Haldiram_IPT_Presentation_On_process.pdf

Packaging and all the details of how the haldiram are best in nagpur and how the process are done in hardilarm

1. IN PLANT TRAINING PRESENTATION
2023-24
AT HALDIRAMS FOODS INTERNATIONAL PVT.
LTD, NAGPUR
SUBMITTED BY
JANHVI A. DAHABLE
ROSHNI R.GADE
PRASHANT S. SAWATKAR
AJAHAR T. SHAIKH

2. OVERVIEW OF DAIRY PLANT
Haldiram’sFoods International Pvt.Ltd.
➢Establishment -1970
➢Owner and Chairman –Mr Vivek Agrawal.
➢Plant Location –Gumthala, Bhandararoad Nagpur (MH).
➢Capacity –5 lakh lit/ day.
➢Unit Name –vivekFoods Ethnics pvt,ltd.
➢Vivek unit establishment –2020.
➢Plantsetupby Gea.
➢SCADA by Schenell.

3. Milk Procurment
•The total reception through tankers is 160000 litres
•The route of milk collection through tanker includes.
•Milk Procured From Ramtek, mauda, Tumsar, Hingna, Railway sindhi,
kampte.
•Total milk collection –2 to 2.5 lakh lit. per day.
•Total No. of BMCs -6.
•Total No. of chilling centers –3
•Collection from simple unit –60000 to 70000 lit/ day

4. RAW MILK RECEPTION DOCK
▪Haldiram’sDairy received milk by tankers as well as in milk cans .
▪Haldiram’sdairy collect daily milk about 2 to 2.5 lakh lit per day( morning
and evening.)
▪Both Cow milk and Buffalo milk is received .
▪RMRD consist of –
1.Unloading
2.Sampling
3.Testing
4.Weighing

5. Milk Reception by Cans at RMRD
Cans of farmers and milk collection Centre.
Milk can conveyor
Remove the lids Of Cans
Collect milk sample(Lab test)
Milk is dump from cans by tipping bar
Nylon filter ( 60 Mesh )
Weighing tank
Nylon filter
Dump tank

6. MILK PROCESSING SECTION
•Following Processes are Performed inprocessingsection.
1)Pasteurization
2)Homogenization
3)Standardization
4)Separation
5)Bactofugation
6)Chilling

7. Milk Reception by Tankers at RMRD
Tanker
weighing bridge
Milk sampling & plungeringpoint
RMRD lab
Unloading of tanker
Pump (7.5HP)
Filters (stainless steel, nylon, magnetic)
Milk chillier
Silo

8. MILK FLOW CHART FOR 20 KL PPASTEURIZER

9. Equipments in processing section
SR NOEQUIPMENT CAPACITY COMPANY
01
MILK PHE 1 20KL Gea
03
MILK PHE 2 20KL Gea
04
Cream PHE 1 3 KL Gea
05
Homogenizer 1 20 KL Gea
07
Cream Separator 1 20 KL Gea
08
Cream Separator 2 20 KL Gea
09
Bactofuge machine 20KL Gea
10
HMST (5 UNIT) 75 KL Gea
11
Cream Tank ( 2 unit )30 KL Gea

10. FILL PACK SECTION
➢Thereare6milkPackagingmachine
and10headofPackaging.Machineis
operatedmechanically.
➢EveryMachinehascapacitytopack
500pouches/Hrs.
➢Thereare2Packagingline.
➢4machinesareofNichromeFilpack
andremaining2areofsamarpun

11. Standards for Packing milk at Haldiram’sDairy
➢Pouch milk have the shelf life of max 3 days from date of packaging .
Types of MilkFAT SNF
Cow milk 3.6 8.6
Tonnedmilk 3.1 8.6
DTM 1.6 9.6
FCM 6.6 9.1
Standardizedmilk4.6 8.6

12. MILK PRODUCTS SECTION
•In Haldiram’sfoods international Pvt .Ltd ‘following products are
manufacture.
1.Dahi
2.Shrikhand
3. Butter milk
4. SMP powder
5.Ghee and Butter
6.UHT

13. 1. Dahi
•Dahiis made by bacterial fermentation of milk. In this fermentation process
lactose in milk converted into lactic acid by using desirable bacterial culture.
Parameter Vynjancup kadhipouch
Taste & FlavourPleasant & AcidicPleasant & Acidic
Texture Uniform Uniform
Milk Fat Min 3.5-4 % for cupMin 0.3-0.4 %
for pouch
MSNF Min 11.4-11.5 %
forcup
Min10.4 % for
pouch
Milk Protein Min 3.6 % for cup Min3.3% for
pouch
Acidity %LA 0.7 –1.0 % 0.7 –1.0 %
Moisture by wtMax 86.5 % for cup Max89.5 % for
pouch
pH 4.2 -5.0 4.2 -5.0

14. Flow chart of Dahimanufacturing
Receiving milk
Filtration
Heating of milk
(90 ⁰C for 10 min)
Storage
preheating 43+2*
Inoculation of starter culture(1-1.5%)
Packaging
Incubation
(at 42+2 ⁰ C for 4 Hrs)
Blast cold room (-10 ⁰ C for 2 Hrs)
cold room
(below 5⁰C )
Dahi(0.7-1.0 %LA)
Standardization
(Fat 3.5 % and
SNF 10.5%)
Homogenization
(I ststage 1400
psi & II ndstage
600 psi)
•Dahiis made by bacterial fermentation of milk. In this fermentation process
lactose in milk converted into lactic acid by using desirable bacterial culture.

15. 2. Shrikhand
•Chakka is a fermented, intermediate dairy product obtained during the
production of Shrikhand
•Chakka is the base material for the production of shrikhand, Amrakhand.
•Shrikhandis a semisoft whole milk product prepared from lactic acid
fermented dahi.the dahiis partially strained through a cloth to remove the
whey and thus produced a solid mass called chakka& It shall not contain any
added colouringand artificial flavouringsubstances .
•Its shelf life is 3 months ,when stored below -10⁰C.
Product Raw Ingrediants
Shrikhand Chakka, Badam, sugar, cardamom, Pista, Jayhal, Salt.
Amarkhand Chakka,Sugar , hapusraja amras.

16. Flow chart of shrikhandmanufacturing
Receiving of milk from RMRD
Filtration
Pasteurization 90
0
C/15sec)
Cooling (@40 to 45⁰C)
Inoculation (culture @ 1 to 1.5 % )
Incubation (40 to 45⁰C for8-10 hr)
dahi(0.7-1.0% LA)
Hanging (10-12 hrs)
Chakka
Seaving
Storage ( At -10⁰C)
planetary mixer (Addition of ingredients)
Shrikhand
Packing
Metal Detector
Weighing
Storage (less than -10
0
c)
Standardization
(fat 3.5% ,SNF 9.0%)

17. Standards of Shrikhand
Parameter Standard
Moisture max42%
Fat Min 8.5%
Ash Max 0.9%
Protein Min9.0%
Acidity Max1.4 %
Sugar Max 72 %
Standards of Amrakhand
Parameter standard
Moisture Max45%
Fat Min 7%
Ash Max 0.9%
Protein Min9.0%
Acidity Max1.4 %
Sugar Max72 .5%

18. Butter
•Buttermaybedefinedasafatconcentratewhichisobtainedbychurning
cream,gatheringthefatintoacompactmass,andthenworkingonit.Butter
sectionisveryimportantasithandlesfat,whichisthecostliestconstituent.
Thecreamobtainedfromprocesssectionisfullyutilizedforbuttermaking.
•Whitebutterisusedforproductionofghee&oftensuppliedforbulk
demand.Butterismadebyusingbutterchurn(batchmethod)aswellasby
ContinuousButterMakingmachine(CBM).
•Types of butter :-
1.White butter

19. standards
Standard White butter Tablebutter
Colour Whitish tinge Light yellow
Taste and flavour Pleasant,freefrom off odour
and rancidity
Pleasant,freefrom off odour
and rancidity
Acidity Max 0.06 % LA Max 0.06 % LA
MSNF Max 1.5% Max 1.5%
Milk fat Min 83 % Min 80 %
Texture Smooth Smooth
Added salt Nil Max3 %

20. Flow diagram of manufacturing of Butter
Pasteurized cream in storage tank (max 7-
13°c) fat 37-42% fat
Transfer of cream to CBMM machine
Churning Of Cream
Butter from CBMM outlet⟶Butter milk
Sampling & analysis of butter
Packaging
Weighing
Storage in cold storage at -18 °C
Dispatch

21. Ghee
•Process Overview:
•Butterreceivedfromthebuttersectionismeltedat60-70°C.
•InWhitebutter,fatis82%.
•Granulationofghee
•The melted ghee on cooling forms a large coarse grain suspended or clustered in
a liquid phase. The slow cooling & agitation of ghee to 18-20°C in 2-3 hours
gives smaller granules
Standards Parameter
Colour Goldenyellow
fat 99.8–99.9 %
Moisture Max 0.3 %
FFA 0.35–0.50 %
RM Value Min 28
PV Value Max1-2

22. Flow chart of ghee by prestartification
Pasteurized cream in storage tank
(max 7-13°c) fat 37-42% fat
Transfer of cream to CBMM machine
Butter milk Churning Of Cream
Butter
Melting Vat 70℃
Holding Coil
Ghee Boiler
Settilngfor 30 min
At 40℃ add cultured ( 0.5-1 %0
Heating upto110-112℃ observed berry
colour
settilngit for 30 mins
Filtration-
Settling tank
Holding for 5 Hrs
Ghee Clarifier
Storage @ 50-55ºc
packaging @ 40ºc
Granulation@ 21-24°
Ghee

23. Powder section
•In haldiram’sskimmed milk powder & whey powder are prepared by spray
drying.
•The Dryer is planted by Gea .
•The Milk Powder Section , dryer has capacity of 8 Tones per day and
evaporator has the capacity of 10Tones per day Production .
•The Evaporator is falling film type with 3 effect .
•The Dryer is of three stages (Drying Chamber, IFBD, EFBD) with Rotary
wheel atomizer.

24. OPERATING PARAMETERS
PARAMATERS SMP Whey
TS%OFCONCENTRATE 48 -50 54 -58
DENSITY OF
CONCENTRATE(kg/m
3
)
1240 –1260 1110 -1120
CONC.FEEDING RATE
(kg/hr)
5700 4700
CONC.FEEDINGTEMP(
0
C) 55-65 65-70
DRYERINLLETTEMP(
0
C) 180-190 180-190
DRYEROUTLET(
0
C) 72-75 80-84
NECKCOOLINGTEMP(
0
C) 40-45 40-45
SHIFTERMESHSIZE(micro
meter)
40 40
PACKAGINGTEMP(
0
C) BELOW 40 BELOW 40
STEAMPRESSURE(kg/cm
2
) 18 19
DRYINGRATE(kg/hr) 1200-1300 1200-1400

25. Flow chart
Milk Silo
Balance tank (5KL)
filter
preheater (45°)
PCD (70°)
Regenerative flash vessel-I (75°)
DSI (85-90°)
Regenerative flash vessel-II 78°
cyclone separator
NTP
Calandria 1 (65°)
vapourseparator-I
Calandria 2 (55°)
vapourseparator-II
Calandria 3 (52°)
vapourseparator-II
Dryer feed storage tank
Dryer

26. Spray Drying

27. Air filter (HEPA ) Dryer feed storage
Air delivery fan filter
Steam Radiator Hot Air Drying ChamberCycloneseparator
IFBD
EFBD Exhaust Fan
Shifter
Packaging Recovery room
Metal detector
Storage
Air supply

28. Product Manufactured in Powder plant.
Parameter SMP Whey
Moisture% max 3.5 max 3.3-4
Total Solid % Min 96 Min 96
Bulk Density g/ml 0.48-0.52 0.50-0.55
Fat by mass Max 1.5 Min 2.0
Protein ( on SNF basis )Min 34 Min 10
TitratableAcidity ( % LA )Max 1.5 Max 1.2
Insolubility Index Max 1.5 Max 1.5
Total Ash Max 8.2 Max 9.5
Scorched Particle A A

29. UHT
•UHT treatment is used to increase the shelf life of the products.
•Plant capacity-1lakhltr/ day.
•The milkisutilised to improve the shelf life of product and making nutrition reach products.
•Uhttreatment is given by two types sterilization and retorting.
Retorting process for bottle flavoredmilk.
•Capacity-2000 ltr.
•Pressure –15-20psi.
•Hot watertemp–145-150°
•Retort time-118-120°for18min.
•Steam temp –145-180°.
•320 bottle in one tray and six tray in each batch.
•After retorting it kept to cool up to 60°c in retort after that it removed and cool at ambient
tempfor1hr

30. Process Flow chart for chocolate milk
Receiving milk
Heating of milk
Addition of pectin and maintain the temp at 80°Holding for 15-20 min at 80°c
Addition ofsugar and chocolate syrup
Cooling upto40°c
Addition of flavour
Standardize thebatch
Cool upto15°c
Transfer toretort( 118-120°for 18 min)
Transfer to packing

31. EFFLUENT TREATMENT PLANT ( ETP ) SECTION
water Inlet effluent
Bar screen
Decanter EquilizationTank
DAF
UASB Feed Tank Gas Holder
UASB Tank Gas flare
Aeration Tank
Second Clarifier
Sand Filter
Activated Carbon filter
Treated water
Storage tank

32. Standard of treated water:-
Parameters Standard
Temperature Below 50
0
C
p
H
5.5-9.0
TDS Max 2100 mg/lit
TSS Max 100 mg/lit
COD Max 250 mg/lit
BOD Max 30 mg/lit
Chloride Max 600 mg /lit
Sulphate Max 1000 mg/lit

33. WATER TREATMENT PLANT ( WTP ) SECTION
•Water treatment plant is used to optimized most water based industrial
processes, such as heating, cooling, processing, cleaning, and rinsing so that
the risk of contamination of product should be reduced.
•In Haldiram’sDairy around 25-30 lakh lit water treated through WTP every
day.
Equipments Capacity Use
Raw water Tank 2500000 Ltr
Soft water storage tank100000 Ltr
Sand filter - Used to remove the sand, soil, small stones etc.
CarbonFilter - Used to remove the smell and fine impurities.
Resin filter - Used to remove dissolved minerals i.g.
calcium, potassium, magnesium
etc .

34. WTP Flowchart
Water from DAM/LAKE/CANOL
Pump ( 7.5 HP )
Raw water storage tank
Sand filter
Activated carbon filter
Resign filter
Soft water storage tank
Soft water transfer pump ( 40 HP )
Soft water to different sections
REVESE OSMOSIS PROCESS
Soft water after resign filter
Sand filter
Cartage filter
Pump ( 4 HP )
RO Membrane
Retaindent
Raw water tank
UV lamp
Storage Tank

35. Boiler
•Boiler is an enclosed vessel in which fluid such as water is heated to produce steam
or the vaporized form of liquid.
Sr.no. Parameter Standards
1 Boiler type Combipac
2 Manufactured by Thermax
3 Fuel Wood chips/ Biomass
4 Set point pressure 23 kg/cm
2
5 Capacity 15 tone
6 Efficiency 70%
7 Temperature of flue
gas
160-180
0
C
8 Furnance Fluidized bed
9 Coal GCV 3500-3800 Kcal/kg
10 FurnanceTemperature 850-900 *C

36. Flow chart for boiler
Coal
Hopper
Coal Crusher
Moving Conveyor
Floor Storage ( 50 ton Capacity )
Conveyor Belt
Bucket Elevator
Live Bottom Bunker
Coal Feeder
Furnace 800-900ºc
Memory Panel [ Tubes contains –Water
Shell contains –Flue gases ]
Feed Water Shell [ Tubes contain –
Flue gases
Shell containsWater]
STEAM
FlueGases
Steam Header
APH
Steam to Different Section
Bag Filter
Cyclone
Chimney

37. Thank you