INDEX 1. Introduction to industrial training, Purpose and objective of training 2. Introduction to Mother Dairy. 3. Ice Cream - Definition, Composition 4. Process of Manufacturing – Flow Diagram 5. Ingredients and Properties of making ice cream. 6. Details of machinery used in ice cream manufacturing. 7. Type of Mix. 8. Varieties of ice Cream. 9. Packaging Material 10. Storage 11. Equipment Maintenance 12. Hygienic Maintenance 13. Cleaning & Sanitization. 14. CIP 15. Quality Assurance 16. Judging and grading of ice Cream 17. Engineering Section i. Water ii. Boiler iii. Refrigeration iv. Compressed Air v. Soft Water vi. Electricity
Transcript
INDEX
1. Introduction to industrial training, Purpose and objective of training
2. Introduction to Mother Dairy.
3. Ice Cream - Definition, Composition
4. Process of Manufacturing – Flow Diagram
5. Ingredients and Properties of making ice cream.
6. Details of machinery used in ice cream manufacturing.
7. Type of Mix.
8. Varieties of ice Cream.
9. Packaging Material
10. Storage
11. Equipment Maintenance
12. Hygienic Maintenance
13. Cleaning & Sanitization.
14. CIP
15. Quality Assurance
16. Judging and grading of ice Cream
17. Engineering Section
i. Water
ii. Boiler
iii. Refrigeration
iv. Compressed Air
v. Soft Water
vi. Electricity
NATIONAL DAIRY DEVELOPMENT BOARD (NDDB)
The National Dairy Development Board (NDDB) was designed in 1969 on Anand Dairy Cooperative outlines of creating district cooperative of milk producers at village level which aim at collection of whatever amount of milk they produce and payment to them according to the quality of milk they supply. Then this milk is processed and supplied to the people at metropolitans and other cities at nominal charges.
For about 5 yr., NDDB was dormant till the time they received presents of Whole Milk Powder and Butter Oil from European Union and came into action with the help of Indian Dairy cooperation.
Operation flood was started in 1970 under the guidance of Dr. Kurein, Chairperson NDDB, Anand and Mr. Jamnadas Patel in Khera, Gujrat. The objectives of Operation Flood are:
To buy the milk from the farmers and villagers as much milk as they could supply at reasonable prices and keep the price of milk stable whole year.
To operate, procure, process and market milk and milk products.
Production of good milk after its qualitative and quantitative estimation.
System to eliminate middleman.
Providing technical inputs and services to yield of milch animals.
Organizing an efficient transport system to collect milk from villagers.
Set up of balancing dairies and storage system to convert excess milk to milk powder and butter oil.
Train personnel to plan and manage the system as well as operate the services described.
To meet out these objectives, NDDB started dairy plants all over India and Mother Dairy was one of them. It was set up in 4 major cities at Delhi, Mumbai, Chennai and Kolkatta.
Operation flood was a major dairy development program. Funds were generated by the sale of dairy commodities donated by the World Food Program (FAO-UN) which assisted project to carry out its mission.
This included establishing dairy cooperatives in rural milk sheds, setting of animal husbandry units, constructing modern dairies in cities, organizing storage and long distance transportation and project planning with manpower development. The first phase of operation flood was completed in 1979, followed by second phase (1979-1988), assisted by European Economic Community. It’s third phase ended in 1996.
MOTHER DAIRYPROFILE
Mother Dairy was set up under the operation flood project on second December 1974. It is equipped with latest technology. Products are prepared as per the PFA standards.
The dairy was established on behalf of the Govt. of India, Ministry of Agriculture (Dept. of Animal Husbandry and Daring). Mother Dairy is being managed by NDDB as a subsidiary unit retaining its independent character.
For the purpose of managing the dairy NDDB appoints managing committee. All the policy matters decided by the management committee but the execution of all the policy decision and management of dairy rests with General Manager.
QUALITY ASSURANCE
Mother Dairy follow a strict system of quality assurance to maintain a high quality of milk provided to the consumer. Every batch of incoming milk is tested for Fat, SNF, Acidity and bacteriological quality, adulterants and presence of any preservative or neutralizer which are not permitted by the law. The outgoing milk is also checked for bacteriological and keeping quality besides Fat and SNF.
QUALITY POLICY
Our commitment is to excellence. The evolving needs of our customers drive our continuous innovation in product development, application of state-of-the art technology and selection of appropriate processes to be used by our employees and our vendors.
To ensure that we are second to none:
We maintain a vibrant work environment that encourages excellence. We empower our people that lead to continuous improvements in our
processes and systems. We choose such processes that ensure quality at competitive price
while protecting the environment, in which we work and live. We apply HACCP (Hazard Analysis Critical Control Points)
principles for safety of our products to customers.
We shall constantly strive to be leaders in the dairy industry in Delhi, in India and in the World.
ENVIRONMENTAL POLICY
We are committed to be a leader in Dairy Industry in India by being a benchmark in environment protection.
We shall continue to improve our environmental performance by :-
Adopting processes, procedures and systems for clean production, pollution prevention and continual improvements in all our activities.
Optimizing resource utilization including energy and water. Complying with applicable environmental regulations and
legislation. Continuing distribution of milk through environment friendly
vending systems. Maintain green environment through horticultural activities. We pledge ourselves towards providing quality and safe
products under clean and hygienic environment.
Mother Dairy also have HACCP certification as per ISO 15000 : 1998
National Accreditation Board For Testing And Calibration Laboratories (NABL), MDTL, Delhi has been accredited to Mother Dairy on the basis of its compliance to NABL – criteria which are based on Chemical Testing Discipline. This accreditation is valid for a period of 3 years.
PRODUCTS
NDDB has also set up an oil storage unit by the name of edible oil tank farm (EOTF) in this area which has a capacity to store 50000 MT TONNES of mustard oil. Adjoining this, is also an oil lab notified by the govt. of India that do the job of testing of oil at the time of purchase and dispatch. It aims at providing the farmers the nominal charges for their oil produce according to its quality and to prevent hoarding of oil by private people.
Mother Dairy has also set up an ice cream plant (ICP) about 5 years back. Through ICP Mother Dairy markets the ice cream in and around Delhi at nominal charges and in varied flavors. Mother Dairy also markets Safal frozen vegetables, Verka, Parag, etc.
Mother Dairy has obtained the International std. Certificate issued by International Organizations of Standards (ISO) for its 23 years service, it’s the first in Indian food sector to receive it.
MOTHER DAIRY VISION:
With total commitment and teamwork, we at Mother Dairy shall strive to delight our customers with quality products and services.
We shall create an environment where employees feel happy to work.
Through innovation, consistent learning and continuous improvement, we shall achieve sustained growth and excellence and provide remunerative returns to farmers and other stakeholders.
MOTHER DAIRY MISSION:
“We are the market leader in fluid milk in Delhi. Our mission is to retain the leadership and further serve our customers in and around Delhi by providing quality milk and select dairy and food products.
We shall strive to delight our customers by providing regular and timely services at convenient points under clean and hygienic conditions, with a product mix for different income segment. We shall create an environment of commitment and teamwork where employees feel happy to work.
By innovation, continuous improvement, training and development and most efficient use of resources we shall achieve consistent and sustained growth and provide remunerative returns to farmers and other stakeholders.”
Mother Dairy has received the ISO 9002 certificate in 1994 for the quality of its food products.
FUNDAMENTAL KNOWLEDGE OF MILK
Milk is the secretion derived after complete milking of healthy milch animal, excluding that obtained within 15 days before or after 10 days of calving.
COMPOSITION OF MILK
01. Milk Fat Milk fat is the mixtures of 19 fatty acids. The bulk of fat in milk exist in the form of small globules with size approx. 0.1 to 22microns. It is an oil-in-water type emulsion.
02. Proteins Protein are the most complex organic substances. They are vital for living organisms as they constitute an indispensable part of the individual body cell. The protein of milk consist of Casein, Lactoglobulin and Lactoalbumin. It is in colloidal state. Casein is only found in milk. It is easily coagulated by heat treatment.
03. Water It provides the medium in which all the milk constitutes are either dissolved or suspended. Most of it is free and only a small portion is in bound form, being firmly by protein and phospholipids.
04. Lactose(Milk Sugar) It is found only in milk. It exist in true solution phase and is fermented by bacterial to yield lactic acid. It is very important for cultured milk products. It can also cause souring in milk and its products.
05. Mineral Matter: Although it is present in small quantity, it is very essential for human body. These are mostly salts like Mg, Na, P, N etc. It influences physio-chemical properties of milk and also affect the nutritive value.
06. Phospholipids: There are three types of phospholipids (Lecithin, Cephalic and Sphingomylein). Lecithin is important constituent as it helps in the formation of outer membrane of fat globules.
07. Pigment: There are two type of pigment present in milk, Fat Soluble and Fat insoluble. Carotene is fat soluble and is responsible for the yellow colour of milk. The other two are Xanthophylls and riboflavin. Carotene also acts as an anti oxidant and as a source of Vitamin A.
08. Milk Enzymes The important milk enzymes and their specific action are as follows:
- Anise (diasterase) Starch- Lipase Fat splitting, leads to rancid flavour- Phosphatase It is capable of splitting certain phosphoric
esters.- Protease It is capable of splitting proteins.- Catalase decomposed hydrogen peroxides.
09. Vitamins
Vitamins are present in minute quantities in milk or any other food but play a very important role in vital functioning of human body. There are 25 vitamins present in milk. These are fat soluble e.g. Vit. A, D, E,K. apart from fat soluble there are water soluble vitamins as B-complex(B1, riboflavin or B2, pantothenic acid, niacin, pyridoxine or B6.)
Role of milk in human life
Milk is one of the most complete food available in nature for human consumption. Milk contains all nutrients in balanced proportions to meet the demand of humans. It is not only necessary for children but it is every essential for adults too. Milk proteins are one of the most high quality proteins. It is essential proper growth of body. Casein, the milk protein, is only found in milk. Milk contains lactose (milk sugar) which is only found in milk and on hydrolysis gives galactose and glucose. Lactose on fermentation gives butter, cheese and dahi, which have high nutritive value and thus is very important for human life.
1 Liter of Cow’s milk gives 720 Calorie (3000J) of energy. 1 Liter of Buffalo’s milk gives 1100 Calorie (4600J) of energy. 1 gm of milk fat gives 9 Calorie of energy. 1 gm of Protein gives 4 Calorie of energy 1 gm of Carbohydrate gives 4 Calorie of energy
Most milk is composed of 80 to 90 percent water. The remaining 10 percent consists of an abundance of the major nutrients needed by the body for good health, including fats, carbohydrates, proteins, minerals, and vitamins.
Cow milk typically contains about 3.5 to 5 percent fat, which is dispersed throughout the milk in globules. In addition to providing milk’s characteristic taste and texture, fat supplies vitamins A, D, E, and K, as well as certain fatty acids that the body cannot produce on its own.
Lactose, a kind of sugar found only in milk, gives milk its sweet taste. Making up about 5 percent of milk’s content, lactose is a carbohydrate that is broken down by the body to supply energy. Infants digest lactose easily, but many adults, especially those of Asian and African ancestry, have lost some of their ability to digest this sugar. When these adults drink milk, they often suffer gastric distress and diarrhea.
The most important protein in milk is casein, accounting for 80 percent of milk protein. Casein is a complete protein, meaning that it contains all of the essential amino acids, which the body cannot manufacture on its own. Casein molecules and globules of fat deflect light rays passing through milk, giving milk its opalescent appearance. Other proteins present in milk include albumin and globulin.
Milk contains many minerals, the most abundant of which are calcium and phosphorus, as well as smaller amounts of potassium, sodium, sulfur, aluminum, copper, iodine, manganese, and zinc. Milk is perhaps the best dietary source of calcium—one liter (about 1 qt) of milk supplies as much calcium as 21 eggs, 12 kg (26 lb) of lean beef, or 2.2 kg (5 lb) of whole wheat bread. Milk is an excellent source of vitamins A and B2 (see riboflavin). All other vitamins are present also, but in lower doses. Vitamin D is typically added to commercially sold milk. Vitamin A, which is found in the globules of fat, is removed when fat is skimmed away to make low-fat or skim milk. Generally, vitamin A is replaced during the production of commercially sold low-fat milk.
STEPS IN ICE CREAM MANUFACTURE
Making the mix:
In order to make good ice cream, the milk products and other ingredients must first be selected and combined so as to produce the desired body and a delicately blend flavour. The selection of good, wholesome ingredients and calculation of a satisfactory composition proceed the mixing of the ingredients in a vat, where they can be heated to facilitate dissolving, blending and pasteurizing. The order in which ingredients are added as follows: liquid ingredients, basically milk, are placed in the jacketed vat provided with a power stirrer and the agitation and heating started at once. Powder is added at 350C and sugar, emulsifier and stabilizer is added while the liquid material as agitate. Butter is added at about 600C. The mix is agitated and heated to 65 – 700C and then pumped to duplex filter.
Filtration
The mix is then filtered using a duplex filter in order to make the mix completely free of extraneous matter and give the mix a smooth consistency.
Homogenization
Homogenization of the ice cream mix is essential. The main purpose of homogenization is to make a permanent and uniform suspension of fat by reducing the size of the fat globules to a very small diameter, preferably not more than 2 microns. Advantages of homogenization are-
It prevents fat separation during ageing Produces more uniform ice cream with a smoother texture Improves whipping ability Decrease the risk of churning occurring in the freezer and Leads to the use of slightly less stabilizer
Here a pressure of 1500 psi at first stage and 500 psi at second stage is applied.
Pasteurization
Proper pasteurization destroys all pathogenic or disease producing bacteria, thereby safeguarding the health of the consumer. The advantages of pasteurization are:
i) It renders the mix completely free of pathogenic bacteriai) It dissolves and helps to blend the ingredients of the mixii) It improves flavouriii) It improves keeping qualityiv) It produces a more uniform product
The pasteurization time temperature combination in the ice cream plant here is 85 + 50
C for 25 seconds.Chilling
The mix is then chilled to about 70C to facilitate ageing and after which it is pumped over to ageing vat.
Aging the mix
After cooling the mix the mix is pumped to ageing tanks and it should held in ageing tanks until used. Ageing refers to holding the mix at a low temperature for a definite time before freezing. Ageing produces the following results.
i) It improves the body and texture of ice creami) Improves whipping capacity of the mixii) Increased maximum overruniii) Increases melting resistance
The purpose of this step is to allow hydrocolloids to swell, the casein to become hydrated, the viscosity to increase, the texture to become finer, to increase the resistance to melting, the whip ability to improve, fats to crystallize out and aroma to develop uniformity throughout.
Freezing
Freezing of the mix is one of the most important operations in the making of ice cream. The freezing process may be divided into two parts.
a) The mix is quickly frozen in the freezer while being agitated to incorporate air in such a way as to produce and control formation of small ice crystals so necessary to give smoothens in body and texture and
b) When ice cream is partially frozen, it is drawn from the freezer into packages and quickly transferred to cold storage rooms where the freezing and hardening process is completed without agitation.
Fast freezing is necessary to obtain the desired small crystals which means that efficient scraping off, large temperature differences, high rpm and high heat transfer coefficients are required. The mix enters the freezer at a temperature of just above 0 C after the amount of air necessary for the required over run has been added. The exits temperatures are -3.50C to -70 C depending on the required consistency of the ice cream, which in turn depends on the subsequent requirements.
Process of Manufacturing
Selection of IngredientsToned MilkSMPWhey Protein ConcentrateSugarStabilizerWhite Butter
Figuring the mixFatProteinStabilizerSugar
Making the mixmix transfer pump
Duplex Filter
Homogenization of mixI stage 1500PSIII stage 500PSI
Raw milk chillerHMT Ltd. (Auranganad India)Type: CM4402M/C: 3719
HP HomogenizerTaliaFBF Italia BRLVia A Frank 1049044 Stradella di callecchicParma – ItlayMachine type: TS3Capacity: 2000LPHWorking Pressure: 210barInstalled power: 16KWSupply Voltage: 415VSerial No.: 98050665Manufacturing Year 1998Weight: 700kg.
HomogenizerCapacity: 1000kg (old)(Alfa laval)Alfa laval India ltd.DA PODIBombay, pune road, Pune – 411012
Flavour tank No. 3India Dairy machinery CompanyVithal Udyognagar – 388121Job No.:700Type: Flavour Mixing Tank.Year of Manufacturing: 1992Capacity: 600 liters
Flavour tank No. 4India Dairy machinery CompanyVithal Udyognagar – 388121Job No.:2224Type: Flavour Mixing Tank.Year of Manufacturing: 1999Capacity: 1000 liters
Flavour tank No. 5India Dairy machinery CompanyVithal Udyognagar – 388121Job No.:2224/2Type: Flavour Mixing Tank.Year of Manufacturing: 1998Capacity: 1000 liters
Flavour tank No. 6India Dairy machinery CompanyVithal Udyognagar – 388121Job No.:2224/1Type: Flavour Mixing Tank.Year of Manufacturing: 1999Capacity: 1000 liters
Flavour tank No. 7Industrial Aidess90492 HSIDC Kundli – 131028Distt. Sonepat (Harayana)Type: Flavour Mixing Tank.Year of Manufacturing: 2001Capacity: 1000 liters
Flavour tank No. 8Industrial Aidess90492 HSIDC Kundli – 131028Distt. Sonepat (Harayana)Type: Flavour Mixing Tank.Year of Manufacturing: 2001Capacity: 1000 liters
Flavour tank No. 9Industrial Aidess90492 HSIDC Kundli – 131028Distt. Sonepat (Harayana)Type: Flavour Mixing Tank.Year of Manufacturing: 2001Capacity: 1000 liters
Freezer no. 1 (Line No. 1)Alfa lavalGelmark 600Flow rate: 600LPHAlfa laval (India) Limited, DapodiBombay Pune Road, Pun – 411012Machine type: Gelmark 600Serial No.: 92060001Electrial DataVolts: 415Hz: 50Ph:3Total installed Power: 20.5KW.
Freezer no. 3 (Line No. 2)Alfa lavalGelmark 600Flow rate: 600LPHAlfa laval (India) Limited, DapodiBombay Pune Road, Pun – 411012Machine type: Gelmark 600Serial No.: 92060003Electrial DataVolts: 415Hz: 50Ph:3Total installed Power: 20.5KW.
Freezer no. 4 (Line No. 4)Alfa lavalGelmarkFlow rate1 60LPHAlfa laval (India) Limited, DapodiBombay Pune Road, Pun – 411012Machine type: Gelmark 600Serial No.: 92060001Electrial DataVolts: 415Hz: 50Ph:3
Total installed Power: 6.0KW.
Freezer no. 5Catta 2740056 Crespelland(BO) itlay via Della Solid Arieta.Modeled – Frzk 300AC.Matricola – 274606002, 27460600Anno Di Costruzione – 1998Voltagigo: 415 Volts.Fasi:3Hz: 50Potenza installata: 12KW, 34AmpRefregerante: Tipo R22, 6 kg.
Freezer no. 6 Line No. 10Catta 2740056 Crespelland(BO) itlay via Della Solid Arieta.Modeled – Frzk 300AC.Matricola – 258800005Anno Di Costruzione – 1998Voltagigo: 415 Volts.Fasi:3Hz: 50Potenza installata: 12KW, 34AmpRefregerante: Tipo R22, 8kg..
Freezer no. 7Catta 2740056 Crespelland(BO) itlay via Della Solid Arieta.Modeled – Frzk 300AC.Matricola – 258800005Anno Di Costruzione – 1998Voltagigo: 415 Volts.Fasi:3Hz: 50Potenza installata: 12KW, 34AmpRefregerante: Tipo R22, 8kg.
Freezer no. 8Catta 2740056 Crespelland(BO) itlay via Della Solid Arieta.Modeled – Frzk 300AC.Matricola – 258800006Anno Di Costruzione – 1998Voltagigo: 415 Volts.Fasi:3Hz: 50Potenza installata: 12KW, 34AmpRefregerante: Tipo R22, 6 kg.
Freezer no. 9Catta 2740056 Crespelland(BO) itlay via Della Solid Arieta.Modeled – Frzk 300AC.Matricola – 274606002Anno Di Costruzione – 1998Voltagigo: 415 Volts.Fasi:3Hz: 50Potenza installata: 12KW, 34AmpRefregerante: Tipo R22, 6kg.
Freezer no. 10 Line No. 7Catta 2740056 Crespelland(BO) itlay via Della Solid Arieta.Modeled – Frzk 300AC.Matricola – 274606003Anno Di Costruzione – 1998Voltagigo: 415 Volts.Fasi:3Hz: 50Potenza installata: 12KW, 34AmpRefregerante: Tipo R22, 3.5 kg.
Freezer no. 11 Line No. 6Catta 2740056 Crespelland(BO) itlay via Della Solid Arieta.Modeled – Frzk 300AC.Matricola – 25840014102Anno Di Costruzione – 1998Voltagigo: 415 Volts.Fasi:3Hz: 50Potenza installata: 12KW, 34AmpRefregerante: Tipo R22, 3.5kg.
Freezer no. 12 Line No. 8Constuttore manufactureFabric ant BauerSidamIndirizzo address adresse adresseVia Fabio Filiz 3720032 Cormani(mi) - ItlayModeled – Freezer KF75/1DEMatricola – 8.810111Anno Di Costruzione – 1998
ExtrusionLine:Hardening Temperature: -36OC to -45 OC.No. of plates: 600
In Extrusion line temperature is maintained in the hardening tunnel around -45OC. Forced convection is evaporators are used in the hardening tunnel. Liquid ammonia is in the tube and fan is rotating continuously back side of the evaporator. Cool buddies ice cream are manufactured in this machine.
Temperature should be maintained below 90C before use in production.
EFFICIENCY OF THE MACHINE
OEE = Overall Equipment Effectiveness.
OEE = Availability x Performance Rate x Quality Rate.
Availability should be more than 90%.. Performance should be more than 95%. Quality Rate should be more than 99%.
OEE = AxPxQ = 90%x95%x99% = 85% (OEE)
Availability means how much machine works in 24 hours.Availability = Machine working time/Total timePerformance Rate: Current Capacity of the plant / Total capacity of the plant.Quality Rate: No. of Right products manufactured / Total No. of Products.Bench mark: Capacity of the equipment in LPH.
FRUITS AND NUTS MANUFACTURING
Chocolate Cone 50ml:o Weight: 9gm (empty cone)o Con Biscuit wt. : 7gm.o Weight of nuts and crackles: 1.6gmo Topping weight: 3.4gm to 4gm.o Spray Weight: 6gmo Ice Cream Weight: 22gm.o Temp. of cone syrup: 50OC.o Speed of cone filling machine: 44cone/min.
Kulfi Cone:o Total weight: 53.8gm.o Stick Weight: 1.2gm.o Lid Weight: 1.2gm.o Kulfi Cone(without lid & stick): 23.3gm.o Empty kulfi cone weight: 5.8gm.
Kaju Kishmish (100ml cup):Weight of kaju kishmish in 100ml cup.
Procedure:1. Take 100ml cup of kaju kishmish ice cream.2. Draw the ice cream in a beaker.3. Dissolve the ice cream with the help f pipette.4. Filter it with the help of filler cloth.5. Nuts is taken in Petri dish.6. Weight the dish & note down.
7. then keep the dish in hot air oven at 101+-1OC for 1 and1/2 hour.8. Remove the dish from the hot air oven and cool it in a desicator.9. The weight the dish & note down.10. Nut is takenout from the dish.11. Weight the nuts in paper with the help of weighing machine.
Chillz Chocolate Treat:o Total weight: 68.3gm.o Centre filling weight: 8gmo Wheat crispy weight: 2.5gm. (should be 2gm)o Toping weight: 10.5gm.(should be 12gm).o Stick weight: 1.1gm.o Wrapper weight: 1.4gm.o Chocolate ice cream weight: 41.2gm.
Strawberry ice cream cone (100ml).o Weight of rice crispy: 0.6gm.o Topping weight: 4.3gm/6g,/o Empty cone weight: 12gm.o Spray weight: 11.5gm/8gn.o Lid Weight: 1gm.o Total weight: 78gm.
Chillz mango Bar:o Plain Mix Temperatue: 6OC.o Mago Pulp Temperature: 8OC.o Wrapper Weight: 1.4gm.o Total weight:54.9gm.o Cup weight: 2.8gm.o Cup + plain mix = 27.2gn.o Cup + Mango Pulp: 54.1gm.o Mango Pulp Coating Weight: 54.1 – 27.2= 26.9gm.
Strawberry Crush fruit weighto Cup weight: 2.9gm.o Total weight (cup with ice cream): 65.4gm.o Strawbery weight + cup weight: 6.1gm.o Strawbery fruit weight: 6.1 – 2.9 = 3.2gm/100ml.
Keep the fruit in metal dish and then keep in hot air oven at 101+-1OC for 1.5hour. After 1.5 hours dish is taken out and weight the dish. Calculate the moisture and substrate it from the strawberry fruit weight: 3.2 – 0.9 = 2.3gm/100ml.
Mango & Raspberry (60ml)
o Cup weight: 3.3gm.o Cup + Raspberry weight: 34.5gm.o Raspberry weight: 34.5 – 3.3 = 31.2gm.o Wrapper + stick + Mango = 32.5gm.o Mango = 32.5 – 2.6 = 29.3gm.
1. Processing of Cashewnut, Pista and Badam- Cutting in nuts and fruits cutting machine- heating in hot air oven at 85 +/- 5OC for 11/2 hours.- Cool to room temperature- Sorting based on different varities of ice cream.- Storage of low temperature.
2. Processing of Kismiss and Tutti Fruity- Complete washing to remove any dust extraneous matter etc.- Washing in 25 ppm chlorine solution for 5 minutes- Remove the water completely and store in cold store
3. Processing of Litchi- Cutting of tin using the cutting machine and transfer the contents to clean
dish- Allow liquid glucose which is added in proportion of 20 lichi : 1 glucose is
added and allow it act for 30 minutes.- Wash with flow of water- Cold storage
4. Mango Pulp- Cut the tins and transfer the contents to a clean dish.- Add necessary amount of sugar to mango pulp andmix well for about 62 kg pulp -
19 kg. Sugar is added- Store under 4OC until used.
5. Processing of Saffron1) Take necessary amount of mix and dissolve it in water to make 50%
concentration syrup.2) Heat to boiling.3) Take calculated amount of saffron which has been previously treated to
50OC for 10 minutes, is taken and dissolved in the mix.4) Heat it to 30 C for 15 minutes5) Cool and filter the mixture6) Add the saffron mixture into mix and rest saffron is grinded and added
to mix itself.
6. Processing of StrawberryThe strawberry crush in tins is first opened
- The syrup is drained and the strawberry is transferred to filter then- Flavour and colour is added and stored in cold storage
All the fruits and nuts processing is done in one day prior to the use of that particular fruits and nuts
FLAVOUR
S..No. Name Flavour Quantity1 Bars Chocolate Bars 65ml
Mango Bars 65mlPine Apple Bar 60mlRaspberry Bar 60mlMini Chocolate Bar 45mlChocolate Treat 75mlButter Scotch Treat 75mlMega Bar 100ml
2 Cones Chocolate 100mlButter Scotch 100mlStrawberry 100mlMini Chocolate Bar 50ml
3 Milk Lolly Banana, Pine Apple, Rose
35ml
4 Ice Candies Orange Candy, 60mlMango Candy, 60mlLemon Candy, 60mlCola Candy, 60mlMango Raspberry 60mlOrange with strawberry centre
o Milk and milk products, o Sugar, o Permitted emulsifying & stabilizing agent, o Contains permitted synthetic food colour and added flavour.
Choco Chips Ice CreamIngredients:
o Milk and Milk products, o Cocco solids, o Sugar, o Permitted emulsifying and stabilizing agents, o Contains permitted synthetic food colours and added flavoured.
Butter scotch Ice CreamIngredients:
o Milk and Milk products, o Sugar, nuts, o Permitted emulsifying & stabilizing agents,
o Contains permitted synthetic food colors and added flavors.
FRUIT CLASSICS
Black Current BlissIngredients:
o Milk and milk products,o Sugar, o Black current fruit, o Permitted emulsifying and stabilizing agents., o Contains permitted synthetic food colours and added flavour.
Cool Buddies:Vanilla & Strawberry flavoured ice cream bar:
Ingredients:o Milk and Milk products,o Sugar, o Permitted emulsifier and stabilizing agents, o Contains permitted synthetic food colors and added flavour.
Cool buddiesRocketVanilla & mango flavoured ice cream bar
Ingredients:o Milk and milk products, o Sugar, o Mango pulp, o Permitted emulsifier and stabilizing agent, o Contains permitted synthetic food colors and added flavour.
Cool BuddiesVanilla & Orange ice cream being:
Ingredients:o Milk and Milk products,o Cane Sugar,
o Permitted emulsifier and stabilizing agent, o Contains permitted synthetic food colours and added flavour.
Chillz Mango Bar:Ice Cream with ice candy covering
Ingredients:o Milk and milk products,o Cane Sugar, o Mango pulp, o Liquid glucose, o Citric acid, o Permitted emulsifier and Stabilizing agent.
Ingredients:o Milk and Milk products,o Cane Sugar,o Liquid Glucose,o Fruit Pulp,o Citric acid,o Permitted Stabilizer and emulsifying agent.
Chillz Mega Bar:Vanilla Flavoured ice cream with chocolate covering:
Ingredients:o Milk and Milk products, o Cocoa solids, o Cane sugar, o Wheat crispy, o Permitted emulsifier and stabilizing agent, o Contains permitted synthetic food colors and added flavour.
Chillz Chocolate Treat:Chocolate ice cream with chocolate covering
Ingredients:o Milk and Milk products, o Cocoa solids, sugar, wheat, crisp, o Permitted emulsifier and stabilizing agent, o Contains permitted synthetic food colors and added flavour.
Chillz Pineapple bar:Vanilla flavoured ice cream with pine apple flavoured ice candy covering
Ingredients:o Milk and milk products,o Cane Sugar, o Liquid Glucose, o Pine apple pulp, o Citric acid, o Permitted emulsifier and stabilizing agent.
SmilyCola Flavour
Ingredients:o Water,o Cane Sugar,o Liquid Glucose,o Citric acid,o Permitted emulsifier and stabilizing agent, o Contains permitted synthetic food colors and added flavour.
Ingredients:o Milk and Milk products,o Cane Sugar and permitted emulsifier and stabilizing agent, o Contains permitted synthetic food colors and added flavour.
Lic lolleez (milk lolleez)Rose and Milk
Ingredients:o Milk and milk products,o Cane sugar. permitted emulsifier and stabilizing agent, o Contains permitted synthetic food colors and added flavour.
Fruit classicPine apple wonder (with pine apple pieces)
Ingredients:
o Milk and milk products,o Sugar, o Pine apple pulp, o Fruit, o Permitted emulsifier and stabilizing agent, o Contains permitted synthetic food colors and added flavour.
Chillz Strawberry Cone 100mlIngredients:
o Milk and Milk products,o Sugar,o Wafer biscuit,o Cocoa solids,o Rice crispy,o Permitted emulsifying and stabilizing agents.
KulfiesBudam kulfi
Ingredients:o Milk and milk products,o Sugar,o Nuts, o Permitted,o Emulsifying and stabilizing agent, o Flavoured with badam.
Pista Kulfi:Ingredients:
o Milk and milk products,o Sugar,o Nuts,o Permitted emulsifying and stabilizing agent.o Flavoured with Pista.
Kesar Kulfi:Ingredients:
o Milk and milk products,o Sugar,o Nuts,o Permitted and stabilizing agents, o Flavoured with kesar.
Fruit Classic
Mango Marvel: With real alphorrso.Ingredients:
o Milk and Milk products,o Sugar, mango pulp,o Permitted emulsifier and stabilizing agent, o Contains permitted synthetic food colors and added flavour.
Sundae magicShahi mava malaiKheer flavoured ice cream with saffron sauce:
Ingredients:o Milk and milk products,o Sugar,o Nuts (kaju and badam),o Saffron extract,o Liquid glucose,o Permitted emulsifier and stabilizing agent, o Contains permitted synthetic food colors and added flavour.
Chillz mini chocolate barIngredients:
o Milk and milk products,o Cocoa solids,o Cane sugarm permitted emulsifying and stabilizing agents.
Kulfi pistaIngredients:
o Milk and milk products,o Sugar, o Nuts, o Permitted emulsifier and stabilizing agent.
Nuts and Fruit RoomProcessing and Storage of Nuts:
Issue of nuts from store for processing
Sorting
Cutting
Roasting (85+-50C for 90min.)
Cooling in normal temperature.
Put in dry basket.
Weighment
Storage.
Processing of Kaju, Pista and badam.
1. Cutting the nuts by machine.2. Keep the nuts in oven for (85+-5oC) at 1.5 hours.3. After roasting cool the nuts at normal temperature (room).4. Filter the nuts by steel mesh.5. Grinding the nuts according to the different ice cream.
Processing of Chikki
1. Break the chikki strip in small pieces with the help of hammer.2. Filter the chikki by steel mesh according to the different ice cream.
Processing of Kishmish & Tutti Fruiti
1. Wasing the fruits.2. no dirt or dust should come on the surface of fruit.3. Washing in 50ppm chlorine. Solution for 5 min.4. Taking out remaining water.5. Keep the fruit in cold storage for cooling.
Processing of Litichi
1. Open the tin of litichi by in cutting machine carefully.2. Keep the fruits in liquid glucose and then drain out from water.3. Keep the litichi in cold store for cooling.
Processing of mango pulp
1. Cutting the tin of mango pulp.2. keep the mango pulp in clean utencils.3. Mix the sugar according to the requirement (1kg pulp, 300gm sugar)4. Store at 4OC till it is utilized.
Processing of kesar
1. Take the appropriate quantity of mix.2. Dissolve in water of 250% concentrate/3. Boil the solution.4. Add roasted kesar at 50OC for 10min.5. Heat it at 80OC for 15 min.6. Cool the mixture and filter it.7. Mix the solution in mixture and add remaining leaves after grinding.
Flow Chart
Kesar
Keep in Box
Keep in hot air oven (roasting, 50OC for 10min.)
Plain mix
Standardized(1:1)
Mix
Heated (85OC)
Mix with kesar
Boiling
Filtration
Grinding
Mix with plain mix
Storage
Strawberry
Flow Chart
Strawberry (Box)
Open the lid
Filter (Drain the syrup)
Keep the strawberry fruit in vat.
Add strawberry flavour(1kg fruit and 2 ml flavour)
The material is viscous semi liquid with a characteristic odour. It is light yellow to brown depending upon whether it is bleached or unbleached. Lecithin is obtained from egg or edible vegetable oil seed by suitable dehydration or solvent extraction. Using food grade solvents. It may also be obtained from animal sources.
Kesar (Saffaron)
Flow Chart
Saffaron (Stigma)
Spread in a Tray
Keeping in Oven at 500C for 10mn.
Stir in Hot milk for 5-6 min.
Strain saffaron extracted milk
Retenate (kesar)
Grind to paste
Mix with ice cream mix in flavour tank.
Black Current Processing:
Black current fruit
Sorint
Keep in vat
Washing
Filter
Washing
Filter
Washing
Filter
Add water 40 liter.
Add 25ml chlorine
Washing
Filter
Keep in box processing
QUALITY CONTROL LABORATORY(ICP)
Solutions used in ICP laboratory.
1. Potassium Dichromate2. Ammonia Buffer solution3. Erichrome Black T indicator4. N/50 EDTA5. AgNO3 (N/10)6. 10% K2Cr2O4 (Potassium Chromate)7. N/10 HCl8. Cupric Sulphate Solution9. Potassium Sodium Tartarate.10. Methylene blue indicator.11. Lead Acetate12. P. Rosolic acid solution13. N/10 oxalic acid14. Phenolphthalein solution15. Potassium Chloride16. N/10 NaOH solution17. Phenophthalein indicator
18. Rosalic Acid.
Preparation of chemicals
1. N/50 EDTA: Dissolve 3.72gms of EDTA in 1L of distilled water.
2. N/10 AgNO3:Dissolve 16.9gm AgNO3 in 1L of distilled water.
3. 10% potassium chromatic:Dissolve 10gms K2CrO4 in 1L of distilled water.
4. Neutral lead acetate:Dissole 41gms of lead actetate in distilled water and neutralize with CH3COOH or NaOH (using litmus paper) anmd then dilute to 100ml.
5. Nesslers Reagent:Mix solution A (8gm HgCl2 in 150ml of distilled water) and solution B (60gm NaOH in 150ml distilled water). Add solution C (16gm K.I in 150ml distilled water). Make volume to 500ml.
6. Rosalic acid solution (0.05%):Dissolve 2.5gms of rosalic acid powder in 5 L of 60% alcohol (3L of distilled rectified spirit and 2 liters of distilled water).
7. Sodium Hydroxide (N/10 NaOH) solution:Dissolve 4gms of NaOH pellets in distilled water and make up he volume to 1 L. Standardize with N//10 oxalic acid.
8. N/50 EDTA;Dissolve 3.72gm of EDTA in 1L of distilled water.
9. N/10 AgNO3:Dissolve 16.9gm AgNO3 in 1L of distilled water.
10. 10% Potassium Chromate:Dissolve 10gm of Potassium Chromate in 1L f distilled water.
11. Natural Lead Acetate:Dissolve 41gm Lead Acetate in distilled water and neutralize with CH3COOH or NaOH (using litmus paper) & then dilute to 100ml.
12. Eriochrome Black:Dissolve 0.5gm eriochrome black T in 100ml rectified spirit.
13. 50% Hydrochloride:Dilute 50ml of concentrated HCl with 50ml of distilled water.
14. N/10 HCl solution:Dilute 25ml concentrate HCl to 2.5 litre in distilled water ( 10ml concentrated HCl in 1 litre of distilled water).
15. Oxalic acid (N/10): Dissolve 6.30gm in 1000ml of distilled water.
16. Phenolpthalein Solution (0.5%):Dissolve 5gm phenolphthalein powder in 50% alcohol (500ml) and then add 500ml of distilled water to make up the volume 1 Litre.
Standardization:
NaOH (0.1N):
1. Prepare a concentrated stock solution of NaOH by dissolving equal parts of NaOH (pellets, AR grade) and water in a flask.
2. Tightly place stopper with rubber bung and allow it to stand for 3 to 4 days. The impurities (Na2CO3 and NaHCO3) will settle down as turbid solution at the bottom.
3. Decant the clear supernatant for standardization of either 1N or 0.1N solution. This is standardized against 11N or 0.3N oxalic acid.
Silver Nitrate (AgNO3):
1. Prepare 0.1N solution be dissolving 17.5gm of AgNO3( eq. wt. 169.67) in the halogen free water and dilute to volume 1Litre.
2. Store the reagent in amber colour bottle.3. Standardize the AgNO3 solution against a solution of NaCl of known strength by
volhard method in the following manner.4. Place on a watch glass about 5gm of NaCl (eq. wt. 58.5) and dry in an oven at 250
to 350OC for 1 to 2 hour. Cool in a desicator.5. Weigh accurately in a treated beaker 5.85gm of the dried salt.6. Dissolve the salt in chloride free distilled water and transfer quantitatively in 1 litre
volumetric flask.
7. make up volume to the mark with halogen free distilled water.8. Mix it well and store in reagent bottle.9. Fill up prepared AgNO3 solution in burette.10. Pipette 10ml of 0.1N NaCl into 150ml conical flask.11. Add 2ml of 5% potassium chromate indicator and titrate wth NaCl solution.12. Rotatingthe flask continuously until the addition of one drop of the AgNO3 causes
the turbid yellow liquid to move towards a reddish colour (Brick red) which persists after briskly shaking the flask.
13. Repeat the titration until concordant result are obtained.14. Deduct from the value, the amount of AgNO3 required to produce the similar
changes of colour in a mixture of 20ml of distilled water.15. 2mkll of indicator and produce approx. the same degree of turbidity.
EDTA
1. Dissolve 3.8gm commercial AR disodium ethylenediamine dihydrogen tetra acetate, which has been dried at 800C for 1 hour in distilled or deionized water and make the volume to 1 litre.
2. Mix it well. Store in polyethylene reagent bottle.3. Standardize it against 0.01M CaCO3 or CaCl2.4. Prepare standard Ca solution (1mLength=1gm CaCO3 mWidth=100) by weighing
1gm CaCO3 dried overnight or longer at 105oC into 500ml concialflask or beaker and adding dilute HCl through tunnel until CaCO3 is dissolved.
5. Add 20ml water, boil to expel CO2 and cool.6. Add few drops of mehyl red indicator and adjust colour intermediate orange
(Brownish red) with dilute NH4OH or HCl as required.7. transfer quantitatively to 1Litre volumtrai flask and make up the volume to the
mark.8. Shake it well and store in air tight readent bottle.9. Rinse and then fill burrette with prepared EDTA solution.10. pipette 25ml of standard CaCO3 solution into 250ml standard CaCO3 solution into
250ml concial flask.11. Add 1ml ammonia buffer and 3-4 drops of Erichrome Black T indiactor.12. Titrate with EDTA solution until colour changes from wine red to dark blue with no
reddish tunge remaining..13. Calculate the molarity of EDTA (m1v1 = m2v2), if excess follow the procedure for
the standardization of NaOH.
14. After final standardization, recheck the molarity and it should be 0.01M.
HCl
Specific gravity = 1.18 at 20OC, strength = 12N & 36% by weight.
For preparing various normal solution the eq. wt. is not used but commercial ly normal strength (12N) is taken for calculation. The prepared solution can be standardized with solution of anhydrous Na2CO3 using methyl orange as an indicator with orange to red end point.
OXALIC ACID:
1. Weigh accurately 6.304 (1N) or 0.6304 (0.1N) oxalic acid (eq. wt. 63.04) which has been previously dried at 103-105OC for 30min and cooled in desicator. Using a clean dry weighing bottle or small beaker.
2. Add some distilled water and dissolve with the help of a glass rod.3. Transfer the solution quantitatively (washing beaker and glass rod with distilled
water) in a 100ml volumetric flask through a funnel.4. Make up the solution with distilled water to the mark.5. Shake it thoroughly and store in a clean dry reagent bottle. The strength remains
unchanged for a long period.6. take a clean burette and rinse it with little (5ml or so) . prepared sodium hydroxide
solution and clamp it vertically on a stand.7. Pipette 10ml of oxalic acid solution in a 100 or 150ml conical flask.8. Add 2-3 drops of phenolphthalein indicator and shake it well.9. Titrate it with sodium hydroxide solution with shaking until permanent faint pink
colour persists.
CHEMICAL ANALYSIS OF ICE CREAM
OVER RUN
Procedure:
1. Clean and weigh the over run cup.2. Fill the brim with ice cream mix and weigh.3. Record the weigh of the mix.4. Clean, Dry and weigh the over run cup.5. Fill the brim with ice cream and scrap the top.6. Record the weight of ice cream.
Note:Specific gravity of Gerber Sulphuric Acid: 1.84Specific Gravity of amyl alcohol is 0.82Specific Gravity of plain mix is 1.1Specific Gravity of milk lollees is 1.04Specific Gravity of Candy mix is 1.08Specific Gravity of Kulfi mix is 1.17Specific Gravity of Chocolate mix 1.1Specific Gravity of Fat is 0.93Specific Gravity of SNF is 1.3
Determination of Sucrose
(A) Determination of Original Reducing Sugar.
1. Weigh 10gm of ice cream sample into 250ml conical flask.2. Add 150ml water and mix thoroughly.3. Add neutral lead acetate drop by drop with rotating gently, until no further
precipitating form.4. Add one drop of alumin cream.5. Mix and keep it for few minutes with occasional rotation to ensure complete
precipitation of protein.6. Add just sufficient sodium oxalate to precipitate any excess of lead.7. Filter through filter paper no.1 into 250ml volumetric flask.8. Wash the precipitate with hot water.9. Collecting all the washing in flask.10. Cool and make up the mark.11. Carry out titration against 10ml Fehlings solution.
Original reducing sugar(%) = (25xX)/(SxW)
Where,
X = mg invert sugar equivalentS = ml of the dilute filtrate used for titration.W = Weight in gm of the sample.
(B) Determination of Reducing Sugar after inversion:
1. Take 10ml diluted filtrate into a 200ml volumetric flask.2. Add 25ml water and 10ml 6.34N HCl.3. Invert as described in the preparation of standard dilute invert sugar solution,4. Carryout titration against 10ml Fehlings solution
Sucrose = (Reducing sugar after inversion – Reducing Sugar before inversion) x 0.95.(by wt.)
The value of X can be determined by standardization of 10ml of Fehlings solution.
PACKAGING MATERIAL
GSM ( Gram Square Meter).
GSM is calculated to find the strength of the material.
Procedure:1. Take a brick of ice cream of any size.2. Cut it one side rectangular piece.3. Findout the area and weight of rectangular piece.4. Calculate the GSM.
Types of Packaging MaterialCBX (Cerugated Box) Specification
1. Take different types of CBX of ice cream.2. Cut it into rectangular pieces of each CBX of ice cream.3. Fold the rectangular pieces and keep in water beaker.4. After 1/2hour drawn the pieces and separate it into three different layer.5. Keep the layer in hot air oven (101+- 1oC) till it becomes dry.6. Draw the piece from the hot air oven.7. Measure its dimension & weight.8. Calculate the GSM (Gram Square Weight).
Laminate GSM
Procedure:
1. take different types of laminate of different variety.2. Cut it into rectangular portion.3. Measure its dimension and weigh.4. Calculate the GSM.
Bursting Strength of Packaging material
Appratus: Bursting strength tester.
Principle: When the packaging material is pressed from both sides and pressure is applied by liquid filled ball from bottom, it cause bursting of the material. The pressure indicated by pressure gauge is noted.
Procedure: Tighten the packing material between the seats of the tester and press the button, which increase the pressure and the pressure is noted from pressure gauge.
Bursting strength of Packaging material (CBX should be 4kg/cm2)
Corrugated boxesSpecification
S.No. Description Paper GSM Face Bursting strength (kg/cm2)Influte inside
Principle:Gerber acid dissolves all the constituents other than fat and amyl alcohol reduces the surface tension & helps in separation of the two media.
Procedure:1. Put 10ml of Gerber Sulphuric Acid in ice cream butyrometer.
2. Pour some amount of water in the same.
3. Now put this butyrometer in cylinder on the weighing machine and set its weight to zero.
4. Weigh 5gm of sample into ice cream butyrometer. The sample should not tuch the walls of the ice cream butyrometer.
5. Add 2ml amyl alcohol.
6. Now pour some distilled water to make up the volume.
7. Keep this butyrometer in a centrifuge at 1400RPM for 5min.
8. Keep out from the centrifuge and note the percentage of fat
9. Divide this reading by weighing of the sample taken & multiply this value by 5, so exact percentage fat will come out in 5gm of sample.
Fat% = (Ice-cream butyrometer reading x 5)/wt. of sample.
Principle:The carboxylic group of alpha amino acid cannot be accurately titrated with alkali as it result with basic amino group to from zwitter ion that are not decomposed completely at the end point of the decomposed completely at the end point of the reaction. The amino acids are first neutralized with formaldehyde which black the terminal group of amino acid and can be sharply titrated with alkali. The amount of alkali required for the purpose is proportional to the carboxylic group of amino acid.
Procedure:
1. Wash the beaker with water, clean it with tissue paper.
2. Weigh, clean, dry an empty beaker and set its weight to zero.
3. Weigh exactly 10gm of sample into beaker.
4. Make up the volume of 50ml.
5. Add 1ml of phenopthalein indicator into the beaker. Shake it well.
6. Add 0.4ml of saturated potassium oxalate in the beaker.
7. Wait for 2 minutes.
8. Titrate the contents with Std. NaOH solution (to pink colour).
9. Now add 2ml of neutral formaldehyde.
10. Shake it and titrate against std. NaOH solution.
11. Calculate the protein percentage by the formula.
Protein percentage: 1.7x vol. reading.
Acidity Test:
Apparatus: Beaker, Pipette, Burette
Reagent:Phenopthalein, Std. NaOH (0.1N)
Principle:The titrate acidity test is employed to find out the acidity of the mix prepared, which of higher can reduce its keeping quality. The principle is the simple acid-base titration in which phenolphthalein is used as an indicator, which gives pink colour in alkaline medium and is Colourless in acidic media.
Procedure:
1. Wash the beaker with water, clean it with tissue paper.
2. Weigh a clean, dry and empty beaker and set its weight to zero.
3. Weigh exactly 10gm of the sample into the beaker.
4. Make up the column of 50ml by adding distilled water.
5. Add 2 to 3drops (1ml) of Phenopthalein indicator into the beaker.
6. Titrate against N/10 NaOH solution.
7. Note the reading of the burette in terms of ml of std. NaOH and utilized multiply this value by 0.09 and divide this fraction by the weight of sample taken to get acidity of given sample.
Percentage Acidity: 0.09x vol. reading.
Neutralization Test:
Object: To check the neutrality of the sample.
Apparatus: Pipette, test tube, rosalic acid solution in 60% ethyl alcohol.
Reagent: Rosalic acid solution in 0% ethyl alcohol.
Principle: Mix is having slightly acidic pH of 6.5 to 6.7. Rosalic acid in acidic pH gives orange pink colour.
Procedure:Take 1ml rosalic acid and 1ml of sample in test tube and shake well.Petal red indicates positive test.Slightly orangish shade: Negative test.
Phosphatase test:
Object: To test for pasteurization of the sample.Apparatus: Pipette, Test tube.Reagent: Phosphatase dye.
Preparation of phosphatase dye:
Base – Alkaline buffer (sodium carbonate and sodium bicarbonate).2,3 para nitrophenyl phosphate + Orthophosphate indicator.Phenyl group of indicator + Acid phosphatase of milk.Yellow colour (phenyl derivative).
Principle: On pasteurization of mix, enzyme acid phosphatase gets destroyed. If sample gives fluorescent yellow colour with the sample, with 30 minutes of the set up, it shows that the acid phosphatase is active and sample is not completely pasteurized.
Procedure:1. Take 1ml of sample in test tube.2. Add 5ml phosphatase dye and shake well.3. Now incubate for 2 hours at 370C.4. Yellow colour indicates mix is pasteurized while lemon yellow colour
appears the acid phosphatase is active.
Percent Fruit:1. Take weigh of ice cream.1. Dissolve in water and separate the fruits using sieve.2. Dry the fruit in filler paper.3. Weigh the fruit.
% Fruit = (wt of fruit/wt of ice cream) x 100.
Specific gravity:
Apparatus: Picnometer, weighing balance.
Procedure:1. Wash the picnometer with water. Clean it with tissue paper.
2. Keep the picnometer in hot air oven (101+-10C) for 10minutes.
3. Taken out the picnometer from oven and put in desiccators at normal temperature.
4. Weigh the picnometer and note the reading (W1).
5. Put into distilled water up to the head.
6. Stopper it with knob.
7. Weigh the picnometer (W2).
8. Drain the distilled water.
9. Put the sample in picnometer.
10. Stopper it with knob.
11. Weigh the picnomenter(W3)
12. Calculate the specific gravity by the formula.
Sp. Gravity = (W3 – W1)/ (W2 – W1)
Moisture of Sugar
Object: To determine moisture% in sugar.
Apparatus: Metal dish, weighing balance.
Procedure:1. Heat the two metal dishes in hot air oven at 101+-1OC) for 1 hour.
2. Put into dessicator at the normal temperature.
3. Weigh the dish on the weighing balance and note the reading (W1)
4. Put the 2gm of sugar and note the reading (W2).
5. Exactly the same procedure is done for another dishes to find out the No variation.
6. Keep in hot air oven for 1½ hours at 101+-1OC).
7. Cool in a desicator for at least 10 minutes.
8. Weigh the both dish (W3)
%TS = (W3- W1) / (W2 – W1) X 100
Moisture = 100 – TS%
Brisk
Object: To determine the brix of candy mix.
Apparatus: Refratometer, pipette.
Procedure:
1. Clean the prism where a drop of mix is to droped by tissue paper.2. keep the drop of mix with the help of pipette.3. Close the shutter.4. Adjust the light with the help of screw.5. Find out the brisk of candy mix.6. Sugar% <12%.7. RI = 1.8798. Sugar = 28%
Free Fatty Acid (FFA)
Object: To determine the FFA of cocoa butter.
Apparatus: Beaker, pipette, hot plate, weighing machine.
Reagent: N/10 NaOH, Phenopthalein spirit.
Procedure:
1. Take 10gm of cocoa butter.2. Melt the sample.3. Weigh 50ml spirit.4. Neutralize with adding 1ml Phenopthalein.5. Titrate against N/10 NaOH till pink colour appears.6. Mixing with melted cocoa butter.7. This mixture is boiled to its boiling point with the help of hot plate.8. Then it is titrated against N/10 NaOH till the pink colour appears.9. Calculate the FFA% by formula:
FFA% = 2.82x Vol. Reading / Sample weight.
=2.82 x 3.15/ (10.1- sample weight).
FFA = 0.879%.
REFRIGERATION
Capactity: 250TR
Refrigeration is the process to bring the temperature of the system lower w.r.t the temperature of the surrounding.
Unit of Refrigeration: TR (Ton of Refrigeration).
One TR is the amount of heat which is being required to withdraw from 1000kg of water at 0oC to convert it into ice of 1000kg at 0OC within 24 hours.
Latent heat of vapourization = 540Kcal/kg.Latent heat of ice = 80Kcal/kg.
If the refrigeration cycle is running properly:Evaporator load = Condenser load.
Condensor capacity:270 TR / 250TR300TR / 250TR
COP ( Coefficient of Performance)
COP = Evaporator Load / Compressor W.D
= (EE – ED) / ( EA - EE)
for good running condition, COP > 4
Compressor
Capacity I & II is 203TR
In Mother Dairy (ICP), the two stage compressor are used. This is because
1. Energy Saving.2. Deep Chilling
In Walzer and extrusion line we have to maintain temperature -35 to -450C.Type: 4 Single stage & EconomizedSwept volume: 470 to 860 m3/h (270 to 507) (FM) at 2940/min (RPM).Minimum discharge pressure: 25bar (363 PSI)
The Principle of compressor is to take the vapour at low pressure and low temperature and compressed it to high pressure and high temperature.
The compressor is the heart of the refrigeration system. A compressor is equipped with sucion, discharge starting bypass, suction bypass and surge valves. Three general types of compressor are used in dairy – reciprocating, rotary and centrifugal. Reciprocating compressor are the most commonly used ones. Usually two or multiple cylinder vertical single-acting compressor are used. Two – cylinder compressors have speed from 360 to 425 rpm and are used for ammonia. Multi-cylinder compressor are used for Freon-12 and Freon-22 also, and have speed between 600 to 1800 rpm. Horizontal double acting compressor may be used in a very large dairy plant.
Rotary compressor are suitable for low pressure range and small tonage capacity. Any of the common refrigerant can be used in these units.
Centrifugal compressor are adaptable to a wide range of temperature from -20OC to 10OC and are flexible under varying loads. Their speeds normally vary from 4000 to 6000 rpm. They operates best with refrigerants possessing a high specific volume and therefore are used for Freon-12 or Freon-22.
Screw Compressors:
The screw compressor is a more recent invention. The principle components are two helical rotors which ate installed in a common housing. As the rotor turn, the gas is drawn into the gaps between the teeth and is trapped in the clearances. As rotation takes place, the volume between the teeth is continuously reduced as the capative gas is conveyed along the teeth of the rotors. The gas is gradually compressed and the pressure increases. The compressed vapour continues to condensers. Oil is sprayed on the meshing faces in most screw compressors in order to reduce the leakage between the gaps in the rotors. In this way it is possible t obtain high efficiency also at low speeds. The oil is removed from the vapour in an oil trap before the condenser.
Screw compressor are used in large installations where the refrigeration capacity exceeds 500KW. One of the greatest advantage of the screw compressor is that the capacity can be varied down to 10% of the full power without excessive losses of electric energy.
High Stage Compressor:Suction pressure: 2 to 3 barDischarge Pressure: 9 to 14barSuction Temperature: - 10oC.Discharge Temp: 60 to 75OC.Oil Pressure: Below 17bar.Oil Temperature: 30 to 60OC.Oil difference pressure: More than 2 bar.Cooling water pressure in oil temperature: around 2 bar.Motor temperature: below 50OC.Oil level in oil separator: Normal (2 Glass).
Oil Separator:Oil Filter used in oil separatorItem Code: 160122Part No.: 1898-516-2Des 1: Filter Sil – 6 For oil Separator RVA Screw.Des 2: Compressor, stal mint Mark-II, Type R59 KDes 3: Article No 1898-516-2Des 4:Des 5:Des 6:Des 7:Make – York Refrigeration
CondensorThe condenser removes the heat from refrigerant carried from evaporator and added by compressor and convert the vapour refrigerant into liquid refrigerant. The condenser and other equipments in the system between the compressor discharge and expansion valve are often referred to as high pressure side equipment. There are three general types of refrigeration condensers.
Air-cooled, water cooled and a combination of air and water cooled usually refered to as an evaporative condenser. The size of a particular type of condenser chosen for a given load depends upon:
1. The heat transfer characteristics of the surface of the refrigerant and of the cooling medium.
2. The temperature of the refrigerant and of the cooling medium.
3. The physical properties of the refrigerant allowances are also made for dirt and scale collection on the surface.
AIR COOLED CONDENSERS
WATER COOLED CONDENSERS
i. Water cooled condensers.ii. Double-tube condensers.
iii. Shell and tube condensers.
EVAPORATIVE CONDENSERS
Shell and Tube Condensers:They are large modern installation and with the smaller compressors when fouling of the water is possible. The shell and tube condenser consist of a shell with a tube sheet securely fastened to each end. Each tube sheet has an easy removal header type cover, which is often baffled to cause the water to flow back and forth through the shell several times. This baffling increases the water velocity for a given flow and in turn the heat-transfer coefficient. These condensers are available from 2 to 1000 tones capacity.Condenser Capacity: 270TR.
Pump (Centrifugal Pump):Through the pump the warm water goes to the cooling tower.
Cooling Tower: Cooling towers are used in water cooled heat exchanger or a shell and tube condenser. In cooling towers the warm water is sprayed in air stream. Some of the water evaporates. The heat required for the evaporation comes from the remaining water which is cooled. The more the water evaporates the cooler will be the remaining water. To increase the efficiency of a tower, the contact between the air and the water must be the best possible. This indicates that there must be sufficient quantity of air and the water must be broadly dispersed. An efficient tower will cool air to within 3.5 to 5OC of the air wet bulb temperature. 4OC being considered the most economical.
The most common towers utilize forced or induced draft produced by fans, which blows or draw large quantities of air through the tower structure. Instead being sprayed water passes over a large no. of surfaces called the packing of the tower. In the past, the packing was made of a large quantity of redwood or cypress state laid closed together. However, molded plastics forms are becoming more common now.When the water required for condenser is inadequate and expensive then the same water is re-cooled and used again and again. The cooling towers are is used for larger installations, absorption refrigeration units and centrifugal refrigeration units.
The cooling tower may be classified as atmospheric or natural drafts of the spray type. The water from the condenser is sprayed through the nozzles. To expose the maximum of water to the air to allow the droplets surface to evaporate and cool the water.
The major disadvantage of this is that, it requires more floor area per kg of water than any other system used cooling.
The size of the equipment required is affected by:
1. The cooling temperature range of the water.2. The difference between entering air wet bulb temperature and leaving water
temperature and,3. Time of contact of air and water.
In Mother Dairy’s ice Cream Plant, there are 5 cooling tower
2 are of 80,000LPH 3 are of 1,20,000 LPH
Cycle of Concentration:The circulating water becomes concentrated with respect to the solid content due to the evaporation loss of the circulating water. The COC is the term of employed to indicate the degree of concentration of the circulating water compared to the feed water and is measured in relation to any one parameter (TDS, Total Hardness or Cl content).
Scale Formation:Dissolve mineral matter mainly consisting of carbonates and bicarbonates reach a stage due to concentration when they precipitate from solution as scale.
Corrosion:Corrosion is promoted by a number of factors:
Corrosion Inhibitors:A corrosion inhibitors decrease the corrosion rate and is effective when added in small concentration to the circulating water. They are composed of chromate. Phosphate and zinc salt in combination. These inhibitors act by forming a protective film on the metal surface thus prevent the surface from electrochemical phenomena of corrosion.
Microbial Fouling:Various types of organism are continuously introduced into the water through wind blown dust. These can cause the algae deposition and corrosion thus lowering the cooling efficiency.
Control:1. Control of scale formation2. Control of corrosion3. Control of fouling
Control of Scale formation:Scale can be defined as solids in solution which are deposited on heating surface. Major scale forming constitute laid down by re-circulating water consists of CaCO3 Calcium sulphate calcium phosphate. The solubility of calcium phosphate depends on pH temperature and calcium concentration. Thus lowering of pH with H2SO4 helps to prevent scale formation in most cases. Polyphosphates along with organics have also been used for scale prevention.
Control of Corrosion:The different corrosion control measures can be divided into three categories viz. corrosion control by the use of inhibitors and corrosion control by cathodic protection. Corrosion protection by use of inhibition has been widely used. Zinc has also been used in many inhibitory properties.
Control of fouling:Fouling is opposed to scaling is the deposition of solids normally in suspension in the circulating water.
Fouling can be of two types:
1. Natural.2. Artificial.
Natural:Natural fouling involves material that exist in the system as a result of factors external to the system. This can be salt clay, mud, natural organics, sand, iron etc.
Artificial Fouling:Artificial fouling is caused more by system characteristics such as corrosion product, clarifier carryover, aluminum & iron phosphates, microbial growth and products contamination.
The method of control:
1. Reduction of suspended solids by clarifying the make up water.2. Locating the tower far from dust and contaminants.3. Side stream filtrations and use of dispersants.
Microbial Fouling:They can be generally classified as:
Oxidizing Non oxidizing biocides Bio-dispersants
Oxidizing biocides literally ‘burn-up’ any microbe, they came in direct contact, chlorine is a very commonly used biocide because it is inexpensive. Chlorine should be introduced directly in the basis and carefully monitor in the return water and chlorine level in return water should not be allowed ti exceed 1PPM otherwise can lead to severe damage to tower wood.
Use of Non oxidizing biocides available but they can not be directly disposed off in blow down.
Some of the non-oxidising biocides are:
1. Sodium pentachlorophenate. (NaPLP)2. Quaternary ammonium compounds.3. Methylene b is –thiocynate4. Dichloro Diphenyl Methane.
Cooling of water from cooling tower depends upon: Area water. Air Evaporation
Liquid Receiver:The receiver is a vertical or horizontal storage tank in which the liquid refrigerant is held under pressure ready to be used in the evaporator. The receiver is equipped with a valve connection to change the system with the proper amount of refrigerant.
Specification:Make: Indian Dairy Machinery Co. Ltd.Client: Mother Dairy Delhi.Year of Manufacturing: 1998
Manufacturing Serial No.: 2129-2Purchase order No. and date: NL 601 12-01-98Design Code: 152825-1969Class 1AWorking Capacity: 2140Ltr.Empty Weight: 940kg.Working Temperature: 70oC.Working Pressure: 16kg/cm2.Hydrotest pressure: 27kg/cm2.Operating fluid: NH3.
Air PurgerAir purger is fitted on top of the receiver. In the receiver the liquid ammonia is in the bottom and remaining vapour ammonia is at the top. The function of air purger is to take the air from liquid ammonia. It prevents te air to go in the system. Air Purger works on the principle of refrigeration cycle.
Oil Rectifier:It is a shell and tube type. Hot gases (vapour ammonia) is in the tube and liquid ammonia and oil is in the shell. Due to contact in hot gases liquid ammonia vapourized and goes to the LG Cooler. Due to gravity oil come at the bottom which is drained out. Sometimes oil come from the compressor and goes to receiver and then oil rectifier. Oil and vapour come together from the compressor.
Specification:Make India Dairy machinery Co. Ltd.Vithal Udyognagar – 388121 GujaratIndia.Client Mother Dairy Delhi.Year of manufacturing: 1998Working Capacity: 0-65m3.
Economizer:The function of economizer is to minimize the cooling load. It is shell and tube type. Liquid ammonia is in horizontal tube at 35OC and pressure 11bar. Liquid ammonia and vapour are in shell. Its temperature and pressure are -10OC and 2.8 bar. Before the liquid ammonia enters the tube in economizer there is thermo static expansion valve which reduce the pressure and expand the liquid. Cooling occurs between liquid to liquid ammonia. The vapour ammonia
which remains in the receiver then comes to economizer is discharged to high stage compressor at 11bar. And 35OC and discharge at 20OC. It is fitted with between LG cooler and receiver.
Specification:Make: Indian Dairy Machinery Co. Ltd.Client: Mother Dairy Delhi.Year of Manufacturing: 1998Manufacturing Serial No.: 2129Purchase order No. and date: NL 601 12-01-98Empty Weight: 450kg.
LG Cooler:The function of LG cooler is to reduce the pressure and temperature of liquid NH3. This is the shell and tube type. Liquid NH3 is in the tube and in the shell. The cooling is in between liquid to liquid NH3. Here pressure raise to 11bar to 12bar and temperature drops to 35OC to 10-15OC. The liquid ammonia HN3 in the shell has a temperature of -10OC and pressure 2.8bar.
SpecificationMake: Indian Dairy Machinery Co. Ltd.Client: NDDB, Delhi.Manufacturing Serial No.: 2129Purchase order No. and date: NL 601 12-01-98Design Code: 1S-2825-Class 1AEmpty Weight: 750kg.Working Temperature: 60OC. (max.)Working Pressure: 15kg/cm2.Design Temperature: 100OC.Design Pressure: 18kg/cm2.
Accumulator:
Liquid NH3 having a pressure of 12bar and temperature 10-15OC passes through the accumulator. In the accumulator the liquid ammonia passes through the deep freezer 1, 2, Extrusion line, walzer-2. In the DF1 and DF2 heat is exchanged. Liquid NH3 takes the heat from the storage and converted into vapour ammonia. This vapour ammonia passes through the accumulator. Here again cooling is in between vapour NH3 and liquid NH3. Here liquid NH3 passes through the DF1, DF2, Ext, W1, W2 and vapour goes to the low stage compressor (booster compressor). The vapour NH3 having a pressure of 0.7bar & temperature -40OC goes to the LSC and compressed it into 2.8 to 3 bar and temperature 70-75OC. The discharge of the booster compressor passes through the LG cooler. Vapour ammonia mix in the LG cooler and drops the temperature to -10OC and pressure becomes 2.8bar. From LG cooler vapour ammonia having a 2.8bar & -10OC passes through the HSC.
Expansion Valve:It is the device which controls the rate of flow of the liquid refrigerant between high pressure and low pressure sides of the system.
Changes which takes place before and after expansion:
BEFORE AFTER
Temperature More LowPressure High LowState Liquid LiquidMass Same Same
Evaporator:AN evaporator is that part of a refrigerating system in which refrigerant is vapourized to produce refrigeration. The refrigerant come to evaporator below the temperature that is required to maintained in evaporator/product. The evaporator is also known as cooler or freezer.
Capacity of Overall Refrigeration Plant:
STALL:Booster Compressor 1: 90284Kcal/h = 35TR.
2: 61910Kcal/h = 25TR.
High Stage Compressor: 214981Kcal/h = 80TR.Total Capacity of Refrigerant (Ammonia) Plant:203+(60x2)+80+35+25= 460TR.
GRASSO:Hig Stage Compressor I & II: 203TRBooster Comprssor I & II: 60TR.
Boiler is a closed vessel exceeding 22.75 liters (5 gallon) in capacity, which is used for generating steam under pressure and includes any mounting or other fittings attached to such, which is wholly or partially under pressure, when steam is shut off. There are two types of boilers viz. Fire tube and water tube type boiler. At Mother Dairy, Two Fire Tube Boilers are installed.
The fuel used here is L.D.O (Liquid Diesel Oil). The fuel is allowed to mix with air in ration 1:15 ( one part of L.D.O to 15 parts of O 2). The fire generated from the L.D.O inside the tube is allowed to move in spiral movement. The tube is having 3 turns inside the vessel to get maximum efficiency.. This tube is surrounded with the water to be heated and converted to the steam. The heating of water is through the heating surface of the tube by conduction. The heating effect obtained from the L.D.O fuel is between 180OC to 220OC. For complete combustion of fuel mixture the tube should contain approximately 20% oxygen, which is injected with the help of blower. Completeness of combustion can be detected by analyzing the gases released from the chimney. 3 – 4% O2 concentration or 12 – 13% CO2 concentration indicates complete combustion of fuel. Another method of detecting the completeness of combustion is by analyzing the color of the gaseous mixture then is released from the
chimney. The ideal color should be light brown Grey. The temperature of released gases at 180OC and above. The steam so produced has temperature more then 150OC.
Causes of Incomplete Combustion :-
Less air Improper mixing of fuel and air, poor atomization. Nozzle Worn or Plugged. Oil Temperature too low. Heat loss for every kilogram of un-burnt carbon is 8084
Kcal.
Checking of Improper Combustion :-
Flame length should be 2/3 to ¾ of furnace length. Smoke should be light brown. Carbondioxide in fuel gases should be 12%. Oxygen should 4 to 4.5%. Color of flame should be golden orange or dark yellow. Stack Temperature in oil fired boiler should be 180 to 220OC.
Energy Conservation :-
Leakage in oil line: Leakage @ 1 drop/second result in 4000 Liter per year loss of oil approximately Rs: 70 per day.
Leakage of steam through 3mm hole at 7kg/cm2 pressure is 32000 liters oil of a year is approximately Rs: 550 per day.
1 mm soot boiler tubes means 5% loss of fuel oil. 200C increase in stack temperature is equal to 1% fuel loss. 60C increase in water temperature is 1% saving of fuel oil. Condensate return used 100% is 10% saving of fuel.
EFFICIENT OPERATION OF BOILER :-
Gap of electrodes 5 to 6 mm, Voltage should be 14500 V. Chimney smoke should be light brown Grey. Flame should not feeding, it should be steady. No oil is dripping near burner or in oil lines. Flame length should be adjusted according to the length of furnace. All the safety control devices are in proper working condition.
Any abnormal sound in boiler pump, motor should be observed.
Unprocessed milk may contain small dirt particles invisible to the naked eye. In order to remove these particles the milk has to be processed.
In any kind of industry various processes are undertaken to process the raw materials to obtain the final product. So each such process can be divided into discrete steps which when undertaken one by one lead to the complete process.
In our case at Mother Dairy, the process is to process the raw milk in the required standard conditions and to reach the final processed milk at the desired standards. The milk processing plant at the Patparganj unit is engaged in receiving any kind of the raw milk from the state dairy federations and process it to produce Toned Milk, after doing the pasteurization. The standards for the processed Toned Milk are as follows:
Before reaching the final state the raw milk is subject to various processes shown below:
FLOW AND PROCESSING OF MILK
RAW MILK RECEPTION :- This is the first stage of the milk processing. In this stage the raw milk being received from the dairy federation tankers/ milk being received from distant federations by the rail route, milk prepared at the dairy plant after reconstitution/ high fat processing is chilled and stored in the Raw Milk Silos. When a Silo is full, then a sample is taken in the process lab and is tested for its constituents.
MOTHER DAIRY PLANT SPECIFICATION
Equipment Number of unit installedPasteurizer 05Homogenizer 04Clarifier 06Silos 14Ice Silos 02Raw milk Silos 05
Processed milk silo 07
PLATFORM TESTS
1. CHECK FOR CLEANLINESS First of all cleanliness of containers is checked and appropriateness of seal is also checked.
2. PRESENCE OF FOREIGN MATTER The milk is taken, filtered and seen for presence of any foreign matter. Physical condition of milk is also noted from top i.e. for presence of any flies.
3. TEMPERATURE Temperature of milk is then tested and should not be greater than 10°C
4. ORGANOLEPTIC EVALUATION Check., taste and flavour of milk
5. COB TEST Conduct COB test by taking about 2 ml milk in a test tube, boil on the flame of a spirit lamp formation of clots in the test tube indicates COB positive milk and is unacceptable.
6. ACIDITY TEST Taking 10 ml milk in 10 ml conical flask. Titrate against N/10 NaOH using phenolphthalein indicator to check acidity. Acidity above .153% is not acceptable or use acidometer for titratable acidity.
7. ROSALIC ACID TEST To 2 ml rosalic acid in a test tube add 2 ml of milk . Rose red colour development indicates neutralizer presence in milk and formation of flakes indicates disturbed salt balance.
8. ALCOHOL Alcohol test is done to know the quality of milk. To 2 ml milk in a test tube add 2 ml 68% alcohol. The presence of flakes indicates alcohol positive and such milk is rejected. The alcohol test determines the susceptibility of milk to coagulation due to developed acidity, salt unbalance or high albumen content.
9. FAT & SNF Fat & SNF can be determined using gerbers method or using a milcoscan.SNF can also be determined using lactometer reading and Fat value and putting the formula CLR/4 +Fat x .2 + .29
Milcoscan is the latest technology machine for scanning of milk and uses infra red rays to analyze the milk for
Fat Protein Lactose SNF
10. MBRT TEST To 10 ml of milk in a sterilized MBR tube add 1 ml of MBR dye Plug with a sterilized cork, invert the tube to mix the contents and incubate at 37°C in a water bath. Check the tube for decolourization just after 10 minutes Next time after 30 minutes and subsequently every hour. Milk with MBR time of less than 10 minutes is unacceptable.
11. TEST FOR PRESENCE OF UREA Take 2 ml milk in a test tube add 2 ml DMAB solution andmix the contents. Appearance of yellow colour indicates the presence of urea making the milk unacceptable.
12. SUGAR TEST
Take 3 ml of milk add 5 ml dilute HCL(1:2 containing resorcinol 0.1 gm resorcinol dissolved in 100 ml dilute HCL) Mix well and keep the test tube in boiling water for 5 minutes. Brick red colour formation indicates sugar positive.
13. STARCH TEST Take 3 ml milk in a test-tube, boil and cool under tap water. add 2 drops of 1% Iodine solution. Appearance of blue colour indicates the presence of starch.
14. SALT TEST Take 5 ml of silver nitrate (0.134%) solution in a test tube and ad 2 drops of potassium dichromate (10%) solution. It will give brick red colour. To this add exactly 1 ml of milk and mix. Observe the colour if yellow colour appears then it shows salt test positive. If not then the salt test is negative.
15. B.R. READING Extract ghee from milk by centrifuging about some milk in centrifuge for 5 minutes and creamy layer is separated and melted and heated and ghee is prepared. Put few drops of melted ghee on clean prism of butyro-refracto-meter and close it gently. Allow it to stand for 1 minute. Note down the reading at 40°C. If B.R. reading comes in the range of 40 to 45 then only milk is accepted otherwise rejected. After use clean the prism with rectified spirit.
16. MINERAL OIL TEST (HOLDERS TEST) Take 1 gm of ghee extracted from milk in a 250 ml conceal flask and to this add 22 ml alcoholic KOH and keep the flask on boiling water bath or hot plate and saponify it till there is no oil droplets. To this add 25 ml boiling distilled water and swirl the flask. Development of turbidity indicates the presence of mineral oil. Such milk is unacceptable. No turbidity indicates absence of mineral oil.
MAIN LABORATORY TESTING
For collecting samples allow cotton soaked in alcohol on the sampling cock to sterilize it. Allow approximately 2 litters of milk to flow into bucket then collect the sample in sterilized sample bottle.
FAT & SNF Fat & SNF of milk is tested for each batch for each silo milk for standardization purpose and also for finished milk so as to ensure that milk is ready for dispatch. Fat and SNF is tested using a milcoscan. The temperature of the sample should be 40+-2 degree centigrade. It is a latest technical machine for scanning of milk and uses I.R rays to analyze milk for Fat ,SNF, Protein, Carbohydrate, TS.
HOMOGENIZATION EFFICIENCY
1. Draw milk sample from outlet valve and note the homogenization pressure.
2. Take 10 ml milk in centrifuge and see for any fat separation
3. If doubtful, prepare a slide and observe under micro scope the size of fat globule should not be more than 2 microns
4. In case unsatisfactory, the matter and cause is seen into.
PHOSPHATASE TEST
Principle Raw milk contains phosphatase enzyme. It destroyed when the heat treatment (pasteurization) of milk is done. But when the milk containing phosphatase is incubated with p–nitro phenyl disodium orthophosphate, the liberated para-nitro phenol gives yellow color under alkaline condition of the test. The yellow color indicates the presence of phosphatase and that the milk has been contaminated after the heating process by raw milk.
Procedure:1. Draw milk sample from the silo in a clean sterile
sample bottle.2. Take 1 ml of milk in each of the two sterilized MBR
test tube.3. Heat One Tube to boil to act as control sample.4. Add 5 ml of Phosphatase dye in each Tube and mix
well.
Incubate at 37 dig.C in water bath, observe the color after 10 minutes, 30 minutes and finally after two hours. Yellow color indicate positive test result.
Phosphatase dye:Dissolve 0.15gm of p-nitro phenyl disodium orthophosphate salt in 100ml of buffer solution.
Buffer solution: Dissolve 3.5gm of sodium carbonate and 1.5gm of sodium bicarbonate to make 1liter of solution in distilled water. Keep the buffer solution in cool place.
METHYL BLUE REDUCTION TEST (MBRT)
Principle: This test is based on the principle that methyl blue (an oxidation-reduction dye or indicator) which is blue in its oxidized state, is reduced to colorless compound (leuco form) as a result of the metabolic activities of bacteria in milk. When a solution of dye is added, the organisms present in milk consume the dissolved oxygen and lower O-R
potential to a level where methyl blue or similar indicators are reduced or decolorized.
Procedure: Take 10 ml of milk in a sterilized MBR tube. Add 1 ml of MBR dye. Plug with a sterilized cork. Invert the tube to mix the contents and incubate at 370C in a water bath. Check the tube for de-coloration first after 10 minutes and subsequently every hour milk. For pasteurized milk time should be 5 hrs or at least 4 hrs. whereas for raw milk time is 30 min.
KEEPING QUALITY OF MILK Keep milk samples of first and final testing in sterilized 125 ml glass bottle in incubator at 37°C.Note the time. Check for COB after 3 hrs first and then every hour till it becomes COB positive. Note down the % TA. Note total hours taken for milk to become COB positive. Observe for any abnormality such as cream layer, fat or powder separation
TITRABLE ACIDITY Take 10 ml milk sample to it add 10 ml distilled water add Phenopthalein and titrate against N/10 NaOH .
acidity% = titrate value x.09
Titrable acidity of milk from PM silo should not be greater than .14.
COB Take 2 ml milk in a test tube and kept in a boiling water bath for 5 min. The formation of curd indicates the poor heat stability and hence the positive COB test.
NEUTRALIZERS To 2 ml Rosalic acid in a test tube add 2 ml of milk. Rose red colour indicates neutralizer present in milk and formation of flakes indicates disturbed salt balance. The neutralizer test results of processed milk should be negative so as to ensure that there is no misappropriation or mishandling during processing.
After ensuring that fat percentage is 3.05 and SNF 8.58 minimum and all other tests are giving satisfactory results the milk is send or marked for
dispatch.
PROCEDURE FOR FINAL INSPECTION & TESTING OF MILK
(1) Samples are drawn from filled dispatch tankers parked in the hard parking bay. Normally temperature of milk in tanker is checked from the sample drawn from delivery valve. If temperature is found more than 7°C it is confirmed by taking sample from the top. Sample of few tankers is checked from top also for observation, temperature and MBR.
(2) The sample are tested for neutralizer test and for fat and SNF. If sample meets the requirements, the tanker is accepted and recorded. Few tankers are also tested for MBRT and if the MBRT of a tanker is found to be less than 4 hrs, milk of tanker is called back from retain outlets.
(3) If it fails to meet Mother Dairy dispatch standards, the tanker is rejected and shift in charge is informed.
(4) The system is so made that weighment of milk for dispatch is done only when the test results are found correct so as to ensure that quality milk leave Mother Dairy.
(2) Regeneration-I : The milk is pumped to the balance tank from there the milk is pumped to regeneration-I wherein it gets heated to about 40-45°C because of outgoing milk and hence reducing its temperature. Regeneration system helps in energy saving both for heating as well as cooling milk
(3) Clarification: Clarification is the process of removing suspended foreign by centrifugal sedimentation – clarifies are used for this purpose.
(4) Regeneration-II The milk from clarifier is sent to regeneration-II wherein the milk is further heated by the pasteurized milk hence raising the temperature of incoming milk and reducing the temperature of outgoing milk and also regeneration-II raises the temperature of milk so as to enable efficient homogenization which is the next step.
(5) Homogenization :- Homogenization is a process wherein fat globules are broken down to 2 microns or less under high pressure Homogenizer is a machine which cause sub-diversion of fat globules. It consists of a high-pressure piston pump that forces the milk and thereby subdivided into smaller particles of more uniform size.
Effect of homogenization
The fat globules of milk are surrounded by a membrane 5-10 mm thick. The membrane has properties of an emulsifier and keeps the emulsion, milk stable. During homogenization the original membrane is destroyed and the first result is a rise in interfacial tension soon falls again. The new emulsion therefore remains stable even after homogenization.
Homogenization effect is produced by three collaborating factors:
(a) Passage through the narrow gap in the homogenizer head at high velocity subjects the fat globules to very powerful shear forces, which deforms elongate and shatter the spherical globules.
(b) The acceleration of the liquid in the gap is accompanied by a pressure drop. This creates cavitation in which the globules are subjected to powerful implosive forces.
(c) Further shattering takes places when the fat globules impact at high velocity in the homogenizing head.
Make APV GAULINCapacity 18000 LPHI Stage Pressure 1800-2400psi (140 bar)II Stage Pressure 500-700psi (14bar)Motor 125 HP
(6) Pasteurization:. Here milk is heated using plate-heat chiller to a temperature of 76-78°C and the temperature should not be less than 75°C so as to ensure proper pasteurization and not greater than 79°C so as to ensure that overheating has not taken place as overheating may harm the nutrients present in milk. Pasteurization of milk is done with the help of hot water. The water in a small tank is passed through a heater steam wherein the water is heated using steam. The hot water is then passed through PHE to heat up milk to the desired temperature. After the milk is heated the milk pass over to the holding section wherein it pass for 15 seconds at that temperature. The temperature of the outgoing milk is transmitted with the help of a temperature transmitter, which is connected to temperatures indicating controller, which controls the flow of steam according to the temperature. If the temperature is too high it limits steam injection
in heater and if too low the steam level is enhanced through a system of pneumatic valves.
The milk then passes through the flow diversion valve which decides the forward or deflected flow of milk. If the temperature of milk is below 75° C the FDV diverts the flow of milk to balance tank and if above 75°C the forward milk flow is maintained. But by continuous monitoring it is ensured that the temperature is maintained at 76-77°C. At the same time it is also seen that the temperature do not exceed 79°C and according to the fluctuation the steam injection is controlled. From the pasteurization section milk flows to regeneration II and then regeneration I and finally chilling.
(7) Chilling : Here milk is finally chilled to 4-5°C using chilled water which are being pumped from ice silos. The chilled water temperature ranges from 1.5 - 3°C and chilled milk temperature from 4 - 6°C. If the chilled milk temperature exceeds 9°C the milk will be again circulated through the systems so a temperature transmitter continuously displays the temperature on monitor so that continuous monitoring can be done and if temperature rises continuously the refrigeration section take necessary action in this regard so as to reduce the temperature. After chilling, milk is pumped to the silo’s.
(8) Vitamin A addition:Toned milk during processing is fortified with vitamin A. Vitamin A addition is done using vitamin A acetate. Vitamin acetate is added in the balance tank for each shift. The amount added is 180 ml of vitamin A acetate in one lakh litres of milk so that the milk contain 2000 IU of vitamin A.
(9) StandardizationThe milk, which reaches the raw milk silos, is of different fat and SNF composition. Normally raw milk silo 1, 2, 3 contains mixed milk and 4 & 5 comprises of skim milk which may contain different proportion of fat and SNF. Now to obtain toned milk of 3% fat and 8.5% SNF different proportion of milk from different silos is calculated and processed and are directed to processed milk silos. For this first total amount of batch of milk is determined or fixed and amount of SNF and fat requirement for this batch is calculated. Now amount of mixed milk and skim milk is processed and diverted to processed milk silos and now the remaining quantity i.e. quantity decided is made up using chilled UV water directly into the process milk silo hence obtaining a batch of appropriate fat and SNF values. For complete mixing of different batches of milk, agitators are provided.
Now after this samples are drawn from PM silo and tested for fat and SNF and if found unsatisfactory it can be again corrected using calculated amounts of water or skim milk. After assuring that the fat and SNF valves are up to the mark silo is marked for dispatch.
DESPATCHAfter the fat SNF and quality testing of PM silo is done and the quantity is full, the Silo is marked for dispatch. Before dispatch milk is pumped over to glycol chillers and the milk is chilled to 2°C in glycol chillers. Here instead of chilled water, chilled glycol of approximately –0.5°C is passed into the chillers. The chilled milk is then filled in tankers and the tankers then go to the milk vending shops for sales.
CLEANING IN PLACE (CIP) SYSTEM
Containers and machines working on milk are subject to the gradual growth of bacteria with the passage of time. So in order to ensure the proper processing of milk is done and no bacteria passes to the processed milk the milk containers i.e. the silos and the plants have to be cleaned after eight hours of use with milk. So in order to ensure proper cleaning a proper CIP plant is required. This plant is used to clan the silos and the plants in their own place. Further the CIP process is dependent on the type of the machine/container and there are only slight variations to the general procedure.
The cleaning process in general contains the following steps:
FLUSH WITH FRESH WATER TO RECOVERY
FLUSH TO DRAIN WITH
RECUP WATERLYE RINSE
FLUSHING WITH HOT WATER
ACID RINSEFLUSHING WITH HOT WATER
PROCESSING PARAMETERS
PASTEURIZER
Milk flow in the plant 16000-18000 LPH Pasteurization temperature 76-780C Chilled water temperature 1-20C Chilled milk temperature 4-70C Milk pressure in the plant 2-3Kg/cm2
Regeneration Efficiency More than 90% Milk/water leakages No leakage
CLARIFIER
Oil level 1/2 of level view glass Speed 6250 RPM Milk pressure in clarifier 4 bar
STERILISATION WITH HOT
WATER
FLUSH WITH FRESH WATER TO RECUP TANK
Make up water pressure 1.5 kg/cm2
Flush water pressure 1.5 - 2kg/cm2
Motor current 30-34 amps Discharge interval 20 minutes Discharge qty 10 Liters (approx.) Abnormal sound No Abnormal heating No Abnormal vibration No Leakages No
HOMOGANIZER
Lubrication oil level 1/2 of level view glass
Lubrication oil pressure 1bar(Minimum) Milk pressure in HVA 2000 PSI Cooling water for piston spray should be visible
Cooling water for oil Visible in the drain point
Tension of belt Normal Oil leakage No oil leakage Milk leakage No oil leakage Water leakage No oil leakage Abnormal sound No Abnormal heating No Abnormal vibration No
MILK PUMPS
Shaft seal leakage no leakage Milk flow in the pump 16000-18000ltrs/hr Proper fixing of pump cover Yes Abnormal sound No Abnormal heating No Abnormal vibration No
REFRIGERATION PLANT
SCREW COMPRESSOR
Suction Pressure 3 bar Suction temperature 40C Discharge Pressure 12 bar Discharge Temperature 80 deg c Oil pressure 7-8 bar Oil temperature below 600C Oil differential pressure below 1kg/cm2
Cooling water temp-in 300C Cooling water temp-out 340C Cooling water pressure 2 bar Motor current 500 amps Abnormal sound No Abnormal heating No Abnormal vibration No
Oil/Gas/water leakage No
COOLING TOWER
Oil level in gear box Normal in level marker
Water flow thru distributor Even distribution Inlet/Out let water temperature 40C delta t Water quality (hardness) 150 ppm Pump gland leakage No Abnormal sound No Abnormal heating No Abnormal vibration No Oil/water leakage No
CONDENSER/RECEIVER
Inlet/Out let water temperature 40C delta t Inlet/Out let water pressure below 1 bar deferential Liquid level in receiver minimum 1/3 level gauge
PUMP SEPARATOR
Liquid level Normal Functioning of solenoid making on/off as per level Liquid temperature 20C Seal leakage No Abnormal sound No Abnormal heating No Abnormal vibration No
PLATE HEAT EXCHANGER (PHE)
Inlet/Out let water temperature 80C delta t Inlet/Out let water pressure 3-2 kg cm2
ICE SILOS/PUMPS
Water level Full Ice thickness 35 mm
SOFTNER
Water quality Below 100ppm hardness Water Flow 30000 LPH in each softner Water pressure 2.5-3.5 Kg /Cm2 Brine Qty tank full Operation of pumps 2 pumps at a time Pump current around 14 amps Raw water level in reservoir Above minimum level
AIR COMPRESSOR
Lubricating oil pressure 1.5-2 Kg/cm2
Lubricating oil level Normal level Cooling water Continues flow Loading unloading system Loading at 6.0Kg/cm2
Un loading at 7Kg/cm2
Suction filter Dust free Air leakage No leakage Water leakage No leakage
COMPRESSOR MOTOR
No load current 15-17Amps Load current 33-35Amps Belt tightness Normal Vibration level Normal
DE HUMIDIFIER
Temperature 3-60C Pressure 6-7 KG/CM2
Air Pressure 6-7 KG/CM2
Functioning of timer ½ hr intervalfor condensation drain
BOILER
LDO in tank Normal level in service tank Water level in boiler Normal level Inlet oil pressure 20 KG/CM2
Return oil pressure 6KG/CM2
Feed water pressure 7-8 KG/CM2
Functioning of air modulator Normal Functioning of solenoid valve Normal Functioning of ignition electrode Gap between electrode 3-5mm Stack temperature 180-2000C CO2/O2 level 12±5%/ 3-4%" Functioning of PRV 3-4 KG/CM2
Functioning of safety valve 9-10 KG/CM2
TDS of water below 5000ppm Hardness of water Below 10ppm Blowdown of feed water Twice in a day for
1minute
ROTARY BLOWER
Lubrication Oil level Half of the view glass Suction filter Dust free coupling Fully tight Foundation Bolt fully tight Alignment Proper Air pressure 3 bar Air leakage No leakage
DEHUMIDIFIER
Chilled water inlet pressure 3 kg Chilled water outlet pressure 2 kg Chilled water inlet temperature 20C Chilled water outlet temperature 80C steam inlet pressure 3 bar steam outlet pressure 2 bar Outlet air temperature around 400C Relative humidity around 20
TRIBLENDER
General cleaning dust free abnormal sound smooth running vibration no vibration alignment proper
Belt tightness proper Load current Below 20 amps Mixing rate 3ton/hr
BUTTER MELTER
General cleaning Dust free Foreign material No deposition Leakages No steam leakages Butter leakage No Filter No deposition of foreign
material Level Sensor Pump operation as per level Function of drum Smooth function of drum Temperature of butter 60-650C Steam Steam pressure 3-4 Kg/cm2
EFFLUENT TREATMENT PLANT
Raw Effluent Pump On / Off operation of pumpStopping on low level .Staring on high level.
Smooth running No vibration Abnormal sound No Abnormal heating No Normal operating current Below 20 amp
NUETRALIZATION TANK
Water level Normal level Agitation Proper air supply PH 5.5-9 ppm
AERATION TANK
Working of aerators No vibration Abnormal sound No Abnormal heating No Normal operating current around 30 amp Dissolved Oxygen 0.7-1.3
POWDER HANDLING SYSTEM
ROOTS BLOWER
Make Kay International Type Roots Conveying gas Air Motor RPM 1440
DEHUMIDIFIER
Make Virtex Engineering Type Heat Exchanger Gas Air
DUMPING PIT
Make IDMC MOC AISI 304
BLOW THROUGH VALVE
Product name Milk Powder Make DMN Westinghouse Type BL 300
ROTARY VALVES
Product name Milk Powder Make DMN Westinghouse Type AL 250
BAG FILTER
Make Reico Type Bag type
QA & RND LABORATORY
MILK POWDER
- On arrival of powder, draw sample from store godown- Note down the source, batch number, date of manufacture and bag number from
which sample is drawn- With the help of store staff keep six bags, possibly of different batches from each
truck, one bag after unloading 70 bags- Open the bags carefully and take a composite sample of the truck from all the six bags
in polythene bags/bottles. Also take one bacteriological sample
i) Switch on the instrument. Light will start blinking in start key.
ii) Press on/off/zero bar. Screen will display weight. Reset zero by pressing the rezero bar, the balance is ready for worker.
iii) Set the temperature and time
SMP - 6 min. - 100 CWMP - 6 min. - 100 C
To set the temperature, press the key showing thermometer and the temperature will be displayed. The required temperature can be adjusted by pressing key up or down, then enter for time press the key indicating watch and set the required time, then enter.
iv) Open the top of the instrument and spray powder on the pan evenly distributed till the balance achieves the 5 gms weight of powder and close the top.
v) Press 'start'. The balance will show zero. After completion of time start key will start blinking and the balance will display the percentage of moisture.
2) Titrable Acidity
Material required: 100 ml beaker, 10 ml pipette, glass rod, and phenolphthalein indicator, N/10 NaOH
Procedure
Weigh accurately 1 gm of the sample in a 100 ml beaker. Add 10 ml of hot distilled water and make a solution using a glass rod. Cool to room temperature. Add 1 ml phenolphthalein indicator and titrate against N/10 NaOH till a faint pink colour persists.
Result: - The acidity present as volume of TA% = (NAOH used x 0.9)
3) Fat
Gerber's method
It is a common method of determining the fat content of milk
Reagents: - Sulphuric acid (1.0 - 1.812 specific gravity) Amyl alcohol (0.85 specific gravity)
Procedure:
1.69 gm of milk powder is weighed accurately and dissolved in minimum amount of home-distilled water. It is then carefully added to the 10 ml concentrated sulphuric acid in a milk powder butyrometer so as not to allow mixing of milk with acid. Add 2 ml amyl alcohol to it and close the butyrometer. Mix the contents until all curd has been digested. Transfer the butyrometer in the water bath at 65 C for 3 min. Place the tube in the centrifuge at 1100 rpm for 5 min. Transfer the butyrometer in the water bath at 65 C for 5 min. Adjust the fat column with the scale of butyrometer and note the reading.
4) Rosalic Acid test:
Take 2 ml rosalic acid (0.05% in 60:40 alcohol In distilled water) in a test tube. Add 2 ml reconstituted powder. Rose red colour indicates neutralizer presence in powder and formation of flakes indicates alcohol test positive.
5) Scorched particles:
Observe the bottom of the flask in which powder is reconstituted after keeping undisturbed for some time. Filter the reconstituted milk through scorched particle tester and compare the filter pad with ADMI comparison card. Powder with scorched particles more than disc B reading is rejected.
6) Ash Content
Weigh 3 gm of powder in a well-dried silica crucible and heat on a heater till no smoke comes out of powder. Keep it into a muffle furnace maintained at 550 + 20 C for 3 hrs till grey ash formation. Switch off and transfer to a desicator. Cool and weigh it. Heat the dish again at 550 + 2 C for 30 min. cool in descicator and weigh. Repeat until difference between two successive weighing is less than one milligram. Record the lowest mass.
Ash % by mass = 100 (M2 - M) (M1 - M)M2 = weight of crucible with ashM = weight of empty crucibleM1 = weight of crucible with powder
Ash% on dry matter bases = Ash% by mass x 100 (100 - moisture%)
7) Bulk density
Materials required:- Bulk density meter, electronic weighing balance
Procedure:- Weigh 30 grams of powder in 100 ml cylinder. Fix the cylinder in the frame of bulk density apparatus. Switch on the apparatus. The apparatus will take 30 strokes. Note the volume of the powder in the cylinder.
Density = Mass Volume
8) Insolubility index
Materials required: - Centrifuge tube, centrifuge, and silicone antifoaming agent
Procedure:-Weigh 13 gm of WMP or 10 gm of SMP and reconstitute in 100 ml distilled water at 24 + 0.2 C. Add 3 drops of silicon antifoaming agents and mix it thoroughly in the blender for 90 sec. Further add 3 drops of silicone antifoaming agent to the mixture and mix thoroughly with spoon for 10 sec. Pour the mixture into a centrifuge tube up to 50 ml. Mark. Place the centrifuge tube in the centrifuge and rotate it for 5 min. at 20-25 C. Hold the centrifuge tube in a vertical position and remove supernatant liquid. Add water up to 30 ml mark in a centrifuge tube. Completely dispense the sediment with the stirring rod and make up the volume up to 50 ml mark invert the centrifuge tube 5 times to mix contents thoroughly. Place the tubes in centrifuge and rotate it for 5 minutes at 20-25 C. Remove the tube, hold in vertical position and read the volume of the sediment to nearest 0.05 ml and it denotes the insolubility index.
Adulteration detection tests
1) Rosalic acid
Take 2 ml rosalic acid (0.05% in 60:40 alcohol + distilled water) in a test tube. Add 2 ml of reconstituted powder. Rose red colour indicates neutralizer presence in powder
2) Alcohol test
Take 2 ml of 68% alcohol in a test tube. To it add 2 ml of reconstituted powder. Presence of flakes indicates alcohol positive and such powder is rejected.
3) Maltose dextrin test
Take 20 ml of reconstituted milk sample. Boil and coagulate the milk using 10% citric acid solution filter through whatman's filter paper No.-42 and collect the filtrate. Add 3 drops of iodine solution to 5 ml filtrate and mix.
Chocolate brown colour indicates the presence of maltodextrins
4) Urea detection test
Take 2 ml milk in a test tube, add 2 ml DMAB solution and mix the contents. Appearance of yellow colour indicates the presence of urea making the milk unacceptable.
On getting information from stores about white butter arrival follow as under:
Check the temperature of white butter from three different places i.e. front, middle and rear positions of the van.
Inform the temperature to assistant manager. With the help of store staff keep 6 cartons possible of different batches, one carton after unloading 70 cartons from each van. Take additional one carton for every additional 4 metric tons of white butter. Note down the batch number, source and date of manufacture of all the cartons and also note the condition of packaging/packed material.
After opening the carton check for any visible mould growth/abnormality. With the help of butter trier/spatula take 2 or more plugs from different portions of white butter carton and transfer to bottle/polythene bag. Similarly take white butter from other cartons chosen and make one composite sample for one van. Also take one bacteriological sample from each van.
TESTS
1) Fat, Moisture and Curd
Weigh a beaker previously dried in dessicator. Weigh 10 gm of butter (softened not oiled) in beaker and heat on a hot plate till foaming ceases and curd attains characteristic brown colour. Allow it to cool in the dessicator. Weigh it (Z gm) and calculate the moisture.
Warm the beaker and add 50 ml of petroleum ether/petroleum spirit into it. Mix well with a glass rod. Allow curd portion to settle down. Decant fat portion carefully without disturbing curd portion.
Give 2 more washings with 30 ml petroleum ether. Clean the beaker with cotton soaked in petroleum ether/petroleum spirit from outside.
Dry the beaker in hot air oven at 100 + 1 C for 30 minutes. Cool the beaker in a desiccators to room temperature and weigh(w gm).
Procedure: Weigh accurately 20 gm of butter sample in 250 ml conical flask. Add 90 ml of hot previously boiled water and shake the contents. While still hot titrate with N/50 NaOH using 1 ml phenolphthalein indicator
Calculation
Acidity% = 9 x V x N W
Where
V = volume of NaOH usedN = normality of NaOHW = weigh in grams of sample taken
3) Free Fatty Acids
Procedure: Melt the butter and prepare ghee out of it. Weigh accurately 10 gram of ghee in 250 ml conical flask carefully. Add 50 ml of neutralized rectified spirit to it and heat to boiling. Titrate against N/10 NaOH using phenolphthalein indicator.
Calculation
Free fatty acids = V X 2.82 WV = Volume of NaOHW = Weight of sample taken
4) Butyrorefractometer reading for butter ghee, butter oil etc :
Butro refractometer reading using digital refractometer. Clean the prism of digital refractometer gently. Check the brix value of glass-distilled water at 40 C. It should be zero. Dry the prism properly and put few drops of melted ghee and take reading in nDT at 40 C. Instrument will show refractive index. Convert refractive index reading in BR reading with the help of a chart. After completion of work clean prism with rectified spirit, glass distilled water by using soft tissue paper. Switch off the instrument after use.
PRODUCTS
PANEER
Appearance: -Shall be clear and free from dirt, surface discolouration and insect's contamination. It shall not have any free moisture.
Flavour: -It shall have pleasant odour and characteristic mild acid flavour
Texture; - It shall have a closely-knit smooth texture and spongy body.
Standards
Moisture Max. 60
Milk fat Min. 50 (db)T.A. Max. 0.5
Moisture
2 gm-shredded paneer is weighed in a dish. Mix with 4 ml hot distilled water with glass rod. Wash off the particles on glass rod using 1 ml water. Mix the contents thoroughly. Heat the dish at 102 + 1 C for 4 hrs. Cool in dessicator. Weigh with cover on. Replace for 30 min. again at 102 and 1 C. Weigh. Repeat till difference between successive weighing is less than 1 milligram.
Calculation:
Moisture % = 100 (W1 - W2) (W1 – W)
W1 = dish + sample before dryingW2 = dish + sample after dryingW = Mass of empty dish
Fat - Gerbers Method
Reagents - Sulphuric acid (1.8 - 1.812 sg), Amyl Alcohol (0.85 as specific gravity)
Procedure
- Take exactly 10 ml of gerbers sulphuric acid in butyrometer- Weigh accurately 1.69 gms of shredded paneer and added in 10 ml sulphuric
acid.- Add 1 ml amyl alcohol- Make up the volume by distilled water- Close the butyrometer with rubber stopper and mix the contents until
completely digested.- Centrifuge the butyrometer for 5 min. at 1000 rpm.- Place in water bath.
- Read the fat column.
Acidity
Reagents: N/10 NaOH and phenolphthalein indicator
Procedure
- Grind paneer pieces in mortar and pestle- Weigh 2 gram of paneer sample in a conical flask- Add 20 ml hot water slowly and mix properly using a glass rod- Add 10 ml NaOH and 1 ml phenolphthalein indicator- Titrate against N/10 HCl. End point is disappearance of pink colour.
Calculation
Titrateable acidity % = (10 - Vol. Of HCl) x 0.9 2
DAHI/MISHTI DOI
Colour: - Shall be white, uniform without showing any sign of visible foreign mater.
Body and Texture: -
Should be firm solid and uniform with negligible whey separation
Flavour
It shall have a pleasant and cream acid taste. It should be free from bitterness, saltiness or other off flavours.
To 100 gm of curd in a beaker add 5 ml of strong ammonia to the weighed sample and shake well to make it homogenous. Pipette out 10.75 ml of well-mixed sample of dahi and transfer it to butyrometer containing 10 ml sulphuric acid. To this add 1 ml amyl alcohol. Close the butyrometer with a rubber stopper, mix so as to digest the contents and centrifuge for 5 minutes. Adjust the fat column and take reading. Multiply the result with dilution factor (here 1/20) and add the same to the obtained result.
Acidity
Weigh accurately 10 gm of Dahi in 40 ml beaker. To it add 20 ml distilled water and acidity can be determined using acidometer.
LASSI
Colour: - White, uniform, without showing any sign of visible foreign matter.
Body & Texture: - Smooth and free from gas bubbles
Flavour: - Pleasant and sweetish aroma. It should be free from bitterness, saltiness or other off flavours.
Specifications
Fat% min 3.1TS% min 20
TA max. 0.8
Incubation Test
PH variation 0.3 maxTA - 0.02 maxBulging Test - Negative
i) Fat determination
Gerbers Method
Carefully dispense 10 ml of Gerbers sulphuric acid in a butyrometer. Pipette out 10.75 ml of lassi into it. Add 1 ml of amyl alcohol. Mix the contents well. Centrifuge for 5 minutes. Place in a water bath of 65 C and take the reading.
ii) Total Solids
Total solids can be determined using gravimetric method. Same as that of milk.
iii) Acidity
Weigh accurately 10 gms of lassi in a 50 ml beaker. Add about 30 ml distilled water. Determine the acidity under the curd mode in the acidometer.
FLAVOURED MILK
Appearance: -There should be no separation of fat or sedimentation.
Flavour: - It shall conform to the designated flavour. It shall have no off flavours and visible sediment.
a) pH variation of 7 days incubation max - 0.3b) T.P (variation of 7 days incubation) - 0.02c) Bulging Test Negative
Fat Determination
- Take 10 ml Sulphuric Acid into a butyrometer by means of automatic measure
- Warm to 40 C and cool to 27 C- Mix well- Allow to stand for 3-4 minutes- Transfer 10.75 ml of sample into butyrometer- Add 1 ml amyl alcohol into butyrometer- Close the butyrometer- Transfer to 65 + 2 C water bath for 5 min.- Centrifuge the butyrometer for 4 min.- Take out butyrometer into water bath for 65 + 2 C and allow the
butyrometer to stand for not less than 3 minutes- Take down the reading
Acidity
- Switch on the instrument- System test will appear- Wait for some time- Check user method (3)- Screen will show - recall method, store method, delete method- Use recall method by putting cursor on it- Press enter- Select the program milk using the forward/backward key- Press enter and the milk program will appear- Put beaker having 10 gm of milk and 40 ml distilled water- Stir using magnetic stirrer- Dip the electrode and dispenser and press screen- Acidity will come automatically on the screen- After completion switch off the instrument
Total Solids
Gravimetric Method
Apparatus: Shallow flat bottom dishes of aluminum alloys, nickel, stainless steel, porcelain silica, 7-8 cm diameter, about 1.5 cm in height and provided with easily removable and closely fitting lids.
Procedure
- Weigh accurately the clean dry empty dish with the lid, pipette into the dish about 5 ml of the prepared sample of milk and weigh quickly with the lid on the dish.
- Place the dish uncovered on a boiling water bath- Keep the base of the dish horizontal to promote uniform drying and protect it from
direct contact with the metal of water bath.- After at least 30 min. remove the dish, wipe the bottom and transfer it to a well
ventilated oven at 98 - 100 C placing the lid by the dish- The dish shall not be placed near the walls of the oven- After 3 hours cover the dish and immediately transfer to a desiccators- Allow cooling for about 30 min and weigh- Return the dish uncovered and the lid to the oven and heat for 1 hr.- Return to the desiccators - cool and weigh as before- Repeat if necessary until the loss of weight between successive weighing does not
exceed 0.5 mg. Note the lowest weight
TS (% by weight) = w x 100 W
w = weight in gram of residue after dryingW = weight in gram of prepared sample taken for test.
BUTTER OILSpecification
Moisture % - 0.5 max.
FFA - 0.3 max.
BR - 40-44 max.
Peroxide value- 0.8 max.
Sampling
Select 4/5 drums possible of different batches from each truck; clean the dust and foreign matter from sampling point of the butter oil drum. Note down the source, lot number and date of manufacture. Record these in B.O. testing register.
Break open the seals with a hammer and open the drums using the opening tool. Take a composite B.O. sample from all drums in sterilized glass bottle using a sterilized trier in case the butter oil is hard. Melt at 40-45 C and mix before going for analysis.
Moisture
Clean the dish. Dry in oven for 100 + 1 C for 1 hour. Allow cooling to the room temperature in desiccators and weigh the dish. Weigh accurately 3-4 gms of B.O. sample. Place in water bath for 20 min. Transfer to over 100 + 1 C and keep for 90 minutes. Allow the dish to cool in the descicator and weigh.
Moisture = 100(W1-W2)/(W1-W)
W1 = Weight of dish with butter oil before drying
W2 = Weight of dish with butter oil after drying
W = Weight of empty dish
Free Fatty Acids
Take 10 gm of butter oil in 250 ml conical flask .Add 50 ml neutralized rectified spirit and heat to boiling. Titrate against N/10 NaOH using phenolphthalein indicator.
FFA = (V x 2.82)/W
V = Volume of NaOH, W = Weight of sample.
Peroxide value
Using Photo Electric Colorimeter
- Switch on the instrument
- Check the switch. It should be at % T position.
- Put blacks plastic cuvette inside the hole and close the lid.
- Set zero by rotating the Knob 'set zero' so that 0.00 comes on the screen
- Put the glass distilled water in glass cuvette and by rotating 'set 100 knob' and make the reading 100 on screen
- Change the switch from %T position top OD position and see that the filter should be at a number 5 i.e. 550nm. Put the prepared fat blank in glass cuvette in place of glass distilled water and again set zero by rotating 'set zero' knob.
Put the reagent blank and note the OD of reagent blank check OD of the prepared test. Subtract reagent value from the test samples and note the reading and then calculate the peroxide value as below.
Testing
Transfer with a warm pipette 0.5 gm of B.O. in a test tube.
Pipette 9.3 ml CHC13 and CH3OH solvent in a test tube. Add 1 drop of NH4CNS and one drop of FeCI2 solution and mix well. Make 2 blanks, one reagent blank containing no B.O. and the other a fat blank containing fat NH4CNS and no FeCl2 solution. Mix well and keep the test tubes for 5 minutes and then measure optical density at a wavelength of 550 nm.
Calculate peroxide value
Peroxide value = mg. Of Fe/10 ml solution Wt.Of Sample x 55.84
BR Value
Same as in butter.
TOTAL DISSOLVED SOLIDS IN WATER
TDS is found by using an EC-TDS analyzer at a temperature of 25 C.
Salient features
- Microprocessor based
- Menu driven user friendly
- Auto ranging
- Measures directly the electrical conductivity and total dissolved solids
- Can be used for both aqueous and non-aqueous solution.
Description
EC-TDS analyzer is a microprocessor based analytical instrument for easy and quick measurement of electrical conductivity in leg sample.
A constant AC potential is applied to segment of solution between platinum electrodes and the electrical resistance and through it the conductance is measure. The platinum electrodes are coated with platinum black to increase the surface area and to reduce the polarizing resistance.
Similarly the TDS is also found out.
Principle of operation:
Solutions of electrolytes conduct the electric current by migration of ions under the influence of electric field following Ohms law as electrons in the metallic conductors. Thus for an applied EMF, maintained a constant but exceeding the decomposition voltage of electrolyte. The current will vary inversely within the resistance or directly with the conductance of the solution.
The electrical conductance is a summation of contribution from all the ions present in the unit volume of the solutions and the velocities with which the ions move under the influence of the EMF.
The conductivity of the electrolyte is temperature dependent i.e. proportional to the temperatures rise at a rate of 2% per degree of most ions.
DETECTION OF N a AND K CONTENT USING FLAME PHOTOMETER
Preparation of working solution and milk sample
Stock solution of 1000 ppm for Na.
Dissolve 1.9070 gm. KCl in 1 litre of glass-distilled water.
Working solution
Take 1 ml of stock solution separately for Na and K in 100 ml volumetric flasks and make the volume to 100 ml by adding glass-distilled water.
Preparation of sample: - Take 0.5 ml of well mix sample in 50 ml volumetric flask and make volume to 50 ml by adding glass-distilled water.
Operational Procedure
Flame photometer is having 3 units
Compressor
Flame photometer burner
Digital FPM
- Connect all the three units as per instructions given by supplier
- Attach the cooking gas cylinder to the flame photometer carefully
- Switch on the compressor and adjust the pressure to 0.5 kg/cm2 by rotating air knob, which is fixed on photometer.
- Open the lid of the burner and release the cooking gas simultaneously and ignite the burner and adjust the flame by rotating the knob till the clear blue zone flames comes and close the lid of burner.
- Select the desired filter Na+ and K+ that is fixed on the left side of the flame
photometer
- Switch on the digital FPM unit. It will display some digits on screen.
- Adjust the zero by using the knob 'set zero' of the FPM unit.
- Put a beaker of glass-distilled water below the sippon tube of the flame photometer and again adjust zero. After zero adjustments, remove the distilled water beaker. Put the sippon tube in desired Na+ or K+ working solution and adjust 100% transmittance. Adjust 100% by rotating set zero 'coarse knob'
-
Instrument is ready to use. Put the prepared sample for analysis. Before testing the sample confirm that the required filter of Na+ or K+ is selected. Reading on digital FPM corresponds to mg/100 ml of Na+ or K+ in milk.
BACTERIOLOGY
Purpose- To ensure that the bacterial quality of milk and ice cream manufactured by Mother Dairy conforms to standards.
Assessing Sterility of plant and equipment
1) Swab sample is taken over a 900-cm2 area of the equipment and sterility tested.
2) Desired dilution is prepared from swab sample and plated for SPC
Collection of samples for micro-biological testing of milk
1) Four raw samples from different federations .15 dispatch milk tankers, 4 return milk tankers are tested weekly for SPC.
2) Butter is sampled aseptically and testing is done for coliform, yeast and mould.
3) Milk powder: - SPC and coliform
4) Ice Cream
Sterility tests in a month by taking samples from different process equipments like storage tank freezer pipelines, flavour and ageing tanks and filling machine nozzles.
Mix samples are tested for SPC and coliform once a month if produced during that period.
Ice cream, kulfi and ice candies samples are tested for SPC and coliform
Bacteriological test at milk shop, retailer tanks and container mounted on rickshaw:
1) Swab/rinse samples are collected from milk shop/retailers tank and tested for sterility
2) Milk samples from the above tested for SPC and coliform
3) If the bacteriological results are not within MD norms, a report is sent by QA & QS department to the concerned department for corrective action. After taking corrective action send the same report to QA & QS for repeating the bacteriological tests results after confirmation are sent to concerned departments.
4) Milk samples and water samples from milk shop/retailer tanks/container mounted on rickshaw are tested for SPC and coliform.
COMPOSITION AND PREPARATION OF MEDIA
Plate Count Agar
Ingredients:
Tryptone - 5 gm /1 litre
Glucose - 1 gm /1 litre
Yeast salt - 2.5 gm
Agar - 15 gm
Final pH - 70
Suspend 23.5 gm of ready-made P.C. agar in 1000 ml distilled water. Add 6.5 gm NaCl dissolve and adjust the pH.7. Boil to dissolve the medium completely and fill it in flasks or bottles.
Sterilize in autoclave:
VRBA
Peptone - 7 gm
Yeast - 3
Lactose - 10
Agar - 15
NaCl - 5
Neutral red - 0.03 gm
Crystal violet - 0.002 gm
Final pH - 7.4
Bile Salt - 1.5 gms
Suspend 41.5 gms ready made VRBA in 1000 ml distilled water. Heat to boiling to dissolve agar completely. Do not boil for more than 2 minutes. Do not autoclave. Cool it in water bath at 4.5 C before pouring in plates
BGLB 2% for PCT
Bile 20 gm
Lactose 10 gm
Peptone 10 gm
Brilliant green 0.0133 gm
Final pH 7.2 + 0.2
Preparation: Suspend 40 gm of readymade media in 1000 ml distilled water, warm slightly to dissolve completely. Adjust the pH 7.2 + 0.2. Dispense 10 ml into culture tubes/test tubes with inverted Durham's tube. Cap or plug the tubes. Sterilize.
PREPARATION OF DILUTION
Preparation of phosphate buffer
Dissolve 3 gm of KH2PO4 in 500 ml; distilled water. Adjust pH 7.2 with NaCl. Make up to one liter volume with distilled water.
Preparation of batch dilution plank
Take 1.25 ml stock phosphate buffer solution and make up the volume to one litre with distilled water.
Put it in dilution tubes or bottles so that after sterilization each will contain 9 ml in dilution tube or 99 ml in dilution bottle. Sterilize in autoclave.
SPC
Material required:
1) Plating chamber
2) Petri dishes
3) Plate count agar
4) Auto pipette tip (1.0 ml)
5) Dilution tubes containing 9 ml of batch phosphate buffer solution
Procedure
1) Transfer 1 ml of well-mixed samples to 9 ml dilutent (phosphate buffer solution). Mix well. Transfer 1 ml of the suspension to second tube to make second dilution. Similarly make 2nd or 3rd dilution as per requirement.
2) Arrange 2 petri plates for each dilution to be tested. Mark them with sample number and date.
3) Transfer 1 ml in each plate from respective dilution of sample being tested.
4) Melt the P.C.A. Cool it to about 45 C and pour 10-15 ml of this medium into the petridishes. Mix the agar by rotating plates.
5) Allow the agar to set invert and incubate the plates at 37 + 1 C for 48 hours.
6) At the end of 48 hrs. Remove the plate from the incubator and count the colonies.
7) Also prepare a control plate with 15 ml media for checking its sterility
Counting and expression of results
Count the colonies grown in petri plates. Count only those plates, which have 30-300 colonies
Computation
Count the colonies developed in each plate for respective dilutions. Multiply colonies per plate by dilution used and report the arithmetic average as plate count per milli-litre/gram.
Recording/reporting of results
Record and report the result as SPC/ml/gm
COLIFORM TEST FOR MILK
1) VRB agar
2) Auto pipette with tips
3) Dilution Blank
4) Petri dishes
Procedure for solid media
1) Transfer 1 ml of well mixed sample to 9 ml dilutent/phosphate buffer solution and use well to make first dilution .If required make second dilution by transferring 1 ml of first dilution into 9 ml dilutent
2) Arrange 2 petre plates for each sample. Mark them with sample number and date.
3) Transfer 1 ml in each plate respective dilution of the sample to be tested.
4) Add 10-15 ml of VRB agar previously melted and cooled to about 45 C.
5) Mix the contents thoroughly by rotating the plates and allow the agar to solidify. Pour additional approximately 5 ml of the media over the surface of the solidified medium and allow the solidify again.
6) Invert the plates and incubate the plates at 37 + 1 C for 18-24 hours.
Counting and expression of results
Count dark red colonies measuring at least 0.5 mm in diameter.
Computation – count dark red with red precipitate colonies measuring at least 0.5 mm in diameter in each plates, for each dilution plated. Multiply colonies per plate by dilution used and report the arithmetic average as coliform count …/ml/gm of product.
Recording: Record and report as coliform count....../ml/gm of product.
TEST OF COLIFORM BACTERIA BY LIQUID MEDIA (PCT)
Materials required
Auto Pipette with tips
Brilliant green bile broth
Procedure:
Transfer 1 ml from first dilution of sample into BG Bile broth in 2% tube in triplicate. Incubate for 48 hrs at 37 + 1 C and observe for acid and gas production. Production of gas and opacity in at least two tubes out of 3 constitutes the positive presumptive test.
PCT is positive and simultaneously typical colonies observed on solid media. This confirms the presence of coliform in the sample. If required further confirmation may be done using streak techniques on EMB agar or microscopically
ASSESSING STERILITY
Materials – Swab tube, cotton wool, 30 cm long SS wire, phosphate buffer/saline (0.9% NaCl) and distilled water.
Swab sampling: Press the sterilized swab with rolling motion against the side of glass tube removing excess liquid and take it out of the tube. Rub the swab with the pressure back and forth over the area to be examined so that all the parts of the surface treated twice and for plain surface 900-cm2 areas covered for swabbing over required areas. After scrubbing the required area return the swab to the solution in the tube. Allow the swab to be immersed in the liquid for five minutes and mix by swirling the swab vigorously in the solution 5-6 times. Remove the swab by pressing against the side of the test tube.
Swab testing
Mix the solution thoroughly by rotating the tube between the palms of the hands. Using 9 ml dilution blank prepare Ist dilution of the sample and proceed as per standard plate counts in duplicate plates and add 10-15 ml plate count agar medium and incubate at 37 + 1 C for 48 hours.
COMPUTATION
Multiplication factors for sterility counts
Milk Plant
Silo surface - 300
Pipeline Dairy (72 mm) – 400
Pipe line (filling) – 290
Tanker valve (72 mm) – 400
Hose Pipe (35 mm) - 810
Tanker inside - 300
Ice Cream Plant
Aging Plant surface - 300
Mixing vat surface - 300
Flavour tank - 300
Aging tank valve - 770
Flavour tank valve - 575
Pipeline - 770
Vending Outlet
OHT - 100
CIP Tank - 100
Side tank - 100
Pipe Line - 270
Beaker - 2
BUTTER YEAST & MOULD
Preparation of test portion
Soften butter and mix thoroughly and weigh aseptically 11 gm butter in 99 ml sterilized diluent previously warmed at about 45 C to make first dilution. Transfer 1 ml of first dilution into tube containing 9 ml sterilized dilutent to make second dilution. Similarly prepare third and 4th dilution as per requirement.
Procedure of plating
2) Select 2 consecutive dilution of samples to plate
3) Arrange 2 petri plates for each dilution. Mark them with sample number, date and dilution factor
4) Transfer 1 ml in each plate in respective dilution of the sample.
5) Melt the chloramphenicol agar, cool it to about 45 C and pour 10-15 ml into the petri dish, Mix the agar by rotating the plates.
6) Allow the agar to set, invert and incubate the plates at 25 + 1 C for 5 days. If moulds grow fast and develop into large colonies, plates may be incubated for 3 days only.
7) Count the number of colonies grown in each plate and compute the result. Also prepare a control plate with 15 ml media for checking the sterility.
Counting and computation of yeast and mould colonies to express results.
Counting- Count the colonies grown in two consecutive dilutions in petri plates. Count only those plates, which have 15 – 150 colonies.
Calculation for result – Calculate the number of yeast mould/gm of butter using the following equation:
N = ΣC (n1 + 0.1n2)d
C = sum of colonies counted on all petri plates
n1 = Number of plates on first dilution
n2 = Number of plates in 2nd dilution
d = Dilution factor corresponding to the first dilution.
Round the result calculated to two significant figures. The result shall be expressed as a number between 1.0 and 9.9 multiplied by 10x where x is the appropriate power of 10.
If there were no colonies on plates the number of yeast and mould per plate should be reported as less than 1.
OIL LABORATORY
Oil laboratory deals with complete testing of oil. It is a NABL accredited laboratory. Laboratory mainly deals with the testing of different varieties of ‘Dhara’ refined oil.
Here the following tests are being performed
1) Physical characteristics
a) Determination of smoke and flash point (closed cup method)
The method determines the temperature at which sample will flash when a test flame is applied under the conditions specified for the test.For this fill the cup with oil upto the mark.suspend and secure thermometer in a vertical position half way between the centre and back of the cup. Heat the sample gradually to 250 degree centigrade and occasionally check the flame.
b) Detection of coal tar oil soluble colour in edible oils.
This test is performed to see, if any, presence of coal tar dye in oil. The principle of the test is that the petroleum ether solution of oil sample gives different shades of colour with different concentrations of HCL in the presence of coal tar
2) Chemical Characteristic
3) s
a) Saponification value:
Saponification value is the number of mg of potassium hydroxide required to saponify 1 gram of oil or fat. Here the oil sample is saponified by refluxing with a known excess of ethanolic potassium hydroxide solution. The alkali required for saponification determined by titration of excess potassium hydroxide with standard HCL.
APPARATUS
250ml conical flask,1 m air condenser,Hot water bath/Hot plate
Weigh 2 gm of dry sample in the flask. Pippette 25 mlof alc. KOH into the flask.conduct a blank sample with this.Warm till saponification is complete.Cool it and titrate the excess KOH with std HCL using ph. Indicator.
SAPONIFICATION VALUE= 56.1(B-S)N/W
B= Vol of std HCL required for blank
S= Vol of std HCL required for sample.
N=Normality of the HCL taken
W= Wt. Of the oil taken for test.
b) Unsaponification value :
Here the fraction of substances in oils and fats, which is not saponified by caustic alkali, is determined. The basic principal involved here is that the substances which is not saponified and soluble in ordinary fat solvents are extracted the unsaponifiable matter determined. It mainly includes sterols, higher aliphatic alcohols, pigments, vitamins and hydrocarbons.
c) Iodine value
The iodine value of an oil/fat is the number of grams of iodine absorbed by 100 gm of fat. When determined by using Wijs solution.
The main principal involved is that oil/fat sample taken in CCl4 is treated with known excess of iodine monochloride solution in glacial acetic acid solution. The excess of iodine monochloride is treated with KI and the liberated iodine established by titration with sodium thiosulphate solution.
The iodine value is a measure of the amount of unsaturation in a fat.
d) Acid Value :
Acid value is defined as number of mg of KOH required to neutralize the free fatty acid present in 1 gm of fat. The value is also expressed as percent of free fatty acids calculated as oleic acid.The acid value is determined by directly titrating the oil/fat in an alcoholic medium against standard KOH/NaOH solution.The value when expressed as percentage of free fatty acids is calculated as Oleic, Lauric, rein oleic or palmitic acid.
APPARATUS 250 ML conical flaskREAGENTS Ethyl Alcohol, Phenopthalin indicator, Std aq. KOH/NAOH solutionPROCEDURE Mix oil .Weigh 2-2.5 gm of the sample.Add 50 ml –100ml freshly
neutralized hot ethyl alcohol and 1 ml phenopthalin. Boil the mixture for 5 min. Titrate while hot against std alkali solution shaking vigorously.Vol of alkali used should not exceed 10 ml.
ACID VALUE= 56.1VN/W V= Vol of KOH used N= Normality of KOH used W= Wt. In gm of sample.
3) Identity tests
1) Detection of sesame oil (baudouin test)The development of pink colour with furfural solution in the presence of HCl indicates the presence of sesame oil.
2) Detection of cottonseed oil
The development of red colour on heating the oil with a solution of sulphur in CS2 indicates the presence of cottonseed oil. The test is also given by hempseed oil and fat containing cyclopropenoid fatty acids.
3) Detection of linseed oil (Hex bromide test) The oil in chloroform is treated with bromine and then with alcohol and ether in cold conditions indicates that the linseed oil is present in the oil
4) Detection of groundnut oil (Belier turbidity temperature test) Oils containing long chain saturated fatty acids give a precipitate at a particular temperature which is specific for the oil when their alcoholic soap solution is treated with dilute acetic acid and 70% ethyl alcohol.
4) Detection of Adulterants
1) Mineral Oil TestThe presence of mineral oil is indicated by the development of turbidity when hot distilled water is added to freshly made alcoholic solution of the soap formed by the oil.Here oil is first saponified with .22 ml alcoholic KOH boiled in a water bath and then 25 ml of boiling distilled water is added.Turbidity indicates the presence of mineral oil.
2) RancidityShake 5 ml of the oil vigorously with 5 ml of 0.1% phloroglucinol solution in diethyl ether and 5 ml of concentrated HCl for 20 seconds. A pink colour indicates incipient rancidity
3) Argemone oil (TLC)
Principle: The hydrochloric acid extract of the oil sample containing argemone oil when subjected to TLC for the separation of alkaloid gives fluorescent shots under UV light.
4) Castor oil (TLC)
Triricinolein a characteristic and predominant triglyceride component of castor oil is separated on silica get TLC and visualized by Iodine vapors.
5) Mineral oil (TLC)
Being non-polar mineral oils gives faster moving spots on TLC plates than the triglycerides.
