SUMMER INTERSHIP IN SUMUL DAIRY, SURAT (SURAT DISTRICT

COOPERATIVE MILK PRODUCERS UNION LTD)

In partial fulfillment of the requirement for the degree

BACHELOR OF FOOD TECHNOLOGY

&MANAGEMENT

SUBMITTED BY:-

YASH PATHAK
ROLL NO :- 117094
BATCH (2017-2021)

National Institute of Food Technology Entrepreneurship and Management

Sonipat, India (131028)

ACKNOWLEDGEMENT

It is a great pleasure for me to acknowledge the assistance and contributions of all the people
who helped me to make my industrial training a success. My training would not have been so
successful, without the dedicated assistance given by those individuals.

Regards

YASH PATHAK

Contents
• History of Sumul dairy
• Present status of Sumul dairy

• Raw milk reception dock(RMRD)

• Process & CIP section

 • Butter section

• Buttermilk section

• Ghee section

• Sweet section

• Paneer section

• Elecster section(Sanjivni)

• Dahi section

• Pouch felling section

• Quality control

• ETP

• Refrigeration section

HISTORY OF SUMUL DAIRY

Sumul or Surat Milk Union Limited, which is now renamed as The Surat District Co-operative Milk
Producers' Union Ltd, is one among the 17 district unions which acts as manufacturing units of dairy
products for Gujarat Co-operative Milk Marketing Federation Limited, the marketers of Amul brand of
products.

Surat District has been a Pioneer in India in channeling trade in Cotton and Milk through co-operatives.
Before SUMUL stepped in, traditional Private Milk Traders were dominant in the area.

The private trade was monopolizing the Milk market and exploiting both the Milk Producers and
Consumers alike. The milk procurement price which used to be fixed by the traders (traditional Bhatias)
was very low and was fluctuating from time to time at their sole discretion. These has capitalized on the
absence of any infrastructure and processing facilities and has managed to keep producers from deriving
equitable benefits from the marketable surplus generated. As such their income from milk was very low
and they had no incentive for modern dairy farming. The farmers resented the system, but were helpless in
the face of these traditional constraints and to their own lack of resourcelessness.

Hygienic and pure milk was almost unknown in the market. In fact unbridled adulteration of milk was
practiced by these traders to meet the growing demand of milk in the city. To salvage the poor producers
from the clutches of these Private Traders, Organisation and integration of procurement, processing and
marketing of milk and milk products by the producers themselves on a sound co. operative line was
essential; this would also ensure elimination of middlemen, equitable distribution of benefits to Rural Milk
Producers and indirectly to urban milk consumers as well.
 Hence, the Surat District Co. operative Milk Producers' Union Ltd., SUMUL is trade name and literally
meaning sound price,
came into existence on August 22, 1951.

PRESENT STATUS OF SUMUL DAIRY:

AUTOMATED MILK COLLECTION:-

With the aim of procuring fresh and clean milk at the society level along with enhancing self-assurance
while getting slip showing Milk Fat, SNF, quantity and price of milk supplied by member during milk
collection, Automatic Milk Collection Stations are installed at milk societies. A software package for entire
accounting procedure of the society having modem facility has been incorporated therein. An arrangement
been made that society member pouring milk will get his details on computer.

To get the details of receiving of the societies having BCU, 552 societies are being made online by which
all the details of receiving could be received over here & Milk collection data are being stored over here.
So, whenever problem arises in this regard, details could be received from here.

At society level milk procurement is being done by "Automatic Milk collection station" AMUL AMCS soft
ware application is being planned for the implementation of same milk procurement fashion. If phone
number is being registered by AMUL AMCS software in the computer, he will be provided details of the
milk procurement daily. In addition by AMUL AMCS application in members android phone by which
member will get the details of his milk procurement on his mobile whenever he wants.

Details 2017-2018

Automated Milk Collection Centre 1428

Weighing Scale and Milko Tester 109

Weighing Scale 156

BULK CHILLING UNITS:-

To maintain & control the reasonable standards of the production, to maintain the quality in the
procurement & the processing of the milk & Sumul is the best example in this regard. To make milk
and milk products as per international standards, milk having high quality need to be procured right
from the village level; so Union has commenced "Bulk Chilling Units" having different capacities to
facilitate chilling at the place of production, Which has helped to improve quality of milk; and, milk of
two three times can be brought by single trip as per suitability of time, and also society can collect
milk at their desired time and preserve milk by chilling. Immediate cooling of the milk leads to stop the
growth of the micro organism. So, dairy gets about 77% of milk having MBRT of 4 - 5 hours due to
which we could be able to supply high quality milk in the market.
Details of Bulk Milk Chillers:-

Years Working Chilling Units

2015-2016 482
2016-2017 549
2017-2018 681

DETAILS OF MILK PROCUREMENT:-

Product(Kilogram) 2016-2017 2017-2018
Cow Milk 32,24,63,325 36,63,75,417
Buffalo Milk 17,31,53,354 20,90,20,093
Total Milk 49,56,16,679 57,53,95,510
Total Fat 2,50,78,925 2,94,42,006
Total SNF 4,30,79,046 5,00,27,880

RAW MILK RECEIVING DOCK(RMRD):-

As the quality of raw milk is the most important controlling factor for production of
quality products, separate specially designed dock is built for operation of reception.
The Raw Milk Reception Dock (RMRD) is the primary intake point of liquid milk entry in
dairies/chilling centers. It is specifically meant for the reception of milk brought in cans
from village milk collection centers located over a wide area. It is different from the bulk
milk collection systems, which are also in operation in these dairies. The collection
process starts from the village milk collection centers, groups of which are assigned to
distinct milk truck routes.

Send Enquiry

The milk tankers of individual village milk collection centers from many such routes are
unloaded at the RMRD, after which their milk is weighed & tested separately to issue a milk
receipt statement according to the measured parameters during the daily shift.

Type of milk received

• Cow milk

• Buffalo milk

• Mixed milk

CHECKS FOLLOWED AT RMRD BEFORE RECEPTION OF MILK

  Weighing of raw milk tanker
 Collecting milk sample for RMRD and quality control lab.
 After approval from RMRD lab after organoleptic and Platform tests milk tankers are unloaded
in the RMST tanks.
 There are total 8 RMST (Raw Milk Storage Tanks) of 150KL capacity.
 Raw milk are unloaded in the RMST tanks according to their fat content as low , high, mixed
fat milk.

 After unloading of milk tanker , CIP is done for unloaded milk tanker and then milk tankers
are sent back.

 Milk in RMST tanks is stored at 4-5 C temperature.

PROCESS & CIP:

PASTEURIZATION

Critical Control Point of Process

S No. Process step Control point Control limit

1 Pasteurization Pasteurization 75-78°C

Temperature

2 Storage of pasteurized milk in Storage temp. Below

PMST tank
4hrs

Pasteurization is a heating of every particle of milk and milk product for a definite time and
temperature combination to destroy all the pathogenic organism without effecting flavor and
composition of milk.

High temperature short-time (HTST) pasteurization process is used in dairy for milk
pasteurization.

This was first developed by A.P.V.Co.in the United Kingdom in1922.The HTST pasteurizer
gives a continuous flow of milk .The HTST process involves heating milk to72-78°Cwith a15
second holding time before it is cooled.
 Plate Heat Exchanger

The Plate Heat Exchanger consists of a bank of plates inter-connected (sections) held in a
rigid frame .The main function of the PHE is the exchange or transfer of heat from a hot liquid
(hot water or hot pasteurized milk)to a cooler one (raw milk ,cold water)across a metal plate.

An approximate 3-8 mm space is maintained between the plates by a non-absorbent rubber

seal, which is bonded around hedges of the plate. The liquids, which are sandwiched among
the plates, enter and leave the interspaces through holes in the corners of the plates. Open
and blind holes route the liquids from one set of plates to another. The capacity of the
pasteurizer is secured by a corresponding number of plates.

Regeneration sections: The bank of plates is usually divided into three-four sections
separated by connector grids with inlet and outlet bosses. In the regeneration section, the
incoming cold milk is heated by the hot pasteurized milk and the pasteurized milk is cooled by
transferring heat to the cooling medium. This heat transfers process work most effectively
when the two liquids involved flow in opposite direction, i.e. counter current flow on either side
of the plates. Regeneration section raises the raw milk temperature from 4°C to 67°C and
cools the pasteurized milk from 72°C to 10°C. Thus, PHE saves about 92% of heating and
cooling energy.

The partly cooled pasteurized milk is further cooled in cooling section to 4°C.

The following parts and functions are involved as milk passes through the HTST pasteurization
systems:

1. Float-Controlled Balance Tank (FCBT): Maintains a constant head of milk for feeding
the raw milk pump; also receives any sub-temperature milk diverted by flow diversion valve
(FDV).
2. Pump: Either a rotary positive pump between the regenerator and heater, or a
centrifugal pump with a flow control device to ensure constant output, after FCBT is used.

3. Plates: The Plate Heat Exchanger is commonly used in the HTST system . The plates
are thin stainless steel sheets usually rectangular in shape. The plates are corrugated and
cause a turbulent flow, which increases rate of heat exchange especially for heating to
temperatures which are below the boiling point of milk. The plate heat exchanger is a
compact, simple, easily cleaned and inspected unit. Its plates may be used for heating,
cooling, regeneration and holding. A space of approximately 3mm is maintained between the
plates by a non-absorbent rubber gasket or seal.

4. Regeneration (Heating): The raw cold incoming milk is partially and indirectly heated by
the hot out going milk (milk-to-milk regeneration).This adds to economy of the HTST
process, as the incoming milk requires less heating by hot water to raise its temperature for
holding.

5. Filter: Variously shaped filter units to connect directly to the HTST system are placed
after the pre-heater or regenerative (heating) section. These units, using 40-90 mesh cloth,
are usually cylindrical in shape. Usually two filters are attached but they are used at a time.

6. Holding: The holding tube or plates ensures that milk is held for a specified time, not
less than 15 sec, at the pasteurization temperature of 78°C or more

7. Flow diversion valve (FDV): This routes the milk after heat treatment. If the milk has
been properly pasteurized, it flows forward through the unit; that which is unpasteurized is
automatically diverted back to FCBT for reprocessing. It is usually operated by air pressure
working against a strong spring.

8. Regeneration (cooling): The pasteurized hot outgoing milk is partially and indirectly
cooledbytheincomingcoldmilkandcoldwater.ThisagainaddstotheeconomyoftheHTST process.

9. Control panel: Contains instruments, controls, FDV mechanism and holding system, all
centralized in one moisture proof panel.
10. Hot water set: Circulates hot water through the heating section of the machine to
maintain the correct milk temperature within very fine limits.

11. Automatic control devices: These include steam pressure controller and water
temperature controller.

Steam pressure controller: Maintains a constant hot water temperature for heating milk
accurately to the required pasteurization temperature.

Water temperature controller: Regulates the amount of milk leaving the holding tube/plate.
ThisisanelectriccontactinstrumentthatoperateseitheraFDVoramilkpump,automatically
preventing milk from leaving the holding section at required temperature. Both the frequency
and duration of the flow diversion and the temperature of the milk leaving the holder are
recorded on the thermograph (recording)

 There are 5 pasteurizers (MP-1 to MP-5).Out of that MP-1 is for cream pasteurization which

is separated from milk in the cream separator.

 MP-2 to MP-4 are milk pasteurizers.

 Design pressure of milk pasteurizer is 6 bar.

 Test pressure of milk pasteurizer is 7.8 bar.

 Design temperature of milk pasteurizer is 100 C.

 Capacity of milk pasteurizer is 30,000litre/h.

 Milk is pasteurized at 75-78 C temperature.

 Cream pasteurization (MP-1) temperature is 85-88C.

 Cream is cooled at around 10 C after pasteurization.

 The temperature of holding tube is kept 79-80 C , so that temperature of milk can be

maintained at 75-78C while holding time of 12-15 sec.

 After heating milk is chilled at around 8-10 C temperature and then sent to PMST tank for

storage.

 There are total 9 PMST (Pasteurized Milk Storage Tank) tank out of which 6 are of 150KL

capacity and 3 are of 100KL capacity.

 PMST tank storage temperature of pasteurized milk is around 4-8 C.

  There is in silo standardization of milk for various milks like Amul gold, shakti, taaza, by

adding cream , skimmed milk powder , to the pasteurized cream separated milk.

 There are agitators in the RMST and PMST milk tanks.

Overall process of Pasteurization:-

1. Milk tanker unloading in RMST tank.

2. Milk from RMST to pasteurization unit.

Inside the pasteurization unit:-

1. Milk into the balance tank.

2. From balance tank to regeneration 3.

3. From regeneration milk goes for filtration and clarification.

4. After filtration to regeneration 2.

5. From regeneration 2 milk goes to homogenizer for reducing the fat particles size.

6. After homogenization milk goes to regeneration 1 and from there to heating section to

achieve final temperature of 75-78C .

7. from heating section milk goes to holding tube and from holding tube milk goes to

regeneration section to lower it temperature.

8. At last milk goes to chilling section in pasteurization unit and its temperature is lowered to

around 10C.

9. Milk is stored in the PMST tank.

CREAM SEPARATOR:-

Principle of Separation

The fat is present in milk as fat-in-water type emulsion and is lighter than the skim
milk. The mean density of milk fat is 0.93 as compared to 1.036 of skim milk at 16°C.
Separation of cream is based on the principle that milk fat, because of its lower
density is lighter than the skim milk portion. Hence it tends to rise to the surface and
separates from the serum (skim milk). This principle is applicable to both gravity
method and mechanical method of cream separation.

Mechanical Method

In the mechanically operated cream separator, which is used commercially, the

separation of fat is achieved by application of the centrifugal force. The centrifugal
force acting on the system is about 3000- 6000 times greater than the gravitational
force. Hence the separation of fat, which is governed by the Stoke’s law, is faster
than the gravity method of separation. Fat globules of smaller size separate 6500
times faster in a centrifuge rotating at 5400 rpm than they do by gravity.

PARTS OF CREAM SEPARATORS:-

• Handle connecting piece

• Cream discharge

• Skim milk discharge

• Clamp ring

• Hood

• Centripetal pump chamber lock ring

• Centripetal pump chamber look cover

• Skim milk pump

• Blow top

• Blow lock ring

• Separator disc

• Cream pump

• Feed tube
 • Retaining ring

• Upper disc

• Disc set with distributor

• Spindle nut

• Bowl bottom

• Frame

 Max rated bowl speed in rpm per min for cream separators is 4800
 Max density of feed product is 1kg per 𝑑𝑚3 .
 Min /Max temperature of feed milk should be 5/95 C.
 Min/max throughput in 𝑚3 per hour is 30/35.
 There are 2 cream seperators attached to pasteurization units in
processing area.

Homogenizer :-
 There are total of 2 homogenizer attached with pasteurization unit in
processing area.
 Homogenizer is used to reduce the size of fat particles so fat particles while
storage or processing.
 Max pressure of homogenizer in processing are is 17 Mpa.
 Operating pressure of homogenizer is 5 Mpa.
 Rated flow of homogenizer is 30,000 𝑑𝑚3 per hour.

 Capacity of homogenizer is 25,000 litre of milk per hour.

 Pressure in homogenizers is given by pistons.

CIP(CLEAN IN PLACE):
 There are 2 CIP units old and new.
 There are 5 tanks in both the CIP units
 1) Flush water 2) Hot Water tank 3) Acid tank 4) Detergent tank
5 ) Recupration tank.
 Detergent (caustic soda) of 0.5-1 % concentration is used.
Acid ( nitric acid) of 1-2% concentration is used.

OLD CIP UNIT:-

 TEMPERATURE OF FLUSH WATER TANK 30- 35C.
 TEMPERATURE OF HOT WATER TANK 40-45C.
 TEMPERATURE OF ACID TANK 65C.
 TEMPERATURE OF DETERGENT TANK 68C.
 TEMPERATURE OF RECUPRATION TANK 49-50C.

NEW CIP UNIT:-

 TEMPERATURE OF FLUSH WATER TANK 30- 35C.
 TEMPERATURE OF HOT WATER TANK 75-80C.
 TEMPERATURE OF ACID TANK 70-72C.
 TEMPERATURE OF DETERGENT TANK 70-72C.
 TEMPERATURE OF RECUPRATION TANK 49-50C.

CIP STEPS:-

RECIPES 1:-
Pre rinse > lye > intermediate rinse > acid> final flush after acid > acid flush after lye
> sterilization > drainage.

RECIPES 2:-

Pre rinse > lye > intermediate rinse > acid> final flush after acid > drainage.

RECIPES 3:-
Pre rinse > lye > final acid flush after lye > sterilization > drainage.

RECIPE 4:-
Pre rinse > lye > final acid flush after lye > drainage.
RECIPE 5:-
Final acid flush after lye > sterilization > drainage.

 CIP of bulk milk sylos is done every24 hours by caustic soda.

 For pasteurizer , homogenizer, cream separator CIP is done every 6 hours with
caustic soda, and every 24 hours with caustic soda and acid.
 In recupration there is caustic soda +water which is obtained after 1 rinse after
caustic soda wash .

BUTTER SECTION:

PROCESS OF WHITE BUTTER MAKING:-

1. Cream from 10KL capacity cream tanker to cream balance tank.

2. Filtration of cream through filters.

3. Filtered cream to continuous butter maker.

4. Curning of butter is done at around 1480 rpm and 50 Hz.

5. Churned butter washing with wash water and after washing buttermilk is

separated from butter.

6. Buttermilk is sent to buttermilk section.

7. The churned butter is passed to working section which is screw conveyor.

8. Transfer of butter to butter silo.

9. Butter is sent to packaging area.

 There are 4 cream storage tank of 10KL capacity.

 In cream tanks cream has fat of around 40% , and aging time is of around 25-

27hours.

 There is 1 wash water chiller ,chilling water at around 10-12C.

 Buttermilk (byproduct chiller ), chilling at around 8-10C.

 In cream balance tank of capacity 350KL cream is stored at 10-11C.

 Butter comes out of working area from butter churner at 12-14C.

 Butter from butter sylos goes to packaging area where it is packaged in 15 kgs

boxes.

 Packaged butter is stored in deep freezer.

BUTTERMILK SECTION:

PROCESS OF BUTTERMILK MAKING:-

1. Milk is standardized at 2.5 - 3 % , and 11.5 – 12% SNF.

2. Standardized milk is heated at 37-40 C, and filled in curd tanks.
3. There are total 7 curd tanks out of which 6 tanks are of 20KL capacity,
and 1tank is of 15KL capacity.

4. In curd tank culture is added to standardized milk and incubation is done

at around 35-40C for 4-5 hours.

5. Incubation is done in curd tanks till acidity reaches 1.5 – 2%.

6. After that curd is brought to balance tank in buttermilk section then water
is added to curd, agitated and then sent to pasteurization unit.

7. In balance tank of buttermilk which is byproduct from butter section is

added to maintain the acidity of 1.5-2 % .

8. Buttermilk is pasteurized at 73-75C and then chilled and then stored in

buttermilk tanks.

 There are total 7 buttermilk storage tanks out of which 3 tanks are of 20KL and

4 tanks are of 15KL.

 There is 1 buttermilk pasteurizer and 2 homogenizers for reducing fat particle

size in buttermilk.

 CHN-22 , DSL , YFF-3314 etc cultures are used for buttermilk making.

 Chhash , Masala Chhash , Tan Chhash etc buttermilk products are made.

GHEE SECTION:

PROCESS:-

1. White butter is brought to section.

2. White section is melted in butter melting vat, where white butter is melted

with help of hot steam.

3. Melted brought is stored in the pre-stratification tank.

4. From pre-stratification tank melted butter is sent to ghee boilers where ghee

is made.

5. From ghee boilers ghee is sent in storage tank (ST-4).

6. From ST-4 ghee is cooled with the help of glycol in the coils, and then sent

for filtration and clarification.

7. After filtration ghee is stored in ghee storage tank(ST-1, ST-2, ST-3).

8. After that ghee is sent for packaging.

9. Ghee is packaged in 1 litre, 5 litre 15 litre, tin cans and in 200 ml and

500ml pouches.

10. In pouch packaging machine from 1 head 22 pouches are filled in 1

minute.

 There are 3 butter melting vat.

 There are pre stratification tank of (PST-1,2,3) of 2500 litre.

 There are 3 ghee boilers of 2KL capacity each.

 Ghee Storage tank (ST-1,2,3) are of 5KL capacity each.

  Divine ghee which is made gir cows is lactose free and A2 type ghee.

SWEET SECTION:

 Sweets made in sumul dairy are milk cake , kesar paida, elaichi paida, malai

paida, ghari, , shrikhand, loose shrikhand , matho , kaju katri, gulab jamun ,

mohanthal etc.

Process of Shrikhand :-

1. First standardized milk is taken heated at 85C for around 30 min and cooled to
around 30C .
2. After that lactic culture is added to milk and incubated in maska making vat .
3. Incubation is done till acidity reaches around 0.6 in the maska making vat.
4. Maska is then placed in the muslin cloth and then strained to remove the whey
liquid.
5. Strained maska is then shredded in the maska shredding machine.
6. Maska is then added in the rotating kettle which contains fixed scrapper and
agitator.
7. In that kettle sugar, in equal proportion to the maska is added and dry fruits
and flavors are added according to requirement of shrikhand.
8. Shrikhand is packaged in 500 g, 1 kg etc packs and stored at low
temperature.

Process of Paida making:-

1. First milk is concentrated in the falling film evaporator.

2. In falling film evaporator dry saturated steam at 7 bar pressure is used to
concentrate the milk.
3. That concentrated milk is is sent to khoa making kettle.
4. There are total 9 khoa making kettle in which the kettle are of rotating type and
1 scrapper and 3 stirrers in the rotating kettle are stationary.
 5. Kettle is heated at high temperature which the help of gas to make khoa.
6. Flavours of paida are added while khoa making
7. Khoa is placed in the trays and continuously stirred to remove the air and cool
the khoa.
8. Khoa is then dried to room temperature in room where air is dehumidified with
the help of dehumidifier.
9. Paidas are made from khoa in automatic paida making machine.
10. Paida are then packaged manually in 500gm , 1 kg packs and 100 gms small
packets are then packaged in the modified atmosphere packaging (MAP) to
increase its self life.
11. Packaged paida are then stored at low temperature.

Process for milk cake making:

1. First milk is concentrated in the falling film evaporator.

2. In falling film evaporator dry saturated steam at 7 bar pressure is used to
concentrate the milk.
3. That concentrated milk is is sent to khoa making kettle.
4. There are total 9 khoa making kettle in which the kettle are of rotating type and
1 scrapper and 3 stirrers in the rotating kettle are stationary.
5. Kettle is heated at high temperature which the help of gas to make khoa.
6. Sugar , liquid glucose, ghee, cardamom, preservatives like (E202 , E210) are
added while khoa making for milk cake.
7. Khoa is placed in the trays and not stirred so air is entrapped and hot khoa
is pressed and due to that caramelisation of liquid glucose occurs and there is
presence of brown colour in the middle of the milk cake.
8. Mlik cake is then dried to room temperature in room where air is dehumidified
with the help of dehumidifier.
9. Milk cake is then packaged manually 500gms , 1 kg packs and 100 gms
small packets are then packaged in the modified atmosphere packaging
(MAP) to increase its self life.
10. Packaged milk cake is then stored at low temperature.
 PANEER SECTION:
Process:-
1. From milk storage tank(HMST -1,2) milk is taken in the 200 ltr balance tank
and pasteurized at 85 C temperature and holded in the holding tube for 10

minutes.

2. After pasteurization temperature of milk is lowered to 75C and that milk is

taken to the coagulation vat.

3. In the coagulation vat citric acid( 1-2%) is sprayed on milk from pores in the
pipe and is stirred properly to coagulate the milk.

4. After milk is coagulated whey liquid is drained from the vat and sent to the 2
whey liquid storage tank.

5. Paneer is then filled in the porous boxes which contains muslin cloth inside it.

6. Filed boxes are then pressed in the paneer pressing machine at 2.5 -3 bar
pressure for around 10 minutes.

7. Than from that boxes muslin cloth containing paneer is then dipped in the
dipping vat.

8. In dipping vat pasteurized water at 80C which is cooled to 5-8 C temperature is

used.

9. In dipping vat cold water 5-8 C is sprayed on muslin cloth containing paneer
and it is kept in dipping vat for around 50 minutes.

10. This is done to get proper texture and moisture content of paneer and r

to cool the paneer.

11. Paneer is then sent to packaging area where it is package manaually in

100gm, 200gm, 500gm, 1kg, 5kg, packages. And sealed by vaccum

packaging.
 12. Packaged paneer is then stored at 3-5C.

 There are 4 milk coagulation vat of 2KL capacity.

 There is Citric acid balance tank of 200ltr capacity.
 There are 6 paneer pressing machine .
 There are 3 dipping vat of 1KL capacity.
 There are 2 whey liquid storage tank of 15 KL capacity.

ELECSTER SECTION:

 It is the high temperature treatment plant for milk.

 It is used to make products like Sanjivni, Jome, Diet +, Health+.

 Sanjivni is the eliachi flavoured milk used for angadvadi student under the

government skim. Sanjivni is packed in 200ml pouch.

 Jome is the flavoured milk like kesar , elaichi, AIS(American ice cream soda) ,

rose , mango flavoured milk. This is the flavoured milk for sell in the market.

Jome is packed in 200ml pouch.

 Diet+ is the Skim milk(low fat milk) packaged in the 500ml pouch.

 Health+ is the Toned Milk packaged in the 500 ml pouch.

 In elecster product is heated at 140C .

 Shelf life of Sanjivni and Jome are having shelf life of 30 days .

 Diet+ , and health+ are having are shelf life of 45 days.

 Sanjivni is fortified with vitamin A &D .

Process of Elecster:
 1. Milk from APS tank comes to balance tank of elecster where it is stored at 17C
temperature.

2. Milk is pumped to heat exchanger 1 (Shell and tube type) , where milk is
heated at 73C.

3. Then milk is sent to Homogenizer(88%), where the size of fat particles is

reduced in the product.

4. Then milk from homogenizer is sent to heat exchanger 2 where it is heated to

85-100C.Sent to holding tube for fraction of seconds.

5. Then milk is sent to heat exchanger 3 where it is heated at 140C, where it is

heated with the help of steam at 148-150C.

6. Then milk is sent to holding tube where it is holded for 3-4 sec.

7. After that milk is chilled at around 26-28C with the help of cold water.

8. After that product is filled at 27-28 C in the 500ml packaged.

9. Packaging material is of 5 layers film which contains more air and has size of
100 micron.

10. Packaging material is dipped in 35% H2O2 for sterilization of packaging

material and then it is scrapped to remove H2O2 remained in packet and then it is

passed through UV light.

Dahi Section:

Process:-
1. Milk is heated in the UHT(Ultra high treatment) section at 110C.

2. Milk comes from storage tank to UHT section , where it is preheated at around
25C and then it is heated at 50C and then homogenized .

3. After homogenization milk is heated at around 110C with the help of steam to
 kill the microbes present in the milk.

4. After that milk is cooled to 90 C in the regeneration section of heat exchanger

and then it is chilled to 3-4C.

5. Starter culture is added to milk in the tanks having UHT treated milk at below
10C.

6. After that milk is heated to40-41C and sent to packaging area.

7. Milk is filled in 200gm,500gm cups, 200 gm pouch and 10 kg bucket.

8. There is one old and one new cup filling machine.

9. Sealing temperature of cups is between 255-280C.

10. Cups are then incubated at 40-42C for 4-5 hours.

 Culture like KD-2, or mixture of cultures like CHN-11,YF-L903, RST-744 is

used for making masti dahi.

 Cultures like ABT -5 are used for making probiotic dahi, and YF- L903 is for
making skimmed milk dahi.

 LASSI MAKING :-

 Gold milk > pasteurization at 85C and then cooling at 8C > culture addition at
40 C till acidity reaches 0.9 > then sugar and water addition in the curd till

acidity reaches 0.55> then packaging in pouches.

POUCH FILLING:

 In pouch packaging area products like amul taaza, gold, shakti ,sumul cow

milk, amul slim n trim, chhach, masala chhach , premium chhach are filled.

 Milk in the pouch filling area comes from milk tanks(MT1- MT7) of 20KL

capacity each milk stored at around 4-8C.

 Buttermilk comes from BMT 1- BMT-7 tanks for pouch filling.

 For pouch filling amul taaza is filled at around 2.1C, amul gold at around 2.5C,

and amul shakti at around 2.5C temperature.

 Milk is filled in 250ml, 500ml and 6 litre pouches and buttermilk is filled in

500ml pouches.

 There are total 7 pouch packing lines.

 In packaging line 1 there are packaging machine P 1 to P 6 and P38, in

packaging line 2 there is P7-P12 and P39 , P40, .

 In packaging line 3 there are P13-P18 and P37, in packaging line 4 there are

there are P19 – P24.

 In packaging line 7 there are P41 – P44.

 Some pouch filling machines are high speed which fills 250 ml pouches at

speed of 70 pouches per min per head.

 Some pouch filling machines are high speed which fills 500 ml pouches at

speed of 55 pouches per min per head.

 Some pouch filling machines are low speed which fills 250 ml pouches at

speed of 40 pouches per min per head. Some pouch filling machines are low

speed which fills 500 ml pouches at speed of 45 pouches per min per head.

 Some pouch filling machines are low speed which fills 6 litres pouches at

speed of 10 pouches per min per head.

 In pouch filling rolls comes vertically and pouches are sealed horizontally.

 There are 48 of 250 ml pouches are filled in one milk crate.

 There are 24 of 500 ml pouches are filled in one milk crate.

 There are 2 of 6litre pouches are filled in one milk crate.

 Crates are washed and comes to pouch filling area through bucket elevators

and spiral sliding.

 After pouch filling milk crates are stored in cold room at 4-5C.

MILK FAT SNF

 AMUL TAAZA 3.2 8.7

AMUL SHAKTI 4.7 8.7

AMUL GOLD 6.2 9.2

COW MILK 3.8 8.7

AMUL SKIM 3.2 9.5

QUALITY CONTROL:

 In process testing for pasteurization , homogenization, cream separation, milk

sylos etc.

 For each type of milk and milk products their fat, SNF, MBRT , acidity test

before and after storage in the sylos and also before and after standardization.

 Water testing:- hardness, total dissolved solids, ph, chloride test everyday for

ground water and coliform count , SPC count from different point every week .

Microbial Tests:-

 MBRT (methylene blue reduction test):- done to check the microbial load in the

milk. Time for colour change from blue to colourless is the indicator of microbial
 load. Test time above 5 hours for pasteurized milk and above 4.5 hours for raw

milk is acceptable .Test timing less then 3 hours is poor quality of milk.

 Resazurin reduction test:- provides rapid measure of sanitary conditions and

keeping quality of milk.

 Total count(Standard plate count) test:- used for checking total microbial load

in milk and milk products.

 Enumeration of coliforms :- By plating method through violet red bile

agar(VBRA).

 Coliform test by MPN method.

 Yeast & Mold count :- Important for concentrated , high fat or acidic milk

products.

 Ecoli- , Salmonella Test done 1 or 2 a month for milk and milk products .

 Swab test :- 1) regular swab test in tube , utensils, in processing and storage

area of milk and milk products done for bacterial load. 2) swab test with the

help of machine.

CHEMICAL TESTS:-

 Raw milk samples are taken from all BCU of one route .

 Raw milk sample is centrifuged for 5 min at around 3000 rpm and separated
cream is melted and tested or its BR reading. Range of BR value should r

come between 33.5- 39.5.

 Cream colour of cow milk should be yellowish cream from that of that of buffalo
milk .

 TESTS FOR GHEE:

 1. Moisture content in hot air oven.

2. BR reading( Butyrometer reading)

3. Refractive Index

4. BT (Bounding test) sor sesame oil adulteration

5. RM value. For cow milk should be about 26 and for buffalo ghee it
should be about 32.

6. FFA( Free fatty acid) in % of oleic acid. IT should be less than 0.5.
 TESTS FOR BUTTER:

1. Moisture content

2. Fat content.

3. Curd content= Which is 100-(Fat% +MC%)

4. FFA (free fatty acid)

5. BR reading

6. Colour

7. Refractive index

 For cream DIACETYL TEST is done to check presence of appropriate amount

of culture added to cream needed for the flavor in the ghee.

 Tests for A1/A2 type of milk.

 For tea and other powder material 1) acid insoluble test and 2) water insoluble

test is done.

 Sodium test in milk with the help of electrical sodium analyzer.

 Ph test for various milk and milk products through digital ph meter.

 Moisture content of various milk products through infrared moisture content.

Test for pasteurized milk



TEST OBSERVATION
Organoleptic Normal
 Temperature 6-70C
COB Test Negative

Fat test As observed

SNF test -Do-
Acidity 0.11-0.14% T.A.
Phosphates test Negative

MBRT Min.4 hrs

Coli form & SPC As observed

While packaging of milk continuous pouches are taken in every one-hour

for testing the following:

• Weight
• Leakage

• Drop test for sealing strength

• Length and breadth

Pouch milk is also tested in a shift before dispatch starts for the following:

• Temperature
• Acidity

• MBRT

• Phosphate

• Taste and flavor

• Fattest

• SNF

• Sediment

Testing of packaging material

 Size
 Printing
 Sealing
 GSM
 Bursting Strength
 Colour
 Moisture content

Length & breadth check by screw gauge

Printing check manually

Drop test for check sealing

GSM check by take a weight of different layer of CFC, layer separate by using hot water.

Bursting Strength check by Burst machine.

TESTS PERFORMED IN THE RMRD LAB:-

The tests carried out for milk received in tankers

• Organoleptic test

• Temperature

• COB

• Fat test( BY gerber method)

• SNF test( with the help of lactometer)

• Acidity

• Alcohol test with 68% alcohol

• Test for neutralizers

• Adulterants and preservatives

• MBRT

• Total count

• MILKO SCAN MACHINE IS USED FOR TESTING:- adulterants,

preservatives,neutralizers, fat , snf, acidity, lactose, casein etc.

ETP(Effluent treatment plant):

PROCESS:-

1. Water inlet from plant.

2. To bar screen.

3. To 2 collecting tanks.

4. To 2 equalization tanks.

5. To DAF(Dissolved air floatation). From DAF sludge is separated it is sent to

 decanter then dried and used for animal feed.

6. From DAF water goes to conditioning unit and from there to ICR.

7. In ICR there is addition of bacteria in the and ther is separation of of mrtahne

gas from that.

8. From ICR water is passed to bioreactor from that to MBR tank .

9. MBR(membrane bioreactor) treated water is sent to plant for reuse.

REFRIGERATION SECTION:

 From refrigeration section cold air is sent to all cold storage all over from plant for chilling

and freezing of milk and milk products.

 There are 4 ammonia tanks.

 There 6 screw compressors , 6 colling tower, 5 PHE condenser.

 PROCESS:- From accumulator > cold storage> to accumulator > to compressor

 > to condenser > to receiver > to Expansion valve > back to accumulator.

Conclusion

During the 25 days of training period I got an opportunity to study the system in detail
and have an insight into the organization. The organization has a very well thought out
organizational structure, streamlined procedure and well-motivated workforce.