AProject Report on Dissertation

inMOTHER DAIRY

KolkataPresented by:

Sukanya Halder

B.Tech/M.tech Dual Degree

Year- 5th

Roll Number - 1060070

KIIT SCHOOL OF BIOTECHNOLOGY

◊ Introduction◊ Vision and Mission◊ Milk & Traditional Products◊ Products Manufactured◊ Product Specifications & Details◊ Milk Process◊ Milk Production System◊ Manufacturing & Processing◊ Quality Control◊ Product Testing in QA Lab◊ Tests Carried out in QA lab◊ Test Result & Discussion◊ Picture Gallery◊ Bibliography

Presentation Flow

Introduction MOTHER DAIRY CALCUTTA, a Government of West Bengal project, was started under

Operation Flood II of National Dairy Development Board . It was set up initially to cater to the demand of the Kolkata urban agglomeration spread over the Kolkata Metropolitan area.

Mother Dairy is also reaching out to the consumers of other Districts. The commissioning of the Dairy started in July 1978 and the first Distribution vehicle loaded with milk sachets rolled out of the Dairy in the morning of 8th December 1978. Initially, the management of Mother Dairy was looked after by the National Dairy Development Board .

Mother Dairy safeguards the interest of the rural milk producers by encouraging co-

operative movement & marketing the surplus milk available from the villages, thus helping the milk producers to realize their own potential for organized endeavour & the creation of more rural wealth in the shape of 'Anand Pattern' as profounder by Dr. V.Kurian , The Milk Man of INDIA.

In November 1996 , the management of Mother Dairy was taken over by West Bengal Cooperative Milk Producers’ Federation.

Vision And Mission

Vision – “Provide quality food and beverages to consumers at affordable prices while ensuring fair returns to the producers.”

 

Mission – “Mother Dairy’s heritage is intrinsically linked to the cooperative movement in India. With determination & pride we will continue to serve our farmers, rural India & our consumers. Our values reflect who we are & what we firmly believe in.”

Milk

Conversion of Milk into Traditional Indian Dairy Products

Cultured

Precipitation

Condensed

ShrikhandGheeLassi

Misti DoiRabriKheerKhoa

PaneerSandeshChhanaRasgollaPantodaRasmalai

Barfi Pedha Kalakand

Gulabjamun

Products Of Mother Dairy

Double Toned MilkToned MilkCow MilkMishti DoiProbiotic YogurtFlavoured YogurtPaneerCow GheeIce Creams

Product Details

Product

Milk fat

SNF Sugar Protein

Carb.

Caramel

Flavour

Energy(100gm)

Sweet Yoghurt

3.0 13 18 4.8 7.0 0.2 146 kcal

Probiotic Yoghurt

3.0 11 4.8 71 kcal

Flavoured Yoghurt

3.0 13 13 4.8 7.0 Green-mango Chocolate Pineapple Vanilla

126kcal

Yoghurt

For preparing yoghurt about 11% cultures of each Streptococcus thermopiles and Lactobacillus bulgaricus is used.

Product DetailsSpecific Details of Types of Milk produced in Mother Dairy Kolkata

Type of milk Minimum fat Min. SNF

Cow Milk

3.5 8.5

Toned Milk

3.0 8.5

Double toned Milk

1.5 9.0

Full Cream Milk

6.0 9.0

Cholesterol free Milk

0.5 8.9

Standardized Milk 4.5 8.5

Product Specefications

Cow Milk: Fat-3.5% & SNF-8.5%

Double Toned Milk: Fat-1.5% & SNF-09%

Toned Milk: Fat-3% & SNF 8.5%

Product Specefications

Sweet Yogurt: Fat-3 % & SNF-13% Probiotic Yogurt: Fat-3 % & SNF-11%

Flavoured Yogurt: Fat-3 % & SNF-13%

Some Other Products :-

Different Flavoured Yogurts

Probiotic Dahi

RAW MILK RECEPTION

HOMOGENISATION

PASTEURIZATION

STANDRADIZATION

CLARIFICATION

PROCESSED MILK

DEEP CHILLING DISPATCH

Milk Process

PasteurizationKills all pathogenic bacteria present in the milk. Thus

making it safe for consumption

HomogenizationImproves palatability of milk

StandardisationMaintain uniformity by raising or lowering fat and SNF

(solid not fat) percentage to desired levels

ClarificationMilk is spun at very high speed, removing all dust particles

Milk production system

Manufacturing of Sweet Yoghurt :-

Milk, powder, water and sugar are added in the vat

It is agitated

It is heated up to 90◦C

It is cooled to 45◦C

Culture and caramel is added

It is packaged

It is stored in incubator room at 43◦C for 4-5 hours

It is then transferred to cold room

It is dispatched

Manufacturing Process

Continued.. Manufacturing of probiotic yoghurt :-

Milk, powder and water are added in the vat

It is agitated

It is heated up to 90◦C

It is cooled to 45◦C

Culture is added

It is packaged

It is stored in incubator room at 43◦C for 4-5 hours

It is then transferred to cold room

It is dispatched

In case of probiotic yoghurt commercial cultures like DH-111 and YOLP are used

Continued..Manufacturing of flavored yoghurt :-

Milk, powder, water and sugar are added in the vat

It is agitated

It is heated up to 90◦C

It is cooled to 45◦C

Culture and flavor l is added

It is packaged

It is stored in incubator room at 43◦C for 4-5 hours

It is then transferred to cold room

It is dispatched

Amount of flavour added:-Green mango: 0.5%Vanilla : 1%Chocolate : 0.3%Pineapple : 0.25%

Continued..Manufacturing of mango flavored ghol :-

Curd water, salt and sugar are added in the vat

It is agitated

It is heated up to 90◦C

It is cooled to 10-15◦C

Yoghurt and flavor is added

It is agitated and mixed properly

It is packaged and put in cold room

It is dispatched

Milk is heated at 90◦C

It is brought to 86◦C

Citric acid is added

Curdling of milk occurs and it is allowed to settle for 10 minutes

Agitation is given

Paneer water is drained

Paneer is put in hoof bar

It is compressed for 10 minutes at 4-6 kg pressure

It is then put in cold water at 7-8◦C for 2 hours for the paneer to solidify

ProcessingProcessing of Paneer :-

It is put in brine water solution for 1 hour to increase self life

It is kept in cold room overnight

It is cut into pieces(100gm, 250gm, 1kg and 5kg)

It is put into packets

Vacuum packaging is done

It is kept in cold store and is ready to be dispatched

Continued..

Milk is tested for adulterations and quality at the time of collection

The temperature is judiciously maintained less than 4°C alwaysNo contamination by human hands takes place, since processes

are automated.The trucks that deliver milk have specified guidelinesTravel time between collection and distribution points is always

less than 36 hours to ensure milk freshness.

Quality Control

Why is Testing Necessary ?

Milk testing and quality control is an essential component of any milk processing industry whether small, medium or large scale. Milk being made up of 87% water is prone to adulteration by unscrupulous middlemen and unfaithful farm workers.

Moreover, its high nutritive value makes it an ideal medium for the rapid multiplication of bacteria, particularly under unhygienic production and storage at ambient temperatures.

Product Testing in QA Lab

Some Tests Carried out in QA Labs

Organoleptic EvaluationCheck taste and flavor of milk.

COB TestConduct 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.

Acidity TestTaking 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.

Rosalic Acid TestTo 5 ml 60% alcoholic Rosalic acid in a test tube add 2 ml of milk . Rose red color development indicates neutralizer presence in milk and formation of flakes indicates disturbed salt balance.

Some Tests Carried out in QA Labs

Alcohol TestAlcohol 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.

FAT & SNF Fat & SNF can be determined using Gerber’s 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

Milkoscan is the latest technology machine for scanning of milk and uses infra red rays to analyze the milk for

• Fat• Protein• Lactose• SNF

Continued…Tests Carried out in QA Labs

Microbe Test

For testing the presence of microbe, plating method is done. In this process 1ml of various sample (milk, yoghurt, ghol ,butter and paneer) is collected and its dilution is prepared. Then it is plated according to the drop plate method. For paneer 1gm paneer is grinded with sterile phosphate buffer and then its dilution is prepared. Also for preparing dilutions of other samples sterile phosphate buffer is used.

For plating two types of media is used :•Violet Red Bile media- it is used to observe the coliform growth in the sample•Milk agar media- it is used to determine the total plate count of the sample.

Continued…Tests Carried out in QA Labs

Paneer Test  Appearance -- Shall be clear and free from dirt, surface discoloration 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. 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 100 + 2◦ C for 4 hrs. Cool in desiccators. Observe the final weight.  Calculation :

Moisture % = 100 (W1 - W2) (W1 – W) W1 = dish + sample before drying W2 = dish + sample after drying W = Mass of empty dish

Continued…Tests Carried out in QA Labs

.

Lactometer Test It is an instrument use to measure the SNF present in milk. In this process the lactometer is dipped in milk n it shows the reading.

Calculation: SNF= (CLR/4) + .25f+ .44 CLR = Lactometer reading f = % of fat

Lactometer Test

Details about some Tests carried out in QA Labs

Tests for Free Fatty Acids It is done to measure the % of Oleic Acid

10 gram ghee is taken

Neutralizer is prepared

Neutralizer are added to the ghee

It is kept at 50°C for 15 minutes with repeated shaking

It is then titrated with 0.1N NaOH

Continued.. Protein Test

10 ml Milk + .4ml Saturated potassium oxalate

Keep Undisturbed for 3 minutes

Titrate with NaOH

Then add Formalin solution (2ml)

Titrate with N/10 NaOH

Continued..

Acid Value Test for Butter20 gram Butter + 90ml boiling water

Add Phenolphthalein about 1ml

Titrate it with NaOH

Calculation:2.28*V÷WW: weight of the sample(20gm)V: volume of NaOH usedStandard : 0.06 Maximum

Continued..Gerber Test :-5gm butter /10.75 ml milk is taken and to that 10 ml of Gerber sulfuric acid :(

specific gravity 1.823) at 15-21c is added into Gerber Butyrometer

Add 1ml of iso amyl alcohol and insert the lock stopper grasp the test bottle at the graduated column and shake it until the curd is completely digested.

Adjust temperature of the milk sample to 22-21C°.

Place them in a Gerber centrifuge close the cover and lock. After the required speed of1500 rpm centrifuge for 5 mint, stop the centrifuge.

Standard : 80 to 84%Milk should be heated at 40°C and then brought to room temperature.

Continued..MBR Test

10 ml Milk + 1ml Methylene Blue.

Put in water bath till the color becomes white.

Standard : If Milk quality is good then it will take 6-7 hours to discolour.

BR Test Heat Butter till it forms Ghee/Heat ghee at 40◦C

Filter it and remove the residue

Put in Butyro Refractometer and take BR readings Standard : 40 - 44 %

Continued..RM ValueIt is done for both butter and ghee. In case of butter it is first heated to high temperature to convert it into ghee and then the test is performed. It is used to measure the volatile fatty acid present in the sample.Standard: 21-28

5 gm. ghee/butter is taken

20gm of 98% glycerol is added

2 ml of 50% NaOH is added

Heated till it is clean

It is kept covered and cooled

Continued..

50ml diluted sulfuric acid is mixed

93 ml boiled water is added which was boiled for 15 minutes

3-4 glass balls were added to prevent the flask from blasting and it is heated

Then it is distilled by the process of distillation

Distilled fluid is collected for 1st 20 minutes

Continued..

The fluid is kept at 15◦C for 10 minutes

It is mixed and titrated with N/10 NaOH with 1 ml phenolphthalein as indicator

Calculation: Reading – (0.2)*1.1 Blank reading-- 0.2

Ammonia Test5ml Milk + 1ml Nessler’s Reagent.

Standard : If yellow spot appears at the bottom, then it contains Ammonium Salt.

Test for presence of UreaTake 2 ml milk in a test tube & add 2 ml DMAB solution and mix the

contents.

Standard: Appearance of yellow color indicates the presence of urea making the milk unacceptable.

Continued..

Phosphatase Test The Phosphatase test is applied to dairy products to determine whether pasteurization was properly and also to detect the possible addition of raw milk to pasteurized milk. Pasteurization results in deactivation of Phosphatase enzyme.

1ml of Milk is taken

Substrate is added (5ml)

Put in water bath at 37 ± 1 °C for 2 hours

Standard: If yellow color, then Pasteurization not done properly. If it is colorless, then Pasteurization done properly.

Continued..Milk Powder Test

Milk powder is dissolved in water

It is centrifuge at 1100 rpm for 5 minutes

The sediment is observed

Standard: The layer of the sediment should not exceed 0.5 cm

Continued..Homogenizing Efficiency Test

Take some milk and dilute it with water

Smear the milk on the slide

Cover it with cover slip

Smear it with cedar wood oil

Observe it under microscope

Standard: The size of the fat globule should not exceed 2 micron

Continued..Salt Test The salt used in the plant should be free from iodine. So to test this some amount of freshly prepared starch solution is added to the salt. If blue-black appears then it is rejected

Chlorine Test1ml chlorine + 10ml glacial acetic acid + 2gm potassium iodide

Keep in dark for 5 minutes

Titrate it with N/10 Sodium Thiosulphate till it becomes straw yellow

Add 1ml starch

Titrate it with N/10 Sodium Thiosulphate till it becomes colorless

Calculation: Strength of chlorine at ppm= 3546*(1st reading - 2nd reading)Standard: 40000 minimum

Continued..Caustic Strength Test

10 ml Caustic is taken

Add 2-4 drops of Phenolpthelin

Pink Color appears

Titrate with 2.5 Normal Sulphuric Acid until it becomes colourlessStandard: 0.7 to1.5

Specific Gravity Test for Caustic Cool the caustic till 20◦ C

Immerse the hydrometer

Note the reading on hydrometer

Standard : 1.45

Hardness test

Take 10 ml water

Add 4 drops of ammonium buffer solution

Add 3-4 drops of Erichrone Black solution

Titrate it with N/50 EDTA till the color changes from purple to dark green and note the reading.

pH Test : It is done with the help of pH meter. Standard is 7-8.

Total Dissolved Solid Test (TDS)it is done with TDS instrument which gives the reading directly. The reading varies according to the sample.

Continued..Water Tests

Continued..

Milk Polypack Test

Thickness Test: It is done by dial thickness gauge. Standard is 49-50 microns.

Printing Test: Print should not come out on a cello tape when it is stuck and peeled out.

Width Test: The standard value is 323 (± 2) mm

Drop Test: It should be dropped 2m for 500ml and 1m for 1000 ml.

Milk Polypacks

Test Result And Discussion

Test Name Result And Discussion

COB TEST (Clot On Boli) Formation of clots in the sample indicates COB positive milk and is unacceptable.Generally milk from Midnapur district were sometimes COB positive.

ACIDITY TEST Acidity above .153% is not acceptableAll milk samples have acidity below the given standard.

ROSALIC ACID TEST Rose red color development indicates neutralizer presence in milk and formation of flakes indicates disturbed salt balance.Peach color tends to deepen if caustic (neutralizer) is present depending on the amount of caustic.Generally all sample produce light peach color indicating the presence of little amount of caustic in it, added to increase the self-life

ALCOHOL TEST 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.Majority of the samples tested were alcohol negative.

Test Result And Discussion

Test Name Result And Discussion

FAT & SNF TEST It is done either by Garber method or with the help of MilkoscanMajority of the time the results were according to the standard, if it was more or less than the standard then the batch were rejected.

MBRT TEST Milk with MBR time of less than 7 hours is unacceptable.All the milk samples had MBR time of around 7 hours.

TEST FOR PRESENCE OF UREA Appearance of yellow color indicates the presence of urea making the milk unacceptable.Majority of the samples were Ammonia free.

PHOSPHATASE TEST Yellow color determines that pasteurization was not done properly. Pasteurization results in inactivation of phosphatase enzyme.All samples appeared colorless i.e. properly pasteurized.

MICROBE TEST Microbes were observed only on plates that were plated by Dahi samples. Count of around 400 colonies (approx.) was accepted. More than that were recorded and reported.Generally all samples gave a colony count below the standard.

MOISTURE TEST FOR PANEER

Differences of about 2gm were acceptable before and after drying.e.g.: BNIL paneer weight around 16.7191 before drying and 14.7160 after drying. Therefore the diff is around 2gm

Test Result And Discussion

Test Name Result And Discussion

LACTOMETER TEST Standard for raw milk is around 30.Generally though it never reached exact 30 but around or more than 28.5 is accepted.e.g.: once milk from Midnapur was rejected as it was 26.75

TESTS FOR FREE FATTY ACIDS Standard is around or less than 3.0. It is the % of Oleic acid in ghee.e.g. BLIN ghee has a value of 1.1844

PROTEIN TEST Standard is around 8.5%Below that the sample is rejected. Ones milk from Haringhata was rejected due to lower protein content around 6.2%.

ACID VALUE TEST FOR BUTTER Standard is 0.06%All samples were around the given standard.

GERBER TEST Standard : 80-84%Once milk pouch from BNIL was rejected as it had Gerber test value of around 60%

BR TEST (Butyro Refractometer)

Standard: 40-45%. Below or above that range that sample was rejected.No sample was rejected on the basis of this test.

Test Result And Discussion

Test Name Result And Discussion

RM VALUE Standard: 21-28%No sample were rejected on the basis of this test.

AMMONIA TEST If yellow spot appears at the bottom, then it contains Ammonia. Generally, rarely ammonia was found in the milk samples.

MILK POWDER TEST The layer of the sediment should not exceed 0.5 cm.Generally on samples were rejected on the basis of this test.

HOMOGENISING EFFICIENCY TEST

The size of the fat globule should not exceed 2 micron. It is used to check the efficiency of homogenizer.Once the fat globule size exceeded 2 micron due to fault in homogenizer

SPECIFIC GRAVITY TEST FOR CAUSTIC

Standard : 1.45No samples were rejected.

WATER HARDNESS TEST Standard: .5mlIf the volume of EDTA is more than that then the sample is rejected. Samples were rarely rejected.

Test Result And DiscussionTest Name Result And Discussion

WATER pH TEST Standard: 7-8No samples were rejected

WATER TDS TEST(Total Dissolved Solid)

Standard: 300(approx.)No samples were rejected

SALT TEST Appearance of blue black color in the salt indicates the presence of iodine and the sample is rejected.No sample is rejected.

CHLORINE TEST Standard : 40000More the strength better it is as it is used for CIP (Cleaning In Place). Sample with less than 30000 is rejected and rejection is rare.

MILK POLYPACK TEST Thickness Test: Standard is 49-50 microns.Printing Test: Print should not come out on a cello tape when it is stuck and peeled out.Width Test: The standard value is 323 (± 2) mmDrop Test: It should be dropped 2m for 500ml and 1m for 1000 ml.No samples were rejected.

Some Photos of Production Department

Dahi Plant Set Up

Some Photos of Instruments used in QA Testing Department

Centrifuge

MBRT

Lactometer

Some Photos of Instruments used in QA Testing Department

Milkoscan Attached to Computer

Some Photos of Packaging Department

Polypack Packaging And Final Packaging

Mother Dairy, Kolkata is committed to the

protection of environment by Prevention of

Pollution and Continual Improvement

in our processes and systems to

Improve Environmental Performance.

Minimize Waste generationConservation of resourcesUse of renewable energyRecycling & re-use

Environment and Safety:

Storage Area

o http://en.wikipedia.org/wiki/Mother_Dairy /Calcutta

o http://www.mannventures.com/mother-dairy-kolkata- division.html

o http://www.motherdairy.com/MotherDairyPages/home.aspx

o http://www.motherdairy.com/MotherDairyPages/branddetailpag e.aspx.html

o http://www.deccanherald.com/content/224908/mother-dairy- expand-operations.html

o http://www.hrgms.com/news.html

Bibliography

THANK

YOU