Industrial Training at UCDF (Aanchal Dairy)

Establishment of N.D.U.S.S. – 28th October, 1948
Establishment of industry – 1963
Type of milk procured – Mix milk
Mode of procurement – Milk cans and milk tankers
Number of societies – 526
Average procurement of milk per day – 79679 litres
Procurement Centres – Ramnagar, Kotabagh, Ramgarh, Bhimtaal, Betaalghat, Dhaari, Okhalkanda, Haldwani, Almora etc.
Number of retail sellers – 890
Certificates associated with the industry – Quality Management System (ISO 9001:2008) and Food Safety Management System (ISO 22000:2005)

1. INDUSTRIAL ATTACHMENT
(Horticulture Work Experience)
(HWE-101)
SUBMITTED TO: Er. Tejas A. BhosaleSUBMITTED BY: Siddharth Khanna
ID No.: 16039
COLLEGE OF HORTICULTURE BHARSAR
VCSG UTTARAKHAND UNIVERSITY OF HORTICULTURE
& FORESTRY
PAURI GARHWAL
1

2. INDUSTRIAL TRAINING
AT
AANCHAL DAIRY, NAINITAL DUGDH
UTPADAK SAHAKARI SANGH LIMITED,
LALKUAN
2

3. 1.Introduction
2.Products
3.Layout
4.Utilities
5.Production and Safety Management
6.Laboratory Tests
7.C.I.P. (Cleaning-in-Place)
8.E.T.P. (Effluent Treatment Plant)
CONTENTS
3

4. INTRODUCTION
4

5. •Establishment of N.D.U.S.S. –28
th
October, 1948
•Establishment of industry –1963
•Type of milk procured –Mix milk
•Mode of procurement –Milk cans and milk tankers
•Number of societies –526
•Average procurement of milk per day –79679 litres
•Procurement Centres –Ramnagar, Kotabagh, Ramgarh, Bhimtaal,
Betaalghat, Dhaari, Okhalkanda, Haldwani, Almora etc.
•Number of retail sellers –890
•Certificates associated with the industry –Quality Management
System (ISO 9001:2008) and Food Safety Management System
(ISO 22000:2005)
A GLANCE ON DAIRY
5

6. DAIRY PRODUCTS SALE
MILK 71,087 Ltrs./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
PRESENT STATUS
6

7. Daily Activities.
•Collection of milk from nearby places and different societies.
•Milk is poured in dump tank.
•Milk testing is done for calculating Fat and S.N.F in milk by
taking samples.
•Then Pasteurization is done to kill the bacteria and other
microbes present in milk.
•Chilling is done at <5°C temperature for 1 hour with a
capacity of 10,000 liters milk/hr in ‘Plate chiller’.
•Then milk is packed in Polythene sachet.
•Several other milk products are also made.
7

8. PRODUCTS
Liquid Milk
Skimmed Milk
Double TonnedMilk
TonnedMilk
Standard Milk
Full Cream Milk
High Fat Milk
Products
Ghee
Butter
Coagulated Milk
Products
Paneer
Cultured Milk
Products
Dahi
Mattha
Other Milk Products
Khoa
8

9. PRODUCTS
9

10. •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
PAYMENT TO THE SOCIETIES
10

11. LAYOUT
11

12. 12

13. 13

14. BASIC UTILITIES
OF DAIRY
14

15. •Potable water is available.
•Source –tubewell (underground water).
•Annual quality checks performed by certified laboratory.
WATER
15

16. •Solid fuel fired boiler
•Manufactured by INDCON
•Fuel –mixture of wood and coal
•Number of boilers –2
•Horizontal construction
•2 multistage centrifugal feed water pumps
BOILER
16

17. Refrigeration Cycle –
•Remove heat from the evaporating refrigerant.
•Convert it into liquid state.
•Repeatedly continuous process.
•Gas is compressed and condensed at the normal temperature.
•Done by compressors requiring mechanical energy.
•Refrigeration cycle steps –
–Receiver
–Expansion Valve
–Evaporator
–Compressor
–Condenser
AMMONIA REFRIGERATION
CYCLE
17

18. PRODUCTION
18

19. Product Min.Fat% Min.SNF%
RawMilk >3.5 >8
SkimmedMilk 0.5(max.) 8.7
DoubleTonedMilk 1.5 9.0
TonedMilk 3.0 8.5
StandardMilk 4.5 8.5
FullCreamMilk 6.0 9.0
1. LIQUID MILK
19

20. Raw milk receiving
Chilling (<7C) (CCP 1)
Reconstitution and
standardization
Pasteurization
(78+2 C/16sec.) (CCP 2)
Packaging
Storage (<7C) (CCP 3)
Milk Processing
Unloading of
milk
Filling in
vessels.
Packaging
material.
Storage in cold
chambers.
20

21. HIGH FAT MILK PRODUCTS
21

22. •“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
Product Specifications
•Min. Fat% -80%
•Max. Curd (SNF)% -1.5%
•No added salt
•No added colour
2. BUTTER
22

23. Take Chilled and pre-
heated milk
Cream separation
Pasteurization of cream
(90+2 C) (CCP 1)
Ageing (15-16hrs.)
Churning
Packaging
Storage (<-10+2 C)
(CCP 2)
23

24. “Ghee” means the pure clarified fat derived from milk, curd, desi
(cooking) butter or from cream to which no colouring or preservative
has been added
3. GHEE (CLARIFIED BUTTER)
24

25. Butter
Heating
(110+3 C) (CCP 1)
Settling
Packaging
Storage
(<-10+2 C)
Packing of ghee packets.
25

26. COAGULATED MILK
PRODUCTS
26

27. •“Paneer” means the product obtained from the cow or buffalo milk
or their combination and is made by coagulation with sour milk,
lactic acid or citric acid.
•Moisture –Not more than 70% (dry basis)
•Milk fat –Not less than 50% (dry basis)
4. PANEER
27

28. 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 C) (CCP
2)
Heat sealing of Paneer packets.
28

29. CULTURED MILK PRODUCTS
29

30. •“Dahi” is the product obtained from pasteurized or boiled milk by
souring it naturally or otherwise, by a lactic acid culture
•May contain added cane sugar for sweetness.
•Shall have same minimum percentage of milk fat and milk solids.
5. DAHI
30

31. Standardized Toned Milk in
the double jacketed vat
Heating (93+2 C) (CCP
1)
Cooling (37+2 C)
Addition of culture (1%)
Packaging
Incubation
(40+2 C/2.5-3hrs.) (CCP 2)
Storage (<7 C) (CCP 3)
31

32. Adding culture to milk
32

33. •This refers to desibuttermilk, which is the byproduct obtained when
churning curdled whole milk with crude indigenous devices for the
production of desibutter (makhhan)
•The only difference in the process
of chhachand matthais that chhach
has no added ingredientsin the
form of salt, zeeraor black pepper
6. MATTHA / CHAACH
33

34. 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)
34

35. Double jacketed vat
35

36. Heating in containers
36

37. •Khoa 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)
9. KHOA
37

38. Receiving milk
Heating and
Concentration (85+3 C)
Scrapping of Khoa
Cooling (<7 C)
Packaging
Storage (<7 C)
38

39. Heating and Concentration of milk.
39

40. Product Quantity Marketprice(Rs)
Milk
Fullcreammilk 1lit 50
500ml 27
Standardmilk 1lit 42
500ml 24
Tonedmilk 1lit 39
500ml 22
Doubletonedmilk 1lit 40
500ml 19
Skimmed/jantamilk 200ml 25
Curd 100gm 10
200gm 17
400gm 32
1kg 60
5kg 240
40
Product Quantity Marketprice(Rs)
Paneer 200gm 62
500gm 145
1kg 310
Butter 100gm 37
500gm 180
600gm 240
Ghee 200ml 90
500ml 215
1lit 430
Cream 1kg 320
Khoya 1kg 300
PRICES OF PRODUCTS

41. Monthly Sale Report (January 2020)
41

42. Datewise comparative milk sale report
(January)
42

43. • Leakage loss was 1.0 to 1.5 per cent in the polythene packs.
• 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.
• There were two prominent seasons when demand supply fluctuations
were very prominent. From Oct-Jan, production was more and henceforth
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.
• The margins provided to the agents were not sufficient.
MARKETING RELATED PROBLEMS
43

44. LABORATORY
TESTS
44

45. Procedure
•Open the can of milk.
•Smell Immediately.
•Observe the appearance.
•Taste but do not swallow the milk.
•Check cleanliness of the can lid and milk can.
If everything is up to the mark the batch is passed.
1. ORGANOLEPTIC TESTS
45

46. Procedure
•Mix equal amounts of milk and 68% of ethanol solution in a test tube
(Usually 2ml each is taken).
•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.
2. ALCOHOL TEST
46

47. Procedure
•Boil small amount of milk in a test tube
•Clotting, coagulation or precipitation of milk shows the failure of the
test
•Heavy contamination in freshly drawn milk cannot be detected,
when the acidity is below 0.20-0.26% Lactic acid
3. CLOT ON BOILING (C.O.B)
TEST
47

48. 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
4. LACTOSCAN
48

49. Procedure
•Measure 10 ml of the milk in the conical flask
•Add 1 drop of Phenolpthalein
•Add 0.1N Sodium Hydroxide from burette under continuous mixing,
until a faint pink colour appears
•Volume of Sodium Hydroxide solution consumed is used to express
the percentage of lactic acid
5. ACIDITY TEST
49

50. Procedure
•Add 10 ml sulphuric acid to the butyrometer followed by 10.94 or 11
ml of milk
•Add 1 ml of Amyl alcohol, insert stopper and shake the butyrometer
•Place the butyrometer in the water bath at 65ºC and keep it there
until a set is ready for centrifuging
•Spin for 5 minutes at 1100 rpm
•Remove the butyrometers from the centrifuge
•Put the butyrometers in a water bath maintained at 65ºC for 3 min.
before taking the reading
6. FAT DETERMINATION BY
GERBER METHOD
50

51. Procedure
•Mix the milk sample and pour it into a measuring cylinder
•Put the Lactometer and allow sinking slowly into the milk
•Read and record the last Lactometer degree (ºL) just above the
surface of the milk
•If the temperature of the milk is different from the calibration
temperature of the lactometer, calculate the temperature correction
•Calculate SNF and TS content of the milk with the help of lactometer
reading
7. SNF DETERMINATION BY
LACTOMETER TEST
51

52. •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
8. Adulteration Tests
52

53. CLEANING-IN-
PLACE (CIP)
53

54. Alkali Solution
Hot Water
Acid Solution
Hot Water
Alkali Solution
Cold Water
54

55. PREPARATION OF SOLUTIONS
AlkaliPreparation
•2.5 to 3 kilograms of Caustic is mixed with 700-800 litres of
potable water
AcidPreparation
•35-40 litres of Nitric Acid are mixed with 700-800 litres of
potable water
55

56. TIMINGS OF CIP
Done before and after each batch of milk
processing
Done four times a day
Morning shift CIP involves cleaning of whole plant
and takes one hour
Other CIPs take half an hour each
Potable water treatment is done at the end of the
evening shift
56

57. METHODS OF CLEANING
EQUIPMENTS
1. For plate heat exchangers and pipes, solutions are
passed in a pre-defined manner using pumps
2. Silos are cleaned using Spray Balls located on the
upper side which sprinkles solutions under pressure
which cleans it thoroughly
57

58. 1. Milk cans are cleaned through can washer and rinsed thoroughly by
potable water
2. Cream separator, butter churner, raw milk dump tank, etc. are
dismantled and cleaned manually
MANUAL CLEANING OF
EQUIPMENTS
58

59. 59
Cleaning of plant and equipments.

60. ETP (EFFLUENT
TREATMENT PLANT)
60

61. •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
E.T.P.
61

62. 62

63. Waste water
Bar Screen
Fat, oil, grease
skimming tank
Equalization
Tank
Aeration Tank
Anaerobic
Lagoon Tank
Outlet
63

64. •Processing of milk and its products.
•Storage
•Quality control.
•Industrial management.
•Knowledge regarding manufacturing process of curd,
butter, paneer, pasteurized milk.
•It also gave me exposure to industrial world.
WHAT I LEARNT?
64

65. THANK YOU
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