“INDUSTRIAL TRAINING REPORT”

Submitted by
VRAJ A. MORE
APURV B. RATHVA
SAMRAT K. BAROT

Department of Agricultural Engineering

Parul Institute of Engineering &
Technology (DS), Limda .
(2021-2022)

Baroda District Co-Operative

Milk Producers’ Union
Limited.
(BARODA DAIRY)
 Department of Agriculture Engineering

“Industrial Training Report”

Submitted by
VRAJ A. MORE (190339601013)
APURV B. RATHVA (190339601023)
SAMRAT K. BAROT (190339601002)

In final fulfilment of Industrial Training At

Baroda District Co-Operative Milk
Producers’ Union Limited. (BARODA DAIRY)

Training Guide
Mr. Paresh Shah.

Academic Guide
Prof. Ajay Makwana
Prof. Sandip Rathod
 CERTIFICATE
This is to certify that, the report of “Industrial Training”
Submitted by
VRAJ A. MORE
APURV B. RATHVA
SAMRAT K. BAROT

is a bonofide work completed under my supervision

and guidance in fulfilment of Industrial Training at
Baroda District Co-Operative Milk Producers Union
Ltd., for during 15/12/2021 to 28/03/2022. Work is
done at Baroda Dairy in pouch packing department ,
RMRD department , Ghee section and Butter
section .

Place: -> Baroda,Gujarat.

Date:

Prof. Sandip Rathod. Prof. Ajay Makwana.

Internal Guide. Head Of Department.

Examiner
 Acknowledgement

It is my privilege to acknowledge with deep sense

of gratitude to my training Guide Mr Paresh Shah for
their valuable suggestion & guidance throughout my
training & timely help given to me in the completion
of this training.

I am highly obliged to our respected internal

guide Prof. Ajay Makwana and Prof. Sandip Raathod.
H.O.D of Agricultural Engineering Department. Prof.
Ajay Makwana and entire staff of Agricultural
Department for their kind help & co-operation. I also
take this opportunity to thank all my colleagues for all
possible helps.

VRAJ A. MORE
APURV B. RATHVA
SAMRAT K. BAROT
(Diploma Agriculture Engineering)
 ABSTRACT
All diploma engineering students from Parul University are
required to undergo industrial training. To obtain practical
skills and knowledge to complete 3 years course for the
diploma in agricultural engineering. This attachment is
during 6th semester for their studies. During training,
students are supervised by the respective company staff
members and technicians.

For my industrial training, I did it at Baroda

District Co-Operative Milk Producers Union Ltd.,

I was assigned to the Production section under the

guidance of Mr Paresh Shah and under constant
guidance of all technicians. I was introduced to the
different food process in factory. Also introduced with
the different machines involving in the process.
SR INDEX PG
NO. NO.
1. INTRODUCTION 1
2. HISTORY 2
3. MILK INRODUCTION 5
4. RMRD 8
5. STORAGE TANK 14
6. PASTEURIZATION 17
7. HOMOGENIZATION 19
8. PACKING 20
9. DISTRIBUTION 24
10. CLEANING AND SANITATION 26
OF PLANT
11. FLAVOURED MILK 27
SR INDEX PG
NO. NO.
12. GHEE 31
13. BUTTER 35
 INTRODUCTION

A district level milk processing industry

established on 24'
December1957registered under Gujarat
state co-operative societies act. We know
as the Baroda District Co-Operative Milk
Producers Union Limited (Baroda Dairy),
Vadodara. The farmers own the dairy,
their elected representatives manage the
village societies and the district union.
They employ professionals to operate the
dairy and manage its business. We aim to
provider remunerative returns to the milk
producers and serve the interest of
Indian consumers by providing quality
milk products through our federation - M/S
Gujarat Co-Operative Milk Marketing
Federation Limited. Average milk
procurement in 2017-18 is 650000 liter
Average milk sale in 2017-18 is 417000
litre Milk co-operative societies: 1200+

Page 1 of 42
 HISTORY
India is primarily an agricultural country.
Even then the farmers and milk producers
had to face a lot of difficulties in their
professions.
Especially in the Dairy Industry, the
middle
men were exploiting the milk producers.
They would buy milk of good quality at
very low prices from them. The dairy
industry has always been considered to
be a side business of agriculture. Due to
difficulties in transport and lack of
business skill it could not develop to its
full potential. After India's independence
efforts for social and economic
enlistment of farmers began and with the
help of scientific advancements the
profession of animal husbandry too began
to develop. Thus along with the Green
Revolution started the white Revolution
the farmers of Vadodara District were
involved in the activity of milk production
as a Page 2 of 42
supplementary profession of agriculture.
Animal husbandry and agriculture were
practiced side-by-side for many years.
The farmers used to sell the excess milk in
nearby villages, towns and cities in the
neighbouring district of kheda a Dairy
Business Co-operative called Amul Dairy, Was
established with the help of the village Co-
operatives as an initiative against the
exploitation of farmers by the middlemen.
With the help of Amul Dairy the farmers could
sell their excess milk at a profit and were a
part of the Co-operative .Thereby, with a
great surge of enthusiasm, co-operation, and
unity the SANGH was established. Its first
quarter was at the Tarkeshwar Mahadev ",
situated in the midst of the city. Later on with
the development and enlargement of the
institution it was shifted to a 26-acre land of
the Makarpura - Tarsali Road, which was
acquired with co-operation from the BMC &

Page 3 of 42
50,000 litre capacity plant was setup in
1962.The credit of the establishment and
development of the Vadodara Sangh goes to
Dr.Verghese Kurien , the guiding light of the
'White Revolution', He backed the efforts of the
Sangh with a generous declaration that - any
losses incurred by the Sangh in its initial years
will be borne by the Amul Dairy, With
increasing milk production, a modem dairy
plant inaugurated by Shri Moraji Desai was set
up on 26th April 1965

Page 4 of 42
 MILKINTRODUCTION
Milk is a white liquid produced by the
mammary glands of mammals. All
mammals, including humans, will normally
produce milk to feed their off spring until
they are ready for solid food. Milk is as
ancient as humankind itself, as it is the
substance created to feed the mammalian
infant. Many centuries ago, perhaps as
early as 6000-8000 BC, ancient peoples
learned to domesticate species of
animals for the provision of milk to be
consumed by them. These included cows
(genus Bos), buffaloes, sheep, goats, and
camels, all of which are still used in
various parts of the world for the
production of milk for human
consumption. It contains valuable
nutrients, and it can offer a range of
health benefits. Calcium, for example. Can
prevent osteoporosis. Technological
advances have only come about, very
recently in the history of milk
consumption, and our generations will
Page 5 of 42
be the ones credited for having turned milk
processing from an art to a science. The
availability and distribution of milk and milk
products today in the modern world is a
blend of the centuries old knowledge of
traditional milk products with the application
of modern science and technology. The role
of milk in the traditional diet has varied
greatly in different regions of the world. The
tropical countries have not been traditional
milk consumers. Whereas the more northern
regions of the world, Europe (especially
Scandinavia) and North America, have
traditionally consumed far more milk and milk
products in their diet, In tropical countries
where high temperature sand lack of
refrigeration has led to the inability to
produce and store fresh milk. Milk has
traditionally been preserved through means
other than refrigeration, including immediate
consumption of warm milk after milking, by

Page 6 of 42
boiling milk, or by conversion into
more stable products such as
fermented milks.

Page 7 of 42
RAW MILK RECEPTION DOCK(RMRD)
Raw Milk Reception Dock (RMRD) is the
initial point of raw milk entry in dairies. It
is particularly applicable for the
treatment of milk procured in cans,
from villages situated across a wider
region. It is very much different from the
bulk milk collection system that also
operates in various dairies. The milk
collection process begins from the
villages, groups of which are allotted to
different Milk Truck Routes. The Milk
cans from distinct villages of various
such routes are delivered at the RMRD,
after which the milk is weighed
&examined distinctly to provide a milk
receipt statement basis the unrushed
parameters during the daily shift The
societies send their milk two times a
day, in morning shift & am to 12 pm and
the other in second shift from 8pm to 12
am. The cans are received in this time
period and the tankers or trucks
carrying milk are received all day long.
Page 8 of 42
1) Conveying and unlading of cans: The
cans that are manually arranged over
the conveyors through a
slopeUnloading: Milk cans arrive from
different villages or societies with a
distance of about 45kilometers. The
truck carrying the filled cans is brought
alongside the unloading platform. The
milk cans are then unloaded manually
according to their type that is either cow
or buffalo milk, which is then arranged
on the conveyor.
2) Then transported further in the line it
means an automatic roller type convey
or belt of about 12-15 meters in length
up to the receiving platform The cans
prior to conveying are in way unloaded
by use of a hammer cum rod by tapping
or striking by the workers.
3) Sensory evaluation of milk: the milk
received is then tested organoleptically
in order to judge the sources, and or
curding of the milk, It also gives a
rough idea about the
Page 9 of 42
milk gone "savour". As is what called in
local language the curdled milk is then
separately filtered for any impurities and
is sent to the curd room for production of
buttermilk. While fresh or
organoleptically accepted milk is sent to
the raw milk tank filtration and sampling.
4) Dumping of milk: the milk is received
after that it is made to dump in the tank
having a capacity of about 1 500 litters,
the milk is dumped on the basis of the
coding that differentiates in cow and
buffalo milk the route number and type
of milk along with the sample number is
recorded on the software by personnel
the weight of the cans is then recorded
by the computerized automatic weighing
system attached to dump tank the cow
and buffalo milk are dumped and
weighed separately in two different dump
tanks and according to the route number
the raw milk filter bag has the following
specifications : Mesh -40Length
37"Frequency
Page 10 of 42
to change - as required Cleaning
frequency - after every use
5) Sampling of milk: the milk samples are
collected prior to emptying of the dump
tank differentiating the samples by giving
the sample number to each milk type of
recording of the same in the milk
reception report
„Samples are obtained on the basis of milk
type and route, The metal boxes fitted
with plastic bottles are used to carry
sample with each bottle been given a
code number and is arranged in
particular sequence only. About 40-50 ml
of milk is taken for sampling the milk is
to be tested is avoided to get sour by
adding the solution of potassium
dichromate (about 1-2 ml) into the
sample bottle. This is used as a
preservation as fulfils the desired
requirement without interfering with the
fat and SNF % of the mil and also does
not affect the other quality factors.

Page 11 of 42
6) Transferring of milk into storage tanks: the
dumped milk is then transferred to a basket
type filter via feed pump for partial filtration.
A condenser is attached to the filter output
for maintaining the milk temperature up to 10
degree Celsius for proper storage without any
spoilage. The RMRD storage tank are two in
number with a capacity of 30.000 litres each
Milk from these tank is then to the process
plant for pasteurization and further
processing . The dump tank consists of a
primary strainer filter having following
specifications: Mesh - 25Frequency to change
as required Cleaning - after every shift the
basket type filter has the specifications similar
to that of the strainer.
7) Can Washing: The received cans are
washed and steam dried after every use the
can washer has four compartments
depending upon the type of wash. The first
compartment is of hot water, with the next

Page 12 of 42
compartment being that of soda solution
of strength 0.50 to 0.60. The soda is then
rinsed off with the cold water. Finally,
steam is used for drying of the cans. The
dried cans than move to the outlet
through the conveyor where they are
lidded and is loaded back into the trucks
or lorry. Temperatures are kept as
follows: Hot water = 85-90 degree Celsius
Steam = 100-122 degree Celsius Cold
water = 33-35 degree Celsius Caustic
soda = 75-85 degree Celsius (prepared
by dissolving 3 kilograms soda in 1200
litres of water.

Page 13 of 42
 STORAGE TANK

In a dairy plant, storage tanks are used ffs

raw products, pasteurized products and for
processed products as well. Different
applications of storage tanks
Storage tanks for raw milk usually milk is
held up to a maximum of 72 hours between
receptions and processing in the tank.
The tanks may be cylindrical or oval. They
may also be horizontal/ vertical. The
storage tanks are often kept outdoors with
heads extended through the wall into
processing room. After the whole RMRD
process, the milk received from milk
chilling centres, it has already been
graded, weighed, sampled and cooled.
When milk is received at the milk
plant/dairy, it should be at 5-7 degree
Celsius or below. The milk expected to be
clean, sweet, of pleasant flavour, free from
off- flavour and reasonably free from
extraneous matter.

Page 14 of 42
Contamination with antibiotics,
pesticides and other chemical or metals
is highly undesirable No abnormal milk
is acceptable. Acid development is
objectionable, for not only it indicates
an excessive bacterial count, but it also
reduces the heat stability of milk.

Page 15 of 42
Page 16 of 42
PASTEURIZATION:
Pasteurization is the name of the process
discovered in part by the French
microbiologist Louis Pasteur. This process
was first used in 1862 and involves
heating milk to a particular temperature
for a set amount of time in order to
remove microorganisms.
Definition:
Pasteurization is the process of heat
processing a liquid or a food to kill
pathogenic bacteria to make the food safe
to eat.
Pasteurization of milk refers 63 degree
Celsius for 30 min or 72 degree Celsius for
15 seconds after that the milk is
immediately cooled to 5 degree Celsius
or below.

Aim:
There are two distinct purposes for
the process of milk pasteurization:

Page 17 of 42
1. Public Health Aspect - to make milk and
milk products safe for human consumption
by destroying all bacteria that may be
harmful to health (pathogens)
2. Keeping Quality Aspect - to improve the
keeping quality of milk and milk products.
Pasteurization can destroy some
undesirable enzymes and many spoilage
bacteria, Shelf life can be 7, 10, and 14 or
up to 16 days Need It is hard to though to
supervision over all the milk supplies,
pasteurization makes the milk safe for
human consumption.

Page 18 of 42
HOMOGENIZATION

A considerable portion of market milk is

pasteurized as well as homogenized. It
is located immediately after the
regenerative heating, or between final
heating and holding. Fat and SNF
should me according to its standard
values. If fat content is less cream is
added, if fat content is high so it is done
by cream removal by using cream
separator or by adding skimmed milk. If
SNF content is less skimmed milk
powder is added into milk, if it is high
water is added to reduce it.

Page 19 of 42
 PACKAGING

Although the glass milk bottle is still the

traditional packaging medium for retail
milk distribution single service plastic
containers or pouches are used for
distribution. A beginning in this field has
lately been made in India. As far as milk
packaging is concerned paper is a carrier
for a water proof layer of either
polyethylene or wax. The provision for 5-
10% of synthetic fibres is not to influence
the printing or folding capacitive of paper,
but rather to provide better wet strength.
Dominated in milk packaging, by polyolefin
-
(such as polypropylene and
polyethylene) used singly or blended to
offer a wide range

Page 20 of 42
of materials plastics have superseded
paper in recent time. The polyolefin's of
interest are coating grades for cartons,
film grades for sachets and extrusion or
blowing grades for bottles.
The pouch filling section has 15
automatic packaging machines for milk
packaging and 5 machines for
buttermilk.
The efficiency of the machine is about
22-24 crates per minute. Two pneumatic
machines are used for milk and all the
buttermilks machines are pneumatic,
rest all the machines are mechanical.
The lengths of the pouch is kept to be
about 14.5 centimetres same as the
breathe. The machine has a small
overhead tank of 120 litres capacity The
pasteurized and standardized milk is
then sent to these overheads tanks from
the silo or tanks and enters the machine.
The pouch film is rolled and set into the
machine and enters from two sides and
sealed using a heating
Page 21 of 42
element set about 35 degree Celsius.
This is covered with Teflon to avoid
heating or damage to the Pouch. The
seal id first done on the need and
then sealed on the top side and cut
simultaneously. The temperature of
the milk packaged is kept to be about
11-13 degree Celsius .

Page 22 of 42
Page 23 of 42
DISTRIBUTION

INTRODUCTION

Distribution of milk is the last final

stage of the market milk industry.
Distribution facilities contains of:
1.The physical equipment and
personnel required for transporting
the Products from the milk storage
rooms to the consumer or retailers
2. Sales promotion

3. Advertising

Page 24 of 42
A successful distribution
programmes requires:
1.A product of high quality
2. An attractive package
3. Neat and courteous route salesman
4. Delivery equipment of pleasing
appearance
5. Efficient use of man and
equipment 6.Effective advertising

The milk packed and storage in the

storage rooms 1-2 days prior to dispatch
is then transferred to the milk
dispatching trucks where a set of 10
crates is set according to the demand of
the route. Each crate consists of 24
pouches each of the same type. The
dispatch is done two times, a day one in
the early morning and the other in
evening.

Page 25 of 42
CLEANING AND
SANITATION OF PLANT:
Cleaning or washing of Dairy equipment
implies removal of the soil from the
surface of each machine. Sanitation
(also referred to as sterilization) implies
the Destruction off all destruction of all
pathogenic and almost all non-
pathogenic Microbes from equipment
surface. Detergents or cleaning/washing
compounds Are substances capable of
assisting cleaning.
Sanitizers are substance capable of
destroying all pathogenic microbes.
Milk stones are an accumulation of
dried milk solids and salts from hard
and washing solutions. It consists of
largely of calcium phosphate, milk
protein, precipitated, coagulated and
baked on by heat and insoluble calcium
salts from Water and washing
solutions. It has the following
approximately composition.
Page 26 of 42
FLAVOURED AND
DIFFERENT TYPES OF MILK
Another category of by products is
flavoured milk. The Baroda dairy
cooperative has taken Lead forward
in the national welfare initiative for
the village children i.e., the ICDS
(Integrated child development
services) which caters to the
nutritional needs of the children
Living in the remote areas of the
country. The variant of the flavoured
Milk, sanjeevani commercially
produced milk and IDS milk is
provided to them free of cost and it
has a fat and SNF % of 1.5 and 17.5 -
18.0 respectively. Also it is fortified
with vitamin A, D and E.

Page 27 of 42
Different types of milk:
1. Baroda dairy (sugam) Flavoured Milk

1. Amul gold (Fat: 6.0/6.1, SNF: 9.0/9.1)

Page 28 of 42
 2. Amul Shakti (Fat: 4.5/4.6, SNF:
8.5/8.6)

3. Cow milk (Fat: 3.5/3.6, SNF:

8.5/8.6)

4. Amul Tazza (Fat: 3.0/3.1, SNF:

8.5/8.6)

Page 29 of 42
5. Amul slim and trim (Fat: 1.6/1.7, SNF
9.1/9.2)

Page 30 of 42
 GHEE
Ghee is a class of clarified
butter that originated from the Indian
subcontinent. It is commonly used in Middle
Eastern cuisine and cuisine of the Indian
subcontinent, traditional medicine, and
religious rituals. Ghee is typically prepared
by simmering butter, which is churned from
cream (traditionally made by churning dahi),
skimming any impurities from the surface,
then pouring and retaining the clear liquid
fat while discarding the solid residue that
has settled to the bottom. Spices can be
added for flavour. The texture, colour and
taste of ghee depends on the quality of the
butter, the milk source used in the process
and the duration of time spent boiling Ghee
is 99.9% fat and 1% moisture along with
some fat- soluble vitamins, charred milk
protein fractions among others. Although
the fatty

Page 31 of 42
acid profile of ghee is complicated Most of
it consists of saturated fat and
cholesterol.
Ghee is the name for anhydrous butter fat
in India,where it is prepared in large
quantities.
It is commonly mixed with milk fat of the
water buffalo The butter is melted and the
simmered long enough to boil off all the
water during which time it takes on a
buttery taste. Ghee is the clear butter fat
.by removing the aluminous curd and
water that flavour the growth of organisms
promoting rancidity ,anhydrous butter fat
does not become rancid as readily as a
butter can be stored unrefrigerated for
several months.
Ghee procedure as follows: butter made
from the cow milk is melted over a slow fire
and then heated slowly until the separated
water boils off. The vessel holding the
butter is then allowed to cool ¡semi fluid
clear butterfat
,which makes the finest ghee ‚rises to thetop
of the melted butter and may be poured off,
Page 32 of 42
leaving the curd at the bottom of the
vessel. The curd, which still contain
50% or more butter fat, may be
reworked with the addition of peanut
oil or buffalo milk fat to make inferior
grades of ghee the left out brown
portion or curd particles are then
given to the farms and used as a feed
for cattle.

Page 33 of 42
Baroda dairy GHEE
NET WEIGHT - 500ml (452g)

Baroda dairy GHEE

NET WEIGHT - 15Lit (13.56KG)

Page 34 of 42
 BUTTER
Garlicbutter is the
new Launched product in
BarodaDairy,whichis
prepared only in BarodaDairy.Thesteps
are sameasfor table butter. It is
prepared
by addition of Garlicpowder along
with salt and colour in batch type of
churner.

(a) CreamPasteurization:
Cream is pasteurized at 88-95°C and
immediately chilled at 10°Cor less.
This Chilled cream is stored incream
storage tank
(b) Loading of Cream
inCST(Cream StorageTank):
The chilled pasteurized cream is
received from the process section to
the cream storage Tank,temperature at
below5°C.
Page 35 of 42
(C)Ageing:
Chilled cream is allowed toage
overnight so that crystallization
takes place. It is Essential character
for churning and for imparting
good texture to butter. Avoid Fatloss
separated of butter milk and butter
graineasilyat 15-20 min. (d)Loading
of Creaminthe Churn:
Thechilled cream is to be loaded in
churn to alevel 40-45% of its volume
and its churn. Highervolume causes
fat loss and incomplete churning.
(e)Churning and breaking of cream:
Butter churner is rotated at 30 RPM
for 30-50 min. till the fat particles
are Separated. Fat particles begin to
break and separatemoisture.
Breakingis done For15min.these
facilities quick draining of butter
milk.

Page 36 of 42
Tablebutter churn is being
manufactured by conical shapebatch
type churn. Has Capacity of 2000 kg
cream / batch but total capacity is
5000kg.
(F)Washingof Butter:
Washing is done at 18-21 RPMwith
pasteurized chilled water at 4°Cto
cool the butter. It is repeatedtwice.
(g) SlowWorking:
It is done at 8-10 RPMfor 15 min to
removeextrawater.
(H) Addition of Colour:
Thecolour added @0.9% of the total fat
contained which isconsidered
Standard asit gives desired golden
yellow colour.Colour is of annatto type
(fat Soluble).
(I) DrySalting:
Washed and drained butter is salted
at 3%salting improvestaste,prevents

Page 37 of 42
Growth ofmicroorganisms and
increase theshelf-life.
Amount of salt = expected
quantity of butter X3%
(J)FinalWorking:
Saltedbitter is further rotated at 24-
28 RPMfor 20-25 min to minimize
the Moisture content in butter. Butter
sample is analysed for moisture
content. It Should be between 14-
16%.Make up water is added to get
the required moisturecontent.

Unloading of churn:
Previously sanitized trolley i.e.
niaced bellow churn and churn
is rotated forward and
Backward to allow the better to
slide down to trolley.

Page 38 of 42
Packaging of Table and Garlic
Butter:
Table butter is packed in 100 gm. Pack
under the brand name "AMUL" and it is
marketed by "GCMMF". Continuous
butter packaging machines are there
for packaging 100 gm packet of table
butter and 100 gm of white butter. Both
these machines are installed in a
packaging room. Temperature of
packaging room is maintained between
18-20°C and relative humidity around
85%.

Procedure:
The butter is fed into the hopper with
the help of shovel. The butter is pushed
forward through screw- conveyor.
There is four dice of 100 gm each. Here
is a piston which pushes continuously
pieces of butter. There is four dies
which hold them and rotates. A piece of
butter parchment paper from the paper
roll is cut automatically and block of
100 gm butter is placed over it, the
butter paper is then

Page 39 of 42
wrapped around it then it is put on the
moving conveyor belt. All the
operation are automatic and the
wrapped butter is put inside the
butter sleeve manually code no.,
dated of Mfg. Price is coded on the
sleeve. Coding on the sleeve is done
by the code printer.

Size of Parchment Paper (100 gm

butter): 125 × 185 mm (Width ×
Length)

Storage:
The butter is first stored in cold store
at -3°C under hygienic condition.

Utilization of Residual Butter:

This is done for economic purpose so
as to avoid fat losses. Butter is
collected from churn, trolley,
packaging machine, damaged
Page 40 of 42
packs, overweight or underweight
packs etc. this residual butter is
collected and sent along with white
butter trolley to ghee section.
Shelf life of Table butter when
stored at below 4°C is 12 months.
Cleaning of churning:
Butter churn is chemically
cleaned by following these
steps:
•Pre-rinse with hot water at 65-70°C
•Caustic soda (conc.0.5-0.7%) washes
at 70+ 5°C for 10 min.
• Rinsewith hot water at 70 + 5°C for 5
min.
•Rinse with pasteurized chilled water
with lodophore solution (200 PPM)
for 5 min
• Drain it

Page 41 of 42
AMUL Unsalted Table Butter

100gram package 500gram package

AMUL Butter

100gram package 500gram package

AMUL GARLIC Butter

100gram package
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