PRODUCTION DEPARTMENT

The production department of the Kolar dairy performs the function of developing

Procedures to transform a set of input elements like raw material like milk, money,
machine into

Specified output like curds, butter, ghee, Peda, masala butter milk etc. in assigned quality
and

Best in order to achieve the organizational goals successfully. Production department is the
most

Important and the largest department in the organization.

Komul has a well-organized and totally computerized system of production. The scope of
the

Department is to plan, execute and control all production activities with the available
resources

Inputs and equipment in co-ordination with the other department.

The Production manager heads the production department. The production manager
monitors the

Activities of this department with the support of Deputy Manager, Asst. manager and
technical
Officers.

The production department works 24 hours every day. As much as 100 thousand Kegs

Packets of milk made every day and all are sold every day. The milk from the dairy is

Transported through trucks to the dealers. Out of 4.56 lakh liters of milk procured 100008
liters

Are sold as liquid milk („Nandini‟ Milk) and the rest is converted into milk products like
Butter,

Curds, Ghee, Peda etc.,

MILK STORAGE SILO’S

Three raw milk silos of capacity 1 lakhlitres each are provided. The raw milk storage
tankcontains side mounted agitator to ensure uniform temperature and fat
distribustionwithoutany adverse effect on the contents.thesilos are insulated with puf(poly
urethane foam) toensure that the temperature rise does not exceed 1ºC in 24hrs. apart
form fresh milkReceivedinrawmilktankers,variousstreamenteringtherawmilksilosare:

Rinse milk recovery

Inter silo transfer

MILK PROCESSING

Milk contains all the nutrients required by the neonate and has thus been recognized
asperhaps 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
groupsnamely

Fat soluble, water soluble, solid-not-fat (SNF). The constituents other thanwater 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 productsmakes it extremely useful base material. In some cases, milk
undergoes relativelylimited processing, consisting of heat treatment to increase the
bacterial shelf life of theproduct and homogenisation 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 pathogenicorganisms-, to increase shelf-life up to a period of six months; to help
subsequentProcessing.

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Steps involved in milk processing:

1)Milk Reception2)Testing:

Fat percentage: Gerber method/ Electronic milkotester method/ Fatomaticmethod

SNF: Lactometer reading at 27 °C is noted

3) Chilling:
It is the process of cooling the milk below 4ºC to supressthe bacterial activity, so that the
shelf life is extended upto12-18 hrs and facilitates further processing of the milk.Milk is
chilled by passing through the plate chiller(plate and frame heaiexchangers-.milk and cold
water is passed in counter current manner resulting in the cooling of milkand stored in
silos.

4)Storage of raw milk:

The milk is pumped through a filter storage tank and stored till standardisation.

5)Standardization of milk:

It is the process of adjusting the, fat content_invarieties of milk to meet the

statuaryrequirement;Theseprocessfacilitates raising or lowering of fat content of the milk.
It iscarried out by skimmed milk/cream/skim/milk powder depending on the initial
fat/SNFcontent of milk in the storage tank. Standardization is done on raw milk. DKMU
Ltdmarkets four types of milk.

Toned milk

3% fat .and 8.5% SNF

Homogenized milk

3.5% fat and 8.5% SNF

Shubham-4.5% fat and 8.5% SNF

Samridhi-6.0% fat and 9.0% SNF

Trupti-3.5% fat and 8.5%SNF

•
Healtylife-1.5%fat and 9%SNF

6) Pasteurization:

It is the process of heating the milk to 71.5 °C/15 sec holding and immediately coolingto 5
°C or below. The purpose is to render the milk safe for human consumption bydestructing
some of the pathogenic microorganisms.

7) Cream separation: process where cream and skimmed milk are separated using acream
separation mechine8)Homogenization:

Homogenizationis the process in which size of the fat globules in the milk aredown broken
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 besent
to the homogenizer since the fat will be in solid state and difficult to homogenizehence the
milk sent to it should have a temperature of around 60 °C. Partially heatedmilk from the
pasteurizer is forced towards a small passage with high pressure in anadjustable valve by
multiple cylinder pistons pumps; the shearing effect causes the fatglobules to break down.
Then it is sent back to refrigeration. It is a two stagehomogenizer of 500psi and 2500psi.

)Packing and cold storage:

After the pasteurization, pasteurized milk is packed with thehelp of packing machine.
Packed milk packets are stored at 4 °C till its delivery to milkdelivery trucks. These milk
packets are stored in a separate cold room.

10) Dispatch:

Packet milk is stored in a separate crate and distributed to the dealersThrough organized
tendered contract vehicle.

11)Cleaning in place(CIP):

CIP is an automated process which is done for cleaning and sterilizing of thepasteurizing
and homogenizer equipment. Chemicals used are caustic soda (NaOH) andnitric acid
(HNO3 )

12)Curd processing:

•
Microbial culture: Mixed strain (containing lactobaccilusLactis)

Pure Culture was obtained from NDRI-Delhi

Curd characteristics;

Fat 3.1%

Acidity 0.8-1.0% (sweet curd-0.7%, sour curd-1%)

Protein 3.4g Vitamin A 0.03nig

Storage: Dry condition at room temperature

Shell life: 3 days from packaging

Quality control test: chemical and microbiological test