INDUSTRIAL ATTACHMENT at Aanchal Dairy N.D.U.S.S. Lalkuan

MOTTO of Organisation: “of the people, by the people, for the people”
Uttarakhand Co-operative Dairy Federation Ltd:
Uttarakhand Co-operative Dairy Federation Ltd (UCDF Ltd.) is an apex level state federation of district milk Co-operative unions in the state of Uttarakhand.

It was established in the year 2001, under registration no:555,Dated 12-03-2001, with its head office at Mangal Parao, Haldwani (Nainital) for the successful implementation of the dairy programmes in the state. Product branding is "AANCHAL“.

The UCDF Ltd came into existence as a successor body to the Uttar Pradesh Co-operative Dairy Federation Ltd. after the formation of Uttarakhand as 27th state on 9th Nov, 2000.

The UCDF Ltd is registered under the Uttarakhand state cooperative act in the year 2001.

1. INDUSTRIAL ATTACHMENT (Horticulture Work Experience) HWE-101 Presented By:- Vikas Tiwari UUHF/16031 COLLEGE OF HORTICULTURE , VCSG UTTARAKHAND UNIVERSITY OF HORTICULTURE BHARSAR, PAURI GARHWAL (UTTARAKHAND) Presented To:- Er . Tejas A. Bhosale 1

2. INDUSTRIAL ATTACHMENT PROGRAMME AT “ AANCHAL DAIRY” MOTTO of Organisation : “of the people, by the people, for the people” 2

3. Introduction:- Uttarakhand Co-operative Dairy Federation Ltd: Uttarakhand Co-operative Dairy Federation Ltd (UCDF Ltd.) is an apex level state federation of district milk Co-operative unions in the state of Uttarakhand . It was established in the year 2001 , under registration no:555,Dated 12-03-2001, with its head office at Mangal Parao , Haldwani ( Nainital ) for the successful implementation of the dairy programmes in the state. Product branding is "AANCHAL“. The UCDF Ltd came into existence as a successor body to the Uttar Pradesh Co-operative Dairy Federation Ltd . after the formation of Uttarakhand as 27th state on 9 th Nov, 2000. The UCDF Ltd is registered under the Uttarakhand state cooperative act in the year 2001. 3

4. About Aanchal dairy:- Location Lalkuan Height above Sea Level  600 Mtrs. Dairy Establishment 16-10-1949 Handling Capacity 100000 Ltr . No. of Chilling Centre 5 Chilling Centre Capacity 50000 Ltrs ./ Day Special Product Packed Milk, Dahi , Chhach , Ghee, Paneer , Cream, Khoya , Butter Organised Societies  551 Type of milk procured Mixed milk Number of retail sellers 890 Mode of procurement Milk cans and milk tankers Total Membership 27520 Average Procurement  79679 Ltrs ./ Day Average Sales (Milk)  71087Ltrs./ Day 4

5. SR. No. Milk Union Address 1 Almora Dugdh Utpadak Sahakari Sangh Ltd. Patal Devi Almora 2 Chamoli Dugdh Utpadak Sahakari Sangh Ltd. Simali 3 Dehradun Dugdh Utpadak Sahakari Sangh Ltd. Raipur Road 4 Haridwar Dugdh Utpadak Sahakari Sangh Ltd. Shikarpur ( Landhaura ) 5 Nainital Dugdh Utpadak Sahakari Sangh Ltd. Bareilly Road Lalkuan 6 Garhwal Dugdh Utpadak Sahakari Sangh Ltd. Dhobighat Pauri Road 7 Pithoragarh Dugdh Utpadak Sahakari Sangh Ltd. Vin 8 Tehri Dugdh Utpadak Sahakari Sangh Ltd. H- Block, New Tehri 9 Udham Singh Nagar Dugdh Utpadak Sahakari Sangh Ltd. Kanjabagh Road Khatima District- U S Nagar Pin-262308 Uttarakhand 10 Uttarkashi Dugdh Utpadak Sahakari Sangh Ltd. Matli 11 Aanchal Cattle Feed Factory Kichha by pass Road, Rudrapur 12 Uttarakhand Co-operative Dairy Federation Ltd Mangal Parao 13 Champawat Dugdh Utpadak Sahkari Sangh Ltd Jup Patva 5

6. Objectives of Training:- To find that how the production is taking place in Aanchal i.e;The PRODUCTION UNIT. To study the techniques or methods used for testing the qualities of the milk. Besides these objectives one can get a lot of knowledge in every field related to the food industry establishment. To interact with the industrial personal. Study of milk and milk products from a food science and public health perspective . It also provides an insight into quality control (both chemical and microbiological) analysis of processed milk undertaken in the laboratories of dairy firm, ensuring production and distribution of safe and fresh milk and various milk based products as per demands of the consumers in the city, township. 6

7. VISION OF AANCHAL :-  Organization system works in “ Three Tier System ” i.e. village, district and state level 7

8. Objectives Of Aanchal :- To build and develop village level institutions as cooperative model. To channelize marketable surplus milk from the rural areas to urban deficit areas to maximize the returns to the producer and provide quality milk and milk products to the consumers. To ensure provision of inputs for milk production inputs, processing facilities and dissemination of technical know-how. To carryout activities for promoting Production, Procurement, Processing and Marketing of milk and milk products for economic development of the farming community. To provide technical consultancy to its member milk unions for upgrading their infrastructure and product range. Skill Enhancement of dairy workers and associate producer members, through organized training programme . Strengthening of veterinary infrastructure in the village and provide training in cattle management at village level. 8

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11. Milk chain in Dairy:- 11 Milk Production Milk Procurement Bulk tank & Chilling centers Raw milk receiving and laboratory test Boiling and Processing Milk and milk products & intermediate products Packaging Storage CIP (CLENING IN PLACE) ETP ( EFFLUENT TREATMENT PLANT) Marketing & Distribution Consumer

12. Daily Activity:- 12

13. PRESENT STATUS:- DAIRY PRODUCTS SALE MILK 71,08,7Ltrs./ Day GHEE 1,20,721 kg/year BUTTER 22,316 kg/year CHEESE/PANEER 2,42,247 kg/year CURD 11,38,686 kg/year Source :- www.anchalmilk.com 13

14. Working of Factory:- COLLECTION OF THE MILK (PROCURATION) Milk is collected from the societies. Milk is weighed. Sample of each society’s milk is sent to the laboratory for testing. LABORATORY TESTING SNF and fat % is being calculated. Testing of any Adulteration in milk PROCESSING After the collection of the milk and testing in laboratory, milk is sent for pasteurization before getting treated for different uses. PACKING SECTION Packing of milk, curd and desi ghee is fully automated. Packing of butter, cream, cheese is not automated, it is done manually. DISPATCH After packing, all products are dispatched in vans to different markets as per demand. TECHNICAL STAGES Here after the use of milk for different purposes, the left out part is being treated so that it may not harm the environment. 14

15. The  ' Aanchal ' brand has been registered by the Government of India. 15

16. PAYMENT TO THE SOCIETIES:- Payment to the societies - based on the Fat and SNF part of the milk Societies then distribute money to individual farmers Payment is made ₹35/litre of milk having 6% Fat and 9% SNF ₹280 is paid per kilogram of Fat and ₹186 is paid per kilogram of SNF part in the milk Amount is paid on weekly basis in the bank accounts of societies Money can be withdrawn only when signature of both incharge and field supervisor is present 16

17. Procuration of Milk The milk is procured through the village dairy operatives, which collects milk from different areas- Ramnagar , Bazpur , Rudrapur , Kiccha , Khatima , Halduchaur , Chorgalion , Lamachaur , Jamrani , Haidakhan , Shantipur , Champawat , Bhowali , Almora , Pithoragarh 78,000 litres of milk is procured per day from following centres – Lalkuan – maximum contribution including 20,000 litres at night,21,000 to 22,000 litres in the morning . Rest milk is procured from 3 chilling centres . 2. Choi ( Ramnagar )-16,000 litres 3. kaladhungi -13,000 litres 4. Hedia gaon (Near bhowali ) -14,000-15,000 litres . Milk Tankers from Chilling Centers Milk in cans from Procurement centers 17

18. Ground level info of Procurement center A visit to local procurement center of Aanchal at Ratanpur Village, kaladhungi was made. The Milk is collected two times a day within each Procurement center, mainly in morning and evening hours. Process:- Milk is firstly weighed in cans while filtering it with sieve. A sample of mixed milk taken in viles . The sample is then homogenized and mixed well. The sample is placed then in “MILK ANALYZER MASTER MINI” used for testing Fat, SNF, Protein, Density, Temperature of milk. A light frequency sound indicates the completion of process. A Printed slip with all exact values and price of milk obtained is provided to farmer. A record of all the milk suppliers is made. All the collected milk is then transported to the nearby chilling centres in big cans. Milk Procurement from Local Dairy farmers 18

19. Weighing the quantity Mixing with agitator Quality Evaluation with lactoscan Evaluated Result Payment slip Payment slip provided to farmer Record maintained 19

20. LABORATORY WORK Sampled milk is tested for- 1. SNF ( Solid not Fat) Equipment used: Lactometer Temp. Of milk 30°C. Sample is filled in Lactometer and it gives the reading of density of milk . 2. Fat % Equipment used: Butyrometer FAT %: Whole milk: 6.1% Standard milk: 4.5% Toned milk: 3.1% Double toned milk: 1.5% 20

21. FAT % Test:- Temp. Of milk 27°C. 90ml H 2 SO 4 taken- butyrometer . Milk sample is added. 1ml ethyl alcohol is added. Agitated for uniform mixing in agitator @1100 rpm. After agitating for 5 min sample is observed. Fat gets separated and rises up . For bulk sampling “MILK ANALYZER MASTER MINI” is used for testing Fat, SNF, Protein, Density, Temperature of milk. 21

22. 3) Pasteurization:- The stored milk after weighing and chilling at 4°C is Pasteurized. Pasteurization is a process of heating a food, usually a liquid, to a specific temperature for a definite length of time and then cooling it immediately. This process slows spoilage due to microbial growth in the food. Pasteurization of milk was suggested by Franz von Soxhlet in 1886. The two main types of pasteurization used today are: “High-temperature, short-time” (HTST) . “Low temperature Long time”(LTLT). The HTST process, milk is forced between metal plates or through pipes heated on the outside by hot water, and is heated to 71.7°C (161°F) for 15–20 seconds. LTLT treatment- T˚: 62.5℃ (144℉ ) for 30 min. 22

23. Pasteurization Process:- PASTEURIZATION & STORAGE UNIT 23

24. 4) ORGANOLEPTIC TEST Procedure Open a can Smell Immediately Observe the appearance Taste but do not swallow the milk Check cleanliness of the can lid and milk can . 5) ALCOHOL TEST Procedure Mix equal amounts of milk and 68% of ethanol solution in a test tube 68 % Ethanol solution is prepared from 68 ml 96% (absolute) alcohol and 28 ml distilled water Good quality of milk will show no coagulation, clotting or precipitation, but it is necessary to look for small lumps First clotting can be seen at 0.21-0.23% Lactic acid 2 ml milk is mixed with 2 ml 68% alcohol 24

25. 6) Lactoscan Procedure:- Pour the preliminary prepared sample in the sample holder of the analyzer Put the sample holder in the recess of the analyzer Press the enter button The analyzer sucks the milk, makes the measurement and returns the milk in the waste liquid reservoir 7) Adulteration Tests Different adulteration tests are performed only when procurement is done from sources other than trusted societies Performed with the help of adulteration kit Different adulterants that can be identified are – Urea, Ammonia, Fertilizer, Pond water, Starch, Sugar, Glucose, Salt, Neutralizer, Peroxide, Maltose. Lactoscan analzser Adulteration detection kit 25

26. Aanchal Products:- Liquid Milk Skimmed Milk Double Tonned Milk Tonned Milk Standard Milk Full Cream Milk High Fat Milk Products Ghee Butter Coagulated Milk Products Paneer Cultured Milk Products Dahi /Curd Mattha Other Milk Products Khoya 26

27. 1) Liquid Milk Processing:- Milk Processing unit 27

28. Types of Milk:- Type Colour of Packet Fat% (max) SNF% (Min) Energy (k cal) Protein (g) Carbohydrate(g) Fat(g) Ca(mg) Full cream milk Green 6 9 89 3.3 5.1 60 150 Standard milk Red 4.5 8.5 73 3.1 4.8 4.5 142 Toned milk Blue 3 8.5 59 3.1 4.8 3.1 142 Double toned milk Yellow 1.5 9 46 3.15 5.1 1.5 150 Skimmed milk/ janta milk Violet 0.5 8.7 33 3.2 4.9 0.1 145 28

29. Cream Separation:- According to demand of BUTTER, the milk after pasteurization is used separate cream from milk with the help of “ CREAM SEPARATOR ”. Cream separator consist 136 conical shaped plates which spins with milk and separate cream from milk. The cream less or fat less milk is called “SEPARATED MILK” or simply SEPARATA . The separated milk is stored in containers. Further the cream is pasteurized with water (1:1 ratio) and forwarded for processing CREAM SEPARATOR CONICAL PLATES 29

30. High Fat Milk Products:- 2) White Butter:- “Butter” means the fatty product derived exclusively from milk of Cow and/or Buffalo With or without added common salt and starter cultures of harmless lactic acid and/or flavour producing bacteria. Pleasant taste and flavor , free from off flavor and rancidity May contain permitted food additives It is packed in the 15gm, 100gm, and 500gm packets in the markets. The cream undergoes churning process inside the churner where milk is heated with water. This churning process takes place at 9-10°C and after butter preparation, water and SNF are separated. Product Specifications Min. Fat% - 80% Max. Curd (SNF)% - 1.5% No added salt & No added colour Processed butter Ready for packaging 30

31. Giving shape to butter packets Weighing, Filling & sealing of Packets Churner Butter packets 31

32. 3) Ghee :- “ Ghee ” means the pure clarified fat derived from milk or curd or from desi (cooking) butter or from cream to which no colouring matter or preservative has been added Prepared butter is used to prepare ghee. Butter is heated @ 30℃, when come in liquid form it is clarified. Collected in cans after clarification and sent to packaging unit . Sealing of ghee packets Heating Tank Clarification Tank Sealed packets 32

33. Coagulated Milk Products:- 4) Paneer “ Paneer ” means the product obtained from the cow or buffalo milk or a combination thereof by precipitation with sour milk, lactic acid or citric acid In AANCHAL , Paneer is prepared manually, no machine is used. For acidity production citric acid is used . Moisture – Not more than 70% (dry basis) Milk fat – Not less than 50% (dry basis) Aanchal Paneer 33

34. Weighing Cutting in required shapes Filling and sealing Paneer Packets 34 34 Raw chilled milk (<7  C) Standardization Heating (80 + 2  C) (CCP 1) Coagulation Hooping Pressing (45 min.) Immersion in chilled water (5  C/30 min.) Packaging Storage (<7 ) (CCP 2)

35. Cultured Milk Products:- 5) Dahi :- “ Dahi ” means the product obtained from pasteurized or boiled milk by souring, natural or otherwise, by a harmless lactic acid culture obtained by curdling (coagulating) milk with an edible acidic substance such as lemon juice or vinegar, and then draining off the liquid portion. Milk that has been left to sour (raw milk alone or pasteurized milk with added lactic acid bacteria or yeast) will also naturally produce curd. For curd making a culture is needed . Culture used in Aanchal dairy: Lactococus lactis , Streptococcus thermphilus , Lactobacillus bulgaris . May contain added cane sugar Shall have same minimum percentage of milk fat and milk solids not fat as the milk from which it is prepared 35

36. Curd Preperation Unit Coding units for Curd Cups Prepared Cups Laser Printing 36

37. HOT CHAMBER (TEMP:- 40°C) COOL CHAMBER( TEMP:- 4°C) 37

38. 6) Mattha / Chaach :- This refers to desi buttermilk, which is the byproduct obtained when churning curdled whole milk with crude indigenous devices for the production of desi butter ( Makhhan ) The only difference in the process of chhach and mattha is that chhach has no added ingredients in the form of salt, zeera or black pepper General specifications:- Heating of Milk: 90°C Incubation: 40°C Fat%: 0.5% SNF: 24.16 38

39. Mattha Preperation Unit 39 Standardized Toned Milk in the double jacketed vat Heating (93 + 2  C) (CCP 1) Cooling (37 + 2  C) Addition of culture (1%) Incubation (40 + 2  C/6hrs.)(CCP 2) Adding pasteurized chilled water (<7  C) Homogenization (1000psi) Addition of Salt, Zeera & Black Pepper Packaging Storage (<7  C) (CCP 3)

40. 7) Khoya Khoya is a coagulated product obtained from cow or buffalo milk, or a combination thereof, by rapid drying The milk fat content should not be less than 20% of finished product The optimum moisture content should be 35-40% ( danedar ) Heating and Concentration (85 + 3  C) 40

41. CLEANING-IN-PLACE (CIP):- Preperation of solutions:-

42. TIMINGS OF CIP:- 42

43. E.T.P. (EFFLUENT TREATMENT PLANT) Anaerobic Biological System is the mode of Effluent Treatment being used in the dairy plant at Lalkuan Capacity of ETP is 20000 litres per day 43

44. Annual turnover of AANCHAL Source:- Aanchal sale & turnover report, 2017-18 . 44

45. Product Quantity Market price( Rs ) Milk Full cream milk 1 lit 50 500 ml 27 Standard milk 1 lit 42 500ml 24 Toned milk 1 lit 39 500ml 22 Double toned milk 1 lit 40 500ml 19 Skimmed /janta milk 200ml 25 Curd 100gm 10 200gm 17 400gm 32 1kg 60 5kg 240 PRICES OF PRODUCTS: 45 Product Quantity Market price( Rs ) Paneer 200gm 62 500gm 145 1kg 310 Butter 100gm 37 500gm 180 600gm 240 Ghee 200ml 90 500ml 215 1 lit 430 C ream 1 kg 320 Khoya 1kg 300 Source:- Aanchal revised price report , Jan 2020.

46. 46 Fig.: REVISED PRICES OF PRODUCTS. Source:- Aanchal revised price report , Jan 2020.

47. Various Programmes are implemented in the rural areas:- Emergency veterinary services Natural fertilization. Artificial fertilization. Vaccination. Prevention of sterilization in cattle. transplantation balanced cattle feed distribution, fodder (seed) distribution. In the year 2018-2019, 22,437 cattle were given treatment in 400 veterinary camps. Besides it, Primary Veterinary medicines worth Rupees 15 Lacks were distributed to Dairy Committees in 2018. 47 Source:- Aanchal annual report

48. Points for comparison Anchal Dudhyias Pvt. dairies Local sales   1.Procurement Penetration in villages through societies in the villages Collections from households Collections from other places where it is cheaper Collection from own households 2.Transportation Van Cycles or bikes Middleman through vans Cycles or walk 3.Time of processing Once/twice Twice twice Twice 4.Selling through Agents Self Dealers Self   5. Points of sale outlets Home delivery outlets Home delivery     6. Customers Salaried Class, tea stall, restaurants, Institutional sales Salaried Classes, tea stalls Salaried Class, institutional sales Wage Class, restaurants and hotels 7.Mode of payment   Cash Monthly system cash Monthly system 8.Bargaining on MRP NO Yes Yes Yes MARKETING 48

49. Marketing related problems:- Absence of screening system – Zoonotic, adulteration, contaminants- spoilage of entire batch if one can go undetected. A small quantity of adulteration while procuration may cause large amout of losses and defect to te entire batch of milk . Gap in information- Era of IT- Dairy sector is unorganise d ; No proper record keeping- No back tracking Lack of Infrastructure- Chilling plants and Bulk coolers to prevent spoilage Crate leakage was 0.1 per cent . Vehicles going to Bageswar (80-km from Almora ) depicted leaking problems higher than average due to friction in crates. Leakage loss was 1.0 to 1.5 per cent in the polythene packs . There were two prominent seasons when demand supply fluctuations were very prominent. From Oct- Jan, production was more and hence forth supply was more but demand was less. Hence, excess milk was supplied to Mother Dairy via NMG agreements at lower prices. This led to a crash in procurement prices from farmers and paved the way for farmers demotivation. From April to June, milk procurement decreased due to decline in productivity . But demand increased and rates started skyrocketing . Again, this led to entrance of private players in the market for earning more profits through the channel. 49

50. Comparative Sale Report From 1 st January 2019 To 31 st January2020 S.NO. Particulars Year 2019 Year 2020 Growth % 1 Milk Standard 1438532 1338664.2 - 6.94 2 Full Crème 181764 201845 11.05 3 DTM 500 ml 6511 7940.5 21.96 4 Milk Tonned 500 ml 10985 15071.5 37.20 5 Milk Tonned 1000 ml 2642 2454 -7.12 6 Skim Milk 40808.4 40877.1 0.17 7 STM Milk 1000 ml 743039.5 962208 29.5 Total 2424281.9 2569060.3 5.97 Source:- Aanchal Comparative sale report 1 st Jan 2019 TO 31 st Jan 2020 . 50

51. S.NO. Particulars Year 2019 Year 2020 Growth % 1 Curd 100 Gram 2291.6 1927.8 -15.88 2 Curd 200 Gram 41626.6 33282.2 -20.05 3 Curd 400 Gram 23892 19603.6 -17.95 4 Curd Mast 1 KG 4944 3788 -23.38 5 Butter 15 Gram 625.95 533.4 -14,79 6 Butter 100 Gram 686.6 697.3 1.56 7 Paneer 1000 Gram 10630.5 9743 -8.35 8 Ghee 1000 ml 7540 8178 8.46 9 Ghee 500 ml 7921.5 9027 13.96 10 Ghee 200 ml 1293 1413 9.28 11 Loose Ghee 195 30 -84.62 51 Source:- Aanchal Comparative sale report 1 st Jan 2019 TO 31 st Jan 2020

52. 52 Source:- Aanchal Comparative sale report 1 st Jan 2019 TO 31 st Jan 2020.

53. Suggestions:- Focus on strengthening the indigenous breed to help significantly enhance productivity. Training of the people involved in the ground level procuration, against the different levels of adulteration involved in milk , by performing different adulteration test and thus ultimately savingthe entire batch of milk from getting adulterated and preventing further losses. Ensure good prices of milk to farmers. Encourage farmers for good feeding, hygienic milking & planned infrastructure housing for milking animals. Provide effective services related to quality feed, germ plasm and vet. Services. Increase number of member farmers. Decrease losses - due to poor management at village levels , which leads to heavy losses and ultimately loss in faith. 53

54. WHAT I HAVE LEARNT? Processing of milk and its products. Storage Quality control. Industrial management. Knowledge regarding manufacturing process of curd, butter, paneer, pasteurised milk. about the vivid process and infrastructure by an industry to produce according to public interest. Acquired the knowledge of milk processing. How an industry process maybe controlled by automation system 54

55. THANKS  55