Verka milk plant ppt

verka summer intern report

1. Submitted by: Nishant Sachdeva L-2010-A-03-B.tech FT

2. Industrial Training The Ludhiana District Co-operative Milk Producer's Union Ltd.

3. I ntroduction First Milk Plant, of the State was setup at Verka near Amritsar. The brand name of Milk and Milk Products was adopted as Verka . The Foundation stone of Milk Plant, Ludhiana was laid by Hon. S. Parkash Singh Badal , the then Chief Minister of Punjab in 1970. Commissioning of the Plant was done by Punjab Dairy Development Corporation in 1974. Inauguration was done by Late Smt. Indira Gandhi the Prime Minister of India. The capacity of the plant was 1.00 lac. Litre per day, and now the milk handling capacity is 4.00 Lac Liter per day.

4. Amritsar Bathinda Chandigarh Faridkot Ferozpur Gurdaspur Horshiarpur Jalandhar Ludhiana Patiala Ropar ( Mohali ) Sangrur MILKFED has its milk unions in almost all the districts of Punjab. These district units are:- MILKFED PLANTS LOCATION These plants in all these unions are being run under the brand name VERKA.

5. Present Status No. of societies increased from 94 to 802 and its membership from 5400 to 78500. Milk Procurement has increased from 10200 LPD to 2,50,000 LPD . Highest milk price is being paid to the milk producers as compare to other plants in the states Products being manufactured by Ludhiana Plant are sold at premium rates through out of the country and in the International Market. City supply has increase from 66000 LPD to 1,98,000 LPD . Turnover the plant touched to 283 crores Profit of the union has increased manifold. Capacity utilization of the plant is more than 85%.

6. VERKA MILK PLANT - PROFILE Full name : The Ludhiana District Cooperative Milk Producers Union Ltd. Foundation : Laid by Hon. Sh. Prakash Singh Badal in 1970 Capacity : Then 1 lakh L/day, Now 6 lakh L/day Head office : Punjab State Co-operative Milk Producers Federation Ltd. S.C.O.153-155, Sec. 34-A, Chd . Inauguration date : 31 st October, 1974 Chairman : Sh. Ajmer Singh No. of societies : 816 No. of Chilling centers : 4 Brand name : VERKA Products marketed by : The Punjab State Co-operative Milk Producers Federation. Ltd. Quality certificates : International Quality Certificate ISO-9002 & IS-15000 (HACCP)

7. VERKA MILK PLANT Verka milk plant (VMP), Ludhiana is known as The Ludhiana Dist.-Co-operative Milk Producer’s Union Limited, Ludhiana . It is situated on Ferozpur Road, about 5 km. away from both railway station and main bus stand. The plant has bagged first position in Northern Zone It is fully equipped with modern fluid milk plant facilities. The latest state of art technology in milk drying is available in this plant. The products manufactured by this Plant at present are STM, DTM, FCM, SMP, WMP, Ghee, Butter, Paneer , Milk-Cake, Dahi , Kheer , Lassi . Contd …

8. Some objectives of the Milk Plant are:- To uplift social and economic status of milk producers. To develop dairy as industry allied to agriculture. To provide better and remunerative prices for milk. To provide veterinary aids to animals of milk producers at their doorstep. To provide better quality cattle feed at reasonable rates. To educate the milk producers about lowering down the cost of milk without compromising quality. To create employment opportunities for rural youth by milk production activities. To provide awareness among milk producers for socio-economic change through co-operative set-up. VERKA MILK PLANT

9. PRESENT STATUS OF VMP Product brand name : VERKA Milk handling capacity : 6 lakh litres per day Production of market milk : 2.5 lakh litres per day Production of butter : 13000 Kg per day Production of ghee : 14 MT per day Production of powder : 30 MT per day Production of paneer : 400-450 Kg per day Production of kheer : 200 Kg per day Production of milk cake : 30-40 Kg per day Production of dahi : 1400 Kg per day Production of lassi : 3000 Kg per day

10. Powder section There are definite indication of greater future productions of dried milk & milk products due to their better keeping quality, they require less storage space & lower transportation costs. All these are economically attractive. Dried milk provides a means of handling the excess milk supply in a dairy factory during flush season, while in lean season that meant for the production of dry milk can be diverted to market milk. Thus, dried milk is called the balance wheel of dairy industry. Verka milk plant, Ludhiana has two separate drying plants.

11. POWDER SECTION The Dairy has two separate drying plants, viz : Powder section with MVR unit & TVR unit (30TPD) Powder section with TVR unit only (6.5TPD) Compositional & other Standards maintained :- Parameters SMP Standard grade SMP Extra grade WMP Moisture (%) 3.2-3.6 3.0-3.4 Max. 3 FAT (%) Max. 1.3 Max. 1.2 26.5-27.5 Acidity (%LA) 1.0-1.25 1.0-1.2.5 Max. 1 B.D. Agglomerated (gm/ml) 0.45-0.55 0.5-0.6 0.5-0.6 Insolubility Index (50ml) Max. 0.15 Max. 0.15 Max. 0.5 Ash content (%) Max. 8.2 Max. 8.2 Max. 0.5 Coliform Nil Nil Nil

12. Process control Lumpiness in Powder Ensure proper cooling of powder Dehumidifier should be properly operating Low moisture in Final Product Increase flow rate Adjust outlet temp Burnt Powder Particles Adjust inlet temp Check the function of feed flow controller & feed pump Nozzle of jets are whether chocked partially Sooty Powder Clean or change the filter. Check up air heater Very Fine Powder A Particles Increase in degree of concentration Control the feed temp. Solubility Index Increased Check the outlet temp. Control feed rate

13. Operating parameters for evaporating plant Parameter Standard & extra Grade W.M.P Concentrated milk Milk feed rate (lts/hr) 16000-17000 3500-14500 16000-17000 Steam pressure (kg/sq.cm) 5-6.5 5-6 5-6.5 Thermal vapor recompression (kg/sq.cm.) 2-2.5 2-2.5 1-1.5 High heater (temp o C) 90+/-2 95-100 90+/-2 Holding heater temp ( o C) -Do- -Do-` -Do- Flush vessel temp ( o C) 73-85 73-85 73-85 Jacket temp ( o C) 69+/-1 69+/-1 69+/-1 Vapor Separator I ( o C) 66+/-2 66+/-1 66+/-1 Vapor Separator II ( o C) 58+/-2 58+/-1 58+/-1 Vapor Separator III ( o C ) 50+/-2 50+/-1 50+/-1 Vacuum in condenser 0.9m bar 0.9m bar 0.9m bar T.S. % of condenser 20+/-3 20+/-3 20+/-3

14.   Operating parameters for drying plant Parameters Smp Wmp Chamber inlet air temperature ( o C ) 170+/-10 180+/-10 165+/-5 170+/-5 Vibro fluidier air inlet temperature ( o C) 90+/-5 65+/-10 Chamber outlet temperature ( o C) 80-90 80-90 Vibro fluidier outlet temperature ( o C ) 64+/-2 65+/-2 Chamber vacuum (mm.w.c) 5+/-2 15+/-2 Atomizer load (amp) 55+/-5 55+/-5 Load on exhaust fan (amp) 95+/-5 95+/-5 Powder output (kg/hr) Min. 1375 Min. 1500

15. Powder Plant

16. Drying Chamber Cyclone

17. Control Panel

18. Processing Operations Chilling: Milk is chilled below 4 ºC. The raw chilled milk is utilized for the various products processing operations. The chilled milk is stored in tank called as Silo. The chiller is plate heat exchanger type. Pasteurizing: Milk is heated at 63 ºC for 30 minutes or 75-80 ºC for 15 sec and then cooled immediately below 14 ºC.

19. Type of milk received :- Cow Milk :- Fat Min. 3%, SNF Min. 7.9% Buffalo Milk :- Fat Min. 6%, SNF Min. 8.6% Mixed Milk :- Fat Min. 5.4-5.5%, SNF Min. 8-8.5% RAW MILK RECEPTION DOCK (RMRD) M ake : Cast iron grid tiles, edges are of cast iron planting W idth : To overcome heavy stresses T ypes : 1.5mm S lope : Open C ans : 40 Liters capacity, weighing 6-6.5 kg M aterial : Aluminum

20. Starting the RMRD Unloading and Conveying Opening the lids Grading Weighing and Sampling Cleaning & Washing of cans Recording of cans Loading Closing down RMRD OPERATIONS AT RMRD

21. PRODUCTION SECTION

22. Composition of Milk Characteristic Cow milk Buffalo milk Fat 4.0-4.5 % 6.5-7.0% Carbohydrates 4.5 % 4.7 % SNF 8-8.5 % 8.5- 9.0% Proteins 3.3 % 3.6 % Minerals 0.6 % 0.7 % Water 87-88 % 84-85 %

23. PRODUCT FLOW

24. City Supply Section

25. PANEER SECTION Compositional & other Standards maintained :- Equipments used are- Steam Jacketed Vat, Trolleys, Sealing Machine, Hoops, Automatic Machine For Processing. Cleaning of vats, hoops & muslin cloths is done manually, then they are sanitized with 0.5% teepol & hot water at 55-60 o C Fat Not < 50% of dry mater basis Moisture Not > 70% Texture Soft & spongy Taste & flavor Pleasant

26. Flow diagram for Paneer manufacture

27. DAHI SECTION This dairy plant follows the ISI standard of dahi . Mostly it is manufactured every two alternate days in flush seasons. Compositional & other Standards maintained :- Equipments used are- Steam Jacketed Vat, Weighing Balance, Cans, Incubation Chamber, Dahi Packaging Machine. Fat 4-5% Protein 3.2 -3.4 % Acidity 0.8-1.0% Taste Cream-sour Flavor Acid

28. Flow diagram for Dahi manufacture

29. BUTTER SECTION Ludhiana milk Plant is engaged in making two types of butter viz Table Butter White Butter (White Butter is made and stored as stock and is used in lean season for recombination and is also used as base material for ghee & often supplied for bulk demand). The dairy produces butter by batch churn method. There is also a provision for continuous butter making machine. The packed butter is stored at -17 to -29 o C till dispatch.

30. Operating Parameters for Table Butter Loading of churn 1/3 rd volume of drum capacity Loading temp ( o C) < 10-12 o C Churning temp ( o C) < 10-12 o C Color addition 1ml/kg fat Spray water temp ( o C) Max 5 Speed of churning 28-30 rpm (1 st gear) 14-18 rpm (2 nd gear) 7-8 rpm (3 rd gear) Salt addition (dissolved in pasteurized warm water) 22mg/kg of butter yield Vacuum during operation 300-350mm FAT % in cream 40-42

31. Flow diagram for Table Butter manufacture

32. GHEE SECTION Compositional & other Standards maintained :- Equipments used are- Butter Melting Vat, Pre-stratification Tank, Ghee Boiler, Settling Tank, Filling/Storage Tank, Ghee Clarifier, Electronic Weighing Balance, Closure Punching Machine, Pouch Filling Machine. Flavor & color Pleasant & white or yellow Moisture Max. 0.25% F.F.A (% Oleic Acid) Max. 0.03% B.R. reading at 40 o C 40-43 Peroxide value Max. 1 Sediment Absent

33. Operating parameters Pre-melting temp ( o C ) 75-80 Cooking temp ( o C ) 105-112 Batch time ( hr ) Max. 4 Steam pressure in kettle (kg/sq.cm.) 2 Filtration Falalin cloth Clarification temp ( o C ) 95+/-5 Setting time ( hr ) Min. 6 Ghee filling tank temp ( o C ) 43+/-5 Ghee filling temp ( o C ) 42 +/-5 °C After packaging the packed corrugated boxes are kept in granulation room for 24 hrs. Then the boxes are transferred into storage room till dispatch.

34. LASSI : Lassi is a drink made of standardized milk with 50:50 dilutions with water. Receiving milk ↓ Standardization (4.5%fat and 8.5%snf) Heating of milk 85°c /5min Cooling down to 40°c Inoculation with culture at 1% at 40 °c Inoculation at 40 °c (till acidity reach 0.67%) Addition of pasteurized chilled water 2% Breaking of coagulum ( acidity o.54%) Packaging Cold storage less than 5°c

35. Kheer is concentrated heat desiccated indigenous dairy product.

36. Thank you Any question ?