AMUL Summer Internship Report........pdf

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Summer internShip trAininG report
KAirA DiStrict co-operAtive milK proDucerS union
ltD., AnAnD

Submitted to: Kaira District Co-operative Milk Producers Union
Ltd.
Submitted by: Tanvi N. Raulaji
B. Sc (Microbiology)
M.B. Patel Science College, Anand

ID No :1443
Training Period :2 month (Approx)
1 month Amul Plant, Anand
24 days Chocolate Plant, Mogar

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ACKNOWLEDGEMENT
We sincerely express our deepest sense of hearty gratitude to the following people
for supporting and guiding us ahead in the journey of making the project report of
Industrial In-Plant Training.
We express our profound gratitude and indebtedness to The Father of “The White
Revolution, Dr Verghese Kurien” for envisioning this dairy and helping it
becomes the stage of learning.
We would like to express our thanks to Dr Bina Trivedi (HOD of Microbiology
Department, Anand) for permitting us to do our In-Plant Training in Amul Dairy,
Anand.
We would also like to thank all the professors of our college for supporting and
guiding throughout the training.
We are thankful Dr Amit Vyas, Managing Director, Kaira District Co-Operative
Milk Producers’ Union Ltd. for giving us such prestigious opportunity to undergo In-
Plant Training in the organization.
We are also thankful to all section In-charges and operators who gave us positive
response and guidance during our training period.
Last but not the least, we express our deep feelings of love and affection to our
beloved parents for providing us valuable opportunities which helped us to stand out
on our own feet at this stage. During this whole training I got a lot of Experience and
came to know about the management practices in real that how in the real life.
In Today’s Globalize world where cutthroat competition is prevailing in the market,
Theoretical Knowledge is not sufficient. Beside this one need to have practical
knowledge, which would help an individual in her carrier activities and it’s true that
“Experience is best Teacher”.

Thank You
Place: Amul Dairy, Anand

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INDEX
NO. Content Page
No
Anand Amul Pattern 3
1. Visit to Amul plant 5
2. Introduction: GCMMF Organisation 6
3. Product by AMUL & Plants 7
4. Training Schedule 10
5. A-3 Process 11
6. A-2 Process 14
7. Ghee Section 18
8. A-2 Milk powder packing/F-60 plant 21
9. L & T Milk powder plant 25
10. Butter Section 30
11. Milk Pouch & Dahi Packaging 35
12. Central Lab 48
13. A-2 / Quality Assurance Lab 54
14. Microbiology Lab 56
15. A-3 Reception Lab 58
16. Ag Lab 63
17. Effluent Treatment Plant (ETP) 66
Chocolate Plant Mogar
18. Training Schedule

70
19. Bread Spread Plant 73
20. Malted milk product 78
21. Old Chocolate plant 81
22. QA Lab

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Visti to Amul Plant
 History
Amul is an acronym (Anand Milk Union Limited) of the Indian Multinational
Cooperative Society named Gujarat Milk Marketing Federation based in Anand,
Gujarat. It is under the ownership of Gujarat Cooperative Milk Marketing
Federation Limited, Department of Cooperation Government of Gujrat. It is
controlled by 3.6 million milk producers.

Tribhuvan Das K. Patel founded the organisation in 1946 and served as its
chairman until his retirement in the 1970s. He hired Verghese Kurien in 1949,
initially as the general manager, where Kurien guided the technical and marketing
efforts of the cooperative. Kurien briefly became the chairman of Amul following
Patel's death in 1994, and is credited with the success of Amul's marketing.
Amul spurred India’s White Revolution which made the County the World’s
largest producer of Milk products, and has since ventured into overseas markets.
Amul was found on 19 December 1946 as a response to the exploitation of small
dairy farmers by traders and agents. At the time, milk prices were arbitrarily
determined, giving an effective monopoly in milk collection from Kaira and its
subsequent supply to Mumbai.
Frustrated with the trade practices (which they
perceived as unfair), the farmers of Kaira, led
Tribhuvan das Patel approached Sardar Vallabhbhai
Patel who advised them to form a cooperative. If they
did so, they would be able to directly supply their milk
to the Bombay Milk Scheme instead of working for
Polson. Sardar Patel sent Morarji Desai to organise the
farmers.
Following a meeting in Chaklasi, the farmers formed the cooperative and resolved
not to provide Polson with any more milk. Milk collection was decentralised, as most
producers were marginal farmers who could deliver, at most, 1–2 litres of milk per

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day. Cooperatives were formed for each village. By June 1948, the KDCMPUL had
started pasteurising milk for the Bombay Milk Scheme. Then-Prime Minister Lal
Bahadur Shastri visited Anand to inaugurate Amul's cattle feed factory. On 31
October 1964, he spoke to farmers about their cooperative. After returning to Delhi,
he set in motion the creation of an organisation, the National Dairy Development
Board (NDDB), to replicate the Kaira cooperative in other parts of India. Under the
leadership of Tribhuvan das Patel, in 1973, Amul celebrated its 25th anniversary
with Morarji Desai, Maniben Patel and Verghese Kurien.
The Cooperative was further developed through the efforts of Verghese Kurien and
H.M. Dalaya. Dalaya’s innovation of making skim milk powder from buffalo milk
was a technological breakthrough that
revolutionised India’s organised Dairy industry.
With Kurien’s help the process was expanded on a commercial scale, which led to
the first modern dairy cooperative at Anand. In 1970, the cooperative spearheaded
the "White Revolution" of India. To combine forces and expand the market while
saving on advertising and avoiding competing against each other, the Gujarat Co-
operative Milk Marketing Federation Ltd., an apex marketing body of these district
cooperatives, was set up in 1973. The Kaira Union, which had the brand name Amul
with it since 1955, transferred it to GCMMF.

INTRODUTION: GCMMF
The GCMMF is the largest food product marketing
organisation in India. As the apex organisation of
the dairy cooperatives of Gujarat, it is the exclusive
marketing organisation for products under the
brand name Amul and Sagar. For more than five
decades, dairy cooperatives in Gujarat have created
an economic network that links more than 3.1
million village milk products with Crores of
consumers in India. In 2007, Gujarat Cooperative
Milk Marketing Federation Ltd crossed US$1
billion in its sales turnover and entered the elite
club of food companies having this distinction
from India.

In one more major achievement, the dairy
cooperatives of Gujarat under the GCMMF fold
crossed the mark of milk procurement of
10 million kilograms per day on 27 December
2007, which is the highest ever milk procurement
achieved by any dairy network in India, be it
private or cooperative. The entire quantity of milk
received was accepted without any milk holidays
and was processed successfully into milk and other
milk products.

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In 2018, Amul inaugurated a new chocolate plant in Mogar, Anand, near their
headquarters, with Prime Minister Narendra Modi in attendance. The new plant has
been built with an increased capacity of 1,000 tonnes per month against the earlier
250 tonnes per month capacity. GCMMF has invested around ₹3 billion in this
project. It is a fully automated production factory with minimal human intervention.
Amul and the Michigan Milk Producers Association (MMPA) collaborated in 2024 to
introduce fresh milk to the US market.
 PRODUCT BY AMUL

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 LOGO OF AMUL
The logo if AMUL is ring of four hands encircled by the words “KAIRA DISTRICT
CO-OPERATIVE MILK PRODUCER UNION LIMITED”. The essence of this logo is
co-ordinate effort of four groups of people.
First hand is for farmers or producers With out whom the organization would not
be existed. Farmers are the inspiration of the Amul the taste of India.
Second hand is for the representative of processors by whom the raw milk
process in to different finished products.
Third hand is for marketers without whom the products would not been able to
reach the consumers.
Fourth hand is for customers with out whom the organization could not carry
on because they are the people who consume the products.
 PLANTS
Frist plant is established at ANAND Gujarat, which engaged in the manufacturing
of Milk, Butter, Ghee, Milk powder, flavoured milk, Dahi, Buttermilk.

Second plant is established at MOGAR which engaged in manufacturing
chocolate, sweets, Amul delicious, wheat & bakery items…

Third plant is established at KANJARI which occur cattle feed factory

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.
Fourth plant is established at KHATARAJ which engaged in cheese production.

TRAINING SCHEDULE
Time: 8:30 AM to 12:00 PM [Weekly off Sunday]
No. Section Training period Reporting officer
1. A-3 Process 09 – 10 May 24 Shir Akshay Gupta/
Sri Dharmesh
Shukla
2. A-2 Process 11-13 May 24
3. Ghee section 14-15 May 24 Kamlesh Pawar
4. A-2 Powder Packing / F-60
plant
16-17 May 24 Shri K. S. Mehta
Gaurang Shah
5. L & T plant /A -3 (L/T
powder packing)
18-20 May 24 Shri Pinal Patel
Ajay Dixit
6. Butter Section 21-22 May 24 Mr. Akshay Gupta
7. Milk pouch & Dahi Packing 23-24 May 24 Shri Rakesh Amin
8. Laboratory 25 May to 08 June 24 Mr. Gokul krishnan
Ms. Dhwani Shah

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Amul -3 MILK PROCESSING PLANT
Reception dock is the very first department of any dairy. Where milk is unloaded &
simultaneously tested. Raw milk at Amul-3 is received only through road tankers
coming from different village chilling units & chilling Centres. There are 3 Milk
Reception Line (RMRD) each having capacity of 30,000 L\hr.

Process Description
o As milk tankers arrives in line first agitation is carried out for 15 min by using
plunger. QA staff process operator after inspection of the integrity of seals, draw
a sample to check temperature, pH and other quality parameters and further
record the result. The QC officers permit to accept the milk having acidity up to
0.15% L.A and temperature should be 10°c. In case of acidity is high they
reported to in production for further action.
o In case, milk do not confirm to the specificity, process staff consults their
immediately supervisor for further action. In case of higher acidity in milk the
tanker is sent to Amul-2 process plant for unloading to processing for the
another products
o The entire process of milk reception, storage, processing and dispatch is
controlled through (programmable logic controller).
o After All test the raw milk from the tanker after chilling is send to raw milk
buffer tank having capacity of 15,000l. Then this raw milk is sending to clarifier
in which the undesirable solid Particles are removed by Centrifugation. This
Particles called as sludge.
o After every 15 min undesirable sludge discharge in sludge tank (capacity-5000 l).
Then it sends to sludge treatment tank in which heat treatment gives to sludge
and then it used to produce casein.
o After clarifier milk is store in raw milk silos at 4°c. There are 5 raw milk silos, 4
silos having capacity to 1.5 lakh and 1 having capacity to 60,000l. From the raw
milk silos milk is pumped to balance tank of pasteurizer and undergoes
pasteurization (77°c/18sec). There are 5 pasteurizer one is for cream
pasteurization rest are for milk pasteurization. Meanwhile after preheating milk
is separate the cream and skim milk.
o The cream is sent to cream buffer tank and milk is sent to milk silos. The
self standardization is done is ALFAST unit ie, Alfa level fat analysing

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standardization unit. The separated milk is used for manufacturing powder. i.e,
WMP, SMP, Amul spray and Amulya.
o Cleaning process of Amul-3 plant Milk tanker process
First step is a milk tanker wash with the water for 10 min at ambient
temperature and the tanker are further passed throw the lye circulation for 30
min. Then the fresh Water circulation in a tanker for 6 min at ambient
temperature and acid are circulated throw the tanker and the last the fresh water
are passed throw the milk tanker for 10 min.
In a plant the pasteurizer, silos and transfer line are also cleaning with the same
process. First of the water are rinse for 10 min at ambient temperature and the
lye are circulate in all plant’s part for 20 to 30 min at high temperature and the
fresh water are passed throw the pipe line, pasteurizer and silos for 5 to 7 min at
ambient temperature. Then the acid are circulate throw the pasteurizer and silos
and transfer for 15 to 20 min at 60°c and at the end of the process fresh water are
also circulate in a pasteurizer, silos and transfer line.
As milk tanker arrives in line

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Amul-2 milk processing plant
PASTEURISATION :
Pasteurisation is one of the main food processing steps that make milk safe for
human consumption. This process involves heating milk at a high temperature. One
of the most common methods of pasteurisation is High Temperature Short
Time Pasteurisation (HTST). Milk must be heated to at least a temperature of
72°C for 15 seconds before being cooled down immediately. HTST ensures that milk
is heated uniformly to the required temperature and is designed to kill heat resistant
pathogens called Coxiella and Burnetii.
These are both commonly found in raw milk before it’s treated. For this
pasteurisation to be carried out properly, a dairy processing plant must be equipped
with a continuous pasteurisation system.
HTST also helps to improve milk’s shelf life. Enzymes that would usually contribute
to spoiling milk are also destroyed. So the quality and shelf life of milk is drastically
increased after a proper pasteurisation process has been undertaken. After the milk
is pasteurised.it should be safe to consume for a period between 16-21 days. For
consumer safety, dairy manufacturers will often reduce the number of days to help
push the products off the shelves.
The key steps involved in pasteurisation:
1. Chilling
While this is technically not a step of pasteurisation, it is a necessary process
before pasteurisation can begin. After the milk is extracted from a cow’s udder,
its temperature must be reduced immediately to prevent bacterial growth.
Farmers typically ensure that milk is cooled and stored to a temperature of 2°
C to 5° C.
2. Pre-heating
After milk is transported to a dairy processing plant it goes through a process
of heating. The milk is heated to a temperature of 40° C with a regenerative
heating system. This system uses the heat of the already pasteurised milk to
heat the incoming milk coming from the chilled milk vat. At the same time, the
counter flow of the cool milk helps to cool down the pasteurised milk. This
process saves energy both to heat the incoming milk and cooling the
pasteurised milk.
3. Clarification
The clarification process is used to remove all foreign matter from the milk.
Solid particles are removed in the past this was generally done running the
milk through tubular metallic filters. The most dairy factories these days a
clarifier is then used to remove all sediments and soil from the milk. The
clarifiers use centrifugal force where the milk enters a machine which is

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spinning at high speed, this separates the heavy solid particles to the outer
edge of the clarifier where it is discharged to waste and the clean milk passed
through the machine. Most dairy processing plants use separators which also
act as clarifiers they are designed to separate the skim milk from the cream
again they use centrifugal force the milk enters a set of spinning plates which
forces the heavy skim milk to the outside of the machine and the lighter cream
is forced to the inside as the milk is pumped into the separator, the separator
has valves on the exit for both skim milk and cream which control the amount
exiting the separator and by adjusting these values the fat percentage of the
cream and skim milk can be controlled.

4. Standardization
The standardisation process will ensure milk is produced to the same
consistent quality. This process is the addition of cream back to the skim milk
that is produced by the separator. The amount of butterfat reminding depends
on what’s being produced. Milk types such as high fat milk require more cream
to be added back to the skim than say low fat milk where less of the cream will
be added, skim milk will have no cream added back to the skim milk. Some of
the smaller factories who use clarifiers will standardize their milk by adding
skim milk to the whole milk to lower the butterfat percentage to the required
amount.
5. Homogenization
Homogenization is a process which breaks down the milk fat globules within
the milk. Fat globules are broken down into tiny droplets to prevent cream
separation in the milk. The end result is milk fat that remains uniformly
distributed throughout the milk.

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6. Heating
section the most important part of the pasteurisation process is the heating
section. The milk’s temperature is heated to 72° C to effectively kill harmful
bacteria. Hot water which has been heated by steam is used to achieve this
temperature while milk is being moved in a counter current motion. At the
end of the heating section the milk enters the holding tube
7. Holding section
At the start of this process, milk flows through holding tubes at a flow rate that
ensures they stay in the tubes for at least 16 seconds. This ensures that the
target harmful bacteria are killed. If any milk reaches the end of the holding
tube below the target temperature of 72 C it will automatically be diverted
back to the holding tank at the start of the pasteuriser. When milk makes it to
the end of the holding tubes it flows to a regeneration section where it is
cooled down to approximately 30° C, using the cooling action of the cold
incoming milk in the regeneration section

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8. Cooling/chilling section
After the initial cooling stage, pasteurised milk is moved to the cooling section.
Here the milk is cooled and chilled to a temperature of 4° C. This chilled milk
is then pumped into packaging machines for packaging and storage in a cold
room.
Temperature for Pasteurisation: 75-78 degree Celsius for 15 secs.
Thermisation is carried out at 62 – 65 degree Celsius temperature.
 CIP of Amul-2:
CIP steps Pasteurizer Silo tanks Transfer lines

Time
(min)
Temp.
⁰C
Time
(min)
Temp.
⁰C
Time (min) Temp. ⁰C
Rinsing
with
water
5-8 50-55 5-8 50-55 5-8 50-55
Lye
circulation
(1.5%)
40-45 80-85 9-11 80-85 15-20 80-85
Fresh
water
circulation
5-8 50-55 5-8 50-55 5-8 50-55
Acid
circulation
(0.8%)
40- 45 70-75 9-11 70-75 15-20 70-75
Fresh
water
circulation
8-11 50-55 5-8 50-55 8-11 50-55

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GHEE SECTION

Process

 In a Ghee section the butter or cream are used for the making of a ghee. Ghee
making process only white butter or non salted butter are used for the process
of ghee section.
 Butter are transfer to the butter section and directly process for ghee making.
Butter are melted at 85-100°c temperature the butter are melting in melting
tank.
 The melted butter are passed to the fat separator tank and the fat are separate
to the butter and butter milk also separate in a other tank and collect the butter
milk.
 The separated fat are purified and pure fat are heated at high temperature and
the ghee are transfer in a setting tank for 4 hours.
 Then after the ghee are transfer throw the clarifier and after clarification the
ghee are transfer in a storage tank. In a storage tank ghee are stored for 10 to 12
hours.
 The ghee are packaging at 40-45 °c temperature.
Specific temperature (pure fat convert in ghee)
1. Normal ghee -100-115°c temperature
2. High aroma ghee- 121-130°c temperature
3. Brown ghee-140-150°c temperature
Four type of ghee
• Amul pure ghee
• Amul cow ghee
• Amul high aroma ghee
• Amul brown ghee

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Amul Ghee is a clarified butter made from cow's milk. It is made by the Amul
brand, which is owned by farmers in Gujarat, India. It has a rich, creamy taste
and is often used in Indian cuisine for cooking, baking, and frying.
Amul ghee is made from fresh cream and has a characteristically rich aroma as
well as a granular texture. It does not use the traditional bilona method for
ghee-making. Amul Ghee is an ethnic product made by dairies with decades of
experience that is high in vitamins A, D, E, and K.
How Amul Ghee Is Formed?
Amul ghee is formed by churning the cream, which is the top layer of the milk.
This cream is then boiled, and the butter that is formed is skimmed off the
surface. The butter is then clarified by heating it, and then the impurities are
removed. Finally, the pure clarified butter is allowed to cool and set, resulting
in the formation of Amul ghee.
Is Amul A Pure Cow's Ghee?
Amul ghee is not made from pure A2 cow milk (Indian Desi cow milk), but
rather from a combination of Indian cow, Jersey cow, and buffalo milk.
According to Ayurveda, A2 ghee made from A2 milk is the purest form of ghee
and is also hand-churned with a wooden churner called the bilona method. All
of these factors contribute to the purest form of ghee.
Process Flowchart of Ghee:
Sour cream/sour milk/
Serum/curd/whey fat
↓
Butter churner Buttermilk
(45 min, capacity- 2000 to 3000 L)
↓
Addition of chilled water for washing
↓
Churning (15 min)
↓
Draining of water
↓
Hard grain of fat
↓
Melting vat (95℃, 1hr) Clotting, buttermilk serum
↓ ↓
Fat contain Serum Portion
↓ ↓
Settling tank (2 hrs) Serum Tank
↓

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Melting pot Fat Recovery
(110 to 115℃, for brown ghee
143 to 145℃, for 45 min)
↓
Ghee tub
↓
Filter
↓
Clarifier Ghee
Residue
(In brown ghee clarifier is not used)
↓
Cattle feed Packaging (packed at 45℃)
↓
Storage
o Shelf life:
o Pouch packing- 9 months
o Tin packing- 12 months
o Jar packing- 6 months
o Bulk packing- 12 months
o CIP of Ghee Plant:
After use of every melting system, hot water of 70-75℃ is filled up & flushed. Then it is cleaned
with 0.2 – 1% of lye solution at temperature 70℃ and circulated and drained. After this the
cleaning procedure is carried out with hot water of 70-75℃ without lye. The system is washed
third time with water for 25–30 min. Finally rinsing is done.
o CIP of clarifier: Detergent solution, hand brush cleaning with hot water having temperature
of 40- 45℃ is used for cleaning after every use.
o Specification of Ghee:
Characteristics AGMARK Specifications FSSAI Specifications
Fat % Min. 99.70 -
FFA content as % oleic
acid
Max. 1.5 Max. 3.0
Moisture % Max. 0.3 Max. 0.5
Butyro-refractometer
reading
- 40-43.5
RM value Min. 28 Min. 24
Polenske value 1-2 -
Peroxide value 0.60 0.60
Baudion test -ve -ve

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A-2 POWDER PACKING / F-60 PLANT
:

Powdered milk, also called milk powder, dried milk, or dry, is a manufactured
dairy product made by evaporating milk to dryness. One purpose of drying milk is to
preserve it; milk powder has a far longer shelf life than liquid milk and does not need
to be refrigerated, due to its low moisture content. Another purpose is to reduce its
bulk for the economy of transportation. Powdered milk and dairy products include
such items as dry whole milk, nonfat (skimmed) dry milk, dry buttermilk, dry whey
products and dry dairy blends.
Powdered milk is used for food as an additive, for health (nutrition).
powdered milk is usually made by spray drying nonfat skimmed milk, whole
milk, buttermilk or whey. Pasteurized milk is first concentrated in an evaporator
to approximately 50 percent milk solids. The resulting concentrated milk is then
sprayed into a heated chamber where the water almost instantly evaporates, leaving
fine particles of powdered milk solids.
Alternatively, the milk can be dried by drum drying. Milk is applied as a thin film
to the surface of a heated drum, and the dried milk solids are then scraped off.
However, powdered milk made this way tends to have a cooked flavour, due to
caramelization caused by greater heat exposure.
Another process is freeze drying, which preserves many nutrients in milk,
compared to drum drying.[8] The drying method and the heat treatment of the milk
as it is processed alters the properties of the milk powder, such as its solubility in
cold water, its flavour, and its bulk density.
Dried Milk Powder results when the water is removed by boiling the milk under
reduced pressure at low temperature in a process known as evaporation. When we
talk of Dried milk powder we generally talk of Whole milk powder (WMP) and
Skim milk powder (SMP)

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Principle of Drying
Drying is a mass transfer process consisting of the removal of water or another
solvent by evaporation from a solid, slurry or liquid. The science behind drying is
that dry air comes in contact with food and absorbs some of the moisture from the
food. This air then has to be blown away and be replaced with dry air so that the
process of extracting moisture from the food can continue until the food is dry.
Processing and Manufacturing:
1. Reception of Milk
Raw milk on arrival at the factory is rapidly tested for its SNF, fat, acidity,
smell, temperature, hygiene, antibiotics, water addition and adulteration. On
acceptance, the milk is pumped into a silo storage tank at the processing plant
and held at temperatures below 7° C and usually below 5 °C.
2. Standardization
It is done to adjust the ratio of fat and solid-not-fat in raw milk to meet the
legal requirements. When the raw milk arrives at the manufacturing plant it is
usually separated into cream and skimmed milk to enable standardization of
the fat content. Good players of dairy industry can automate this cream fat
standardization using an inline “standomat” which doses cream back into the
skim to give the correct fat % in the milk to be processed.
3.Pasteurization
The milk is then high-temperature short-time pasteurized (HTST)by heating it
to at least 72.3 °C and holding at or above this temperature for at least 15 seconds (as
per requirement an equivalent temperature/time combination can be used). It has
been noticed in industries that (MAP – Mycobacterium avium subspecies
paratuberculosis may be capable of surviving pasteurization.) So, most high-volume
liquid milk plants now operate on a higher holding time of 25 seconds to 35 seconds
as a precaution over the possible survival of MAP which can cause Crohn’s disease in
humans. The latest research (2019) indicates that the optimum time and
temperature combination for liquid milk is 72.3C for 26 seconds.
4.Concentration/Evaporation
It is an important stage before drying for reasons of energy efficiency as it is far
cheaper to evaporate the water than to spray dry it directly. It is generally done by
falling film evaporators because of their overall low energy consumption. The
amount is tried to be removed in the concentration stage.
5. Spray Drying
It is a continuous process for transforming liquid feed into dried particulate form by
spraying the feed into a hot medium The milk is fed from the top and is concentrated
in a series of calendrics in an evaporator to around 40-60% total solids. Milk, when

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passed down the tubes wetting the surface whilst steam, is passed from on the other
side of the tube and the vapours extracted from the centre by vacuum. Vapours are
normally recompressed in a vapour re-compressor making evaporators very
efficient. Water from evaporators can be recovered and reused

Working:
Concentrated milk and hot air (180-200°C) is sprayed into a drying chamber which
is usually a stainless-steel jacket with a conical bottom by the help of an atomizer.
The drying chamber is usually a stainless-steel jacket with a conical bottom, the
drying gas dries the particle before it touches the chamber.
Heavy particles get collected at the bottom of the drying chamber while the fine
particles get collected in the cyclone separator, still, some fine particles remain in
the air which is filtered using a filter bag.
In some companies, the spray drying process is typically a two-stage process that
involves the spray dryer at the first stage with a static fluid bed integrated into the
base of the drying chamber.
The second stage is an external vibrating fluid bed. Product is moved through the
two-stage process quickly to prevent overheating of the powder. Critical control
point: 90-92degree Celsius temperature
There are two plants:
• Condensed plant
• Drying plant

o Process Flowchart of F – 60 Powder Plant:

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Standardized milk Ingredients
↓
Balance Tank
↓
Preheater 1
st
to 7
th
↓
Low heat pasteurizer (85
o
C)
↓
High heat pasteurizers (85-92
o
C)
↓
Hot well (60
o
C)
↓
Calendria 1
st
(75
o
C)
↓
Calendria 2
nd
(71
o
C)
↓
Calendria 3A & 3B (68
o
C)
↓
Calendria 4A & 4B (64
o
C)
↓
Calendria 5 (56
o
C)
↓
Finisher
↓
Atmospheric air Concentrate tank
Feed pump
↓

Airfilter Atomizer (Rotary) 15,000 rpm Exhaust air
Vibro Fluidizer Fine Particle
↓
Vibro Shifter Lumps
↓
Bulk packaging (25 kg bags)

↓

↓

Air Heater ( 212 - 217
o

C ) Spray drier Cyclones
↓

Hea ted Air (110
o

C ) Static Fluidi zed Bed Drier
( SFB) Cyclones
↓

↓

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L & T Powder Plant\ Powder packing
Introduction:
 L & T stands for Larson & Turbo. L &T plant is a fully automated Tall Form
Drier plant in which two stage drying of standard Milk takes place. In Spray
Dryer and Vibrio Fluidized Bed drier.
 The capacity of the plant is 60 MT/day.
 Milk is received from processing site is used to make milk powder using different
Procedures. In the plant Skimmed milk powder, Whole milk powder, Dairy
whitener (Amulya) and Infant milk food (Amul Spray) are produced.
Amul Spray & Amulya-----Agglomerated
SMP & WMP----- Non agglo OR Agglomerated.
o Dryer Principle:
Spray drying operation involves the conversion of concentrated liquid milk to
dried powder. This is Carried out by transforming the liquid milk into milk
droplets and contacting these droplets with hot air in A controlled fashion. Due
to the enormous area available for heat and mass transfer, the Water
evaporation From milk droplets and drying takes place.
o Process Flow chart
Standardized milk from silos (4-5℃) + Ingredients
↓
Balance tank
↓
Pre heater (6 to 1)
↓
Flash vessel (regeneration)
↓
Swirl heater- HHP (90-95⁰C)
CCP↓
Holding tubes
↓
Flash vessel
↓
Calandria1
st (70-73⁰C)
↓
Calandria & vapour separator (2 to 5)
↓
Hydro cyclone
↓
Concentrated milk (50% TS) in Concentrate tank

26

↓
Scrapped surface heat exchanger
↓
Feed pump
↓
Homogenizer (as a high-pressure pump)
↓
Atomizer (nozzle) Fines
Non Agglo
Heated Air(183
0C) Tall form dryer (TFD) Cyclone
↓ Agglo
Vibro fluidizer (12mm WC vacuum) Fines
↓
Vibrating sieve Lumps
↓
Bulk packaging (25 kg) Hopper
↓
Dense phase vessel
↓
Pneumatic conveyor
↓
Powder silo
↓
Vibrating tubes
↓
Rotary valve &Rotary Sifter
↓
FFS packaging machine
o Specifications:

Parameter Amul
Spray
Amulya SMP WMP
Fat 18.5% min 20.5% min 1.5% max 26% min
Moisture 4% max 4.5% max 4% max 4% max
Protein 22% 20% 35% 15%
Lactose 31% 32% 50% 50%
Sucrose 17% 17-18% - -

27

Ash 8.5% 5.5% 8.2% 7.3%
o The whole plant is divided in the five sections:
1. Feed Preparation
2. Evaporation system
3. Drying section
4. Powder conveying & storing section
5. Packaging section
1) Feed Preparation:
o Milk from milk silos first comes to the section. The section has two milk silos
each having 40000 lit. Milk Capacities.
o In the Dairy Whitener and Infant milk food sugar is added as Syrup prepared in
sugar Dissolving Tanks having 3000 lit Capacity. The tanks are double Jacketed
for heating.
o The prepared solution is pumped in to milk silo through inline double Filters.
Trisodium phosphate (for pH adjustment) and Vitamins (A, D, B, C) & Mineral
mixture (both for Amul Spray only) are added in the milk silo.
Preparation of various Additives:
 Addition of BHA (for WMP only) – BHA @ 50g per metric ton of milk powder
is added by Dissolving BHA in 2 -3 L in lukewarm water and is added to milk
in silo.
 Addition of TSP – Addition of buffering salt @ 0.2% for SMP, 0.6% for Amul
Spray and 0.3 %.
 For Amulya. TSP is not added to IMF – 1 and 2 WMP.
 Sugar – Water is taken into sugar vats and heated to 50 – 60⁰ C. Required
quantity of sugar. Is Added into sugar vat and dissolved. Sugar solution is
pumped to milk silos through filter.
 Vitamins and minerals – Vitamin A + D mix is dissolved in milk and added
into sugar Solution. Water soluble vitamins and mineral premix is mixed in
lukewarm oil and added to Vegetative oil Cream. Lecithin is mixed in
lukewarm oil/ghee and heated to about 60 -70⁰c. In order to melt lecithin in
Free Flowing form and added into vegetable oil cream mixture.
2) Evaporation section:
 Milk is pumped from these silos into a feed balance tank of evaporator.
typically milk is Concentrated from 14% solids to 48% solids in evaporator.
 Here mechanical arrangement is made such that milk inside tube comes in
contact with hot steam Which heats the milk and some of its water parts about
35 %, is evaporated During this section and we get 48% total solid (TS) in milk.
For concentration of the milk, Multiple Effect Evaporator (5 effect) with
Forward Feed Mode of Evaporation is used.
 Concentration milk from evaporator is gathered in concentrate tanks.
3) Drying section:

28

 The milk concentrate (50% TS/ 500C) is pumped through a scraped surface
HE where it is Further Concentrated and then to the Spray dryer with the help
of a high pressure Homogenize.
 Homogenizer has 3 functions, main function to pump liquid up to the head of
the dryer (fifth floor), To raise the temperature of condensed milk to 70⁰c and
to partly Homogenize the milk.
 The Spray Dryer is of Tall Form design of 8 nozzle spraying atomizer, which
consists of Air dispersing system, Electromagnetic hammers, Cyclones, Fire
Extinguishing system and Vibro fluidizer.
 The drying chamber is a cylindrical vessel with 450Conical bottom. The
drying process Proceeds in a Co current mode.
 Milk is atomized by nozzles at from the top. Cyclones are present for
collecting fines by centrifugal force. In case of agglomeration these fine
Particles are added back in the dryer along with milk
 Vibro fluidizer is a vibrating housing which is divided into two parts by a
special perforated Plate.
 Air is blown into lower part which is called Plenum chamber and the powder
is Fluidized in the upper Vibro shifter.
 There are three regions in vibro :-
1. Initial heating region – 60°c
2.Heating with dehumidified air – 45°c
3.Dehumidified cooling – 40°c
Vibrator mounted on the lower side produces the vibration. The vibro fluidizer
operates at a Vacuum of 12mmWC. At the outlet of vibro there is a sieve for
removal of lums. Lums are Reconstituted into milk.
4) Powder conveying section:
 The powder coming out of vibro sieve enters the dense phase conveying unit
and from there it is Pneumatically conveyed into powder silos.
 The powder from the silos is conveyed through vibrating tubes to packing
machine.
5) Packing section:
o The powder is packed in pouches. The pouches are inserted in cartons.
o The cartons are collected & put into cases. Cases are sealed & conveyed to
stores on a belt Conveyour.
Automatic packaging
o For automatic packing, powder is taken into powder silos. Each silo has 3000
kg capacity. With the help of dense phase vessel, powder is conveyed through
vibrating tubes, rotary valve and rotary shifter and is taken into packaging
machine hoppers. Form fill and seal machine packs 50 gm pouches of Amulya
and 1kg and 500 mg pouches for Amul spray.
o Types of powder made in this section:
a. SMP (Skim Milk Powder)
b. WMP (Whole Milk Powder)
c. Infant Milk Food- Amul Spray
d. Amulya- Dairy Whitener

29

30

Butter section

Introduction
o The Utterly Butterly Delicious butter of Amul is one of the most popular
Product of Amul dairy along with the famous butter girl. The Butter section is
located in Amul-3 which manufactures table Butter, White Butter.
o The section is completely computerized and is equipped with most modern
imported equipment. Amul white and table butter is exported to USA and Gulf
countries. Amul Table butter Maintains AG Mark standards.
o Butter section of Amul-3 has capacity 70 MT per day. The capacity utilization in
flush Season is 55-60 MT, usually it produces 20 MT per shift.
Process:
o The cream for manufacturing Butter is receiving from Amul-3 processes while
Standardization of milk. The Milk fat will be separated at above 60oC; the
centrifugal cream separators in line with milk Pasteurizer Separate this as
cream.
o The cream thus separated is pasteurized and then pumped by positive
displacement pump to the cream buffer Tank and then to the cream silo.
o After ageing at 8
0 C for 24 hours cream is pumped to cream chilling unit in the
butter Section. There the Temperature of cream is adjusted to the required
churning temperature (9-11
0C
) of Continuous butter making Machine. There are
three continues butter making machines.
o Butter milk produced by churning is collected in buttermilk tank. This
buttermilk Is used for washing of butter. Excess of buttermilk is stored in silo. A
blender of 5 MT capacity is installed which blends butter obtained from the two
CBMM.
o Salt dosing is done by salt Dozer @ 10-110 lit/hr. Annatto colour is added to
Brine @ 2.5%, the strength of brine being 70 80%.

31

o This is prepared in a tank and Fed to CBMM using a reciprocating pump.
Working of butter is done in blender Under vacuum. Butter is then collected in
butter silo of 3.5 MT capacities.
o Butter Is pumped into hoppers of packaging machines.
o The white butter is packed in 15 kg blocks. It is utilized in ghee section for
making ghee and also sent to other co-operation for the same purpose. White
butter has a shelf life of 60 days at 0⁰c or below & table Butter has a shelf life of
12 months at refrigerated storage.
o The butter is kept in cold store for minimum 5 Days before dispatch, during
which a sample of the lot is analysed by QC lab.

Major section of the CBMM

32

1. Churning section
o This section has a horizontal cylindrical with the cooling jacket and beater for
churning of Cream. The Churning process lasts for 2 to 3 sec during which the
oil in water emulsion of the cream is Broken into Water in oil emulsion
existent in butter.

o The water content of the granules and the fat loss in the Buttermilk depend
largely on beater speed and the temperature of cream at the time of Churning.
The Beater is driven by power transmitted from a motor through a V-belt. The
speed of the Beater is adjusted So that butter granules have a suitable size
when they press through the separating Section.
2. Separating section:
o This section has horizontally positioned cylinder resting on rollers and the
other supported by a bearing. the cylinder is fitted with paddles, which stresses
the granules suspended in the butter Milk to librated Most of their buttermilk
content.
o A draining section is provided where the granules are Separated from the
Buttermilk and are then passed into the working section. The speed of paddles
is 34 rpm.
3. Kneading section:
o The kneader consists of two contra rotating augers 40 to 60 rpm that are in
mesh with one Another. The Front screw ends in perforated discs there are 3
agitating blend per screw operating Sequentially between the perforated discs.
o Spacer rings ensure the distance between the perforated discs. In the Kneader
the Gear unit driving the screw is driven by a v-belt through a motor. All parts
of beater, draining unit Washing unit and kneader are made up of high alloy
chromium nickel steel
4. Salt dosing unit:
o Salting for adjusting the water content or for water content or for salting the
butter, water or Salt solution Can be added through an opening immediately
in front of the perforated plates. salting is carried out by injection of 50/50
salt/water slurry into butter early in working stage To avoid color Mottle in
the butter a micro fined salt less than 50 micron is used.
o The salt slurry is loosely Filtered through Wire gauze before injection. The
slurry is metered to the butter maker by positive Displacement pumps. The

33

Dosing system may also be used for adding water to unsalted or slightly salted
butter to Maximize yield.
o Process Flowchart for colour & salt solution:
110 L Pasteurized Water
↓
100 Kg Salt
↓
2000 to 4000ml Annatto
↓
15 min Agitation
↓
Filtration
↓
Add in to Salt dozer
o Packaging Machine:
• SIG machine
500 gm packing – Capacity – 60-62 pack /min
• BENHIL case packer machine
100 packing – Capacity – 150 pack /min
• HASSIA butter Tub filling machine (Blister pack)
10 gm packing - Capacity – 525 packs /min
• Tin packing machine
400 gm Tin - Capacity – 36 packs /min

Shelf life: Best before 12 months from packaging when stored refrigerated at 4
o
C or below
Storage condition: At 4
oC or below
o CIP of Butter Section:
CIP is done after every 24 hrs (usually in third shift).
Melting of residual butter is done with hot water for 25 min and molten butter is
drained into recovery tank. Degreasing is done for 10 min.

34

***********
************

35

Milk pouch & Dahi Packing

o In amul-2 milk pouch section are packaging a various Types of milk and Dahi
section are packing a Dahi, butter milk, jeera butter milk.
o Milk is Collect to the silos of AMUL 2 and 3 processing plant and milk is passed
throw the horizontal milk storage tank. Then the machine is packed milk
pouch. And the milk is stored in a cold storage.
o Butter milk is a liquid left behind after churning of butter to cream. It is
prepared in amul-2 it is standardized and then the pouch Are packed.
o In a process plant the milk is pasteurized and the pasteurized milk are transfer
to the tank and add inoculation culture in a tank and given a desired
temperature.
o After 15 to 30 min Dahi are packed and transfer the Dahi in a hot temperature
room and after 6 to 8 hours the Dahi are stored in a cold storage. and second
day Dahi sample are analysis and after analysis the product are transport.

Milk Packaging Products
 Amul Shakti
 Tea special milk
 Amul gold milk
 Amul Taza
 Butter milk packaging
 Amul Masti special buttermilk
 Amul probiotic buttermilk
 Dahi packaging
 Amul Masti Dahi (200gm, 400gm, 1kg, 5kg)

Two types of milk also occur:

36

 Toned Milk
Toned milk refers to milk obtained by the addition of water and skim milk
powder to whole milk.
In practice, whole buffalo milk is admixed with reconstituted spray dried skim
milk powder for the production of toned milk.
Under PFA rules toned Milk should contain a minimum of 3.0% fat
8.5% SNF

 Double Toned Milk
Double Toned Milk is milk which is also obtained by addition of water & skim
powder to whole milk.
Under PFA rules toned Milk should contain a minimum of fat 1.5 %
SNF 9.0 %

A. Milk pouch Processing Lines:

37

Raw milk from HMST (15KL*1 & 8KL*1)
↓
Centrifugal Pump
↓
Float Control Balance Tank
↓
Stack Filter
↓
Milk into Pasteurizer
(Capacity 30KLPH)
Kelvion Ind. Pvt. Ltd. Year:2016
↓
Regeneration 1(Temp 38℃)
↓
Westfalia Separator (Capacity 30KLPH)
GEA Westfalia Separator Germany
↓
GEA STANDOMAT
(Automatic fat standardization method)
Cream Fat (40-42% Fat)
↓ ↓
Skim Milk (0.1% Fat) Cream
Chiller
↓
↓
Regeneration 2 (Temp. 71℃) Amul-3 Processing
Section
↓
↓
Heating Section (by hot water) Further
processing
↓
Temp outlet (76℃)

38

↓
Holding Section (15 sec)
↓
FDV
↓
Back to FCBT Back to Regeneration 2,1 (Outlet
temp. 12℃)
↓
Chiller (by chilled water, Temp.
outlet 4℃)
↓
Storage in PMST (Capacity 1
lakh*6)

B. 10 KLPH Butter Milk Process Line:
Butter Milk from Amul 3 butter section is being processed in Amul 2 andprepared
for commercial buttermilk. Its demand is high in Summer.

Buttermilk form Amul-3 Butter Section
↓
Buttermilk HMST (Capacity 1Lakh)
(Fat 1.1 %, SNF 5.5-6%)
↓
Balance Tank
↓
Regeneration (Temp 60℃)
↓
Homogenization (capacity 10KLPH)
Trepko Micron Industries PVT. Ltd.,
Mumbai Pressure 40 Bar in 1st Stage and
5 bar in 2nd stage
↓
Heating Section (temp 76℃, Holding for 16 min.)

39

↓
FDV
↓
Back to FCBT Cooling (Temp. 8℃)
↓
Heating Section (40-42℃) for culture addition
↓
Chilling Section (Up to 5℃)
Process
o Buttermilk from butter section of Amul-3 after pasteurization at 72-75℃ for 18 sec is sent to
buttermilk tanks in Amul-2 Section.
o In buttermilk tank, the standardized & pasteurized mixture is at heated 39-41℃.
o DVS Culture is added & is inoculated at 1% buttermilk quantity.
o The acidity is checked every 3hrs. Once the Acidity reaches 0.350 %, chilling takes place till the
temperature is dropped to 9℃& then sample is tested in quality analysis laboratory for total
solids (T.S).
o The buttermilk is sent for pouch packing via pipelines. Packing is done at temperature less than
8℃. Pouches are stored to temperature less than 5℃ and dispatched after storing for at least 1-
2 hours in cold store at minimum 5℃.
o Shelf life: 48hr from the date of packing if kept under refrigeration below 8℃. Specification
of Butter Milk:
Sr.
No
Parameters Specification
1 Temp. of dispatch Not more than 8oC
2 Acidity (%) LA 0.35 - 0.45 %
3 Fat (%) Min. 1.00
4 SNF Min 5.5%
5 Total solids Min. 6.5%
6 Organoleptic Test
(OT)
Fresh, free from any off
flavour
Specifications of buttermilk

40

Dahi Preparation
 Definition:
Dahi or curd is a semi solid product, obtained from pasteurized or boiled milk by souring,
using harmless lactic acid or other bacterial cultures. Dahi may contain additional cane
sugar. It should have the same minimum percentage of fat and solids-not-fat as the milk
from which it is prepared.
Where Dahi or curd, other than skimmed milk Dahi, is sold or offered for sale without any
indication of the class of milk, the standards prescribed for Dahi prepared from buffalo milk
shall apply.
Method of Making Dahi
 Selection of raw material
Production of cultured/fermented milk demands high quality raw materials with respect to
physical, chemical and microbial standards.
 Filtration/clarification
Fresh raw milk is heated to 35 to 40 C to aid clarification or filtration process then it is
filtered to ensure that, milk is free from extraneous matter.
 Standardization: Fat: 0-5%, SNF: 11-13%
Fat is standardized based on type of product ranging from fat free to full fat and SNF level
is increased by min. 2% than that of milk. It is common to boost the SNF content of the milk
to about 12% with the addition of skim milk powder or condensed skim milk.
Increased SNF in turn increases the protein, calcium and other nutrients and resulted with
improved body and texture, custard like consistency. Higher milk solids
prevent wheying off of the product during storage.
 Homogenization: 175 Kg/cm
2

The standardized milk is subjected to homogenization after heating to 60 C to increase the
efficiency. Homogenization reduces the cream layer formation during incubation, Single
stage homogenization with 175kg/cm
2
pressure would be sufficient to improve texture
of Dahi.
 Heat treatment: 9 C/23min
Milk intended for Dahi or any other fermented milk product is given severe heat treatment
i.e. 90 C for 10min.
Following are the benefits of high heat treatment
 Denatures and coagulates milk albumin and globulins which enhance the viscosity and
produce custard like consistency
 Kills contaminating and competitive microbes
 Development of relatively sterile medium
 Removal of air form the medium more conducive for the growth of culture bacteria
 Effective thermal breakdown of protein releasing peptones and sulfhydryl groups, this in
turn provide nutrients to starter bacteria
 Packaging and fermentation

41

 The heat treated product mix is cooled to 37 C and it is inoculated with specific Dahi culture
at the rate of 1 to 1.5%. Starter culture is the most crucial component in the production of
high quality fermented milks.
 Proper selection of culture strains decides the good quality of product. Dairy cultures are
available in various forms like freeze dried, liquid and frozen forms. After the product mix
is inoculated with Dahi culture it is thoroughly mixed and filled into plastic cups, sealed
properly to avoid any contamination and spillage of the product.
 Dahi is packed in food grade polystyrene and polypropylene cups in 100g, 200g and 400g
pack sizes. Various packaging machines of up to 400cups/min speed are available to package
cultural dairy products in different sizes.
 The packaged product should be stored at < 5 C for extended shelf life. Thus packed product
is arranged in cases or crates and transferred to incubation room maintained at 37

to 42 C.
The product mix is incubated till its pH reaches 4.4 to 4.5 and then it is cooled rapidly to less
than 5 C by exposing the cups to high velocity cold air.
 Storage
Dahi is normally stored at 4 - 5 C. Storage area should be maintained clean and tidy to avoid
any cross contamination.
Masti Dahi:
1. Pasteurized homogenized milk having fat 4.5% is taken.
2. It is then standardized to 3.2% to 3.3% fat & SNF 11.1% to 11.2% by addition of skimmed milk
or SMP.
3. It is then pasteurized at 90℃ for 10 min.

Amul Masti Dahi
4. It is then transferred to vat, where DVS culture is added with agitation (15-20 min).
5. DVS culture used for making Masti Dahi is RST 744.90 units and CHN11:10 units per 1000 lit
of milk.
6. Then it is packed in pouches & cups and kept in crates.
7. It is then incubated at 42℃-43℃ for 3hrs.
8. The acidity is checked every 3hrs. Once the acidity reaches to 0.6 – 0.7% LA, it is transferred to
cold store (8℃) where it is kept for 24 hrs.
9. After 24 hrs acidity reaches to 0.8% - 0.9 % LA & the Masti Dahi is ready for dispatch.
10. It is stored in cold storage at below 5℃.

42

11. Amul Low Fat Dahi:
12. Amul Lite Dahi manufacturing process is same as that of Masti Dahi; the difference is in its
standardization.
13. In case of Amul Lite Dahi, pasteurized milk is standardized to 0.5% fat.

Amul Low Fat Dahi
Flowchart of Dahi

Masti Dahi Product Details

43

Description Curd made from Pasteurised Toned Milk
Packing Poly pack-200 gm,400 gm,1kg*
PP cup-200 gm,400 gm,100 gm*
Composition Fat: 3.1% SNF: 11.2%
Pasteurised Toned Milk
Nutritional information Amount per 100 gm
Energy, Kcal 61.5
Total Fat 3.1 g
Saturated Fat 2 g
Trans Fat 0 g
Total Carbohydrate 4.4 g
Added sugar 0 g
Protein 4 g
Calcium 138 mg
Shelf Life For Cup 15 Days
For Poly pouch 7 Days from the date of
manufacturing
Storage condition Refrigerated under 4c or below

44

Flavoured Milk

o Process Flowchart of Flavoured Milk:
Sugar in bags Pasteurized milk from Amul 2 & Amul 3
↓ (Min. 3.5% Fat & Min. 8.5% SNF)
Sugar Hooper ↓
↓ Storage tank (Capacity-10KL)
Screw conveyor ↓
Provat-1&2
(Capacity-5KL & 2KL)
↓
Balance tank
↓
Plate Heat Exchanger
(Temp.- up to 70℃, Capacity- 5000 L/hr)
↓
Homogenization
(2
nd
Stage 80-100 kg/cm
2
& 1
st
stage 180-200 kg/cm
2
)
↓
Chilling in bulk cooler at 8℃
↓
Addition of colour and flavour
↓
Mixing
↓
Filtration
↓
Overhead tank
↓
Can filling machine
[Automatic filling, sealing and washing machine (60-70 bottle/min)]
↓
Placing filled bottles/cans in metal crates

45

↓
Sterilization (121℃, 1.1 to 1.3kg/cm² for 15 min)
↓
Cooling by fans in the cooling Rooms/ Incubation room
↓
Labelling & Shrinking Wrapping
↓
Storage at ambient temperature
 Pack size:
• 200 ml glass bottles
• 200 ml cans
• 125 ml cans
 Shelf life: 375 days at ambient temperature

 Following drinks are made:
• Amul Kool Café
• Amul Kool Koko
• Amul Kool (Kesar, Badam, Pistachios, Elaichi)
• Amul Shakers (Mango, Strawberry, Chocolate)
• Amul Pina colada
• Amul Irish Drink
• Amul Gur Doodh
• Amul Haldi Doodh
• Amul Kadhai Doodh
• Amul Honey Doodh
• Amul Star Anise Doodh
• Amul Saffron Doodh

 Equipment:
1 PROCESS VAT
Manufacturer – Dalal Eng. Pvt. Ltd., Number-2, Capacity-5000lph
2 PHE
Manufacturer- Alfa Laval, Capacity- 5000lph
3 HOMOGENIZER
Manufacturer – GEA, Number- 1, Capacity – 5000lph
FFS Packaging Machine

46

4 HOMOGENIZED STORAGE TANK
Number- 3, Capacity- 100000 litre
5 CONTINUOUS BOTTLE FILLER
Manufacturer- Shriyan, Pune; Number-2
Capacity: Shriyan 1- 120 bottles/min, Shriyan 2- 60 bottles/min
Washing- 1 bottle/sec
Filling: 32 heads in Shriyan 1, 12 heads in Shriyan 2
Corking – 6 heads
6 STERILIZER
Capacity-2250 bottles/batch, 3050 cans/batch
Working Temperature – 122.5⁰C
Time: 21 min for koko bottles and cans, 15 min for other bottles and cans
Working pressure – 1.1 to 1.3kg/cm²
Number - 3
7 CONTINUOUS CAN FILLER
Manufacturer- SPANKAK, No. of cans/min- 60, Filling- 6 cans at a time
Bottom sealing: at 5.2kg pressure
8 SEALING MACHINE
Type- shrink wrapping, Temperature- 160-165⁰C, Manufacturer- silva
9 BULK COOLER
Manufacturer- IDMC, Capacity- 2000 lit, Number- 3
10 SHRINK WRAPPING OF BOTTLE
Manufacturer- Samarth engineers, Capacity- 25 bottles/min
11 PRINTING MACHINE
Type- Ink Jet Labelling, Make- Video Jet
 Specifications:
Product Fat (%) TS Sugar (%)
Amul Shakers
(strawberry, mango,
badam)
4.5 24.0 8.0
Amul kool café
classic)
(hazelnut, 4.5 20±1 8.0
Irish drink 4.5 23.1 8.8
Amul Pina Colada 4.5 Above 20.0 8.0
Amul Kheer 9.0 - 3.0-4.0

47

Amul Kool Koko 3.0-3.3 20±1.0 8.0
Amul Kadhai Milk 4.6 20.1 5.0

 CIP Process:
Cleaning of sterilizer: All the sterilizers are cleaned manually from inside daily. Condensate
lines are dismantled, brushed and cleaned with water once in a month. All Sterilizers crates are
cleaned manually once in a month by brushing with 0.3-0.5% Teepol Solution and rinsing with
water.
CIP for process vats, storage vats, PHE, bulk chiller, Homogenizer and pipelines:

CIP steps Time (min) Temperature (℃)
Rinsing with water 20 60
Lye circulation (0.8
%)
40 80
Fresh water
circulation
20 60
Acid circulation 30 70
Fresh water
circulation
20 60
CIP for equipment
CIP for can filling machine, overhead tank/bottle filling machine:

CIP steps Time (min) Temperature (℃)
Rinsing with water 5-10 50-55
Lye circulation (0.5-
0.8%)
20-30 75-80
Hot water circulation 15 50-55
Acid circulation (0.4-
0.6%)
15-20 72-75
Hot water circulation 15 50-55
Lye circulation 5-10 75-80
Hot water flushing 20 50-55

48

Laboratory
Why check milk to every step????

Central Lab
The Dairy Factory produces a variety of dairy products like Powder, ghee, butter etc.
The various tests are carried out to check its quality. it’s all products check in this
lab.
 BUTTER
Following the tests carried out to check the quality of butter:
 Determination of moisture content
 Determination of salt content
 Determination of SNF Content
 GHEE
Following the tests carried out to check the quality of Ghee:
 Organoleptic grading test
 Moisture content
 Free Fatty acid Test
 Iron test
o Equipment in this Lab:

PRINCIPLE: The working principle of the
Spectrophotometer is based on Beer-Lambert's
law which states that the amount of light absorbed
by a colour solution is directly proportional to the
concentration of the solution and the length of a
light path through the solution.

49

 Test for Flavoured Milk
1) pH
Procedure:
• Calculate the pH meter using standard buffer solutions of known pH values.
• Take a known quantity of flavoured milk in a beaker.
• Immerse the pH meter electrode in the milk and record the pH value.
Interpretation:
The value of pH should be 6.3 to 6.5.
2) Fat
Procedure:
• Weigh a known quantity of flavoured milk and transfer it to a beaker.
• Add a suitable solvent such as ether or petroleum ether to the milk and mix well.
• Transfer the mixture to a separating funnel and allow the layers to separate.
• Collect the upper layer and evaporate the solvent.
Fat (%) = (Weight of residue / Weight of milk taken) × 100
Interpretation:
• Koko- 2.4 to 2.5
the principle of centrifuge operates by using
the sedimentation principle- Here the substances
are separated based on their density under the
influence of gravitational force. When spin rapidly,
lighter particles stay at the top and heavier particles go
to the bottom during centrifugation.

50

• Cafe - 4.85 to 4.90
• Shakers- 3.4 to 3.5
3) SNF
Procedure:
• Weigh a known quantity of flavoured milk and transfer it to a dry flat-bottomed dish.
• Dry the dish and milk in an oven at 100-105°C until a constant weight is obtained.
• Cool the dish in a desiccator and weigh it. Record the weight as W1.
• Boil the milk in the dish until it coagulates and filter it through a filter paper.
• Dry the filter paper and residue in an oven at 100-105°C until a constant weight is
obtained.
• Cool the dish in a desiccator and weigh it. Record the weight as W2.
SNF (%) = [(W2 – W1) / Weight of milk taken] × 100
Interpretation: Value should be 8.6 to 8.8
4) Cream Index
Used to check the efficiency of homogenization Procedure:
• Cool the milk sample at 20°C & take 50ml in each of the 2 centrifuge tubes.
• Centrifuge the tubes at 1000 rpm for 15 min.
• Using fine pointed pipette take 5ml upper part of the layer & collect in a beaker.
• Then collect the remaining milk in another beaker.
• Determine fat content of A & B.
Cream Index = (Volume of cream formed / Total volume of milk taken) × 100
CI = (A-B)/B×100%
Interpretation:
It should be <10%
o Aflatoxin M1 Rapid Test Kit is a lateral flow assay that determines a qualitative
level for the presence of aflatoxin M1 in raw cow’s milk.
o Aflatoxin M1 is a chemical compound of the aflatoxin class, a group of
mycotoxins produced by three species of Aspergillus – Aspergillus flavus,
Aspergillus parasiticus, and the rare Aspergillus nomius – which
contaminate plant and plant products.
o Aspergillus flavus produces only B-type aflatoxins. Aflatoxin M1 is the
hydroxylated metabolite of aflatoxin B1 and can be found in milk or milk
products obtained from livestock that have ingested contaminated feed. The

51

detection of mycotoxin residues such as Aflatoxin M1 in raw milk is of great
concern for the dairy industry because of the potential interfering and adverse
effects of mycotoxin residues frequently found in raw milk.

Test for Ghee
o Oils and fats including ghee commence to decompose from the moment they are
isolated from the natural living environment. The presence of free fatty acids is
an indication of lipase activity in ghee or
milk from which it has been prepared.
o Changes occur during storage, which results
in the production unpleasant taste and
odour. Such ghee is referred to have become
rancid and is the result brought about by
atmospheric oxidation (Autooxidation).
o Acid value of ghee along with its peroxide
value can give the idea of the quality of
ghee.
As rancidity is usually accompanied by free fatty acid formation the
determination of acid value of ghee is often used as a general indication of the
condition and edibility of ghee.
Desiccators are important for drying reactants
prior to their use in chemical reactions. They are
usually sealed air-tight to prevent water vapor
from entering, and contain a desiccant in order
to absorb any water vapor that does enter the
chamber.

52

o The acid value of ghee is defined as the number of mg of
potassium hydroxide required to neutralize the free fatty acids in 1 gram of the
sample.
o The result is often expressed as the percentage of the free fatty acids (FFA). The
acid value of ghee is determined by titrating 1 gram of ghee and alcohol against
standard alkali solution in the presence of phenolphthalein.
PROCEDURE
o Take 50 ml alcohol and 1 ml indicator carefully neutralized with 0.1N NaOH.
o Dissolve 1 to 10g melted ghee in the alcohol after boiling it for 15 minutes and
titrate against 0.1N NaOH solution.
o Shaking constantly until a pink colour which persists for 15 second is obtained.
o The titration should preferably not exceed about 10 ml or otherwise 2 phases
are liable to separate. This can however be avoided if hot alkali is used.
Acid Value of Ghee = titer value in ml× 5.61 / weight of the sample used Or FFA as
Oleic acid = Acid value / 2 According to standards, ghee should have minimum of
96% of fat, 0.3% maximum moisture, 0.3% maximum FFA (as oleic acid),
peroxide value less than 1%.

MOISTURE CONTENT
o As per FSS Regulations, the moisture content in ghee should not be more than
0.5 per cent; as per Ag Mark, it should not be more than 0.3 per cent. Moisture
content in all the brands was less than 0.3 per cent. PEROXIDE VALUE:
o The PV of fresh ghee would be zero. Peroxide value is a measure of the
oxidative rancidity of ghee. It is determined by the amount of peroxide present
in the ghee, which is formed by the oxidation of fats. The peroxide value of
ghee is usually expressed in terms of mg/kg.
o The easiest method to check the purity is by melting it in a pan. Put a pan on
medium heat and let it heat for a while; now add a teaspoon of ghee to it. If the
ghee melts immediately and turns dark brownish in colour, then it is pure
ghee. Milk powder test
Moisture Test 2.6-3.2
Fat Content Not less than 18.5
Solubility 0.2-0.3
Nitrogen Content Less than 10

53

Moisture content:
o The moisture content of a powder is the loss in weight (%) after oven drying at
102°C until constant weight is obtained. This is an accurate standard method
which may be used for milk powder and all other powdered dairy products
which do not contain Crystallized lactose (α-lactose-monohydrate).
Principle:
o The sample is dried by oven drying to constant weight at 102°C ± 2°C for 2
hours. The oven drying is repeated until the two successive weighing do not
differ more than 0.5 mg. 4. Apparatus 4.1 Drying oven, with thermostat and
without forced air circulation. 4.2 Analytical balance, sensibility ± 0.1 mg. 4.3
Desiccators with colour-indicating desiccant (e.g. silica gel). 4.4 Weighing
dishes with lid.
Procedure:
o Dry weighing dish with open lid in the oven, and cool it in desiccators. Weigh
the empty dish (a), add approx. 3 g of powder and weigh again Place the
loaded dish with open lid in the oven at 102°C ± 2°C for 2 hours. Cool closed
dish to room temperature in desiccators, and weigh.
o Continue drying the loaded dish with open lid in the oven at 102°C ± 2°C for 1
hour. Repeat the cooling and weigh again.
Colour reader
o It is used for simultaneous and accurate determination of several parameters
such as moisture, protein, and fat content (38% - 42%).

54

Microbiology Lab
 Testing dairy products for bacteria is essential for the quality and safety of end
products in the dairy industry. A whole range of pathogens can have a
detrimental effect on milk quality, and dairy microbiology testing is a highly
effective set of methods for detecting them.
 What is Dairy Microbiology?
Dairy microbiology is the application of various microbiological analysis
methods in the testing of milk and other dairy products, part of which, is how to
test for bacteria in milk.
Microbiological analysis of uses various methods to detect, identify and quantify
microorganisms in materials, including food. Many of the microorganisms that
microbiology tests can cause diseases in, and spoilage of food.
 Microbiological analysis includes these methods:
Biological
Biochemical Molecular Chemical.
 What Does Dairy Microbiology Test?
Dairy microbiology can identify microbial threats in dairy products, including:
E.coli and coli forms
Salmonella
Listeria monocytogenes
Cronobacter
Enterobacteriaceae
Staphylococcal enterotoxin
Coagulase positive Staphylococci
Clostridium perfringens
Thremo tolerant Campylobacter spp.
Bacillus cereus
Somatic cells
Moulds
Probiotics.

55

 Some of these pathogens, such as salmonella, can affect a wide range of dairy
products, including powdered milk and infant formula.
 Others, such as E.coli , are limited to raw milk and derivatives. But because
there can be such a diverse set of organisms present in dairy production and
products, it’s important to have testing methods that are clearly effective in
detecting a whole range of them.
 Some bacteria found in dairy products are especially dangerous, such as
cronobacter, which can cause severe neonatal infections, including septicemia
and meningitis. And certain bacteria are more of a threat at different stages of
the dairy production cycle.
 For example, you can find Enterobacteriaceae in dairy products from
insufficient pasteurisation or sterilization, or from recontamination due to lower
hygiene standards.
 Dairy testing extends to testing for antibiotics in milk. These can be present due
to treating cattle for mastitis, a disease of the udder that can affect milk yields.
Milk hygiene and dairy testing are critical issues for farms and other dairy
producers. Dairy microbiology offers the means to provide accurate and efficient
testing for quality control and quality assurance.
 How Do You Test for Bacteria in Milk?
One method for testing for bacteria in milk is to use a culture method, such as
the Charm Microbial Peel Plate. This microbial test will detect E.coli and coli
forms, aerobic bacteria, and Enterobacteriaceae in milk samples.
 What Equipment Can You Use for Dairy Testing?
There is a range of dairy testing equipment for use both on-farm and in the lab.
This includes Charm multipurpose analysers that can conduct different ATP
tests.
These analysers can test milk for pasteurisation levels and the presence of
microorganisms by reading a range of different ATP swab tests.
 Other dairy testing equipment includes the Charm Epic, which tests the shelf
life of UHT milk for spoilage, and the Lacto scan Somatic Cell Counter.
 This tests milk for somatic cells. These are an indicator of milk quality because
most of them are white blood cells, also known as leukocytes. These cells
increase in milk as the cow’s response to mastitis-causing pathogens.
 Essentially a lower somatic cell count (SCC) indicates better animal health
which, in turn, should provide a better quality of milk yield.
 How important is Dairy Microbiology Testing?
The problem with milk and dairy products is that they provide the perfect
environment for many different types of bacteria to thrive in. Therefore, dairy
producers must monitor their products and test them constantly for the
presence of bacteria and other contaminants.
 This involves testing for specific microorganisms, such as salmonella, but also
for the presence of antibiotics.
 Effective dairy testing is a food safety issue for consumers, but also an economic
issue for dairy farmers and other producers.

56

 Milk production in Great Britain is predicted to top 12 billion litres, and it's a
highly competitive marketplace. Plus, various factors are driving down farmers'
margins. Maintaining quality is, therefore, a key factor in milk production.
 Microbiological analysis of milk and milk products provides valuable
information regarding:
Market milk control and grading
Improvement of practices of production (at farm)
Handling and processing Screening of milk supplies for their suitability for
processing or preparation of milk products Public health aspect
Standard Plate Count Method (SPC):
This method employs universal standardization of equipment, materials and
incubation methods. It aims at determining the population of viable bacteria in
the sample of milk/ milk products.
 A small quantity of the sample is mixed with the appropriate nutrient agar
medium and poured into a Petri dish.
 The agar is allowed to set and plates are incubated at specific temperature for a
definite period of time. The bacterial colonies grown on the agar surface during
incubation are counted presuming each colony to have grown from one
bacterium or bacterial clump present in the inoculum.
 The standard plate count is estimated by multiplying number of colonies with
dilution factor.
 This method is specifically suitable for following purposes:
Estimation of number of bacteria in pasteurized milk or milk products
In-line testing of products at various stage of processing
Detection of the sources of contamination.
Cultured dairy products or dairy products, to which a bacterial culture has been
added, however are not tested ordinarily by this method.
 Compact Dry Disk
Compact Dry is a ready-to-use test method which helps to reduce the time
needed to perform microbial testing. Therefore, it allows maximum
productivity by increasing efficiency. The plates can be used to test raw
materials as well as finished products like food, beverages, cosmetics or
pharmaceutical products.
Storage and shelf life:
Keep at room temperature, from 1 to 30 °C. Shelf life 18 months.
Compact Dry CF-L is a ready to use dehydrated media plate used to detect
coliform bacteria in dairy products such as cheese, milk, yogurt and any
products containing lactic acid bacteria. Monitoring and identification of
coliforms is a critical quality control parameter throughout the food production
process.

57

Compact Dry™ Prepared Media Plates
Compact Dry™ is a simple and safe procedure to
determine and quantify microorganisms in food
and beverage, raw materials, cosmetics and
pharmaceutical industries and internal environmental
monitoring. The ready-to-use Compact Dry™
chromogenic plates are suitable for both in-process and final product
controls.
 Ready-to-use
 Self-diffusing media - no need for a spreader
 Room temperature storage vs competitive
products with storage at temperatures less than
or equal to 8ºC
 Rigid transparent plates with removable lid - no leakage
 Innovative stacking design
 Easy to label
 Ability to subculture without damage to colonies
 Widest available parameters and broadest application
 Convenient, fast and accurate results
Amul-3 Reception Lab
Following are the test of Raw milk:
 Determination of Titratable acidity in raw milk
 Clot on boiling Test
 Alcohol Test
 Methylene Blue Reduction Test
 Fat Test
 Determination of Phosphate Activity
Acidity Test

58

The test is quick & simple. It is based on instability of the proteins when the
levels of acid & rennet are increased and acted upon by the Alcohol.
Also increased levels of Albumen {Colostrum Milk} and Salt concentrates
{Mastitis} that’s Results in a Positive Test.

Bacteria that normally developed in Raw Milk produce more or Less of Lactic
acid. In the acidity test the acid is neutralised with 0.1 N Sodium hydroxide. the
amount of alkaline is Measured. From this Percentage of lactic acid can be
calculated.
The titratable acidity test is employed to ascertain if milk is of such a high acidity
as to reduce its keeping quality and heat stability. The acidity of milk is of two
kinds.
1. Natural acidity which is due to citrates and phosphates present in the
milk and dissolved CO2 during the process of milking
2. Developed acidity which is due to lactic acid produced by the action of
bacteria on lactose in milk.
Generally the acidity of milk means the total acidity (Natural + developed) or
titratable acidity. It is determined by titrating a known volume of milk with
standard alkali to the point of an indicator like phenolphthalein. The titratable
acidity test measures the amount of alkali which is required to change the pH of
milk from its initial value of about 6-6 to 6.8, to the pH of the colour change of
phenolphthalein added to milk to indicate the end point (pH 8.3). In fact, the
method measures the buffering capacity of milk and not the true acidity.

Measuring milk acidity is an important test
used to determine milk quality. The acidity
of fresh milk is due
(Natural acidity): phosphates, casein and
whey proteins, citrates and carbon dioxide
dissolved during the process of milking.
(Developed acidity) which is due to: lactic.
acid produced by the action of bacteria on lactose in milk. Titratable Acidity: The
Acidity that results from accumulation of Natural and Developed acidity.
Milk Acidity TA%=0.12% - 0.16% the average 0.14% If it increased more than
0.16%, is an indication of lactic acid by bacteria. Acidity is expressed as
percentage of lactic acid because lactic acid is the principal acid produced by
fermentation.
Method:
1. Mix the milk sample thoroughly by avoiding incorporation of air.
2. Transfer 10 ml milk to conical flask or beaker.
3. Add equal quantity of distilled water.
4. Add 3-4 drops of phenolphthalein indicator and stir.

59

5. Rapidly titrate the contents with 0.1 N NaOH solution, continue to add alkali
drop by the drop and stirring the content till first definite change to pink colour.
6. Note down the final burette reading.
Result and Calculation:
Lactic acid %= (0.1M NaOH X vol. of NaOH (in liter) X 90.08) x 100 Weight of
the sample 90.08 g/ mol is the molecular weight of La Lactate.
Normal range =0.12% - 0.16%
Methylene Blue Dye Reduction Test
o Methylene Blue Reduction Test (MBRT) helps in evaluating the
contaminant factors as involved due to the presence of microbes in milk.
Whereas the Standard Plate Count (SPC) denotes the number of aerobic
microbes present in the milk.
o for Assessing the Raw Milk Quality Methylene Blue Dye Reduction Test,
commonly known as MBRT test is used as a quick method to assess the
microbiological quality of raw and pasteurized milk.
o This test is based on the fact that the blue colour of the dye solution added to the
milk get decolourized when the oxygen present in the milk get exhausted due to
microbial activity.
o The sooner the decolourization, more inferior is the bacteriological quality of
milk assumed to be. This test is widely used at the dairy reception dock,
processing units and milk chilling centres where it is followed as
acceptance/rejection criteria for the raw and processed milk.
Grading of raw milk based on MBRT:
MBRT test may be utilized for grading of milk which may be useful for the milk
processor to take a decision on further processing of milk.
Procedure
1. Take test tubes & pour 10 ml of milk sample in each test tubes.
2. Then labelled the test tubes.
3. Add drops of Methylene Blue Dye in each test tubes.
4. Next incubate the tubes at 37 C in water bath for 15 minutes.
5. That results absorb the colour of tubes with respect to times period.
6. If the colour is changed its means that the milk sample having contamination
and that quality of milk is not good.
7. While if there is no colour changed in the test tubes, it’s mean the quality of
concern milk sample is good.
Interpretation

60

Gerber’s test:
o Total Fat Analysis in Milk using the Gerber’s Method.
o The Gerber Method is a primary and historic chemical test to determine the fat content of
milk and other substances. The Gerber Method is the primary testing method in Europe and
much of the World. The fairly similar Babcock test is used primarily in the United States.
Although the Gerber Method also enjoy significant use in the U.S. as well.
o Fat is the most important constituent of Milk as it is used as a basis for fixing the purchase
and sale price of milk. It helps to detect adulteration like watering and skimming of milk.
Gerber’s method commonly used in Europe & India.
o Dr N Gerber of Zurich Switzerland invented this method in the year 1892-1895.In this test
H2So4 is used to increase specific gravity of milk serum which makes greater difference
between milk serum and fat globules. It also destroys stickiness of milk by dissolving all the
SNF. The free fat globules rise to the surface by subsequent application of centrifugal force
to this mixture and heat produced due to mixing of acid and milk, causing melting if fat. It
facilitates the fat particles to come to the surface freely.
o The specific gravity of the fat is 0.9 and that of acid milk mixtures is 1.43. this situation
promotes complete separation of fat when proper centrifugal force is applied.
o Due to application of centrifugal force lighter substances (Butter fat) are thrown towards
centre and rest of serum portion that is heavier is thrown towards the peripheral.
o Addition of amyl alcohol helps for separation of fat from the milk acid mixture and also
prevents the charging of fat and sugar by the H2SO4.

61

Procedure:
1. Put the clean and dry butyrometer in a butyrometer stand with open mouth upwards.
2. Run 10 ml of sulphuric acid with the tilt measure in the butyrometer.
3. Pipette out 10.75 ml of milk sample gently by the side of butyrometer, whose temperature
is about 15- 21 degrees C.
4. Pour 1 ml. of amyl alcohol with tilt measure.
5. Stopper the butyrometer with the help of lock stopper using regulating pin/guiding pin.
6. The tube is well (mixed) shaken till mahogany red colour is obtained. Keep the butyrometer
in hot water bath till it attains 15-21 degrees C and the butyrometer are placed in the centrifuge at
1100 rpm for 4 minutes.
7. Take out the butyrometer in an upright position with the stopper end down wards.
8. Keep the butyrometer in hot water bath at (65 degrees C) for some time.
9. Note the reading. Reading should be taken from bottom of the fat column to lower border of
meniscus on the scale.
Result and Calculation
The weight of the fat in the area is equal to Volume × Density = Mass
0.125 x 0.9 = 0.1125 (because density of fat = 0.9 g/lit)
If 1 % represents 0.1125 then 100 % will be represented 11.25 g.
As per this, we should be pipetting 11.25 g of milk, but there are
certain impurities due to iso-amyl alcohol, which affects the fat
reading. These impurities are estimated at 2.5-3% (average
(2.5+3)/2 = 2.667%). So the fat is 1.125-(1.125×2.667/100)
= 1.095 g.
o According to this we should be pipetting 10.95 g of milk.
This is equivalent to 10.65 ml of milk (10.95/1.02547, the denominator being the density of
milk). Since 0.1 ml residual milk remains in the glass pipette sticking to the walls, we take
10.75 ml of milk.
Alcohol Test:
o The alcohol test is used on fresh milk to indicate whether it will coagulate on thermal
processing. This test is especially important for the manufacture of UHT milk, evaporated milk
and milk powders. This test is more sensitive than Clot-on Boiling (COB) test.
o Test stability of milk to heat Processing Mineral Balance of milk
o To detect abnormal Milk- Colostrum, Late lactation and
Mastitis milks
o Milk sour/acidic- lactic acid formation by bacteria equal
quantities of milk and 68% alcohol
Mixed presence of flake or clot
o Positive test: Protein in sour milk precipitate not fit for heat
processing that’s means Rejected
o Negative Test: Indicates low acidity good heat stability of the milk sample
o Procedure
For routine testing, 5 ml milk is mixed with 5 ml of ethanol solution.

62

If the tested milk is of good quality, there will be no coagulation, clotting or precipitation.
Presence of flakes or clots indicates poor quality milk.
Clot on Boiling (COB)
o Procedure
o This Test is detected for increased acidity of Milk.
o To find out suitability for pasteurization & Boiling
o Heating small amount of milk for 5 minutes milk is sour or acidic Smell the milk for any sour
odor and observe the milk for appearance of clots/flecks.
o Result
o Precipitated milk or clots
Positive COB test: Acidity above 0.17% as a result Milk is Rejected or Handled separately
o No coagulation
COB Negative Good Quality of Milk as a result Milk can stand heating operations
The “clot on boiling test” (COB) is a test done with an inspection of the warmth stability of
milk through processing. As raw milk cannot be kept at standard room temperature or even at
lower temperature without preventing it from spoilage, pasteurisation is needed.
Interpretation
The acidity of milk that gives a positive test is generally
above 0.22% (as lactic acid) or has an abnormally high
percentage of protein like colostrums milk. Such milk
cannot stand the heat treatment in processing and is
therefore not suitable for distributing as liquid milk or
for processing. Such milk must therefore be rejected. Please take note that at high altitude
milk boils at a lower temperature. This test is not very sensitive to slightly sour milk.
Alkaline Phosphatase Test for Pasteurized Milk
o Alkaline Phosphatase is an enzyme which is Naturally present in milk, but is destroyed at a
temperature just near to the Pasteurization temperature.
o Alkaline Phosphatase test is used to indicate whether milk has been adequately pasteurised or
whether it has been contaminated with raw milk after pasteurisation.
o This test is based on the principle that the alkaline phosphatase enzyme in raw milk liberates
phenol from a disodium para-nitro Phenyl phosphate & forms a Yellow coloured complex at
alkaline p H.
o The intensity of yellow colour produced is proportional to the activity of the enzyme.
o The test is not applicable to sour milk & milk preserved with chemical preservatives. That’s
result are expressed as micrograms of phenol pre ML of milk.
o Procedure
1 ml of milk + 5 ml phosphate buffer

63

Put in water bath (37c) 20 min

o Results

AG Lab AMUL 2
AGMARK is a certification mark for agricultural produce, assuring that they
conform to a grade standard notified by Directorate of Marketing & Inspection
(DMI), Department of Agriculture, Cooperation and Farmers Welfare, Ministry
of Agriculture & Farmers Welfare under Agricultural Produce (Grading
Marking) Act, 1937.These standards differentiate between quality and 2-3
grades are prescribed for each commodity. Till date, grade standards for 222
agricultural commodities have been notified. These include fruits, Vegetables,
cereals, pulses, oilseeds, vegetable oils, ghee, spices, honey, creamery butter,
wheat, atta, besan, etc.
Certifying
agency
Directorate of Marketing and
Inspection, Government of
India

Effective
region
India
Effective
since
1986
Product
category
Agricultural products
Legal
status
Advisory
Website agmarknet.nic.in/agm_std1.htm

 AGMARK is a certification mark employed on agricultural products in India,
assuring that they conform to a set of standards approved by the Directorate of
Marketing and Inspection, an agency of the Government of
India. The AGMARK is legally enforced in India by the Agricultural Produce
(Grading and Marking) Act of 1937 (and ammended in 1986). The
present AGMARK standards cover quality guidelines for 205 different
commodities spanning a variety of Pulses, Cereals, Essential Oils, Vegetable
Oils, Fruits & Vegetables, and semi-processed products like Vermicelli.
The term agmark was coined by joining the words 'Ag' to mean agriculture and

64

'mark' for a certification mark. This term was introduced originally in the bill
presented in the parliament of India for the Agricultural Produce (Grading and
Marking) Act.
 Agmark Laboratories: The Agmark certification is employed through fully
state-owned Agmark laboratories located across the nation which act as testing
and certifying centres. In addition to the Central AGMARK Laboratory
(CAL) in Nagpur, there are Regional AGMARK Laboratories (RALs) in 11 nodal
cities (Mumbai, New
Delhi, Chennai, Kolkata, Kanpur, Kochi, Guntur, Amritsar, Jaipur, Rajkot, Bhopa
l). Each of the regional laboratories is equipped with and specializes in the testing of products
of regional significance. Hence the product range that could be tested varies across the
centres.
 Commodities and tests: The testing done across these laboratories include chemical
analysis, microbiological analysis, pesticide residue, and aflatoxin analysis on whole spices,
ground spices, ghee, butter, vegetable oils, mustard oil, honey, food grains
(wheat), wheat products (atta, suji, and maida), gram flour , soyabean seed, bengal
gram, ginger, oil cake, essential oil, oils and fats, animal casings, meat and food products.
 As an essential part of the food safety ecosystem, the Authority has created a network
of 232 laboratories to full fill its mandate on food testing and analysis. The network
comprises of 142 accredited primary food-testing laboratories from both government and
private sphere, 72 state food testing laboratories and 18 referral laboratories of which two are
under the direct control of FSSAI.
 The Act empowers the Central Government to make Rules for
(a) Fixing grade designations to indicate quality of any scheduled article.
(b) Defining the quality indicated by every grade designation,
(c) Specifying grade designation marks to represent particular grade designation
 These RAL(s) are assigned to carry out the following important functions:
(i) Analysis of research samples of agricultural commodities for framing their standards
(ii) Analysis of check samples of Agmark certified commodities for ensuring conformance
with prescribed standards.
(iii) Training to the chemists of authorised packers/approved laboratories in the grading of
agricultural commodities.
The testing done across these laboratories include
 Chemical analysis
 Microbiological analysis
 Pesticide residue
 Aflatoxin analysis.
 So, in this way can be do Agmark for any related for agriculture products and food products
but in AMUL Anand get take only 2 products for AG mark…
• Ghee
• Butter
Standards of Ghee

65

Characteristics All India In Winter In Summer
Baudoin Test Negative Negative
Phytosterol Acetate Test Negative Negative
Butyro Refractometer
Reading
40.0- 43.0 41.5-44.0 42.5-45.0
Reichert-Meissl Value Not Less Than 28.0 Not Less Than 23.0 Not Less Than 21.0
Polenske Value 1.0-2.0 0.5-1.2 0.5-1.0
Moisture % Not More Than 0.3 - -
% OF Free Fatty Acids(Oleic)
Special Grade Not More Than 1.4 - -
General Grade Not More Than 2.5 - -
TESTS TO DETECT ADULTERATION IN GHEE
Butyro refractometer reading
Properly filtered ghee whose temperature is around 40°C is taken; 2-3 drops of it are
poured in to the butyro refractometer by the side of the glass rod. Now the reading is
noted by the scale placed above the meter. Care has to be exercised to maintain the
temperature of water that is flowing over the thermometer to be at 40°C. If the
temperature deviates, then the results obtained may not be accurate.
Baudoin Test (Detection of adulteration of ghee with vanaspathi) As per the
prevention of food adulteration act, it has been made mandatory to add 5% sesame oil
to vanaspathi in order to detect the presence of vanaspathi in ghee through Baudoin
test. The principle behind the test is development of permanent crimson red colour
with furfural in the presence of concentrated hydrochloric acid in
ghee adulterated with vanaspathi.
How to detect?Take 5 g of molten filtered ghee in a test tube and add 5 ml of
concentrated hydrochloric acid and 0.1 ml furfural solution in alcohol (2%) and mix
the contents thoroughly and it is allowed to remain undisturbed for 10 min.
Development of crimson red colour shows that the ghee is adulterated with
vanaspathi.
Detection of mineral oil in gheeAbout 2 g of ghee is saponified with 25 ml of 50%
alcoholic potassium hydroxide for one hour. Then the saponified content is
transferred to a beaker containing 100 ml of water. Development of turbidity indicates
the adulteration of mineral oil in ghee.

66

Effluent Treatment Plant (ETP)
o Collection tank
The waste water from the dairy plant from various outlets is collected in one
tank and is stored for further processing. This initial storage tank is called
collection tank. The capacity of collection tank at Amul dairy plant is around
155m*3

67

o Equilization tank
Equilization tanks are holding tanks that allow for flow to be equalized over a
specific period of time. These tanks are provided in order to make the
characteristics of waste water uniform and consistent. This is done by proper
and thorough mixing pf wastewater collected in equalization tank.
The waste water discharged from various batches has different waste
characteristics such as high BOD or COD loading, different pH which can
increase the load or decrease efficiency of further treatment units. Hence the
wastewater in equalized in order to make it uniform and consistent for further
treatment units.
o Anaerobic reactors:
Once the waste in equalized, it is transferred to anaerobic reactors where
degradation of organic waste present in wastewater takes place anaerobically.
The organic matter in wastewater acts as food for the micro-organisms and thus
they degrade the organic matter in absence of oxygen. Because of anaerobic
reaction, various gases such as CH4, H2S are involved.
o Raw biogas balloon& Purification and bottling
The gases H2S, CH4 evolved in anaerobic reactors are then stored in biogas
plant balloons and then they are purified and bottled and then can be either sold
or used for energy generation purpose.

68

o New Up flow Anaerobic Sludge blanket (UASB)
The up Flow anaerobic sludge blanket reactor (UASB) is a single tank process in
an anaerobic centralised or decentralised industrial wastewater or blackwater
treatment system achieving high removal of organic pollutants.
A suspended sludge blanket filters and treats the wastewater as the wastewater
flows through it. Wastewater enters the reactor from the bottom, and flows
upward. A suspended sludge blanket filters and treats the wastewater as the
wastewater flows through it. Bacteria living in the sludge break down organic
matter by anaerobic digestion, transforming it into biogas. Solids are also
retained by a filtration effect of the blanket.
The Up Flow regime and the motion of the gas bubbles allow mixing without
mechanical assistance. Baffles at the top of the reactor allow gases to escape and
prevent an outflow of the sludge blanket. As all aerobic treatments, UASB
require a post-treatment to remove pathogens, but due to a low removal of
nutrients, the effluent water as well as the stabilised sludge can be used in
agriculture.
o New Aeration tank
The tank where raw or settled wastewater is mixed with return sludge and
aerated. Also called aeration bay, aerator, or reactor. From primary
sedimentation tank or UASB, the waste water flows to the aeration plant and is
mixed with the activated sludge.
Air is continuously introduced into these tanks either by diffused air aeration
(Air Diffusion) or by mechanical aeration or sometimes by combination of both.
o Secondary Clarifier
A secondary clarifier also called as secondary settling tank or humus tank is
used for settling the effluents from activated sludge process or from a filter and
is provided with recirculation of its filtered settled waste with larger capacities
so as to provide adequate settling time with a detention period of 1.5 to 2 hours
and overflow rate raging between 40000 to 70000 litres per sq.m
o Sludge drying beds

69

The digested sludge from the digestion tank is dewatered or dried up on drying
beds. Further disposal of sludge from drying beds is done either by dumping or
burning.
o Pressurized sand filter (PSF)
These filters are the most popular method for removal of turbidity from water.
The Pressure Sand Filter consists of a multiple layer of sand with a variety in
size and specific gravity. These Filters are designed to remove turbidity and
suspended particles present in the feed water with minimum pressure drop.
These Filters are custom designed to suit the process requirement. Waste water
flows down wards through the filter bed and as the suspended matter, which is
treated by addition of a coagulant like alum or poly electrolyte, is retained on
the sand surface and between the sand grains immediately below the surface.
There is steady rise in the loss of head over a period of time and the flow reduces
once the pressure drop across the filter is excessive. The filter is then taken out
of service and cleaning of the filter media is affected by flow reversal also called
as backwash.
To assist in cleaning the bed, the backwash operation is sometimes preceded by
air scouring by way of agitation through the under-drain system. The air
scouring agitates the sand with a scrubbing action, which loosens the intercepted
particles. The filter is now ready to be put back into service.
o Activated carbon filter (ACF)
An activated carbon filter works on the principle of adsorption. The filter
medium adsorbs or reacts with the pollutant molecules and hold them in the
filter media and mothen the filtered water is drained out. Because of the
nanopores of the activated carbon media, the pollutants remain adsorbed on it
thus giving clear water. Final treated water tank: The treated effluent from the
activated carbon filter is then stored in tank from where it can be used for
gardening, plantation or irrigation purpose.

70

Chololate Plant
Mogar

TRAINING SCHEDULE
Time: 9:00 AM to 1:00 PM[Weekly off Sunday]
No. Section Training period Reporting officer
1. Bread Spread Plant 10-14 June 24 Mr. Axit Parel
2. QA Lab 15-18 June 24 Mr. Amit Mache
3. Malt Milk Food 19-23 June 24 Mr. Rajesh Chaurasia
4. Old Chocolate 24-30 June 24 Mr. Ravi Patel

Visti to CHOCOLATE Plant
o
History

In 2018, Amul inaugurated a new chocolate plant in Mogar, Anand, near their
headquarters, with Prime Minister Narendra Modi in attendance. The new plant
has been built with an increased capacity of 1,000 metric tonnes per month
compared to the earlier 250 tonnes per month capacity. GCMMF has invested
around ₹3 billion in this project. It is a fully automated production factory with
minimal human intervention.
In 1974 Amul set up a plant to manufacture High Protein Food, Chocolate and
Malted food Mogar about 8 km south of Anand.
The union put up a Bread Spread Plant at Mogar with the assistance of NDDB in
1994 and proved that a farmer’s co-operative can also manufacture various food
products.
Mogar is the only chocolate plant in the entire network of the Gujarat Co-
operative Milk Marketing Federation (GCMMF) the apex body of all the district

71

milk unions of Gujarat that markets brand in country after Cadbury, Ferrero,
Nestle.
The Mogar plant was set up by Father of India’s White Revolution late Dr
Verghese Kurien in 1973 to prevent exploitation of cocoa bean growers of south
India, especially kerala by the multinationals.

Strengths
1.Parent Support
2.High demand of Amul Milk Cholocate
3.Can make good utilization of establishd good will
of better channel
4.Good margin of profit
Weaknesses
1.No advertisement & Promotions are made for AMUL
cholocate.
2.Raw material supply volatile prices.
3.Cholocate-comparatively small business unit.
opportunities
1.Low penetration consumption
2.Scope of launching new variants & extension.
3.Growing Population
Threats
1.Foreign multinationals.
2.Change is needed accoring to trend and
customers preferences.
3.Amul has number of competitors like Nestle,
Cadbury etc. Amul chocolate has not those
much good advertising strategies to win over its
competitors.
SWOT Analysis
of AMUL
Chocolates

72

Bread Spread Plant

Choco Buttery Spread AMUL Lite

Garlic Buttery Spread Amul Unsalted Butter

o Product Name Delicious Fat Spread
o Description
Delicious Fat Spread is characterized by a physical consistency similar to butter
and is commonly known as butter substitute. Delicious is prepared exclusively
from vegetable oils and fats
o Packing

73

100g 500g tub & Single serve pack
o Process Flowchart of Bread Spread:
Oil Phase Emulsifier Phase Aqueous Phase
Oil received in tanker Palm Oil Sweet Butter
↓ ↓ ↓
Quality testing addition of emulsifier milk
↓ (Lecithin + Distilled Monoglyceride) ↓
Storage tank [1-8] (50-60ºC) Addition of salt solution
↓ ↓
Automatic phase batch weigher Aqueous phase Blending tank
↓ ↓
Heating (72℃) in Plate Heat Exchanger Filter
↓ ↓
Storage tank A-B Plate Heat Exchanger

Hard & Soft Batch Tank (HSBT)
↓
Intermediate bland tank
↓
Duplex filter
↓
Plate heat exchanger (72+ 2
o
C)
↓
Balance tank
↓
High pressure Triplex Pump
↓
Cool (below-15 to -18
o
C) in perfector
↓
Resting tube (21
o
C)
↓
Packing machine (butter parchment paper)
↓
Online check weigher
↓
Metal detector
↓
Card board packing
↓
Storage in cold storage (below 4
o
C)
o CIP
It is done after every 15 days.

74

24 hr all line, all tank Hot water flashes
↓
1% costic soda
↓
0.5% nitric acid
↓
Flashing all tank & pipeline
↓
Still the normal water pH
↓
Outlet water
↓
Laboratory test (pH 7.5)

o Nutritional Information (Amount per 100gm)

Energy, Kcal 680
Total fat, gm 75
Total carbohydrate, gm 0.7
Added sugar, gm 0
Sodium, mg 750
Saturated fat, g 37
Added Vitamin A, mcg 900
Added Vitamin D, mcg 5

o Product Features
It is Contains O Cholesterol
Fortified with vitamins A & D
Delicious fat spread is a preferred choice for people with cardiac ailments due to
zero Cholesterol level.
This is widely used as a Low cost substitute for butter.
o Application
For use as a butter substitute in all applications.
Suitable for use as a cooking medium. Can be heated to high temperatures.
Ideal as a spread on bread/Toasts/Sandwiches. For shallow frying or sauteing
(Frying quickly in a little fat).

75

For use as topping on variety of items, viz; pav-bhaji, parathas, khichari, pulao,
soups etc.
o Ingredients:
Annatto bixin colour, vitamin A & D premix, butter flavour blend, butter milk,
palm oil/fat, citric acid- maintain the PH 5.2 to 5.6, pro sorbate.
o Shelf life:
Best 9 months under in refrigeration from packing, when stored refrigerated at 9o
C.
o Product Name: AMUL Lite
o Description
AMUL Lite milk fat spread is India’s 1
st milk fat spread and the only one that us
made wholly from milk and dose not contain any vegetable oil unlike other fat
spreads available in market.
It Contain approx. 20% lower fat and calories than butter pr margarine.
So, you can now enjoy the delicious, creamy taste without worrying about the extra
calories.
o Features
Amul Lite Milk Fat Spread is made from AMUL Butter and does not Contain any
Vegetable Oil.
Its light and just right. Enjoy a delicious creamy spread without worrying about
the calories.
It can be used to bake, saute and cook various dishes also.
o Shelf life:
Best 9 months under in refrigeration from packing, when stored refrigerated at 9o
C.
o Nutritional Information (Amount per 100gm)

Energy, Kcal 587
Total fat, gm 65
Total carbohydrate, gm 0.3
Added sugar, gm 0
Sodium, mg 725
Protein, g 0.1

76

Malt Milk Food
Amul Pro
Product Name Amul Pro
Description Malt Based Food
Packing 500 g cube jar: The cube jar is a unique
pack in the category, giving Amul PRO a
distinct advantage of standing out of the
clutter on retail shelves.
Composition Ingredients: Malt extract (42%), sugar,
Milk Solids (7%), Caramel, Cocoa Solids
(2%), Permitted emulsifiers, Raising
agent(E500), DHA and Salt
Nutritional Information Approx values per 100g
Energy 392 kcal
Energy from Fat 19.8 Kcal
Fat 2.2 g
Saturated Fat 1.3 g
Trans Fat 0 g
Carbohydrate 85.0 g
Added Sugar 32.7 g
Dietary Fibre 0.7 g
Protein 8.0 g
DHA 3.0 mg
Shelf Life Amul PRO is best before 12 months
from the date of manufacture when
stored in a cool, dry and hygenic palce
Storage Condition Ambient

o Amul PRO is a Malt based milk additive, which not only enhances milk’s
nutritive value but also makes milk a very tasty drink for people of all ages,
especially kids, who need milk and nutrition for healthy growth. It comes from
the house of Amul, the brand which is known all over for providing quality
products at value for money price.
o Whey Protein: Muscle Building & Immunity
Whey Protein is the purest and most essential form of protein. It is easy to digest
and helps muscle building and nurturing growth. Why Protein is often referred
to as “Fast Protein” provides quick nourishment to muscles, helping your child
strengthening the immunity and stay healthy.
o DHA:
Brain Development Docosa hexa aenoic Acid is an essential fatty acid
required for optimal development and function of the brain, eyes and central

77

nervous system of a child. It plays an important role in enhancing your child’s
immunity by protecting it from allergies like Asthma.
 Process Flowchart:
Raw Material
↓
Kettle:1 sugar, caramel, cocoa flavour
(2 hr, 91±1°C)
↓
Kettle: 2,3: low fat powder, cheese whey powder, salt
(30min at 50-55°C)
↓
Filtration tank
↓
Evaporator (4-5hr, 55°C)
↓
Spreading machine (1 tray- 2.5-3 kg)
↓
Vacuum dryer (75-90°C for 2hr) (1 dryer- 42 tray)
↓
Cooling (at room temperature for 45 min)
↓
Scrapping & Grinding
↓
Sampling (Moisture 2-4%)
↓
Bulk bag filling (25 kg pack)
↓
Hopper
↓
Packaging (Temp- 26°C, humidity- 40%)
↓
Metal detector
↓
FFS machine (pack in pouch,500gm)
Rollatainer machine (500gm plastic jar)
 Specifications:
Constituents Specification
Moisture (%) Max 4.0
Protein (%) Min 11.5
Fat (%) Min 8.0

78

Total ash (%) Max 5.0
Acid insoluble ash (%) Max 0.1
Solubility (%) Min 90.0
Cocoa powder (%) Min 5.0
Total bacterial count cfu/g Max 50,000
Coliform count in 1g product Max 10
 CIP of Plant:
Hot water 90-100°C 1hr
Caustic soda Conc. 0.05 1hr
Hot water 90-100°C 1hr
o CIP done after every 25 batch.
o Trays are washing every Sunday.
o Shelf life: 12 months when stored at cool, dry & hygienic place
o Price: 20 Rs/50 gm
o The preparation of malted milk consists of combining milk with the mash liquor
resulting from a mash of barley malt and wheat flour. Barley malt not only
supplies the malt flavour, but also contains diastase, which converts starch into sugar.
Briefly the process may be divided into the following stages:
1.Production of mash liquor:
The malted barley is sieved to remove dust and other foreign matter. It is then
crushed using in line roller mill and mixed with high-grade wheat flour. Usually
about 2.5 times as much dry barley malt is used as wheat flour. The mix is
conveyed to mash tanks, where water at 40°C is continuously added to prepare
uniform slurry.
The slurry is continuously heated and stirred and the temperature gradually
increased to 70°C within about 40 min. The slurry is held at 70°C for about 35
min. During this process the whole of the starch is hydrolysed by diastase,
present in malted barley, into maltose, dextrin and malto-dextrins, while the
complex cereal proteins are converted into simpler protein substances.
The slurry temperature is gradually raised to 78°C and held at this temperature
for about 20 min to stop further activity of enzymes and also to achieve
maximum cereal solids (28-30%). The mash is Passed through centrifugal
separator to remove the insoluble husk and to obtain clear liquor, known as
‘wart’.
2.Mix preparation:
The wart derived from the mashing section is mixed with predetermined
quantities of standardized milk, diluted and pasteurised (85°C) malt extract,
sugar, salts, minerals and vitamins in a mix preparation tank. Milk solids

79

increase nutritional value of the product by providing high quality fat, proteins,
minerals and vitamins.
o Milk fat enhances flavour and energy level of final product. Malt extract provides
desired level of colour and typical caramelized flavour to the finished product.
Salts are added to optimize product pH to improve digestibility, enhance flavour
and to provide essential salts, especially calcium. The percentage contribution of
each ingredient depends upon final formulation of the product.
3.Evaporation and drying:
The mix at about 26% solids is concentrated in the vacuum evaporator until one
half to two-thirds of the water content has been removed. The product is then
transferred to a steam jacketed evaporator provided with stirring gear, where a
high vacuum is maintained, and agitation being constant in order to facilitate the
removal of the water and to prevent excessive caramelization.
The concentrated mass with an average of 80% solids is finally dried within a
level of 2% moisture to a sponge-like, swollen mass usually in a vacuum tray
drier. Dried product is cooled in an air-conditioned room to avoid moisture pick
up, scrapped off the trays and milled into fine powder.
The milled product is conveyed to inline mixers to mix salts, dry vitamins and
minerals and then packed in bottles or refill packs. Malted milk powder will
dissolve freely in hot or cold water or milk, the resultant beverage being very
palatable besides possessing an agreeable odour and flavor derived from the
hydrolysed cereal starch used in its manufacture.
4.Spray Drying of Malted Milk
The malted milk food is generally prepared by tray-drying method under vacuum that is
essentially a batch operation and hence adds to the cost. Spray drying method will reduce the
cost of product owing to high volume of continuous and automated operation.
Thus the production of good quality, low cost malted milk
food with improved physical characteristics like better
dispersibility and wettability appears to be better proposition
for the dairy industry to consider, than continuing off with
the traditional tray-drying method. The concentrate from
first stage evaporation at average 50% solids is atomized
using either rotary or nozzle atomising system. Malt-milk
based food products are highly hygroscopic, due to high
level of added or process converted sugars. Proper drying
of these products is possible using modified design of three
stage dryers, preferably having an air-broom system. In view
of product quality and hygienic standards, spray-drying
process is a potential future technology for drying malt-milk
based food products to meet local as well as international
requirements.
o Ingredients:
Malt extract (42%) Caramel
Sugar milk solids (10%) Cocoa Solids Salt
Whey solids (7%) Permitted Emulsifiers DHA

80

Old Chocolate
o Chocolates are manufactured at Food Complex facility. The chocolates are
manufacture in two plants. First plant is old chocolate plant and second plant is
new chocolate plant.
o In old chocolate plant the most processes carried out are manually done while in
case of new chocolate plant it is completely different here the plant is fully
automatic less labour is required in new chocolate plant compared to old
chocolate plant.
o Many varieties of chocolates are manufactured like: Dark Chocolate, Milk
Chocolate, Dark Compound Chocolate, Milk Compound Chocolate, Enrobed
Bars and Assorted Chocolates.
o Today the golden foil packaging has been replaced with modern sealed packs to
keep the chocolate contents intact & the flavors fresh. Amul has introduced more
than 40 new chocolate products including variants of milk, dark & white
chocolate, chocolate syrup & baking chocolate.
o A big leap from 6 small packs to an entire range of delightful treats and loads of
research that gave way to new product development.
o Cocoa beans are main ingredient for production of chocolate. The chocolate
production process consists of fermentation, drying, roasting, grinding of cocoa
beans, mixing of all ingredients (cocoa mass, sugar, cocoa butter, emulsifiers,
aroma, and milk components if needed), Conching, and tempering. Major
chemical reactions occur during fermentation, drying, roasting of cocoa beans,
and Conching of chocolate mass.
o These reactions are the most important for flavore and aroma development.
Fermentation of cocoa beans is a process in which growth of yeasts and bacteria
occur in the pulp and it is conducted at cocoa plantations as a part of the cocoa
beans’ production.
o In this stage, breakdown of sugars and mucilage occurs. It consists of three
phases: The first phase is dominated by anaerobic yeasts and lasts for 24–36
h. In this phase, low content of oxygen and low pH (<4) are present.
o the second phase is dominated by lactic acid bacteria. They are present from
the beginning but become active between 48–96 h.

81

o Third phase is dominated by acetic acid bacteria when aeration increases.
During this last phase, an exothermic reaction (conversion of alcohol into acetic
acid) occurs, responsible for a temperature rise (50 °C or higher). These phases
of cocoa bean fermentation are; Fermentation is the key stage for the production
of precursors for development of proper chocolate aroma.

o Drying of cocoa beans is conducted after fermentation to lower the moisture
content and complete oxidative processes induced during fermentation of cocoa
beans. After drying, cocoa beans have 6–8% moisture. Low moisture content
prevents mold growth and makes the beans more stable for transport and
storage. Roasting of cocoa bean is usually conducted in a chocolate factory as a
first stage of chocolate production.

82

o It is a high temperature process, usually conducted at temperatures between 120
and 140 °C, which is important for the occurrence of Maillard reactions.
Roasting reduces contents of undesirable components, produces chocolate-
specific aroma and flavor, and decontaminates the cocoa beans.
o In this phase, all precursors formed in the previous phases react and form
numerous compounds. Grinding and mixing of all chocolate ingredients are very
important for achievement of the right particle size of all ingredients.
o The main ingredients used in chocolate production are cocoa liquor (obtained
by grinding cocoa beans), cocoa butter (obtained by pressing cocoa liquor),
sugar, and milk (in the case of milk chocolate).
o Conching is a mixing and heating treatment that is conducted to produce liquid
chocolate (all solid particles are coated with fat), evaporate volatile acids, achieve
a proper viscosity, remove excess moisture, and develop a desirable color.
o Tempering is a process by which to obtain a stable product. Tempering is
conducted thermally and results in stable and consistently sized crystals of cocoa
butter which then affect growth of a stable crystalline network during cooling.
o Process Flowchart of Chocolate
Cocoa powder, sugar, SMP
↓
Pre refiner
(2 roller 28-30°C, size reduction 200 micron)
↓
Refiner
(5 roller temp- 26°C, 26°C, 45°C, 55°C, 28°C)
↓
Conching
(Time- 7 to 8 hr, 50-60°C)
↓
After 7hr add cocoa butter, flavour, emulsifier (soya lecithin)
↓
Chocolate storage tank (Capacity- 4T)
↓

83

Tempering (31°C)
↓
Depositor (plastic in mould)
↓
Cooling through cooling tunnel
↓
Demoulding (Flipping the mould plates)
↓
Metal detector
↓
Packaging (Temp25°C)
↓
Cold Storage (Temp- 16 to 18°C)
o Types of Chocolate:
Major category Sub category Variants
Amul chocolates

Classic dark chocolates

55% dark (150g, 40g, 15g,
100g,
250g)
75% dark (150g)
90% dark (150g)
99% dark (125g)
Premium dark chocolate

Tropical orange 55% dark
(150g)
Fruit n nut 55% dark (150g,
40g)
Mystic mocha 55% dark (150g)
Green T 55% dark (150g)
Sugar free 55% dark (150g,
35g)
Exotic milk variants

Milk chocolate (150g, 40g,
20g,12g,
100g & 250g gable top)
Belgian milk chocolate (125g,
35g)
Camel milk chocolate (150g)
Hazelnut chocolate (150g)

84

Raisin N almond (150g)
Choco cracker (150g)
India origin milk
chocolate(125g)
Exclusive white chocolate

Super fruit (150g)
White limon (150g)
Amul wafer bar
chocolates

Dark passion (15g &300g tub)
Bindaaz (15g)
Amul Mini
Chocolates

Chocomini (250g)
Chocozoo (250g)
Amul filled bars

Almond bar (35g)
Energy bar (40g)
Amul syrups

Chocolate syrup (650g,250g,
30g
sachet)
Amul Institutional
chocolate

Dark chocolate (500g)
Milk chocolate (500g)
White chocolate (500g)
Choco chips packet (5kg)
Types of Chocolate
1) Almond Bar

85

o Ingredients:
Sugar, liquid glucose, cocoa butter, almond, milk solids, cocoa solids,
common salt permitted emulsifier and acidity regulator, added flavour
(artificial flavouring substances vanilla).
o Shelf-life: Best before 12 Month from packing when stored at 15-20
o
C in dry
place.
o Nutritional Information (Amount per 100gm)
Energy, Kcal 471
Total fat, gm 19.8
Total carbohydrate,
gm
66.7
Added sugar, gm 36.1
Saturated fat, gm 0.1
Trans fat, gm 0
Protein, gm 1)
Nutritional information of Almond Bar
2) Chocozoo / Choco mini

o Ingredients:
Sugar, hydrogenated edible vegetable fat, (plant kernel/oil) milk solids, cocoa
solids, permitted emulsifiers, contains added flavor (artificial flavoring substances –
vanilla).
o Shelf- life: Best before 12 Month from packing when stored at 15-20 C in a dry
place.
o Nutritional Information (Amount per 100gm)
Energy, Kcal 545

86

fat, gm 31.2
Saturated fat, gm 27.1
Trans fat, gm 0
Total carbohydrate, gm 60.7
Added sugar, gm 51.1
Protein, gm 5.5
Nutritional information of Chocozoo / Choco mini

2) Amul Milk Chocolate (smooth & creamy )

Amul Milk Chocolate
o Ingredients:
Sugar, milk solids, cocoa butter, cocoa solids, permitted emulsifier, contains added
flavors (artificial flavouring substances – cocoa & vanilla).
o Shelf – life: Best before 12 months from packing when stored at 15–20o C in a
dry place.
o Nutritional Information (Amount per 100gm)
Energy, Kcal 550
Total fat, gm 32.6
Saturated fat, gm 12.8
Trans fat, gm 0
Total carbohydrate, gm 55
Added sugar, gm 40
Protein, gm 1.2
3)Bindaaz

87

Amul Bindaaz
o Ingredients:
 Choco layer: sugar, partially hydrogenated refined vegetable oils, milk solids,
cocoa solids & permitted emulsifier.
 Water 47 %: wheat flour, sugar, partially hydrogenated refined vegetable oils,
milk solids, emulsifier, raising agent & flour treatment agent.
 Contains permitted synthetic food colour and add cocoa, condensed milk, vanilla,
& strawberry flavours.
 Shelf – life: Best before 9 Month from packing when stored at 15-20o C, store
in cool, hygienic & dry place.
 Nutritional Information (Amount per 100gm)
Energy, Kcal 521
Total fat, gm 25.8
Saturated fat, gm 4.3
Trans fat, gm 0
Total carbohydrate, gm 66.4
Added sugar, gm 50.7
Protein, gm 5.7
Nutritional information of Amul Bindaaz
4) Dark Choco Slab

Dark Choco Slab
 Ingredients:
Sugar, refined hydrogenated vegetable fat, cocoa powder & permitted
emulsifier (E492 & E322).
 Shelf - life: Best before 12 Month from packing when stored at 15-20
o C in a
dry place.

88

 Nutritional Information (Amount per 100gm)
Energy, Kcal 543
Total fat, gm 30
Total carbohydrate,
gm
61
Added sugar, gm 50
Protein, gm 4
Nutritional information of Dark Choco Slab

5) Dark Chocolate

 Description
Amul Dark chocolate is made with the finest ingredients and delicious cocoa.
For the better texture, the finest particle size is achieved through World class
refining, leaving you to indulge in the exquisite taste of rich dark.
 Composition
Sugar, Cocoa Solids, Cocoa Butter, Permitted Emulsifiers, also
contain added Flavours Substances like Cocoa & Vanila.
 Nutritional Information
Energy, Kcal 557
Total fat, gm 33.7
Total carbohydrate,
gm
57.3
Added sugar, gm 43.0
Protein, gm 6.0
Nutritional information

89

 Shelf - life: Best before 12 Month from packing when stored at 15-20
o C in a
dry place.
o Receiving – visual inspection, use of chemical free materials, building
maintenance
o Splitting – Magnetic separator, sanitized equipment, personal hygiene
o Fermentation– visual inspection, regular maintenance of fermentation tanks
o Drying – visual inspection, observation of time and temperature
o Roasting – correct time and temperature to kill pathogens
o Grinding – visual inspection, sanitization of equipment
o Conching – visual inspection, proper maintenance of equipment
o Tempering – visual inspection, sanitized equipment
o Moulding – ensure moulds are clean
o Packing – metal detection, food grade inks, appropriate packaging materials,
correct labelling.

90

QA Lab
o In the QA lab, raw material analysis, in process checks, finished product analysis,
packing test, water analysis, air Quality checking are done. Quality Assurance also
monitors the overall hygiene of the plant. It also confirms the legal specification
of the product Manufactured.
Equipment in Chemical Lab
o Weighing balance
o Micro balance
o Lovibond Tintometer- Strength of Colour
o pH meter o Moisture balance
o Melting point Apparatus
o Soxhlet’s Determination Apparatus
o Planetary Mixer
o Electric Heater
o Water Bath
o Electronic Digital Micrometer
o Deep Freezer Equipment In Microbiological Lab
o Laminar Air Flow Chamber
o Double window incubator
o Autoclave o Hot Air Oven
Tests done for products:
1) Bread Spread
Raw material Analysis:
o Vegetable oil – value, Peroxide value, Moisture, Slip melting point & colour
o White butter – Fat, Moisture
o Emulsifier
o Lecithin, Acid value, Benzene insoluble matter, Moisture
o Antioxidant, TBHQ – Solubility
o Vitamin A + D3 – QA certificate
o SMP – Colour, Taste, Appearance, Moisture
o Salt – Visible impurities (procured from ISI Certified supplier)
In process checks:
o Standardization of the emulsion – Moisture and Fat
o Running packing line – Moisture, Salt, Acid value and unsaponifiable matter
o Finished product analysis – Weight, Heat sealing integrity, Declarations,
Organoleptic test, Moisture, fat, Salt, Unsaponifiable Matter, Acid value & Shelf
Life (6 months).
2) Chocolate
Raw material Analysis:
o Cocoa Powder-Moisture, fat, Sieve test
o Cocoa Butter-FFA

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o Vegetable Oil- Acid value, peroxide value, Moisture
o Sugar-Physical Appearance, Moisture
o Choco Whip- Moisture, Ash o Emulsifier
o Milk Powder- Physical Appearance, Moisture, fat
o Flavour-Test Certificate
o Liquid Glucose-pH, TS
o Almond & Raisin- Taster, Infestation, Foreign matter, size
In process checks:
o Conching - Moisture
o Molding – Fruit & Nut %
o Enrobing - % chocolate coating
o Packing – all packing parameters
o Finished product analysis – Weight, Heat sealing integrity, Declaration,
Organoleptic test, Moisture, Fat, Protein, Salt & Shelf life (2 years).
3) Malted Milk food
Raw material Analysis:
o Malt Extract- Organoleptic test, Sediments, Acidity, Protein, TS
o Cocoa Powder – Moisture, Fat, Total Ash, Acid insoluble Ash
o Cocoa Butter- Fat, FFA, Slip melting point
o Milk Powder- Physical Appearance, Moisture, Fat
o Caramel – Neutral Tannin test, Acid tannin test, phosphoric acid test, Density,
Test certificate, Emulsifier
o Sugar-- Physical Appearance, Moisture
In process checks:
o Evaporation-TS
o Drying-Organoleptic test, Reconstitution test
o Scraping-Iron Particles
o Finished product analysis- Organoleptic test, Reconstitution test, Burnt & Iron
Particles, Milk Coagulation, Moisture, Fat, Protein, Solubility
Methods used for the assessment:
• Swab method
• Air sampling by exposure method
o Microbial contamination of food Microbial contamination is the most common
type of food contamination. It can be done if the food is contaminated by
microorganisms such as bacteria, viruses, mold, fungi, and toxins.
o Many reasons lead to microbial contamination that including undercooking
chicken, storing and preparing raw foods near to ready-to-eat food, and this
leads to cross contamination. Also, the vectors of biological contamination
include food handlers and that can be caused by aerosol droplets from coughing
near the production line.
o Moreover, vectors include packaging materials, equipment, and tools used; an
example of this is using the same cutting board and knife in raw food and ready-

92

to-eat food. Contaminated water is also an important factor to cause microbial
contamination.
o Furthermore, pests such as insects and rodents are factors of contamination.
Therefore, food hygiene practices must be implemented to prevent
contamination that including personal hygiene, separating raw and ready-to eat
food at all stages of processing, washing raw fruits and vegetables, and pest
control on the premise.
Chemical contamination of food
o Chemical contamination is any food contaminated by a chemical agent. For
example, food is contaminated by cleaning agents and that can happen when
using chemical cleaning during processing or when using chemical cleaning on
tools and not cleaning well.
o Furthermore, there is natural chemical contamination such as toxins in some
fish, such as methyl mercury. Also, contamination can happen in agriculture
production when they spray fertilizers and pesticides close to food when it is
growing. Therefore, it must be ensured that chemical agents are away from the
food area.
o Always follow the manufacturers’ instructions before using chemicals. Food
must be covered when cleaning and dealt only with approved chemical
suppliers. There are many potential chemical contaminations related to
chocolate that can happen at any stage of the food chain, which includes the
existence of environmental contaminants such as pesticides above the allowance
level, as well as presence of food additives in dark chocolate or heavy metals or
addition of food additives, which are not permitted for use by government
regulations.
o This type of contamination, either industrial contaminants or pesticides, is most
commonly related to chocolate products in Africa, South America, and Asia.
Physical contamination of food
o Physical contamination of food is any food that contains a foreign object at any
stage of the production process. That foreign substance causes health issues for
consumers, such as broken teeth or choking. There are many food products
recalled every year because of physical contamination, which causes consumers
health issues and costs less.
ELISA READER:
Product name
o Total Aflatoxin ELISA Kit
o Detection method
o Colorimetric
o Assay type
o Competitive

93

o Sensitivity 0.02 ng/ml Assay duration
o Multiple steps standard assay
o Product overview
o This Total Aflatoxin ELISA Kit (ab285282, E4747) is based on the Competitive
ELISA method. It can detect Aflatoxin (AF) in samples, such as grain, peanut,
formula feed, etc.
o The microplate provided in this kit has been pre-coated with coupled antigen.
During the reaction, AF in the samples or standard competes with coupled
antigen on the solid phase supporter for sites of anti-AF antibody.
o Then Horseradish Peroxidase (HRP) conjugate is added to each micro plate
well, and TMB substrate is added for color development. There is a negative
correlation between the OD value of samples and the concentration of AF. The
concentration of AF in the samples can be calculated by comparing the OD of
the samples to the standard curve.
o PRO-Clean™ is the easiest and most accurate way to verify the cleanliness of
food equipment surfaces. Simply swab a surface and release the reagent.
o If protein residue is present, the reagent will turn purple – the more
contamination, the quicker the color changes and the darker it becomes. PRO
Clean instantly validates surface hygiene, allowing immediate corrective action
to be taken.
o Clean-in-place (CIP) is an automated method of cleaning the interior surfaces
of pipes, vessels, equipment, filters and associated fittings, without major
disassembly. CIP is commonly used for equipment such as piping, tanks, and
fillers. CIP employs turbulent flow through piping, and/or spray balls for large
surfaces.
o As a food, dairy, or beverage processor, you understand the importance of
maintaining a hygienic process environment to ensure product quality and
purity.
o That’s where a good Clean-in-place (CIP) System comes in. CIP systems have a
vital role in processing because of the need to keep processing components free
of bacteria.

94

o Cleaning occurs in process piping, tanks, heat exchangers, and other equipment
to prevent product contamination and maintain processing efficiency.

o Every CIP cleaning cycle has its own unique set of parameters, so there’s really
no such thing as a “typical” CIP cycle. The elements, sequence, and duration of
the cleaning process can vary widely from one system to another, but some
common steps are included in most cleaning cycles.

95

CONCLUSTION

This training report is a culmination of all activities done by us at Amul Dairy,
Anand. It was a matter of pride for us to be a part of Amul Dairy, Anand. AMUL
spurred India’s White Revolution, which made the country the world’s largest
producer of milk & milk products.
Here in AMUL, we learned about the practical working at the Industrial level and
the various problems that can occur and the different ways to troubleshoot them.
During the course of training at AMUL dairy, we got the chance to compare
theoretical knowledge with practical realities.
I am proud of getting the chance to do my training in this beautiful and very reputed
dairy. This training experience will help me to become a better food technocrat in
near future. I hope that Amul Dairy,
Anand always Run on the path of success.

thAnK You

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