KATRAJ DAIRY

का�त्रज दुग्धा�लय

INTRODUCTION

KATRAJ DAIRY- PAST TO PRESENT

Katraj Dairy was incorporated in 1960 with an intension of

providing an organized facility of milk collection for the village level

farmers situated in Pune district. Katraj Dairy started with milk collection

of about 0.30 lakh (30.000) liters per day in the first year of operation and

today, has steadily grown to over 1.50 lakh (0.15 million) liters per day

and has a financial turnover of over Rs.150 crores (US$ 33 million).

Katraj Dairy has achieved ISO 9001:2000 & HACCP

certification from DNV in Oct. 2006 & maintained. In Oct. 2009 Dairy

has achieved ISO 9001:2008 & HACCP 2006 Dutch Standard from

Dr. Norskey Veritus.

Katraj Dairy with its eight chilling plants and 12 BMC spread

almost all over the district has an installed milk handling capacity of over

5 lakh (0.50 million) liters per day. The main plant of Katraj is equipped

with modern Pasteurizer, homogenizer, Cream separator, Ghee

processing, automatic packing of milk and milk products and other

quality testing devices and well equipped labs. Katraj Dairy has an

installed processing capacity of 2 lakh (0.2 million) liters per day.

Katraj dairy manufactures / Distributes milk and milk products

like Pasteurized/ Homogenized-Cow milk, Toned milk, Double toned

milk, Standardized Milk, Full cream milk, Cow & Buffalo Cream and

Ghee, Shrikhand, Amrakhand, Malai Paneer, Dahi, Flavored Milk, Lassi,

Jeera Tak, Table Butter, Milk Powder, Softy Ice cream, pedha, Khoa and

in the near future plans to introduce sterilized milk in 200ml bottle and

hard ice-cream with different flavors in different pack sizes.

All these products are available at Katraj owned parlors at

various locations in Pune City and through appointed distributors and

retailing circuits. Very soon, Katraj plans to introduce an online ordering

system for its distributors/ retailers and consumers.

Katraj products have been in use in thousands of homes in Pune

since 1961. Katraj Milk, Katraj Ghee, Katraj Shrikhand, Katraj

Amrakhand, Katraj Lassi, Katraj Jeera tak (buttermilk), Katraj cream

have made Katraj a leading food brand in Western Maharashtra. Today

Katraj is a symbol of high-quality milk products sold at reasonable prices,

the genesis of a vast co-operative network triumph of indigenous

technology, the marketing savvy of a farmers' organization.

OBJECTIVES OF KATRAJ DAIRY

The objectives of Katraj Dairy are, to build a valued chain of

farmers to source milk at an organized level, manufacture products at a

very high quality level and create a demand for their products in the

competitive market without having any reasons to be pointed at.

This organization has a unique advantage, its strategic location.

Based in Pune city, a place with historic, cultural importance and a major

district in Maharashtra, India. The city is known as ‘the city of students’

because of its large number of educational centers. Another major

advantage is that Mumbai is just 180km. away. Thus using these key

factors, they want to serve the state with their superior quality of milk.

They want the state to crave for this superior quality of milk.

THE FARMERS & KATRAJ DIARY

Prior to Katraj Diary, farmers use to sell their milk to

middlemen. These middlemen were never trust worthy as the farmers

milk was always adulterated with water, promises that were never

fulfilled, the true price at which the milk was sold was never known and

the farmers didn’t get their money most of the time, if they ever got it at

all. Although the farmers didn’t like this system, they didn’t have a

choice, as there were no other alternatives.

However, as Katraj Dairy came along, a new picture was

painted. Katraj simplified this system to eliminate the problems of the

farmers and create a win- win situation for both of them. Katraj

strategically placed collection centers in the middle of the villages. Thus

making it very convenient for the farmers to contribute their milk. Further

more, the farmers are paid their money on the spot, based on quality and

quantity of milk. This also creates a meeting point for all the farmers to

discuss various new methods and techniques to increase their cattle’s

milk producing capacity. It also gives the farmers a sense of pride, as they

can be proud of the quality of milk being produced by their cattle.

HOW DOES KATRAJ DAIRY HELP THE FARMERS?

The collection centers pay the farmers for their milk on the spot

based on quality and quantity of milk. Because of which the farmers

don’t have to wait on their money. Katraj teaches and educated the

farmers with new dairy technologies, thus keeping them up to date with a

global market. Katraj also provides the farmers with vitamins for their

cattle, to receive a better quality of milk. They also teach the farmers

what type of fodder is to be fed to the cattle when. They also provide

medical assistance for the cattle, to their limit.

Katraj is also trying to promote organic/green milk. Organic

milk is basically milk from cows that have been exclusively fed organic

feed, have not been treated with synthetic hormones, are not given certain

medications to treat sickness, and are held in pens with adequate space.

PRODUCTS PRODUCED AT KATRAJ DAIRY

MILK

Milk is an almost ideal food. It has high nutritive value. It

supplies bodybuilding proteins, bone forming minerals and health giving

vitamins and furnishes energy giving lactose and milk fat. Besides

supplying some essential fatty acids, it contains the above nutrients in an

easily digestible and assailable form. All these properties make milk an

important food for pregnant women, growing children, adolescents,

adults, invalids, convalescents and patients alike.

Milk may be defined as a whole, fresh, clean, lacteal secretion

obtained by the complete milking of one or more healthy Milch animals

excluding that obtained within 15 days before or 5 days after calving or

such periods as may be necessary to render the milk practically

colostrum’s free and containing the minimum prescribed percentage of

milk fat and milk-solids-not-fats.

Pasteurization: The term pasteurization refers to the process of

heating each & every particle of milk to at-least 63° C for 30 minutes, or

72° C for 15 seconds in approved and properly operated equipment. After

pasteurization the milk is gradually cooled to 5° C or below.

Homogenization: Homogenization refers to the process of

forcing the milk through a homogenizer with the object of sub dividing

the fat globules.

CREAM

When milk fat is concentrated into a fraction of the original

milk, that portion is known as cream. Cream is a rich portion of milk fat.

Cream is the product of cow or buffelo milk or a combination

thereof, which contains not less than 25 % milk fat.

Various Types of Cream

Table Cream } Containing 20

- 25 % milk fatLight Cream

Coffee

Cream

     

Whipping

Cream

} Containing 30

- 40 % milk fat

Heavy

Cream

     

Plastic

Cream

  Containing 65

- 85 % milk fat

Katraj Dairy has been manufacturing plastic cream with 65 - 75

% milk fat.

GHEE

Ghee is the pure clarified fat derived solely from milk or from

desi (cooking) butter or from cream to which no coloring matter is added.

Ghee is the clarified butter fat prepared chiefly from cow or

buffalo milk. Ghee is used as a cooking or frying medium, in

confectionary, for direct consumption with rice chappatis etc.

Cow ghee is mainly used in indigenous pharmaceutical

preparations (Ayurveda).

Packing Sizes:

500 gm. Poly pack.

500 ml standy pouch.

15-liter tin.

SHRIKHAND

Shrikhand is a semi-soft sweetish - sour whole milk product

prepared from lactic fermented curd. The curd (dahi) is partially strained

through a cloth to remove the whey and thus produce a solid mass called

chakka (the basic ingredient for shrikhand). This chakka is mixed with

the required amount of sugar, cardamom, jaiphal etc. to yield shrikhand.

Packing Sizes:

100 ml plastic cups

250 ml plastic cups

500 ml plastic cups

For Party or catering purpose available in loose bulk sale.

Best for occasions like Gudhi Padwa, Raksha bandhan, Dasara, Diwali

etc.

Direct consume with Puri, Chapatti, for better test.

AMRAKHAND

Amrakhand is a semi-soft sweetish - sour whole milk product

prepared from lactic fermented curd. The curd (dahi) is partially strained

through a cloth to remove the whey and thus produce a solid mass called

chakka (the basic ingredient for shrikhand). This chakka is mixed with

the required amount of mango flavour, sugar, cardamom, jaiphal etc. to

yield Amrakhand.

Packing Sizes:

100 ml plastic cups

250 ml plastic cups

500 ml plastic cups

For Party or catering purpose available in loose bulk sale.

Best for occasions like Gudhi Padwa, Raksha bandhan, Dasara, Diwali

etc.

Direct consume with Puri, Chapatti, for better test.

MALAI PANEER

Paneer refers to the milk solids obtained by the acid

coagulation of boiled whole milk & subsequent drainage of whey. The

acids commonly used are citric in both natural & chemical forms.

Traditionally paneer has been a variety of pressed channa, used

mainly in preparing cooked vegetable dishes like palak paneer, paneer

butter masala etc.

Packing Sizes:

200 gm rotogravure laminated pouch.

500 gm rotogravure laminated pouch.

1000 gm rotogravure laminated pouch

DAHI

Matka Dahi is a fermented milk beverage. Dahi originally was

set using mud pots since ancestral days for the purpose of getting that

unique flavour & taste gained due to the porous property of mud pots

allowing filtered air flow. But now a days dahi prepared from milk

faormenting with lactic culture & packed in plastic cups 370 ° C.

Packing Sizes:

100 gm. matka.

200 gm. matka.

100 gm. plastic cup.

200 gm. plastic cup.

400 gm. plastic cup

FLAVOURED MILK

Flavoured Milks are milks to which some flavours/ colours and

suger been added.When the milk is used the product should contain a

milk fat % at least equal to the minimum legal requirement for market

milk, but when fat level is lower(1.2%) , the term drink is used.

Packing Size:

200 ml Poly bag

LASSI

Lassi is a fermented Milk beverage popular in all parts of India.

The technology of lassi making is however confined to only households.

Lassi has a great potential in the Indian Market.

Packing Size:

200 ml Poly pack

JEERA / PLAIN TAAK (BUTTERMILK)

Tak is also called chhas or mattha, refers to desi buttermilk. It

is a popular drink during the hot Indian summers, as it helps reduce body

heat and lower the body temperature. Thus a relaxing drink enjoyed by

everyone.

Packing Size:

200 ml Poly pack

TABLE BUTTER

For years together, table butter is being cherished as a tasty

food, popularly eaten with bread. It also forms a good topping on

indegeous food like Pav-bhaji, Thalipith (Pan Cake). Katraj Table Butter

is marketed by Katraj Dairy Manufactured By Dynamix Dairy Industries

Ltd., Baramati, Maharashtra, India.

Packing Sizes:

100 gm.

500 gm.

SOFTY ICE- CREAM

This product is marketed in a soft condition and is ready for

consumption shortly after it is drawn from the freezer. Katraj dairy has

soft churner in their milk factory in the Pune city.

Among milk products ice cream is also rich source of calcium,

phosphorus and other minerals of vital importance in building good bones

and teeth.

It is a very desirable food item for growing children and person

who need to put on weight.

It is excellent source of Vitamin A, good source of Vitamin B

& G, Niacin, and Vitamin E. The digestibility & palatability of ice cream

is also very high.

Packing Size:

60 ml cone

PEDHA

Pedha is preparred using khoa based material. Khoa is mixed

with suger and then heated in a kadhai made of food-grade metal.After

heating desired flavouring and nuts are added to the pedha mass.

Packing Sizes:

1 kg box

500 gm. box

250 gm. box

ICE CREAM

Ice-Cream may be defined as frozen dairy product made by

suitable blending & processing of cream & other milk products, together

with sugar & flavor, with or without stabilizer or color & with the

incorporation of air during the freezing process. According to PFA rules

Ice-Cream is the frozen product obtained from cow or buffalo milk or a

combination there of or from cream and or other milk products with or

without addition of cane sugar, fruit, fruit juices, preserve fruits nuts,

chocolate, edible flavors & permitted food colors.

Nutritive Value; Among milk products, Ice cream is also a

rich source of calcium, phosphorus & other minerals of vital importance

in building good bones & teeth. Being rich in Lactose, Ice-Cream flavor

greater assimilation of calcium in the diet. The protein content of Ice

Cream is also rates high, both in quantity & quality. Ice Cream provides

valuable proteins in a very palatable form. In fact, Ice Cream is most

palatable source of milk protein to the vegetarians. Ice Cream is an

excellent source of food energy. It is a very desirable food item for

growing children & persons who need to put on weights. Ice-Cream is a

rich source of many essential vitamins, without which normal health &

growth cannot be maintained. Thus it is an excellent source of vitamin -

A, a good source of vitamin -B (Thiamine) & G (Riboflavin) & a fairly

good source of Niacin, vitamin - E & in fruit Ice Cream of vitamin -C.

The digestibility & palatability of Ice Cream is also vey high.

Flavors;

Packing Sizes:

50 ml plastic cups

100 ml plastic cups

500 ml Family pack

1000 ml Party pack

2000 ml Party pack

4000 ml Bulk pack

STERILIZED FLAVORED MILK

Sterilized milk may be defined as milk, which has been heated

to temperature of 1210C for 15 minutes. The Milk fit for human

consumption for at least 120 days at room temperature.

Flavors;

Packing Sizes:

• 200 ml Glass Bottles

KATRAJ AQUA (MINERAL WATER)

Katraj Dairy with their well-known products now introducing

mineral water with katraj brand i.e. Katraj Aqua. Water in its purest form

is really a life giving liquid.  Katraj Aqua (to live a healthy family life)

gives the assurance that each drop of water that you consume is full of

energy & freshness. Our dairy is also an ISO- HACCP 9001-2008

certified Dairy and it stands testimony to the quality of product. We

strictly follow the quality measures regarding hygiene and quality of

products.

Packing Sizes:

500 ml Bottle - packed in 24 bottles in 1 box.

1 liter Bottle- packed in 12 bottles in 1 box.

MANUFACTURING PROCESS

Initially, the milk is collected in the collection centers in the

villages. This where all the villagers come and sell their milk to Katraj

Dairy. After which, the milk is transported to the Katraj plant, situated in

Katraj, Pune. The milk is transported in special vehicles designed for the

sole purpose of milk transportation.

[MILK TRANSPORTAION VEHICLE]

Once the milk has reached the plant, it is first checked for its

quality. After which it is primarily filtered and added to the holding tanks.

After which the milk is transferred through pipelines to the boiler unit.

This is where the milk is the milk is boiled to kill germs and make the

milk last longer, known as pasteurization.

[BOILER ROOM]

Pasteurization refers to the process of heating each & every

particle of milk to at-least 63° C for 30 minutes, or 72° C for 15 seconds

in approved and properly operated equipment. After pasteurization the

milk is gradually cooled to 5° C or below.

[REFRIDGERATION DEPARTMENT]

After this process the milk is stored in its specially designed

storage containers. After which it is ready for further processing and

packaging. The milk can be further be utilized in the production of rest of

the products like flavored milk, ice cream, butter, ghee etc.

[STORAGE TANKS]

QUALITY CONTROL

Katraj Dairy is very strict when it comes to the quality of the

milk and its products. It strictly maintains its standard as per ISO

9001:2000 regulations. The work of this department begins, as soon as

the milk enters the gates of the factory. They initially check the quality of

the milk when it is in the milk tanker or milk transportation vehicle. They

do so to ensure that the milk is not spoiled and does not match the

standards of Katraj Dairy. This process is carried out to ensure that; bad

milk does not get added to the rest of the milk in the storage units.

This department uses the method of ‘random sampling’ for

selection of samples to test. It picks up random samples from all the

batches of products produced. If even one product in the batch is not up

to the mark, the entire batch of the product produced is discarded.

This department uses a variety of testing methods for the

various products that are produced at the plant. They usually check for

pH, fat, acidity, water content, saturation levels, lactic acid, etc. A hew of

the chemicals that they use for testing are given below-

Iodine Solution

Sodium Bicarbonate

Lactic Acid

Diastix

Silver Hydroxide

PACKAGING

Katraj Dairy carries out a very simple form of packaging. It is

appealing to the consumer’s eyes even if they are from a metropolitan

city or a local village in Maharashtra. All of their packaging has the local

dilet, ‘Marathi’ on them along with the universal language, ‘English’.

[MILK PACKAGING]

The packaging is done in a very hygienic environment. All the

workers that come in contact with the products have hair caps and gloves

on their hands. They also have a special uniform that has to be worn.

The packaging of all the milk except the flavored milk is done

in polythene bags. The bags are manufactured in other parts of

Maharashtra and are inserted into the packaging machines. The flavored

milk is packaged 200 ml. glass bottles. Ice cream is packaged in plastic

cups as well as cardboard boxes.

DISTRIBUTION

Katraj Dairy has a simple of chain distribution. They follow

two chains of distribution,

1. Manufacturer

2. Manufacturer

R

[CONTAINERS IN, WHICH MILK IS DISTRIBUTED]

A list of distributors that are located in and around the city of

Pune, are given on the next page-

NAME OF DISTRIBUTOR AND AREA OF DISTRIBUTION

Gurukrupa Associates    (Mrs. Deepali V. Bhadale)

Sinhagad Road, Bibavewadi to Swargate

Kaniphnath Milk Agency (Shri. Balasaheb V. Gavhane)

Swargate to Shivajinagar, Ghorpadi, Mundhava, Hadapasar

Shivam Milk Agency      (Shri. Sandeep U. Ghate)

Market Yard, Kondhava Gaon,Undari, Satav Nagar Mahadeonagar, Urali devachi

Balaji Milk Agency           (Shri. Sanjay R. Ambekar)

Vanwadi gaon, Salunke Vihar, Manish Park

Assa Associates            (Shri. Amarpalsing Badh)

Pune Camp, Nana Peth, Bhavani Peth, Koregaon Park

Om Sai Distributors       (Shri. Anil S. Londhe) 

Yerwada, Kalyani nagar, Vadgaonsheri, Viman nagar, Vishrantwadi, Dhanori

Sidhdheshwar Milk Agency  (Shri. Sagar K. Shelake)

Renghill Corner, Bopodi, Khadaki, Dapodi, C.M.E., Sangavi, New sangai

Shevantai Milk Suppliers (Shri. Ravindra D. Takke)

Gokhalenagar, Chaturshrungi Payatha, Paud Phata,  Jaibhavani Nagar to Chandani Chowk

Sayali Milk Suppliers (Saui. Vaishali K. Gopalghare)

Yerandavana, Karve Nagar, Varaje, Uttam nagar, Kotharud gaon

Shriraj Milk Agency (Shri. Rajendra J. Bhargude)

Rakshak Nagar, Sathe Pimple, Kalewadi Phata, Wakad, Dange chowk, Tathawade, Ravet, Punawale

Yamuna Traders(Shri. Ramesh B. Kasarwadi, Pimpari,Kalewadi

Phanse)

Dattakrupa Enterprises (Shri. Subodh N. Kale)

Vivek Vasahat, Shridhar Nagar, Sudarshan Nagar, Udyog Nagar, Bijali Nagar, Chinchwad Gaon

Vyankatsh Milk Agency (Shri. Rohidas K. Lawande)

Akurdi Gaon, Akurdi-Nigadi Pradhikaran,Dehuroad, Talegaon Dabhade,Kamshet, Lonawala

Rudra Enterprises (Sau. Chhaya C Jagtap)

Sant Tukaram Nagar, Ajamera, Neharu Nagar, Balaji Nagar,  Indrayani Nagar, Landewadi, Bhosari Gaon

Kunal Milk Agency (Shri. Rahul D. Takke)

Pashan, Sutarwadi,Bavdhan, Boys Batalian, Aundh gaon

Shri Saikrupa Distributors (Shri. Amod B. Pandhari)

Someshwarwadi, Sanewadi,Parihar chowk, Dattanagar, balewadi, Hinjwadi

Radha Krishna Milk Agency (Shri. Sandip D. Chambhare)

Morwadi, Ajamera, Mohan Nagar, Yamuna Nagar, rupi Nagar, Talawade, Phule Nagar, Chikhali road, Shahu nagar

MAINTENANCE OF THE PLANT

A manufacturing unit like the one at the Katraj Dairy plant has

many machines, electrical units, etc., that needs regular maintenance.

Katraj Dairy has a fixed routine that covers all the maintenance-required

units.

[ELECTRICAL MAINTENANCE DEPARTMENT]

Machinery- All machinery requires maintenance. The maintenance

is determined on the number of hours that it has been operated. Based on

this the wear and tear of the various machine parts can be estimated. The

parts that usually require the maximum maintenance are the rollers of the

packaging units. The machines that come in contact with the milk are was

washed with boiling hot water, then with a chemical, then with boiling

hot water again and then washed with cold water. This process takes

place everyday with the small holding tanks.

Storage Tanks- There are two types of storage tanks when it comes

to maintenance, the big and the small. The big storage tanks are washed

on weekly bases while the smaller ones are washed on a daily basis. The

process involves, washing with boiling hot water, then by a chemical,

then with boiling hot water again and then washing with cold water.

Electrical Department- The electric department is in charge of all

the electrical lies that run through the entire plant. They usually have a

simple job of just changing the parts that whether down or fuse. A major

problem they face is rodents eating their underground wires, however,

they now run the cables through G.I. pipes. The other equipment that

usually burn out are the M.C.B.’s, wires that fuse, motor pumps, etc.

[MAIN ELECTRICAL POWER HOUSE OF THE PLANT]

Refrigeration Unit- This unit is in charge of all the refrigeration of

all the products inside Katraj Dairy. It contains 6 compressors out of

which only 2 operate at a time. Each pair of compressors operates not

more than 6 hours at a time. When the demand for refrigeration increases,

4 compressors run at a time. Ammonia gas is used for refrigeration. If

there is low pressure in the lines of the ammonia gas, Sulphur powder is

added to the gas to help detect any leaks.

Pest Control- Rodents are a problem everywhere. To take care of

them crews of pest control are called every 1-month to spray pesticides to

keep the plant rodent free and hygienic.

BOARD OF DIRECTORS

The boards of directors have the power of all the decisions that

are to made, in regards to Katraj Dairy. The chairman of Katraj Dairy for

the term between 2009- 2013 is Mr. Shri. Rambhau Sambha Tule.

Mr. Shri.

Rambhau Sambha Tule.

Chairman

CONCLUSION

From this report we can conclude that the set up is not a

mediocre one, but in fact up to global standards. The plant is very

hygienic and well maintained. The idea and implementation of the idea of

unifying the farmers and helping them with their problems is nothing but

noble. All the products that are produced are of immense quality and

standard, because of which their consumer demand is growing day by

day.

Thus analyzing this report, we can say that Katraj Dairy is

definitely up to global standards and has the potential to be one of the

leading giants in the dairy industry.