MILK PROCESSING PLANT AT MAHAD,

RAIGAD

A DESIGN DISSERTATION REPORT

Submitted by

SAMIRA S. SHETH.

Under the guidance of

AR. ASHIMA SRIVASTAVA

In partial fulfillment for the award of the degree

Of
BACHELOR OF ARCHITECTURE
In

Lokmanya Tilak Jankalyan Shikshan Sanstha’s

Lokmanya Tilak College of Architecture and Design Studies
Plot 93 / 98, Sector 4, Kopar Khairane, Navi Mumbai 400 709

Affiliated to
University of Mumbai
SEPTEMBER 2017

i
 .

Lokmanya Tilak Jankalyan Shikshan Sanstha

LOKMANYA TILAK INSTITUTE OF

ARCHITECTURE AND DESIGN STUDIES
SECTOR 4, KOPARKHAIRANE NAVI MUMBAI – 400 709

Certificate
This is to certify that the Dissertation titled

MILK PROCESSING PLANT AT MAHAD

Is the bona-fide work of

SAMIRA S. SHETH

Of the Final Year B. Arch. Sem (IX) and was carried out in the college under my
guidance and here by partial fulfilment of the requirements for the degree of the
Bachelor of Architecture under University of Mumbai

Signature of Guide Signature of Principal

Date: ______________ &College Seal

ii
DECLARATION
I hereby declare that this written submission entitled “MILK PROCESSING PLANT AT
MAHAD” represents my ideas in my own words and has not been taken from the work of others
(as from books, articles, essays, dissertations, other media and online); and where others’ ideas
or words have been included, I have adequately cited and referenced the original sources. Direct
quotations from books, journal articles, internet sources, other texts, or any other source
whatsoever are acknowledged and the source cited are identified in the dissertation references.

No material other than that cited and listed has been used.

I have read and know the meaning of plagiarism* and I understand that plagiarism, collusion,
and copying are grave and serious offences in the university and accept the consequences should
I engage in plagiarism, collusion or copying.

I also declare that I have adhered to all principles of academic honesty and integrity and have
not misrepresented or fabricated or falsified any idea/data/fact source in my submission.

This work, or any part of it, has not been previously submitted by me or any other person for
assessment on this or any other course of study.

Signature of the Student:

Name of the Student: SAMIRA S. SHETH

Exam Roll No:

Date: 2017,OCT Place: MUMBAI

*The following defines plagiarism:

“Plagiarism” occurs when a student misrepresents, as his/her own work, the work, written or
otherwise, of any other person (including another student) or of any institution. Examples of
forms of plagiarism include:
 the verbatim (word for word) copying of another’s work without appropriate and correctly
presented acknowledgement;
 the close paraphrasing of another’s work by simply changing a few words or altering the
order of presentation, without appropriate and correctly presented acknowledgement;
 unacknowledged quotation of phrases from another’s work;
 The deliberate and detailed presentation of another’s concept as one’s own.
“Another’s work” covers all material, including, for example, written work, diagrams, designs,
charts, photographs, musical compositions and pictures, from all sources, including, for
example, journals, books, dissertations and essays and online resources

iii
 ACKNOWLEDGEMENT

This dissertation was made possible by the contribution of my faculty guide Ar.
Ashima Srivastava, and my co-guide Ar. Viji Nair. I am deeply indebted to them
for their outstanding supervision, encouragement and guidance throughout the period
of my candidature.

Thanks are also extended to my friends and colleagues for their assistance and
encouragement. I also reserve special words of appreciation for my parents Mr.
Santosh Sheth and Mrs. Amita Sheth for extending all necessary help in
compilation of this dissertation report and for their remarkable understanding,
encouragement and sincere co-operation in this endeavor.

Last but not the least, I express my gratitude towards all those who directly or
indirectly helped me in completion of my studies.

Thanking you,
SAMIRA S. SHETH.

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Table Of Content
1. MILK PROCESSING PLANT ............................................................................................. 1

1.1 Introduction: ....................................................................................................................... 1

1.2 Need for the project: ........................................................................................................... 2

1.3 Aim and objective: .............................................................................................................. 3

1.4 Scope and limitations of the project: .................................................................................. 4

1.5 Methodology ....................................................................................................................... 5

2. Literature study and review .................................................................................................. 7

2.1 History of the milk industry................................................................................................ 7

2.2 Principles involved in planning of milk plant .................................................................. 10

2.3 The story of white revolution. .......................................................................................... 36

2.4 Opportunities and challenges in dairy industry ................................................................ 41

2.5 Dairy sector can milk scope in fortification of foods: NDDB .......................................... 44

3. Case-studies........................................................................................................................... 46

3.1 katraj dairy, pune (live case study) ................................................................................... 46

3.2 dudhsagar dairy, gujarat (live case study) ........................................................................ 58

3.3 banas dairy, gujarat (live case study) ................................................................................ 68

3.4 dr. Verghese kurien memorial – dairy museum (net case study) .................................... 73

4. Site study ............................................................................................................................... 75

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List Of Figure

Figure 1. Stages of milk processing ...........................................................................................................1

Figure 2. First dairy at Anand ....................................................................................................................7
Figure 3. Dr. Vergise Kurian at Anand ......................................................................................................8
Figure 4.Arrangement concept of various sections of dairying in general ............................................. 13
Figure 5. Concept for layout of dairy plant ............................................................................................. 16
Figure 6. Quality control laboratory in dairy .......................................................................................... 21
Figure 7. Section of milk storage tank .................................................................................................... 23
Figure 8. Elevation of silo ....................................................................................................................... 24
Figure 9. Can washer .............................................................................................................................. 25
Figure 10. Pouch filling machine ............................................................................................................ 27
Figure 11. Cream separator ..................................................................................................................... 27
Figure 12. Belt conveyor......................................................................................................................... 28
Figure 13.Plan symbols of dairy equipment ........................................................................................... 29
Figure 14.Flow diagram for processes occurring at a typical milk plant ................................................ 30
Figure 15.Flow diagram for a typical butter-making plant ..................................................................... 31
Figure 16.Flow diagram for a typical milk drying plant ......................................................................... 32
Figure 17.Flow diagram for a typical cheese plant ................................................................................. 32
Figure 18.External view of Katraj dairy ................................................................................................. 46
Figure 19.Location map of Katraj dairy.................................................................................................. 46
Figure 20. Site plan ................................................................................................................................. 47
Figure 21.Key plan.................................................................................................................................. 48
Figure 22. Metal tiles over concrete........................................................................................................ 48
Figure 23. Steel protected corner of dock ............................................................................................... 48
Figure 24. Inlet pipe at dock ................................................................................................................... 48
Figure 25. Dockyard plan........................................................................................................................ 48
Figure 26. Silo......................................................................................................................................... 49
Figure 27. Alco ....................................................................................................................................... 49
Figure 28. Figure ground plan................................................................................................................. 50
Figure 29. Building typology plan .......................................................................................................... 50
Figure 30.Area diagram .......................................................................................................................... 51
Figure 31.Section AA'............................................................................................................................. 51
Figure 32. Plan......................................................................................................................................... 51
Figure 33. Circulation plan ..................................................................................................................... 52
Figure 34. Curd hanging stand ................................................................................................................ 53
Figure 35. Alco ....................................................................................................................................... 53
Figure 36. Cream separator ..................................................................................................................... 53
Figure 37.Tray washing machine ............................................................................................................ 53
Figure 38. Milk pouch filling machine ................................................................................................... 53
Figure 39. Plastic curtains ....................................................................................................................... 53
Figure 40.Expiry printing........................................................................................................................ 53
Figure 41. Ice cream making section ...................................................................................................... 53
Figure 42. Pouch filling machine ............................................................................................................ 53
Figure 43. Paneer pressing machine ....................................................................................................... 53
Figure 44 Entrance of dairy museum ...................................................................................................... 73

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vii
List Of Table

Table 2.1. Annual growth rate

Table 2.2. Milk production in India

Table 2.3. Color code which have been accepted universally.

viii
List Of Abbreviations

C.I.P. -Cleaning In Place

N.D.D.B. -National Dairy Development Board

U.H.T -Ultra Heat Temperature

B.O.D. - Biological Oxygen Demand

C.O.D. - Chemical Oxygen Demand

E.T.P.-Effluence Treatment Plant

R.M.R.D. -Raw Milk Reception Dock

M.L.P.D -Million Liter per Day

T.P.D -Tones per Day

L.LP.D -Lakh Liter per Day

ix
Glossary Of Terms

Cream:

The high fat portion of milk that is separated during processing. Cream is used to produce
products such as ice cream, whipping and heavy cream. Cream is dried and powdered and some
is condense by evaporation.

Dockyard:

It is a place where raw milk tanker are parked. Raw milk enters in processing machines from
dock through pipe.

Homogenization:

A process applied to milk that result in fat globules being reduced in size to allow a smooth
consistency.

Pasteurization:

The process of heating milk or cream to a specific temperature for specific temperature to destroy
any harmful microorganisms and increase its keeping qualities.

Silo:

A tall tower made up of stainless steel used to store raw or pasteurized milk.

Sterilization:

The process of making something free from bacteria or other living microorganisms.

Skim milk:

The product left after the cream is removed from milk. It is also called as fat free milk.

U.H.T. Pasteurization:

Sterilized milk that has been heat-treated at an ultra-high temperature (138 to 158 C) that is to a
higher temperature than regular pasteurization.

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 CHAPTER NO.1
Milk Processing Plant
1.1 introduction

1.2 need for the project

1.3 aim and objectives

1.4 scope and limitations of the project

1.5 methodology

xi
 1. MILK PROCESSING PLANT
Let it flow as pure as Ganges

1.1 Introduction:

One of the initial steps man has taken towards

civilization is to maintain cattle, which help him in
agriculture and food. Therefor dairy is probably
one of the oldest business the man has been doing.
This activity has not only made a vast change in the
eating habits of man but has also opened a profitable
source of income for him. It is for this reason that
innumerable development have been made in the
dairy science, over ages to make it more and more
Figure 1. Stages of milk processing
hygienic and money earning. Milk has an important
place in the predominantly vegetarian diet of our people. It helps physical and mental
development of our body. Therefor dairy is most essential for the economic and social
development of the people.

Dairy industry today is one of the most important wings of the food industry in
India. It has vastly changes from the primitive methods practiced as a cottage industry, just
60 years back when the country gained political and economic independence. Although the
per capita consumption of dairy products in India is not comparable to the consumption of
dairy products in developed nations. The industry is well on the way of making a significant
contribution in providing the products to the ever increasing population of the nation.

India had tremendous milk production in 40 years and has become the world’s
largest milk producing nation with a gross output of 84.6 million tons in 2001. In India
dairy business has been practiced as rural cottage industry over the years. Semi commercial
dairy started with the establishment of military dairy farms and co-operative milk union
throughout the country towards the end of the 19th century. Since independence this
industry has made rapid progress. A large number of modern milk and milk product
factories have since been established.

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1.2 Need for the project:
 Rural development and economy:

Milking generating is spread and scattered over many villages, but the out-come from milk
industry is not satisfying. If properly coordinated under co-operative sector or allied means,
it will become revenue earner for the villagers with proper environment dairy farming is
financially beneficial and in turn would serve as worthwhile contribution to the national
economy as the living condition of milk producer’s would improve because of more return.
About 70% of our population live in the rural area. Dairying has many advantages in a
rural economy. It is an important source of subsidiary income to a large number of farmers
and agricultural labors. It provide gainful employment to farmers during the lean months
of the agricultural operation. This particular project will serve to some extend of
bringing up village welfare.

 Employment:

Livestock sector provides employment to 18 million people and nearly 70 per cent of them
are women. Further, dairy sector is the major source of income for an estimated 27.6million
people. Among these, 65 to 70 per cent are small, marginal farmers and landless labor. The
dairy sector supports around 10 million members / farmers through one lakh cooperative
societies existing in the country. The dairy sector can play an important role in
providing jobs for rural communities. Dairy production and processing provide
employment, not only to people who work on dairy farms or in dairy plants, but also to the
whole sector, from upstream inputs and services providers to downstream marketing of
finished products.

 Impact on Infrastructure of rural area

Participating farmers have become aware of their responsibility to the community. Every
year they generously contribute a portion of their cooperative’s profit towards the overall
development of the village, such as:

• Improving the village approach road condition

• Providing facilities to youth through establishing village libraries
• Contributing to educational institutions and village primary health centers
• Cooperative dairying has therefore shown a significant socio-economic impacting
rural development

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1.3 Aim and objectives:
 My aim is to synthesis a fairy complex industrial process into a powerful building
form with minimum use of mechanical aids.

Objective:

 To design a dairy complex in such a way that there will be minimum length of service
pipe, easy flow of traffic, maximum natural light and ventilation, adequate sanitary
facility.
 To provide habitable and comfortable industrial environment and maintain hygiene.
 Provision of infrastructure for effective collection, transportation, processing and
marketing of milk from rural areas for meeting the demand of urban areas.
 To design a dairy complex in such a way that the people from outside can see the
process plant without disturbing process and maintaining hygiene.
 To study new technologies and incorporate with design like recycling of water so there
will be a minimum wastage of water.
 To use gravity flow of milk which helps to saving energy.
 To promote standards and to foster the growth of the dairy industry in general and for
the purpose engage in consultancy activities, set up laboratories.
 To provide suitable environment in food industry which helps to promote productivity
and economic growth by considering factors pertaining to environment.
 To provide comfortable environment like proper flooring, ventilation, less odor for
workers. Because high comfort of workers means better productivity.

Design priorities:

 Hygiene
 Requirement of proper circulation
 Proper lighting and ventilation with respect to climate of site
 Aesthetics

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1.4 Scope and limitations of the project:

 Rural development- development of infrastructure.

 Empowerment- job opportunity for youth.
 Indo-tourism – it will work like indo tourism that is people from outside can see
processing plant without disturbing process and maintaining hygiene. We can use
this tourist money in the dairy to increase productivity.
 There is no such a branded dairy in past therefor by introducing this project we can
provide higher nutritional and healthier products to the consumers and also farmer
will get some amount of their raw milk.
 Making sustainable – by using natural light and ventilation, recycling of water and
gravity flow of milk we can save energy.
 Dairy mall/ parlor – to create dairy mall or parlor with open space where people
can enjoy fresh dairy products like ice cream, butter milk, lassi etc. and provide
automatic coin product machine.
 To provide long lasting dairy for educational hubs.

Limitations:

 Capacity of the plant that is per day production of milk will depend upon area of
the site and the number of livestock in near villages.
 There will be no cow shade as it required large area and raw milk will comes from
surrounding villages.
 Production of milk and milk products will only limited for that area and
surrounding villages because capacity of plant depend upon population of that area.
 There will be no residential quarter for workers.
 The plant will not include all type of dairy products, type of dairy products will
depend upon which brand is going to sponsor dairy and the availability of space and
demand of consumer in that area.

4
1.5 Methodology

STAGE - 1
Research
Selection of Process, working,
topic. circulation and scope
of architecture.

STAGE - 2
Analysis
Literat- What are the
requirements of Live/ book/
-ure the project? Comparati- net case
study ve analysis.
Identify study
problems and
issues

STAGE - 3
CONCEPTUAL
DESIGN
Progra-
Literature Develop concept
Site Limitat mme
study of according to
selec ions of and
N.B.C circulation,
-tion the area
rules and requirements of
project analysis
regulations project and
segregation of
spaces.

5
 CHAPTER NO. 2
Literature Study
2.1 History of milk industry

2.2 Principles involves in planning of plant

2.3 Service pipe layout

2.4 Quality control of milk

2.5 Equipment study

2.6 Dairy products

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2. Literature study and review

2.1 History of the milk industry

No one knows when people first used animal milk for food. However the people of ancient
Babylon, Egypt, and India reared dairy cattle as early as 4000 B.C. at that time the family cow
was the chief source of milk. Several inventions and new process helped speed the growth of
the milk industry. Gail Bordon an American inventor patented the manufacture of condense
milk in 1864, the French scientist Louis Pasteur developed the process of pasteurization,
which dairies began to adopt in the 1890’s.

Figure 2. First dairy at Anand

Prior to year 2000, India was not noticed by most international dairy companies, as the
country was neither an active importer nor an exporter of dairy products. Although India has
imported some milk powder and butter oils as aid between 1970 and 1990, exports from India
were insignificantly small and it was not until 2000 onwards, when Indian dairy products
started having more presence in global markets. The transition of the Indian milk industry
from a situation of net import to that of surplus has been led by the efforts of National
Dairy Development Board's Operation Flood programme under the leadership of the
former Chairman of the board Dr. Kurien. Long distance refrigerated rail-transport of milk
from Anand to Bombay since1945.

White revolution

Operation Flood started the White Revolution in India and made our country self-sufficient
in milk and this was achieved entirely through the cooperative structure. Today around 12
million farmers in more than 22 states across the country own around 250 dairy plants
handling around 20 million liter of milk a day. This is a remarkable achievement. Operation

7
Flood, launched in 1970, was a project of India's National Dairy Development Board
(NDDB), which was the world's biggest dairy development program. It transformed India
from a milk-deficient nation into the world's largest milk producer, surpassing the USA in
1998 with about 17 percent of global output in 2010–11. In 30 years it doubled milk
available per person, and made dairy farming India’s largest self-sustainable rural
employment generator. It was launched to help farmers direct their own development,
placing control of the resources they create in their own hands. All this was achieved not
merely by mass production, but by production by the masses.

Operation Flood’s objectives included:

 Increase milk production ("a flood of milk")

 Augment rural incomes

 Reasonable prices for consumers

Figure 3. Dr. Vergise Kurian at Anand

Operation flood was implemented in three stages:

Phase I

It started in July 1970 and ended in 1981. The objective was to set up dairy cooperatives in
18 milk sheds in ten states, so as to link them with the four best metropolitan markets of
Mumbai, Delhi, Kolkata and Chennai.

Phase II

Operation Flood Phase II (1981–1985) increased the milk-sheds from 18 to 136; urban
markets expanded the outlets for milk to 290. By the end of 1985, a self-sustaining system of
43,000 village cooperatives with 4,250,000 milk producers were covered. Domestic milk
powder production increased from 22,000 tons in the pre-project year to 140,000 tons by
1989, all of the increase coming from dairies set up under Operation Flood.

Phase III

Phase III (1985–1996) enabled dairy cooperatives to expand and strengthen the infrastructure
required to procure and market increasing volumes of milk. Veterinary first-aid health care
services, feed and artificial insemination services for cooperative members were extended,
along with intensified member education. Operation Flood's Phase III consolidated India's
dairy cooperative movement, adding 30,000 new dairy cooperatives to the 43,000 existing
8
societies organized during Phase II. Phase III increased emphasis on research and
development in animal health and animal nutrition.

Table 2.1. Annual growth rate

Sr. no year Milk (agr %)

1 1951 to 1961 1.64

2 1961 to 1974 1.15

3 1974 to 1981 4.51 (white revolution)

4 1981 to 1991 5.48

5 1991 to 2001 4.11

6 2001 to 2010 5.77

Table 2.2. Milk production in India

Sr. no year Production (m tonnes) Per capita (g/day)

1 1991-1994 57.5 180

2 1994-1997 66.2 195

3 1997-2000 75.0 215

4 2000-2003 83.4 225

5 2003-2006 95.0 230

6 2006-2009 105.2 255

7 2009-2012 122.8 285

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2.2 Principles involved in planning of milk plant
Milk plant layout:

While designing milk processing plant and milk products plant following points should be
considered:

 Minimum length of services pipes.

 Easy flow of traffic.
 Central position of main process room.
 Maximum amount of natural light and ventilation
 Vehicular traffic should be restricted, only on 2 or 3 sides of building.
 Adequate sanitary facilities.

There are three basic form of milk plant layout.

1. Linear layout:

Advantage:

Machine can be arrange in simplest form. No complicated joints in the pipes gradients of
service pipe can be adjusted.

Disadvantages:

Two different sides for incoming and outgoing trucks, service lines become too large, walking
distance become large, future expansion can takes place in parallel lines

RECEIVING PROCESSING LOADING OUT

2. U- Shaped layout

Since input and output are on the same side therefor one point control.

Minimum amount of asphalt road

Product dairy and milk processing dairy can be treated as two different part of same unit.

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 RECEIVING

PROCESSING

LOADING OUT

3. T-Shaped layout:

Advantage:

Service line and walking distance reduces.

Disadvantage:

Traffic is on all the sides of the main plant building.

RECEIVING PROCESSING PROCESSING

LOADING OUT

Some points considered while designing:

 Administration block especially general manager’s cabin overlook the main dairy
block which keeps better super vision and inspection.
 Gravity flow of milk is followed as far as possible, thus saving energy.
 No green area near to process plant as to maintain hygiene.
 For better loading and unloading process of articles the store has provided on ground
floor only.
 In ordered to maintain the status of various employees of different levels, the entries
should be segregated.
 The central library should near to reception dock and milk processing

11
Single or multilevel design:
The number of floors to be provided in the building obviously affects the planning of
the various sections and the area required. In considering this, it should be remembered as a
general principle that is preferable to keep heavy goods at one level and that liquids are easily
pumped to high level and can flow back by gravity. If the depth of the external system, the
nature of site, and the condition of the ground are suitable, a basement for the supply and
distribution of services should be considered. Such an arrangement allows short, direct
connections to the process equipment on the ground floor and eliminates the necessity for
housing service pipes on the process room.
The number of floors above ground, which the plant should have, depend to some extent on
the scale and nature of the process and area of the site. But mainly on the number of the
products to be manufacture.For a medium size plant dealing with one or two products, it is
also more practicable to have the main section on the same level. Only the tank room need to
be placed on an upper floor. This arrangement is necessary because the staff will be few and
will have a variety of duties, moreover there will generally be only one supervision.
The plan specialized in more than two products then the floor space required would be so
large therefor it will more economical to construct a two story building. Furthermore some
types of equipment required two story operation. For example continuous sterilizes and spray
drivers. Products such as butter or cheese may be packed or otherwise dealt with on a lower
floor.

Arrangement of different sections

Arrangement of different sections of dairy means siting of various sections in relation to each
other in dairy building. Arrangement of different sections in dairy must be done in such a
manner that main rooms are planned and sited in relation to each other first. The product
sections can then be grouped around them. Utility sections are placed near the areas where
services are needed. Garages with facilities for washing and lubrication will be placed
adjacent to workshop. Offices will have separate apartments. Overall layout of the dairy plant
should be of functional design and should give hygienic outlook. Arrangement of different
sections in the dairy plant has effect on energy conservation and product losses. Arrangement
of different sections should be based on the future expansion required in the dairy plant.
Reception and dispatch rooms should be situated on the ground floor and normally should be
at a height above the approach to suit the vehicles concerned. On a sloping site it may be

12
possible to arrange the building so that reception is at higher level on one side of the building
and dispatch is at a lower level on the opposite side thus saving cost in excavation work.

Figure 4.Arrangement concept of various sections of dairying in general

An arrangement concept of various sections of dairying in general will be noticed that product
sections are placed around milk storage and treatment room (main rooms). Product storage is
next to product sections from where they are sent to dispatch dock. Laboratory has been placed
near milk reception and refrigeration machinery room near the product storage. Utility
sections near the area where services are needed.

Dairy Plant Design

Dairy Plant design, involves the estimation of capacity, process scheduling and proper layout
so as to achieve the objective of handling milk at the least cost and greatest safety. However,
the dairy industry and the plant design has to meet certain special requirements and need to
be focused on these. The following are the few aspects that make the dairy industry as a unique
one.

Special Characteristics of Dairy Industry:

 Perishable nature of milk: Milk is one of the most perishable of the agricultural
commodities, and has only few hours of shelf life unless it is chilled and processed.

13
 Hence, the TIME factor is the most important aspect to be involved in the dairy plant
design and layout
 Milk is an essential commodity. It provides nutrition especially to children and aged.
Hence the dairy industry has a high profile in the society, and its functioning is very
essential to the wellbeing of the society.
 Seasonal nature: The dairy industry has to deal with availability of raw milk
fluctuations depending on the season. It is available in certain months, called Flush
season when most of the calving and green fodder is available. During summer
months, when milk availability dips due to most of the animals coming to end of their
lactation period. Hence, OVER CAPACITY is the factor to be considered in plant
design and layout, as the plant is to meet the peak procurement of the flush season,
while in the remaining months it is having excess capacity. Also flexibility of the plant
design and layout has to be considered.
 Milk is a food item, which has to be consumed, especially by children and old people.
Hence, PLANT HYGIENE is the important factor in plant layout and design.
 Effluent disposal of dairy plant is essential as the volume and BOD value of the dairy
effluent is high. Sufficient planning is required to handle this high volume of effluent
to be handled by Effluent Treatment Plant (ETP).

Dairy plant layout

The main objective of dairy plant layout is to design the dairy plant to carry out all dairy
processing operations. The management policies decide the future expansion requirement of
a dairy plant. Management decision with respect to the addition of new of products is
important to be considered at the stage of dairy plant layout. A well designed layout must
facilitate production operations, minimize material handling maintain flexibility of the
operation for alteration and expansion, minimize investment in equipment, make economical
use of floor area, promote effective utilization of the labor and provide for employee
convenience and comfort. It is up-most important to design optimum size of dairy building.

Important factors for planning of dairy building

The following are the basic factors which must be considered before planning the dairy
building.

 Milk handling capacity and variation in milk handled every day.

 Method of milk collection and transportation
14
  Design of milk processing section
 Method of milk packaging.
 Way of milk distribution to consumers
 Source of electric power supply, water supply and waste water disposal.
 Type of fuel for boiler.
 Provision for subsequent future expansion.
 Transportation facilities and conditions of road

The source of water throughout the year is very important in design of the plant. Water may
be distributed by gravity system or hydro-flow system using G.I. pipelines. If power shut
down is frequent, then provision should be made for standby availability of electric power

Planning of dairy processing schedule

Process scheduling means arranging the flow of products through various operations in the
plant in order to achieve maximum use equipment and labor, and the processing of the
products is accomplished in the shortest possible time with minimum delays between
processing of different products.

Operational layouts

Operational layouts describe operations which take place in processing or manufacture of

different products. All operations involved are represented diagrammatically in chronological
way (sequence-wise flow diagram) which can be easily understood by a layman. Even
operational layouts can be shown in pictorial views or three dimensional layouts. Such layouts
would help to understand the sequence of operations to be followed for the manufacture of
various products.

Principles of dairy layout

A dairy plan architect should try to incorporate all the fundamental aspects listed below. This
would help in performing dairy activities economically and efficiently.

 The milk path should be as short as possible. This will minimize the cost of pipeline
and cleaning time.
 Reception and dispatch must be arranged in such a way that congestion of transport
vehicles is avoided.

15
  As general guidelines, a small dairy may have reception and dispatch on one dock but
it is necessary to have them separate for large dairy plants.
 Where space is available, single storye building is most suited. The plan may have a
rectangular shape with roads on all sides.
 Location of milk silo outside the building area may save space and construction cost.
This is widely followed in almost all dairy plants
 As far as possible refrigeration and boiler section are kept little away on the side of
the building on ground floor. Refrigeration machinery room should be near the process
room and cold store to reduce the piping cost and pressure drop.
 Laboratory should have easy approach to reception room and processing room. 8.
Separate building block for administrative offices

Figure 5. Concept for layout of dairy plant

External form of the building

The elevation of dairy building should give advertising image to the people. The form and
shape of dairy building is important as it affects the public reaction as well as upkeep and
initial cost. In addition to several technical considerations, marketing of dairy products needs

16
good site selection and attractive building design. Appearance and look are the primary factors
affecting the marketing of the products. If a brand is having a typical pattern of building
replicated at many places the building pattern itself may become identification for the brand
of the organization.

Advantages of planning and principle of dairy plant designing are mentioned. ·

 A good layout reduces the effort in normal material handling of a worker, cost of
handling by direct labor and hence increased productivity per man hour and indirect
manufacturing cost by decreasing spoilage under difficult handling situation
 It uses only essential space required and eliminate congestion and accident, permits
flexibility for methods improvement and future expansion besides making supervision
easier.
 It also facilitates scheduling and dispatching operation.
 Better hygienic conditions and minimum losses. ·
 Reduction in processing cost
 Optimal height reception dock improves the working efficiency of worker
 Safety of persons working in the plant.
 Better use of services such as water, electricity, refrigeration, air supply etc.
 Better space utilization for equipment and services. .
 Quick communication with different sections of dairy.
 Efficient utilization of manpower.
 Efficient movement of product within the plant and dispatch
 Energy saving
 Saving on building cost

Utilizing principles of planning and applying them for plant construction leads to economical
and effective running of plant. The use of scientific, technical, and logical knowledge can
form a model plant for dairy.

Layout of offices and workshops

Layout of offices for general manager, managers, supervisors and technical officers are
planned in a way, so that all the processing operations can be monitored from the glass
window of the offices. Further the locations and layout of the process control room should be

17
in the center of the processing sections, so that instructions can be given to the operator after
visual monitoring of the activities.

Office layouts and their linking with dairy plants

A dairy factory will not have only technical, dairy professionals, operators, skilled and
unskilled workers, but will also have staff personnel not directly concerned with plant, but
very much associated with dairy. This staff looks after all activities of dairy such as
administration, milk procurement, processing, dispatch, distribution, sales and marketing of
products, establishment, finance and accounts, H.R.D., security (watch and ward) and
management in general. This staff requires office accommodation comprising number of
rooms properly linked. For employee comforts and convenience, staff canteen, toilets,
reception lounge have also to be provided. Size of office varies with the capacity of the plant.

A small dairy may have small office as number of activities will be less. Medium size
dairy plant will have bigger office as compared with small dairy. In this number of activities
will be more and plant may be manufacturing more products. Accordingly, staff will increase.
A large dairy will still have large office with large number of staff employed. Before deciding
number of rooms in office and space requirement, it is essential to know the activities, number
of departments and persons who can handle the work, as number of persons employed will
determine the area and room needed by them. A small dairy may have sections or departments
viz milk procurement, milk processing, milk dispatch and distribution, sales and marketing,
advertising, sanitary control and hygiene, security (watch and ward), establishment, finance
and accounts, dairy technology and dairy engineering.

Medium dairy will have all above departments, but there may be addition of two or
more sections, such as labor welfare department (office), human resource development
(H.R.D. section), personnel department etc. Large number of employee and labor justifies the
existence and importance of additional sections mentioned above. In small dairy office, there
will be one Manager who will be assisted by various Sectional Heads with suitable
designations. Each Sectional In charge will have 2 or 3 Assistants/Clerks and one Peon or
Attendant.

Large dairy plant will have big office layout with large number of employees at different
levels to manage various departments. Staff pattern in large dairy organizations is somewhat
different from other two small and medium size dairy plants. Here above General Manager,
there is Managing Director; Board of Directors presided over by Chairman of the company.

18
2.3 Service pipe line layout
Service pipe line layout for different services required in the dairy plant like steam, well water,
chilled water, hot water, fresh water, refrigeration, air etc. is prepared for minimizing material
requirement, estimating cost of installation, to facilitate selection of different fittings, and to
smoothen the operation. Service pipeline layout is prepared considering safety aspects of the
plant and personnel working. It also helps in deciding the material requirement, mountings
and accessories required in each pipelines. There are different color codes used for different
piping systems. The steam pipe is painted with yellow color, chilled water pipe line is painted
with blue color, well water pipeline is painted with green color and pipelines carrying hot
fluid are painted with red color. The pipe lines carrying hot and cold fluids are insulated with
suitable insulating material.

Color coding for identification of pipe-lines

When a number of pipe lines are running in dairy factory, it becomes necessary to know what
material is being piped through particular pipe. To avoid any sort of accident, it is important
to identify the pipe lines. The American Society of Mechanical Engineers has suggested color
code for identification of all piping arrangement and systems.

Table 2.3. Color code which have been accepted universally.

Sr.no Service pipe line Colour

1. Safe products (air, water etc.) Green
2. Dangerous material (ammonia, flue oil, high pressure steam Yellow
etc.)
3. Protective material piped through the plant to minimize hazard Blue
of dangerous material.
4. Fire control equipment Red

In a milk plant, green color for safe material, yellow for dangerous material and red for fire
control equipment are used. However, an organization can used shades of these colors for
further identification of more pipe lines. For instance, cold water light green, hot water dark
green, chilled light blue etc. A factory using color code for identification of piping must
display at the entrance or at a suitable place a color identification of pipes running in the plant.

19
Milk piping

The layout of interconnecting milk piping system should be decided keeping in view the
method of cleaning. There are two methods which are commonly adopted for cleaning milk
piping. These are:

 Manual cleaning method and

 Cleaning-in-place (C.I.P.) method.

If manual cleaning method is adopted, it must be clear that the pipes have to be dismantled
frequently for cleaning operations and for this purpose, it is essential that approach to pipe
lines is made very easy, i.e., piping system is easily accessible. For this piping supports from
ground (floor) is preferred for supporting overhead pipe lines which are 7 to 8 ft above the
ground level. Piping supports should be placed at a distance of about 3 meters. All pipes
carrying milk are of stainless steel as they are easy to clean. Sanitary piping is recommended
for dairy industry.

For cleaning-in-place method, approach to pipe line is less important as piping will be
dismantled relatively infrequently. Layout of piping in C.I.P. system has to be planned
carefully because the purpose is not only conveying or carrying milk but also cleaning.
Contamination has to be avoided in all cases. In large installations, it will be necessary to
arrange for part of the pipe system to be cleaned while another part is conveying milk, and
precautions and safeguards must be incorporated to prevent accidental contamination of milk
by cleaning solutions or detergents. A milk piping must be so arranged to minimize loss of
product at the end of process run to ensure that all cleaning solutions are removed from plant
before use. For C.I.P. cleaning of pipe lines, milk piping may be supported from ceiling. In
this metal suspension rods are fixed to ceiling. This gives a clear floor area with no obstruction
and operations are carried out smoothly.

20
2.4 Quality control of milk
The central laboratory is the heart of the large diversified milk processing plant and is
responsible for conducting routine bacteriological, chemical and physical examination of raw
and finished products.

Location of lab:

The quality control dairy lab should be located near to the reception dock and processing room
as maximum sampling taken from these rooms. It should be so located so as to avoid vibration
of all kinds and should be away from boiler house.

Figure 6. Quality control laboratory in dairy

Essential rooms

Analytical room:

 Well lighted
 Testing benches with black Formica top for reading accuracy
 Rubber top for benches carrying centrifuge experiments to reduce vibrations
 Provision of stainless-steel sinks wherever necessary
Balance room:
 Location: place where there are least vibration.
 Instruments placed on marble stone platform 1.0 m height from ground level.
 Room should be air conditioned.
Bacteriological room:
 Provision of ultra violet light fitting on the opposite wall of working table to destroy
bacteria in the air. It should be air conditioned.
Wash up room:
 Tile flooring and glazed tile dado up to 2m height from floor level.

21
  Racks in tiled position for easy draining.
 Drain pipes acid/alkali resisting.
Store room:
 Acid and alkalis are stored separately with precautions.
 First aid box provision.

Sanitation in a dairy:
The dairy industry being a food industry requires sanitation of high degree. A well maintained
plant is conductive to a clean, neat and orderly operation. Bacterial contamination happens in
dairy because of poor personal hygiene of employees, prevalence of rats, mice and flies,
unclean equipment and improper inadequate waste or sewage disposal. To avoid this the
following guidelines should be followed.
 All cracks and crevices in the walls should be sealed.
 All pipes opening should be completely cemented or provide with tight metal collars.
 Systematic plan of rat trapping is necessary.
 Reconditioning of equipment.
 Proper and adequate drainage, C.I.P arrangement.
Wall, floor and ceiling:
 Constructed with smooth easily cleanable surface.
 Finished in light colors and painted regularly.
Mold control:
 All interior building surface in processing, handling, and store section of the building
treated periodically.
 Adequate ventilation and the relative humidity maintain.

Maintenance program in dairies:

 Insect prevention: insect like flies and cockroaches, maggots are a menace to the dairy
plants.
 Windows, door, ceiling ventilators should be screened.
 Air conditioning and mechanical ventilation should be used whenever possible.
 Processing rooms should not open directly to the out, but into an intervening room for
dust and debris to settle down.

22
2.5 Equipment study
A plant will be efficient only if equipment installation is in proper order. Proper order means
laying of equipment according to flow pattern of manufacturing process. The equipment must
be laid as per sequence of the operations. Horse has to be put before the cart and not a cart
before the horse. For instance, milk after its reception at Milk Reception Dock, has to be
weighed, dumped into dump tank, chilled through surface cooler or plat chiller before it is
stored into storage tank for further processing. Here a chiller will have to be placed in between
dump tank or milk receiving vat and storage tank. Milk route has to be made as short as
possible. Unnecessary travel of men and material should be avoided as it amounts to waste of
time. It is often seen that wrong planning and faulty installation of equipment leads to
inefficiency, delays and loss of money as plant becomes uneconomical. Therefore, proper
arrangement of equipment is essential for any successful plant.

Milk storage tanks

They are usually cylindrical and mostly insulated. They may be horizontal or vertical types,
depending on availability of floor space. For extremely large quantity of storage, Vertical Silo
tanks are provided outside the Processing section, to avoid tall buildings to accommodate
them. The inner shell of storage tank is of Stainless Steel, and covered with suitable insulation,
and then an outer shell, which may be Stainless Steel or Mild steel. The outer mild steel shell
will be painted to prevent corrosion, which may be of two coats of antirust and two coats of
enamel paint of suitable color, especially cream yellow.

Figure 7. Section of milk storage tank

23
Some of the high viscous products like cream or ghee are also preferably stored in this type
of storage tanks. Due to its shape, the manhole is at the top, and a ladder is provided for
reaching on to the top. The sight and light glass are also provided at the top. Due to its height,
the agitator has to be long, and provided with more than two sets of blades for agitation. An
internal ladder is provided to climb down for manual cleaning. Both the inlet and outlet will
be at the side at the bottom level of the tank. The slope is 1:10 towards the outlet so that there
is free and complete drainage of liquid. Silos are vertical storage tanks of large capacity,
usually more than 30,000 to even up to 1 lakh liters.

Figure 8. Elevation of silo

Straight through can washer

Principles of Operation: Straight through can washer carries the cans through the washer in a
straight line by means of a continuously moving conveyor or slide along rail as they move
intermittently from one jetting position to the next.

Draining: Before passing the cans to the can washer, milk, cream or any other fluid is drained
out by placing the cans in an inverted position over a drip pan before it is rinsed.

Pre-Rinsing: Rinsing of can is done by passing water through the jet to clean the milk film
remaining in the can at a pressure of about 1.0 to 2.0 kg/cm2 for 3-6s, so as to remove the
traces of milk.

24
 Figure 9. Can washer

Hot Water Rinsing 1: Cans are rinsed by clean hot water. The temperature of hot water is
maintained at about 65-70 °C. Temperature should increase at successive stages, as at the
sterilization and drying stage the steam and hot air temperature will be higher than 100 °C.

Caustic Rinsing: Caustic rinsing is done by passing the washing solution through jets at a
sufficient high pressure both inside as well as outside to remove all milk and cream film inside
and outside of the cans.

Hot Water Rinsing 2: This is done to clean the washing solution thoroughly. The water
temperature in this section is about 85-90 °C and this water is drained after use.

Sterilization: Sterilization of can is done by passing dry saturated steam at 1100C for 5 to
10s. Steaming process sterilizes the cans and increases the can temperature which facilitates
the easy and quick drying in the drying section

Drying: The main purpose of drying is to prevent the corrosion of metal due to moisture and
to check the bacterial growth. The drying operation is accomplished by blowing jet of hot air
at 1100C inside the can.

Pouch filling machine:

The Form Fill Seal machines are a genre of filling equipment that can fill in a flexible packing
material. The product should be free flowing type, either liquid or even granular. The
equipment may be controlled electro-pneumatic or mechanically or a combination of them.
The process involves certain steps, which will take place cyclically in auto operation. There

25
is option for variation in size and quantity of the product packed. To a large extent, the market
milk is now being sold by packing in these machines. The following are the operations that
go cyclically.

1. Forming of tube of packing material from film in rolled state

2. Simultaneous operation of filling and sealing

3. Movement of film to form next package

4. Simultaneous separation of filled and sealed packet while filling of next packet.

The overhead tank carrying the fluid to be filled. While filling is taking place, a pair of flat
blades operated by spring keeps the film perfectly flat at horizontal edge so that there are no
folds and horizontal seal is perfect. When the filling of fluid and the horizontal sealing is
complete, the horizontal jaws (as well as vertical jaws) get disengaged, and the nip rollers
start rolling to bring the next length of film tube to be filled for next packet. While the second
packet is being filled, the first packet already filled will be getting the horizontal seal of top
portion of the filled packet. When the next time the jaws open, the first packet drops down by
its own weight because of weakened connection to the rest of the tube. The above cycle of
operation is repeated when the controls are in automatic operation, while single action takes
place when in manual operation during initial adjustment of time and temperature
combination for obtaining proper seal.

26
 Dimension:
length: 1800mm
height: 2800mm
width: 600mm

Figure 10. Pouch filling machine

The separator:
Cream separation is a phenomenon by which
the milk is separated in to cream and skim
milk by centrifugal and gravitation force. The
milk enters the rapidly revolving bowl of the
separator. It is then acted upon by
gravitational and centrifugal force. The inflow
of milk is channelized to the outer wall of the
bowl and fills it from outside towards the
center. The centrifugal and gravitational
forces keep on continuously and act upon to
partition the serum and cream. Obviously
serum is thrown towards the outer periphery
and channelized to skim milk out let, while the
cream is channelized to the central core and
Figure 11. Cream separator
forced out through cream out let, while the
cream is channelized to the central core and forced out through cream out let.

27
Conveyors

Whenever question of material handling comes, thought must be given to available material
handling devices, such as, cart, trolleys, fork lift truck, conveyors, etc. All these devices save
labor and time. The length of conveyor between two pieces of equipment is important and
serves as a storage to aid in synchronizing the speed of the two machines. This storage
function gives the operator a brief period in which to correct minor difficulties with a machine
without stopping the entire line.

Types of conveyors

Conveyors move cases and cans faster and more efficiently than men and this increases the
proportion of time workers who can spend more time on actual production work. The most
common types of conveyors used in dairy industry are:

 Chain conveyor
 Belt conveyor
 Gravity conveyor (roller conveyor)
 Wheel conveyor

Chain conveyors are the type most widely used in the dairy plant to convey crates, cans and
other packages. Chain conveyors are of three types:

 Above floor type,

 In floor type, and
 On floor type.

Regardless of the type, every chain conveyor system consists of 4 basic parts, namely power
unit, conveyor frame, chain, and take up unit.

Figure 12. Belt conveyor

28
Belt conveyors

Belt conveyors are used in dairy plants for carrying cases between floors in multistory plants.
Belt conveyors are not suited for handling milk cans. Wheel conveyors are ideal for
warehouse operations because they are light in weight, portable and are easily moved around
in the ware house.

Bottle conveyors

Bottle conveyors are of two types, namely Flat link, and the lateral curve. Both have a smooth
level surface and can be used for either glass or paper bottles. It will be noted that bottles
require slat conveyors to give the necessary area of flat surface for stability. Bottle conveyor
is a type of chain conveyor using chains which may have from a 1 to a 4 inch pitch. The chain
runs on a frame between the rails. Conveyors are installed as per requirement of a particular
section.

Plan symbols of dairy equipment:

Figure 13.Plan symbols of dairy equipment

29
2.6 Dairy products:
The processes taking place at a typical milk plant include:

 Receipt and filtration/clarification of the raw milk;

 Separation of all or part of the milk fat (for standardization of market milk,
production of cream and butter and other fat-based products, and production of
milk powders); · pasteurization;
 Homogenization (if required);
 Deodorization (if required);
 Further product-specific processing;
 Packaging and storage, including cold storage for perishable products;
 Distribution of final products.

The following flow diagram outlining the basic steps in the production of whole milk, semi-
skimmed milk and skimmed milk, cream, butter and buttermilk. In such plants, yogurts and
other cultured products may also be produced from whole milk and skimmed milk.

Figure 14.Flow diagram for processes occurring at a typical milk plant

30
Butter production

Figure 15. is a flow diagram outlining the

basic processing system for a butter-
making plant. Milk destined for butter
making must not be homogenized,
because the cream must remain in a
separate phase. After separation, cream to
be used for butter making is heat treated
and cooled under conditions that facilitate
good whipping and churning. It may then
be ripened with a culture that increases the
content of diacetyl, the compound
responsible for the flavor of butter.
Alternatively, culture inoculation may
take place during churning. Butter which
is flavor enhanced using this process is
termed lactic, ripened or cultured butter.
Butter made without the addition of a
culture is called sweet cream butter. Both
cultured and sweet cream butter can be
produced with or without the addition of Figure 15.Flow diagram for a typical butter-making
plant
salt. The presence of salt affects both the
flavor and the keeping quality. Butter is usually packaged in bulk quantities for long-term
storage and then re-packed into marketable portions.

Milk powder production

Milk used for making milk powder, whether it be whole or skim milk, is not pasteurized before
use. The milk is preheated in tubular heat exchangers before being dried. The preheated milk
is fed to an evaporator to increase the concentration of total solids. The solids concentration
that can be reached depends on the efficiency of the equipment and the amount of heat that
can be applied without unduly degrading the milk protein. The milk concentrate is then
pumped to the atomiser of a drying chamber. In the drying chamber the milk is dispersed as
a fine fog-like mist into a rapidly moving hot air stream, which causes the individual mist

31
 droplets to instantly evaporate. Milk powder falls
to the bottom of the chamber, from where it is
removed. Finer milk powder particles are carried
out of the chamber along with the hot air stream
and collected in cyclone separators. Products sold
to the consumer market are normally packaged in
cans under nitrogen. This packaging system
improves the keeping quality, especially for
products with high fat content.

Figure 16.Flow diagram for a typical milk

drying plant

Cheese production

Virtually all cheese is made by

coagulating milk protein (casein) in a
manner that traps milk solids and milk fat
into a curd matrix. This curd matrix is then
consolidated to express the liquid fraction,
cheese whey. Cheese whey contains those
milk solids which are not held in the curd
mass, in particular most of the milk sugar
(lactose) and a number of soluble proteins.

Figure 17.Flow diagram for a typical cheese plant

32
 CHAPTER NO. 2
Literature Review
2.7 The story of white revolution
- by Dr. Narsimha Reddy
2.8 Opportunities and challenges in the Indian dairy industry
- by dairy news
2.9 Dairy sector can milk scope in fortification of food
- by Times of India

33
ARTICLE NO. - 1

The story of White Revolution

Dr. Narasimha Reddy
CHENNAI, MAY 17, 2011 11:30 IST

SHARE ARTI CLE

This book is essentially a story of Operation Flood (OF), commonly referred

to as ‘white revolution', covering all its three phases (1970-96). But it is set
within an ambitious framework in terms of both time and space and in the
wider context of the political economy of evolving trade, and the aid policies.
Three lengthy chapters, taking up almost half of the text, discuss the growth
of farm trade from the Age of Mercantilism through Adam Smith, the World
War II, the Cold War era (which saw the poor countries struggling to develop
against odds) up to the 1994 Agreement on Trade in Agriculture.
In the main, the argument runs thus: Food aid is often the benign face of
surplus disposal, benefiting special interests in donor countries and disrupting
farming in recipient countries; Operation Flood is an exception to the rule that
food aid does more harm than good; government-funded agricultural research
could ensure people's entitlement to food better than big commercial ventures;
and India's White Revolution was successful because of the creation of a small
farmer-controlled network of dairy cooperatives.
Operation Flood
Operation Flood, launched in 1970 to make use of the dairy aid offered by the
European Economic Community, met with strident criticism from several
quarters who contended that the liberal foreign monetary assistance would
cause milk prices to crash, disincentives milk production and ultimately make
India permanently dependent on other countries for its needs of dairy products.
The challenge was to see that the flow of the dairy aid is calibrated in a way
that the supplies do not flood the market and to design a consolidated national
plan to mitigate disincentives to the domestic dairy farmers. The strategy was
to “monetise” the aid, invest the profits from the monetized commodities into
34
 capital-intensive but essential infrastructure in the form of National Milk Grid
System (NMGS). This holistic and multifaceted strategy paid off. Not only did
the market supplies were unaffected but the dairy farmers got the right prices,
and the necessary infrastructure was established and streamlined to match the
growing urban demand. The cardinal principle on which the operation worked
was that the entire value chain — from procurement to marketing — should
be the sole and exclusive domain of the farmer, with the small, marginal, and
landless farmers getting greater importance.
Exceptional
In ‘Amul', hailed as the model, the small farmers accounted for about 70 per
cent of milk production, and 22.5 per cent of the rural households' income
came from milk. Operation Flood is held out by the author as one of the
exceptional programmes where India could dispel(vanish) fears that food aid
would reduce it to a state of perpetual (lasting forever)dependence on others,
serving as a market for the surpluses of the rich countries. Those in charge of
running it could exercise necessary autonomy to negotiate with the EEC and
the World Food Programme (WFP) establishment for monetisation of the milk
aid by holding forth that they had the option of switching to the United States,
Australia, or New Zealand. If India could emerge as the world's leading milk
producer, upstaging the U.S., it was thanks to the OF.
The story of the White Revolution — which features heroes like Kurien and
many villains too, and set in Anand (Amul) and beyond (the National Dairy
Development Board) — has been told in a way that is meticulous and
scholarly, what with its extensive notes and references. Such voluminous data
and information do have their uses and value. But, beyond a point, they could
hinder rather than facilitate reading. The narrative is some times episodic,
polemical in some places, combative in others and dramatic on occasions.
Overall, the book makes a heavy read. What comes across clearly, however,
is that Scholten passionately believes that the dairy cooperative movement has
“always helped to provide a safety net to the most vulnerable and marginalized
sections of our population, which otherwise suffer the worst consequences of
any economic crisis.” This echoes the NDDB Chairman's recent statement
affirming total faith in the farmers' willingness and innate ability to join hands
in a spirit of cooperation.

35
 REVIEW NO. - 1

2.7 The story of white revolution. (Article review)

Abstract

Operation Flood, launched in 1970, was a project of India's National Dairy

Development Board (NDDB), which was the world's biggest dairy development program.
Operation Flood was one of the exceptional programmes where India could dispel fears that
food aid would reduce it to a state of perpetual dependence on others, serving as a market for
the surpluses of the rich countries. The strategy of operation was to “monetize” the aid, invest
the profits from the monetized commodities into capital-intensive but essential infrastructure
in the form of National Milk Grid System (NMGS).This holistic and multifaceted strategy
paid off.

Key word – food aid, strategy, monetize, cooperative, self-sufficient.

Review:

The article “the story of white revolution” is about history of milk industry. From
the article we get to know that how the operation flood was carried out. In first two paragraph
writer said that operation flood was an exception and in latter section he describes about how
the operation flood is exception to the rule that food aid does more harm than good. Operation
flood is an exception because it was work on different strategy. The main challenge in
operation flood was producing required amount of products because if the supply will
excessive then there will be competition in market and because of excessive supply there are
chances of spoilage due to which market face loss and at the same time this production should
help to improve nation’s economy. Therefor the strategy behind the operation was monetize
that is to covert dairy aid into currency which was essential for infrastructure. To follow
strategy it was important to get fund from right amount of production.

The outcome of this strategy was good, farmers got the right price and the necessary
infrastructure was established. It transformed India from a milk-deficient nation into the
world's largest milk producer, surpassing the USA. . It made our country self-sufficient in
milk and this was achieved through the cooperative structure.

Inference: Operation Flood was conceived and implemented as much more than a
dairy programme. Rather, dairying was seen as an instrument of development, generating
employment and regular incomes for millions of rural people. Operation Flood can be viewed
as a twenty year experiment confirming the Rural Development Vision.

36
ARTICLE NO. - 2

Opportunities And
Challenges in The Indian
Dairy Industry
By Dairy News India -

Sep 9, 2016

1313

Opportunities And Challenges in The Indian Dairy

Industry

By- Dr K.G. Karmakar 1 and Dr G.D. Banerjee

Dairy industry is of crucial importance to India. The country is the world’s

largest milk producer, accounting for more than 13% of world’s total milk
production. It is the world’s largest consumer of dairy products, consuming
almost 100% of its own milk production. Dairy products are a major source
of cheap and nutritious food to millions of people in India and the only
acceptable source of animal protein for large vegetarian segment of Indian
population, particularly among the landless, small and marginal farmers and
women. Dairying has been considered as one of the activities aimed at
alleviating the poverty and unemployment especially in the rural areas in the
rain-fed and drought-prone regions. In India, about three-fourth of the
population live in rural areas and about 38% of them are poor. In 1986-87,
about 73% of rural households own livestock. Small and marginal farmers
account for three-quarters of these households owning livestock, raising 56%
of the bovine and 66% of the sheep population.

37
New Challenges of Globalisation and Trade Liberalisation –
Perspective 2010

The NDDB has recently put in place Perspective 2010 to enable the
cooperatives to meet the new challenges of globalization and trade
liberalization. Like other major dairying countries of the world, the Indian
cooperatives are expected to play a predominant role in the dairy industry in
future as well. However, India is in the mean time, attaining its past glory
and is once again becoming DOODH KA SAGAR. But, what percentage of this
SAGAR is handled by the cooperatives – just a little over 7%. Since
liberalization of the dairy sector in 1991, a very large number of private sector
companies / firms have, despite MMPO, established dairy factories in the
country. The share of the total milk processing capacity by private sector is
44% of total installed capacity of 73 MLPD (Million Litres Per Day) in the
country. Therefore, the total share of the organized sector, both cooperatives
as well as the private sector is barely 12%. What is, therefore, disquieting is
that as much as 88% share of the total milk production is commanded by the
unorganized sector – who specializes in selling sub-standard, unpasteurised
milk more often than not adulterated with harmful chemicals.

Besides, growth in milk production is likely to continue at the present rate of

4.4% in the near future. Who is going to handle this incremental milk? We
must bear in mind is both income and price what we must bear in mind both
income & price elasticity account for approximatily 15% of the total
expenditure of food. Demand for milk, at current rate of income growth is
estimated to grow at 7% per annum. Interestingly, demand for milk is
expected to grow steadily over the next two decades as the low income rural
and urban families who have higher expenditure elasticity would also increase
their income due to new economic environment. Let us now look at some
other economic indicators.

According to the World Bank, India is the fourth largest economy in the world
going by the purchasing power parity estimates. Further, India has been
identified as among the first 10 emerging markets in the world. India has the

38
vastest domestic market in the world with over one billion consumers – a
majority of whom are vegetarians with drinking of milk as habit.

The untapped potential of the dairy sector is immense and opportunity to set
up a new dairy venture is great. In the works of Dr. Amrita Patel, Chairperson,
NDDB, there is enough place under the scheme for both private and
cooperative sectors. Notwithstanding the above potential it is cautioned that,
entering dairy sector is not going to be a cakewalk.

Conclusion Globalization and Liberalization are the Mantras of the new

economy today, which is now on the fast track. Industrial production is rapidly
moving forward. The dairy industry is no exception. With the World Trade
Organization (WTO) coming into effect, from 01 April 2001 and the imports
and exports getting liberalized in the global economy, the dairy industry,
which includes dairy products, faces both an opportunity for growth as well
as a threat for its growth.

There is no doubt that there is tremendous scope for the growth of the dairy
industry in the new millennium. The product mix of world dairy trade is likely
to shift further towards cheese. This has been developed in the world markets.

As the market opens up, consumption trends associated with these markets
will have increasing influence on the world trade. Whole milk powder is likely
to continue to be a substantial beneficiary and growth substiantially in the
middle eastern countries. As standards of living in the importing country rises,
exporting countries will increasingly concentrate on whole milk powder and
cheese with the assistance of butter and skimmed milk powder. There is vast
potential for the export of dairy products, the cost of milk production in India
being the lowest. The major factor influencing production of bye products is
the newer uses that may be developed through R & D support.There are 7
large-scale cheese manufacturers and 14 manufacturers are producing infant
foods and malted milks. There is immense scope for the broadening of the
products range and some of the products, which are likely to have
considerable demand in the coming decade, have been identified. The cheese
market, presently valued at about Rs.80 crore is growing at about 9%

39
annually. There are more than thousand varieties of cheese, which have been
listed out of which cheddar; mozzarella, gouda and processed cheeses are
being manufactured in India.

Pizza is becoming a very popular item in the market. This segment alone
commands 5% of the share in the cheese market and other area is fermented
milk products. Dahi even though is a Rs.15000 crore market, the share of the
organized sector is only around 10%. This product has immense potential for
growth.

Varieties of milk shakes are also increasing wherein milk and fruit pulp are
mixed in different proportions to produce different beverages. Some of the
milk and fruit based beverages which are likely to have demand are a
combination of milk with mango, banana, sapota, strawberry, papaya, etc.
Some of these beverages can also be produced in dehydrated form and can
be an excellent health food.

There are varieties in traditional milk based sweets, manufactured in the

country. The market size is around Rs.12000 crore. However, there are very
few nationally known brands in this category. Many of the organized dairies
are involved in the manufacture of varieties of milk based sweets: pedha,
paneer, shirkhand, etc.

These are now restricted to certain areas only but can go

national. As the world is getting integrated into one market,
quality certification is becoming essential in the market.
However, there are very few plants in the country, which have
successfully obtained ISO, HACCP certification. There is
scope for introducing newer plants adopting newer processes
by the dairy industry in the country.

Packaging of dairy products is also another very promising area. NRI and
overseas investments can take place in manufacturing dairy processing
equipment, fruit packaging equipment and equipments for biotechnology
related dairy industry.

40
REVIEW NO. - 2

2.8 Opportunities and challenges in dairy industry (Article review)

Abstract:

Dairying has been considered as one of the activities aimed at alleviating the
poverty and unemployment especially in the rural areas in the rain-fed and drought-prone
regions. The NDDB has recently put in place Perspective 2010 to enable the cooperatives
to meet the new challenges of globalization and trade liberalization. Like other major
dairying countries of the world, the Indian cooperatives are expected to play a
predominant role in the dairy industry in future as well. India has been identified as among
the first 10 emerging markets in the world. As the market opens up, consumption trends
associated with these markets will have increasing influence on the world trade. As
standards of living in the importing country rises, exporting countries will increasingly
concentrate on whole milk powder and cheese with the assistance of butter and skimmed
milk powder. There is vast potential for the export of dairy products, the cost of milk
production in India being the lowest.

Key words: globalization, liberalization, economy, scope, growth, potential.

Review:

The article “Opportunities and Challenges in The Indian Dairy Industry” by Dr.
K.G. and Dr. G.D. Banerjee give the idea of scope and opportunities in Indian dairy
industry. The article attempts to analyze the growing demand of dairy milk, products and
how the production is insufficient. Dairy products are a major source of cheap and
nutritious food to millions of people in India, people choose milk over meat for their
protein need. Dairying has been considered as one of the activities which help to reduce
poverty and unemployment especially in the rural areas. The article suggest that dairying
is tool which helps to reduce valley between rich and poor only if the cooperatives and
rural farmers work together.

In latter section, writer said that in India there is 88% share of milk production is by
unorganized section and only 12% share of milk production is by organized section. If the
raw milk production is continue at present rate then what will happen to that incremental
41
 milk. Therefor we will required new dairies to handle that milk or to convert that milk into
products. The writer also suggest that we need dairies because in future there will be
increase in rural people’s income due to new economic environment. And considering
future population growth we need more production. Hence there is tremendous scope for
the growth of the dairy industry in the new millennium.

Among the processed dairy products, the most promising segment both in terms of
consumer demand and business profitability is the cheese segment. Traditionally, India is
not a cheese-consuming nation, but the demand of cheese in recent years, suggest that
India is the next big market in terms of cheese consumption. As seeing response to the
cheese, we can say that there will tremendous scope in India for introducing new dairy
products as the new trade required it. And also there is vast potential for the export of
dairy products, the cost of milk production in India being the lowest.

Inference:

From the article we can conclude that There is a great potential for the dairy industry
to grow as local milk production. The dairy industry is a window through which economic
diversification, poverty eradication, as well as, employment creation can be attained.

42
 ARTICLE NO. - 3

The Times of India|The Economic TimesSign In

Dairy sector can milk scope in

fortification of foods: NDDB
PTI | Feb 9, 2017, 05.59 PM IST
1 COMMENTS

Mumbai, Feb 6 () Fortification of foods, which can address nutritional value of

millions, provides a huge opportunity to the organised dairy sector to increase their
market share, National Dairy Development Board (NDDB) Chairman
Dilip Rathtoday said.
"The organised dairy sector is the only source for milk powder and condensed milk
due to the requirement for specialised equipment.
"High nutritional deficiency disorders can be prevented with fortification of foods
with Vitamin A and D, and it represents an opportunity for the organised sector to
grow its market share," a release here quoted him saying at Anand in Gujarat.
Focused and continuous research and development, keeping in mind the fast-
changing consumer preferences, will also help the organised sector in increasing its
market share, he said.
Similarly, he said, development of longer shelf life dairy products, specialised dairy
based nutraceuticals and wellness products, probiotics catering to different classes
of consumers and niche markets needs can be undertaken by the dairy industry,
especially cooperatives, to increase realisation. Rath said milk is India's single
largest agricultural commodity in value terms and is more than the combined value
of paddy and wheat.
As per reports, the value of the Indian market for milk and milk products is expected
to grow at 15 per cent annually. Of this, the contribution of milk products like
cheese, paneer, fermented milk products, butter and ghee would be significant,
representing both an opportunity and challenge to the dairy industry, he added.
Dairy cooperative network should adopt renewable energy, he said. "These
renewable energy initiatives include use of concentrated solar thermal for pre-
heating of water and solar powered milk collection systems." SM RSY

43
REVIEW NO. - 3

2.9 Dairy sector can milk scope in fortification of foods: NDDB

Abstract:

The organized dairy sector is the only source for milk powder and condensed milk
due to the requirement for specialized equipment. High nutritional deficiency disorders
can be prevented with fortification of foods with Vitamin A and D, and it represents an
opportunity for the organized sector to grow its market share. Dairy cooperative network
should adopt renewable energy, these renewable energy initiatives include use of
concentrated solar thermal for pre-heating of water and solar powered milk collection
systems.

Key word: Nutritional value, deficiency disordered, prevent, fortification, research.

Review:

People are depend on dairy industry for milk powder and condense milk since the
production of this products need special machineries. Therefor by adding nutrient to these
products we can help to keep people healthier and can prevent nutritional deficiency
disorders. But to achieve this dairy industry need to focus and research in nutrient
contained of milk and also need to increase production so that these product can easily
reach to malnourished children and affordable to different classes of consumer. Latter
the writer suggest that dairy industry should researched to make long lasting products so
that there will be minimum spoilage and also to make probiotics.

In the last part of article writer said that dairy cooperative should adopt renewable
energy. By using solar energy and waste water recycling we can reduce production cost
so that all category of consumer afford these healthy food. This is a challenge to dairy
section to make cheap as well as nutritional products and to increase production at the
rate of population increase.

Inference:

Since milk is consumed by all population groups, fortification of milk with certain
micronutrients is a good strategy to address micronutrient malnutrition. Thus, milk is an
excellent vehicle to ensure that Vitamin A and Vitamin D reach a large section of the
population

44
 CHAPTER NO. 3
Case Studies
3.1 Katraj Dairy, Pune - Maharastra. (Live case-study)
3.2 Dudhsagar Dairy, Mehsana - Gujarat. (Live case-study)
3.3 Banas Dairy, Palanpur - Gujarat. (Live case-study)
3.4 Anand Dairy, Anand – Gujarat (Book + Net case-study)
3.5 Dairy Factory, Afyon, Turkey (Net case-study)

45
 3. CASE-STUDIES
3.1 KATRAJ DAIRY, PUNE (LIVE CASE STUDY)

Figure 18.External view of Katraj dairy

Location: Katraj, Pune

Area: 17 acre (71755 sq.m)
Starting year: 10th march 1973
Purpose of study: It is a small dairy and the main purpose of study is to understand basic
working of dairy and flow, circulation and process.
Capacity: 2.5 lac lit/day out of that 1.45 lac lit/day is sell. Daily sell is different. And unsold
milk is used for milk products.
Products: cow milk, buffalo milk, flavor milk, paneer, shrikhand, curd, butter milk, lassi, ice
cream, basundi, ghee.
Surrounding: Pune-Satara highway, residential, school, colleges, shops, zoo, hostel, hotels,
and bus depo.
Location map:

Figure 19.Location map of Katraj dairy

46
Activity plan:

Figure 20. Site plan

47
MAIN PLANT BUILDING
Dockyard:
 It is a platform of height 1.2 m and raw milk’s trucks are park in front of platform.
Raw milk enters in factory through pipe.
 Corner of platform is protected by steel I section.
 It is covered as it have to protect from birds, housefly, insects
 Dockyard has gutter around three side.
 The platform is covered by metal flooring tiles because sometimes tiles were break
down due to milk cans.
Area: 48 sq.m (8m x 6m)
Capacity: three truck can be parked
Size of truck: 4.5m x 2.0m
Weakness: lots of housefly
There is only one inlet pipe. Figure 21.Key plan
Metal tiles.

Figure 22. Metal tiles over concrete

Figure 25. Dockyard plan

Figure 23. Steel protected corner of dock

Figure 24. Inlet pipe at dock

48
  Silo
 It is a big cylender like steel structure
in which raw milk is stored.
 They are on platform of height 1.2m
 There are total 8 cylos out of which 6 are
in used.
Capacity: 30,000 lit Figure 26. Silo
height: 6.00m
Dia: 1.50m
Material: stainlness steel and insulation from
inner
 Alco
It is like niches, from where raw
Milk is enter in factory from cylos. Figure 27. Alco
Weakness: there is no direct access to alco.

BASIC MILK CYCLE

RAW MILK

CHILLING
MILK
PRODUCTS
PASTEURIZATION (BOILING AND COOLING) Milk goes to
different sections
at different
HOMOGENIZATIO temperature
through pipes.

Milk processing time: ½ hour + 1hr (testing). It is continuous day and night process. Raw
milk’s trucks come from chiller and raw milk directly go to processing plant. If pasteurization
machine is already filled with milk then raw milk is stored in silo for 20 to 30 min.

49
TOTAL AREA: 71,755 SQ.M
BUILT AREA: 7,737 SQ.M

Figure 28. Figure ground plan

11%

PROCESSING PLANT BUILT AREA

BUILDING: 2553 SQ.M OPEN SPACE

SERVICES: 2347 SQ.M

89%
OTHER: 2837 SQ.M

Figure 29. Building typology plan

32%
38%

PROCESSING PLANT
SERVICES BUILDING 30%

OTHER
50
 33%

57%

Figure 30.Area diagram 10%

HUMAN AREA

MACHINE AREA

BOTH

Figure 32. Plan Figure 31.Section AA'

51
 Circulation of different products

Figure 33. Circulation plan

52
 Figure 36. Cream separator Figure 35. Alco Figure 34. Curd hanging stand

Figure 37.Tray washing machine

Figure 38. Plastic curtains

Figure 39. Milk pouch filling

machine

Figure 40. Paneer pressing machine

Figure 43. Ice cream making section Figure 42.Expiry printing Figure 41. Pouch filling machine

53
 SERVICES

EFFLUENT TREATMENT
PLANT BOILER
Dairy required large amount of Dairy required steam
water therefor recycling of water is for production and hot
necessary to minimizes the usage of water for washing.
water

TOILETS MAIN MILK CANTEEN (FOOD

(WORKERS, VISITORS, AND DRINKING
PROCESSING WATER)
TRAINEES, OFFICERS)
PLANT

ELECTRICAL ROOM
REFRIGERATION PLANT
Industry need large amount of
refrigeration plant is required for
electricity. To fulfill this need
cold storage as well as air
one cane use solar energy or
condition rooms.
hydroelectricity.

54
Boiler:
There are two type of boiler one is fuel furnace oil boiler and other is solid fuel boiler.
Solid fuel boiler is much cheaper than fuel furnace oil boiler.
Boiler use for steam which is require for ghee making and also use for hot water which is
required to wash steel modules.

Fuel furnace oil boiler

There are two large cylinder of
Dia 2.0m and lengh 3.5m and
one fuel storage tank.
Area: 72 sq.m (8m x 9m)
Capacity: 3 tons/hr.
Pressure: 10 kg/sq.m Figure 44. Fuel furnace oil boiler

Solid fuel boiler

It is cheap and required only wood. There is two structure one is for
Storage of wood and other has boiler.
Area: 15 sq.m (3m x 5m)

Figure 46. Solid fuel boiler

Figure 45. Solid fuel storage

FEUL FURNACE

BOILER WOOD STORE

SOLID FUEL BOILER

REFRIGERATION
PLANT

Figure 47. Key plan

55
Ammonia refrigeration plant
Mostly use for cold storage and it has cooling tower, condenser, compressor. It has low
running cost and easy maintenance.

Figure 49. Cooling tower Figure 48. Ammonia refrigeration plant

Effluent treatment plant

The effluent treatment plant is designed to treat the waste water coming from different
areas of dairy.
Area: 40 sq.m
Fresh water consumption: 2.5-3 lac lit/ day
Capacity of plant: 300 cubic.m/ day
Water return to plant: 165 -200 cubic.m/day
out of that 70% treated water is used for
gardening and 30% is desposed to drainage.

Electrical room Figure 50. Clarifier

Area: 120 sq.m (10m x12m)

Energy distribution:
substation (11000 kv) main supply step down different areas
Weakness: contineous sound

Figure 51. Electrical room

56
 MERITS AND DEMERITS:

Merits:

 Laboratories and offices are on the mezzanine floor above the processing area therefor
it is easy to observed processing area from the office and it is also easy to collect
sample for test.
 In plan central lobby connected to all the section is design which helps for easy
unloading and also segregates human traffic and processing area.
 Dairy plant is situated on the main road therefor it is easy for transportation
 Dairy has its own two dairy parlor where people can enjoy fresh dairy products.
 Large area is available for future expansion.

Demerits:

 No specific area for different milk products.

 No seating arrangement for workers.
 No proper flooring.
 No proper area for tray washing.
 The buffer space around the cold storage is unsufficient so there is lot of heat loss.

57
3.2 DUDHSAGAR DAIRY, GUJARAT (LIVE CASE STUDY)

Figure 52. External view of Dudhsagar dairy

Location: Mehsana, Gujarat

Area: 62 acre (250000 sq.m)
Founder: Moraji bhai Deasai (1963)
Opening (starting year): 1965
Architect: Achyut Kanvinde
Purpose of study: It is award winning project and design by A.P. Kanvinde. Design is
according to traffic flow and circulation. Gravity feed and stack effect are used in design
Brand: Amul, Sagar
Capacity: 17.5 lac lit / day
Products: cow milk, buffalo milk, flavor milk, curd, butter milk, butter ghee, u.h.t milk, and
baby milk powder, condense milk
Total no.of workers: 5500 (contract basis-4000, permanent-1500)
Production: Powder- 125 metric ton/day
Butter- 35 metric ton/day
Ghee- 35 metric ton/day
About external form:
External form is blocky. It has rendered brick skin wall which gives functional as well as
formal aspects. Internal ducts are expressed on the exterior as rhythmic shafts soaring above
the roof, capped with an angular profile.

58
Surrounding: Ahemdabad Palanpur highway, residential buildings, church, gurudwara.
Location map:

Figure 53. Location map

Introduction:

This dairy establishment by Kanvinde was one of his early projects for Dr. Kurien of the
national dairy development board. This dairy includes one milk processing plant and two
powder plant. In this dairy, India’s first powder plant is executed and it was specially
executed for Indian military. The campus of dairy includes one food technology college,
canteen for workers, administrative office, and milk processing plant, powder plant, and
service buildings.

Light and ventilation:

Ducts are provides for natural light and ventilation. Some area has artificial light. In dairy
plant it is difficult to do cross ventilation because machines block openings and light.

Acoustic treatment:
No acoustic treatment is provided in plant. It could be provided to prevent noise released
by machines.

59
Administration building:
It is ground + 6 building and the building is design in such a way EXTERNAL COLUMNS
That the whole building is stands only on eight external column.
The building has support from top by
external eight column and the bottom of
building is hanging. Building includes
following sections:
Ground floor: reception, waiting area.
First floor: training section, screening room.
Second floor: H.R offices.
Third floor: account and civil section
Fourth floor: sell purchase offices.
Fifth floor: veterinary section
Figure 54. Administration building
Sixth floor: store

Electricity:
Daily requirement of electricity: 4000kv – 4600kv
Government: 3200kv
Diesel generator: 1400kv

Water requirement:
23 lac lit/ day.
All the water get recycle and use for gardening. Dairy has water supply from government
and bore well.

Silos:
Silo has 3.00 inch thick insulation layer. Raw milk is stored in silo. Milk store in silo not
more than 12 hr.

No. of silos:
16 no (1 lac lit capacity of each silo)

60
Loading and unloading:
Loading and unloading is done at same area facing each other that is opposite to each other
hence there is only one route for vehicular movement.

Figure 55. Schematic dock layout

Unloading:
There are three ways of milk receiving:
1. By milk cans (old method). Milk cans are placed on moving belt which go inside
the plant where milk cans empty into tank manually. Then empty cans again placed
on washing belt where they get washed automatically and come out of the plant.
This process is done at upper level.
2. Raw milk’s trucks coming from chilling center has already tested milk. They park
at lower level and milk directly go for pasteurization through pipe by pumping
system.
3. Milk receiving is done at upper level. Raw milk’s trucks from village collection
centers are park at upper level then raw milk is tested and if it is fine then only pass
at lower level for pasteurization through pipe. Because of this multi-level design
gravity feed is implemented in the milk collection, storage and processing.

Figure 56. Schematic section showing unloading

61
 MILK FLOW CYCLE
STORAGE TANK (RAW MILK)

PASTEURIZATION

SEPRATION

MILK CREAM (FAT)

SILO SILO

MILK MILK POWDER MILK PRODUCTS

Planning:
 A clear separation between the milk reception and powder processing areas makes the
plan deceptively simple.
 Natural light and air drawn in through slit windows is combine with artificial lighting
in the machinery dominated interiors, enabling better working and hygienic
environment for milk processing.
 Because of long glass partition in lobby visitors can see milk process without
disturbing flow.
 Planning is done according to process chain. Most of the section has cold storage just
next to the packing section therefor packed products directly enter into cold storage
through moving chain. Because of this less buffer space is required for cold storage as
there is less human traffic.

PRODUCT MAKING MOULDING PACKING BOXPACKING

COLD STORAGE LOADING

Different plants:
1. Butter milk plant:
There are two bulk tank of size 2m x 4m which has stirrer. First tank contains mixture of milk
and culture which continuously stir up. Then this mixture is transferred to second tank where
they again get stir up. Then the small (waste) particles get removed which floats on the top.
The water is added into reaming mixture and in this way butter milk is formed.

62
2. U.H.T (Ultra heat temperature) plant:
Milk pasteurize at more than 140 degree. This
section has separate testing lab because sample
from each cycle has to be checked every time.
Large storage is required because u.h.t milk can
store for several months. Packing is done manually
and packing section is connected to storage through
moving belt.

MOVING BELT
Figure 57. Schematic plan of U.H.T plant
2. Powder plant:
It is India’s first powder plant. This plant required large area and height. The height of building
is 18m. The plant has continuous noise and heat. To evacuate the heat generated from plant,
a system of ventilation ducts are used. This ducts provide natural light and also look good
aesthetically.

SPRAY OF
CONDENSE MILK

Light particals of
powder blow into
air and heavy
MILK paricals settle
POWDER down which are
used as milk
powder

BLOW OF
HOT AIR

Figure 58. Basic flow diagram of

powder formation

Figure 59. Schematic section of powder plant

showing stack effect

63
 TOTAL AREA: 2, 50, 000 SQ.M
BUILT AREA: 36, 930 SQ.M
OPEN SPACE: 2, 13, 070 SQ.M

15%

85%

BUILT AREA
OPEN AREA
FIGURE GROUND PLAN

Figure 60. Figure ground plan

TOTAL BUILT AREA: 36, 930 SQ.M

PROCESSING PLANT: 9, 730 SQ.M
SERVICES BUILDING: 17, 086 SQ.M
OTHER: 10,114 SQ.M

28% 26%

46%

PROCESSING PLANT

SERVICE BUILDING

OTHER

Figure 61. Building typology plan

64
 Figure 62. Area plan

26%

44% 40%
53%

21%
16%

LOWERFLOOR UPPER FLOOR

COMPLETE HUMAN AREA

Figure 63. Schematic floor plan MACHINE AREA

BOTH

65
Figure 64. Section AA'

Figure 65. Eastern elevation

66
 PHOTOS OF DAIRY COMPLEX

Figure 67. A view of the complex with the ventilation Figure 66. The elevated deck on the first
shaft creating a distinct skyline. floor

VENTILATION SHAFT

Figure 68. Entrance gate Figure 69. Milk reception dock

Figure 71. Rear view of the complex Figure 70. A view of food Technology
College

67
MERITS AND DEMERITS:

Merits:
 Planning is sustainable, natural light, gravity feed and stack effect are implemented in
planning which help to save energy.
 Planning is done according to process chain.
 Planning shows effective segregation between human and material movement.
 External form is blocky and fortress like structure.
 Good use of contour or natural slope.
 India’s first powder plant is executed in this dairy.
 Optimum ventilation

Demerits:
 Working of dairy is based on old method, no automation system is implemented so
the space are little unhygienic.
 Over all planning is scattered therefor it is difficult to observed processing plant from
administration block. There is no visual connectivity between administration and
process plant.
 Encroachment is observed so we can say that previous planning was done without
considering future expansion.

68
3.3 BANAS DAIRY, GUJARAT (LIVE CASE STUDY)

Figure 72. External view of banas dairy

Location: Banasknath (Palanpur), Gujarat

Area: 110 acre (445000 .00 sq.m)
Founder: Galbabhai Nanjibhai Patel (1969)
Opening (starting year): 1998
Architect: Achyut Kanvinde, Rai, Chowdhury.
Purpose of study: It is largest dairy in Asia and it is complex of three dairies. The dairy works
on new technologies.
Brand: Amul, Amulya, Sagar, Banas
Capacity: 42 lac lit / day
Products: All type of amul milk, flavor (amul cool) milk, curd, butter milk, butter, ghee,
U.H.T milk, amulya milk powder, amul ice cream, cheese, condense milk.
Total no. of workers: 6000 (contract basis-3000, permanent-3000).
There are three shift of worker and amenities like canteen, restroom etc. are provided for night
shift workers.
Surrounding: Ahmedabad Palanpur highway, residential buildings, church, gurudwara

69
Location map:

FIGURE 73. LOCATION MAP OF BANAS DAIRY

Introduction:
Banas dairy is Asia’s largest dairy and produce 35 % of total Amul products. It is dairy
complex includes 3 processing plant, 1 cheese plant, 1 U.H.T. plant and 2 powder plant. There
are 3 dairies Banas-1, Banas-2, and Banas-3 out of which banas-1 is working on old method
and rest 2 are works on fully automation.

Banas-1 (1970) = 7 LLPD (lac lit per day) capacity.

Banas-2 (2006) = 24 LLPD (lac lit per day) capacity.

Banas-3 (2012) = 11 LLPD (lac lit per day) capacity.

Raw milk is received from chilling centers located at surrounding villages. Banas dairy is
associated with 1260 chilling centers and 3 lac farmers. Veterinary services and education is
provided to farmers for better quality of raw milk.

Working:
 Every processing unit works separately, each dairy unit has its own service building
and laboratories. But there is also one centralize laboratories.
 Vehicular movement for each dairy is different as they has different unloading dock
and dispatching dock.
 But there are only one administration office for all three processing unit.

70
About external facade:

The whole complex is made by using grit finish plaster, it gives good appearance. It has high
initial cost but it is easy to maintain or no maintenance cost after construction the overall
complex has good aesthetic. Because of height difference in different plants. Whole complex
appears interesting because of different form of massing.

Figure 74.External wall showing grit finish plaster

Light and ventilation:

Large opening are provided for natural light. Maximum area has artificial light and air
conditions. In dairy plant it is difficult to do cross ventilation because machines block
openings and light.

Acoustic treatment:
It is observed that no acoustic treatment is provided in plant. It could be provided to
prevent noise released by machines.

Electricity:
Daily requirement of electricity: 14000kv
Energy required per lit: 50 paisa per lit. (70v)
Power supply by: Gujarat state power supply
Electricity bill: 3.5 crore per year.

Water requirement:
50 lac lit/ day. Out of which
30 lac lit/ day - from government

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 TOTAL AREA: 44, 5000 SQ.M
BUILT AREA: 58, 455 SQ.M

13%

87%

FIGURE GROUND PLAN

TOTAL BUILT AREA: 58,455 SQ.M

PROCESSING PLANT BUILDING: 44,426 SQ.M

SERVICES BUILDING: 7, 395 SQ.M

OTHER: 6,634 SQ.M

11%

14%

75%

PROCESSING PLANT

SERVICE BUILDING

OTHERS BUILDING TYPE PLAN

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3.4 DR. VERGHESE KURIEN MEMORIAL – DAIRY MUSEUM (NET
CASE STUDY)

Location: Anand, Gujarath.

Introduction:

The Dairy Museum is located within the Campus of Amul Dairy at Anand. This Museum is
dedicated to the Dairy Industry and declared open by Mrs Molly Kurien on 26th November
2000 to mark the 80th birthday of Dr V. Kurien, The Father of White Revolution in India.
The Museum has a Photo Gallery and Auditorium. The Photo Gallery gives glimpses of the
genesis of Amul and its growth in a pictorial form to visitors and infuses confidence in the
principle of co-operation and co-operative organizations.

FIGURE 75 ENTRANCE OF DAIRY MUSEUM

The amul girl

Amul girl refers to the advertising mascot used by Amul. The advertising often been
described as one of the best Indian Advertising concepts because of their witty humour. The
Amul girl dressed in a polka dotted frock with blue hair and a half pony tied up has always
been public favorite cartoon character.

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Walk through and visit of dairy take approx. 2 hours. The campus also include one cafeteria
for tourist/visitors.

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4. SITE STUDY
Location: Mahad, Raigad.
Area: 5.5 acres

Advantages:
• Government proposal site.
• Supply of raw milk
• Power supply, market available, development scope

• Labor availability, transport facility, water supply

• Scope for expansion
• Site is away from any chemical industry.

• Easy for transportation since highway is near

• Educational hub therefor scope of milk products.

Site plan
Pictures of site:

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