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INTRODUCTION OF GOURMET FOODS
In 1987 Gourmet Foods is a family owned partnership business started by Mr. Muhammad
Nawaz Chattha
1st July, 2008 his sons joined him in the business
Business set up is based in Lahore
98 sales outlets in running position supported by 5 units
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MISSION STATEMENT
³Gourmet´ with an aim to make
Delicious
Hygienic
Healthy food
That contributes to positive health
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MILK PROCESSING IN
GOURMET FOODS
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COLLECTION OF RAW MILK
Raw milk received
The farmers
Collectors from the collecting areas of the industry
Transported
Transported to the milk processing plant
Chilled at a constant temperature (40C) after being pumpedinto a storage tank for any length of time
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MILK RECEPTION
Tanker enters into the Gourmet foods, sample is taken by Labtechnician. Then Lab Technicians perform the tests needed
Then tanker comes to the receiving area where finally the
reception of the milk takes place by the centrifugal pumps
Milk comes into storage tank then goes to clarifier
Milk goes toward the PHE where its Chilled
and stored into the big silos
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RECEPTION LAB
The composition of milk and adulteration in milk is usuallydetermined by a number of tests on arrival at the dairy &
adulterated milk is not accepted
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STORAGE OF MILK
After the completion of the reception tests, the tankers are
accepted or rejected if accepted then
Milk from accepted tankers receive in receiving lines
From receiving lines, milk comes in silos
There are six silos in Gourmet Foods unit 3
Capacity of 2 silos are25000 liters
Capacity of 2 silos are15000 liters
Capacity of 2 silos are 10000 liters
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TEST CARRIED OUT TO CHECK
THE QUALITY OF MILK
All the quality tests are carried out at the time of arrival of
milk in the dairy plant in the reception lab.
In reception lab 4 types of tests are performed which are given below.
Physical tests
Qualitative tests
Quantitative tests
Adulteration tests
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PHYSICAL TESTS
Taste
Check taste of milk. It should not give odd taste
Smell
Take in the aroma of milk. It should be of milky odour
AppearanceMilk should be of uniform color and texture
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QUALITATIVE TESTS
Five qualitative tests are performed for raw milk
1. Check temperature of milk
2. pH
3. Clot on boiling test (COB)
4. Alcohol precipitation test (APT)
5. Determination of Acidity
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QUANTITATIVE TESTS
In Gourmet foods Four types of quantitative tests are performed .
1. Determination of Fat in Milk
2. Lactometer Reading (28)
3. Solids not fat (SNF )
4. Total solids (TS)
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ADULTERATION TESTS
In Gourmet foods four types of adulteration tests are performed
1. Detection of Deter gent in Milk
2. Detection of Star ch in Milk
3. Detection of Glucose in Milk
4. Detection of Sugar (Sucrose) in Milk
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PASTEURIZATION OF MILK IN
GOURMET FOODS Milk Silo
Balance tank
Regeneration Section (44-45oC)
Separator
Homogenizer (100-150 bar)
Heating Section (80-85oC)
Holding Tubes (15 Sec)
Regeneration Section (55-60o
C) Cooling Section (7-8oC)
Packing of milk (litter pack)
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POWDER PLANT
Milk powder is the product obtained by the removal of water
from milk by heat
Spray dryer is used for drying and falling film evaporator is
used for the evaporation
The capacity of the powder plant is 24bags in 1 hours of
duration consisting each bag with 25 k g of dry milk powder
Reception and pasteurization of milk is done at unit 3 then
send it to unit 5 for the production of powder milk
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MANUFACTURING OF POWDER MILK IN
GOURMET FOODS
Milk silo
Balance tank
Standardization Pasteurization
Storage of milk into tanker
Milk from unit 3 transfer to unit 5
Evaporation (Brix 40-50)
Spray dryer (remove water)
Packing into bags
Storage cold & dry place
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GHEE
It is desiccated butter
Which have moisture content not more then 0.5 %
Shelf life is up to one year
Gourmet Foods produce its own desi ghee for the purpose of
making sweets
Gourmet desi ghee is not for sale
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GOURMET DAIRY
ICE CREAM
It is frozen product which is obtained by the blending of fat,
SNF, sugar, stabilizer, emulsifier incorporated with air when
we freeze
In Gourmet foods two kinds of mixes are produce for ice
cream manufacturing Kulfa mix and plain mix.
In Gourmet Foods 15 kinds of ice cream are manufacture
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RAW MATERIAL FOR ICE CREAM
1. Sugar
2. Dry Skim Milk
3. Fresh Cream
4. Liquid Glucose
5. Pulsgaurd
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ICE CREAM MANUFACTURE
The basic steps in the manufacturing of ice cream are generally asfollows
Blending of the mix ingredients Pasteurization (80-85oC)
Homogenization (100-150 bars)
PHE (8oC)
Aging the mix (4-6 hours)
Freezing
Packaging
Hardening (-30 to -35oC for 24 hours)
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KHOYA
Khoya is concentrated whole milk product having moisture
per centage 35%
In Gourmet foods Khoya contain 35-40% fat
After the manufacturing of khoya, it is packed
Khoya is also not for sales
Khoya is used for the preparation of sweets
Some time khoya is used in the preparation of kulfa ice cream
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PREPARATION OF KHOYA
In Gourmet food stainless container with steam jacketed are used
for the preparation of Khoya
Take raw milk at 10-12oC in to pan
Heat milk at 85-90oC for 30 minutes and stir
Then addition of milk powder 3k g+3liter water at 65oC
Then cooling at room temperature
Then pack Khoya into 10k g polyethylene bag
Shelf life is 5-8days at room temperature
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PANEER
Paneer is a product obtained by heating and acid coagulation of
milk
It should not contain moisture above then 70% and fat contain
23-26 %
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PREPARATION OF PANEER
Raw Milk is come into paneer section temperature of milk is4oC
Then boil the milk for 1-2 minutes at 95oC and continuously
agitate the milk
Then cool the milk up to 70oC and continuously agitate the milk
Citric acid is added in milk and curd is formed with in 5-6minutes
Ageing is done for 8-10 minutes with slow agitation
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Whey is drained off
Washing of curd with water and whey+water is removed
At this stage curd has not sour taste
Separation of curd by the help of cheese clothes by pressing
the curd
Mining of paneer is done
Then pack and store at 4oC
Paneer is used for the manufacturing of sweets
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CLEANING IN PLACE
Before any operation during milk processing anything must be
clean
Cleaning is carried out by cir culating of cleaning agent in
processing line is called C.I.P
In Gourmet foods C.I.P carried out by following steps
1. Water rinsing for 10 minutes
2. NaoH rinsing for 10 minutes3. Water rinsing for 5 minutes
4. Nitric acid rinsing for 10 minutes
5. Water rinsing for 5 minutes
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WATER SOFTENING PLANT
In Gourmet foods 2 water softening plants are present
Capacity of both plants are 4 tons
Water softening by Na-zeolite
Zeolite react with Ca+2, Mg+2 ions and convert into Ca, Mg
Zeolite
Limit of hardness is 60 ppm
Zeolite should be changed after every year
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BOILER
In Gourmet foods 2 boiler are used for production of steam
It is also called steam generator
The temperature of steam is 180oC
Boiler #1 Boiler #2
Types Fire tube Fire tube
Capacity 4 tons/hour 6tons/hour
Working pressu
re 250PSI 150PSITDS 3000-4000ppm 3000-4000ppm
Company PIE PIE
Modal PIE1011 PIE1016
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Feed water pressure is 10-15 PSI high to boiler pressure
Boiler efficiency depends upon feed water temperature
To increase the temperature of feed water economizer is used
Economizer is placed at the exhaust side of boiler
Economizer increased the boiler efficiency 2-10 %
Gas and fur nace oil is used to operate the boiler
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COMPRESSOR
Gourmet foods three types of compressors are used
1. Ammonia compressor 2. Freon compressor
3. Air compressor
Power rang of compressors are 3-30 hp Hermetic type
Not repairable
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CONDENSER
Gourmet foods 2 types of condensers are used
1. Air cooled2. Shell and tube
Condensers are local & German made
Hermetic type Not repairable
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FREEZER
In Gourmet foods 12 freezers are used
4 freezers are Italy made and 8 freezers are china made
Power range of freezers are 10-15hp
Two types of freezers are used in Gourmet foods
Air blast freezer (storage)
Continuous freezer (ice cream)
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COOLING TOWERS
Gourmet foods 4 cooling towers are used
They are natural type
Capacity of each cooling tower is 150 tons/hour
When water enter in cooling tower temperature is 35oC
When water leaves cooling tower temperature is 27oC
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GENERATOR
Gourmet foods 2 generator are used for the production of electricity in cause of emer gency
Generator # 1 Generator # 2
Model P730P 800F
Color Blue Yellow
Made Ireland U.K Ireland U.K
Power 730KVA 725KVA
Company FG Wilson CAT
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