STUDY

1.1 MILK AND MILK PRODUCTS

1.2 DAIRY INDUSTRY IN INDIA

1.3 KARNATAKA MILK FEDERATION

THE GROWTH PROCESS

Nos 416 16059 16071 16789

Women DCS Nos 4122 4239 4547

STEP Functioning Nos 2199 2299 2375

Avg.Good life sales LLPD 5.28 6.01 6.80

Daily Payment to Rs.Crores 0.09 18.28 18.12 21.41

Nos 416 16059 16071 16789

There are 14 Milk Unions in Karnataka

1. Bengaluru Milk Union

1.4.3 DHARWAD DISTRICT CO-OPERATIVE MILK PRODUCERS SOCIETIES UNION LIMITED:

A) Product/service profile: - Milk and milk products

B) Area of operation – Regional

DAMUl builds and runs under the co-operative institutions such as

 District Co-operative Society.(DCS)

DMU has various competitors in the milk products market such as

Infrastructural facilities of DMU are as follows.

Nandini pasteurized toned milk, nandini double toned milk,

Homogenized toned milk, Homogenized cow milk, Shubham

F) INPUT REQUIRED PER DAY

 Milk Procurement up to 70000 liters

H) FUTURE GROWTH AND PROSPECTUS

I) PRODUCT PROFILE OF KMF AND DHARWAD MILK UNION LTD (DAMUL)

OBJECTIVE AND SCOPE OF THE STUDY

1. Processing, Packaging and milk reception Department

4.1 PROCESSING, PACKAGING AND MILK RECEPTION DEPARTMENT

FLOW CHART OF MILK PROCESSING

Receipt of raw milk cans

Loading to the conveyor and

Screening of cans for Rejects and Discards

Can washing Dumpling pre

Can dispatch QC Check

Releasing into the

Storage in raw tanker washing

Addition & mixing Standardization

Addition of Vitamin A & D in balance

Homogenization HTST Pasteurization

Receiving crates Re-chilling of milk to

Washing through Packing in sachets Received coded packing

Transferring to the cold

Loading milk crates to

1. Milk Reception Dock