INSTITUTE PROFILE

Gurdaspur Distt , Co-Operative Milk Products Union Limited is the leading dairies among

all the Punjab state co-operative milk produces federation limited (Milkfed).

It is situated on the Amritsar-Jammu national

highway in the outskirts of Gurdaspur city. It gets its milk from the various milk societies in

the district.

It modules different types of milk and milk products. In fluid milk like fully

creamed milk, standardized milk, skimmed milk, double toned milk. Other than milk fluids,

paneer, curd, lassi, kheer, ghee etc.

Plant is divided in various sections like production

section, administrative section, engineering section, transport, mechanical section, purchase,

stores, accounts and marketing section.

This milk plant have been awarded with ISO 9002

certificate by BIS.

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PRODUCT PROFILE

1. Pasteurized Milk

a. Standardised Milk

b. Fully creamed Milk

c. Double Toned Milk

2. Paneer

3. Curd

4. Ghee

5. Spiced Lassi

6. kneer

7. Whey drink

8. Skimmed Milk Powder

9. Whole Milk Powder

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RAW MILK RECEPTION

Reception of raw milk in tankers and cans from the societies in an important

operation. The process followed at raw milk reception dock (RMRS) is as follows.

Unloading of cans and placing them on conveyors

Lids removed manually using wooden hammer

Quality Evaluation (Organoleptice Tests)

Milk filtration through cotton cloth

Weighing of milk

Raw milk send to Sampling of milk is done

Cold storage Silo tank (at 6C).

In Sampling Acidly standards are checked along with fat % of the raw milk also.

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Standards: SNF (Solid not fat) and adultrauts

1. Acidity of milk should not be more than 0.14%in terms of lactic acid.

2. If Acidity is above 0.15% Milk is treated as sour milk.

3. If acidity is above 0.25% milk is considered as curd.

MILK PROCESSING

Milk processing means rendering raw milk free of all pathogens and fat along with SNF is

adjusted.

1. CHILLING – All in coming milk is chilled first and then it is diverted to milk storage

tanks. Milk is chilled below 4C . The raw chilled milk is utilized for the various products

processing operations. The chilled milk is stored in tank called silo . The chiller is plate heat

exchanger type.

2. PASTEURIZING – Milk is heated to 63C for 30 min or 75 - 80C for 15 seconds and

then cooled immediately below 4C.

The pasteurizer has following sections:-

a. Chilled water section

b. Regeneration I

c. Regeneration II

d. Hot air Section

e. Holding Section

The pasteurizer is plate heat exchanger type consisting of

Many conducting plates arranged in parallels to form a network of many plates lying side by

side. Alternate plates are for carrying milk and hot water the length and breadth of plates

along with flow rate are so adjusted to give proper contact time to milk for proper

pasteurization. The high temperature short term method (HTST) is being used here.

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FLOW CHART

Chilled raw milk strange tank

Balance Tank

Standardization

Regeneration I (50-55ºC) Heat exchanged between in coming raw milk & outgoing

pasteurized milk.

Filtration

Regeneration II (60-65ºC)

Heating Section (75-80ºC)

Holding (at75ºC for 15-16Sec)

Regeneration I & II

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Chilling

Storage tank (below 5 C)

If milk contain high fat content then after regeneration I , it passes to cream separator. The

cream is sent to cream pasteurizer and skimmed milk is diverted to the pasteurizer.

Fat % in cream – 35 - 40%

Fat % in skim milk – 0.05-1%

Separator efficiency -65-70 %

PREPACK SECTION - To protect milk from contamination, retard or prevent losses

and to facilitates handling the milk and milk product have to be properly packed.

In plant liquid milk is packed is pouches made up of LDPE

(0.92 gm/cl ) . It can be sealed at 150ºC . The packaging is done by automatic form fill and

seal machine called PREPACK MACHINES capacity of machine is 3000 pouches per hour .

Types of Milk packed

S.NO Type Fat % SNF %

1. Standard Milk 4.5% 8.5%

2. Fully Cream Milk (Gold ) 6.0% 9.0%

3. Double Toned Milk (Smart ) 1.5% 9.0%

PRODUCTION UNIT

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Various sections of products under production unit .

1. Paneer Section

2. Ghee Section

3. Curd Section

4. Spiced lassi Production

5. Whey Drink Production

6. Dry Milk production

PANEER SECTION :-

Paneer is one of the most popular indigenous milk product .It is obtained by the

precipitation of milk with sour milk , lactic acid or citric acid .

Basically paneer is milk solids produced by acid coagulation of boiled hot whole milk

and subsequent drainage of whey .

FLOW CHART FOR PANEER PRODUCTION :-

Processed Milk

Standardization of Milk (4.8 % Fat & SNF 8.8%)

Heating upto 90-95 ºC for 5 min. Steam (3.5 kg/sq.cm)

Cooling to 72º -75ºC

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2% of citric Acid Solution (10% Solution in water )

Coagulation

Settling down for 5min

Removal of Whey

Pressing with hoops containing 10 kg for 20-25 min

Dipping in chilled pasteurized water at 4º C for 3-4 hrs

It provides good texture and proper Moisture equilibrium

Removed from the water

Cutting with Knife

Packaging

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Storage at 5º C

Critical Parameters

1. Heating 85-90º C

2. Immersion in Chilled

Pasteurized potable water 05-10º C

Storage Below 10º C

CURD SECTION

Curd or Dahi is a fermented milk product .Curd is made in batches about 300kg of curd is

made daily.

Standardized toned milk with 9.2 % SNF is used for this purpose .The milk is

pasteurized at 80º C and cooled to 32-35º C . The bulk culture prepared from ampoules

bought from NDRI Karnal are then added at a rate of 0.7 –0.8 % .The inoculums is mixed

well with a plunger . The inoculation is done in large cans . Then inoculated milk is

aseptically filled in plastic cups upto 200ml and sealed .The sealed cups are arranged in trays

and sent to the hot air room which is maintained at 35º C with 3-4 hrs the curd is well made

after which it is taken to cold store.

Flow chart

Standardized toned milk (SNF-9% FAT –3%)

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Heating at 80ºC

Cooled to 35-38º C in aluminum cans of 40 Liter Capacity

Adding culture at a rate of 0.8 –0.7 % at 35º C

Mixed thoroughly

Filling in Plastic cups

Sealing the cups

Incubating the cups at 35º C for 3-4 hrs in hot air room

Checking whether curd is well made

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Storage of 4º C in cold storage room

Culture Used :- Mixed culture of Streptococcus lactis ,Streptococcus cremoris,

streptococcus diactylactis

Standards :-

Colour : White

Taste and Flavour : Good

Appearance : Free from extraneous material

Acidity : 0.07-0.85 % tactic acid

Fat : Not less than 3.10%

Ts : Not less than 12.20%

GHEE SECTION

Ghee is manufactured form cream extracted form milk

PROCESS CHART

Cream (Temp 12º C)

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Loading in butter churn .

Removal of whey

Washing the butter with chilled water

Transfer of butter to heating vats (not more than one hour)

Pumped to ghee cooking kettle (CCP)

Cooking (105-110 ° C) about (3-4 hrs)

Steam Pressure 2.5-3 kg/ cm

Filtration through muslin cloth

Settling / cooling (time not less than 6 hrs)

Filling (Temp 40 +2ºC)

Storage

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FAT RECIVERY FROM GHEE RESIDUE:-

Ghee residue is taken in vat. Then steam is supplied to melt the fat . Then it is dissolved in a

chilled water .After dissolving it is allowed to stand which makes fat to solidify and float on

the top due to lower specific gravity than residue . The fat is collected from top layer in cans

while rest are drained out . The fat is again reprocessed in Ghee vat with newly received

melted butter. Fat recovery Ghee residue is about 99.75 %

SKIM MILK POWDER

Skim milk powder is one of the most utilized form of milk product. It is produced both as

skim milk powder and whole milk powder . Skim milk contain milk fat upto 0.05-0.1 % .

FLOW CHART : For milk powder

Skim Milk 0.05-0.1

Condenser

Pasteurization of standardized milk for milk powder

Preheating (88 –90 C)

Holding cell

Evaporation (50% moisture is lost)

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Concentrated vat milk

Atomization

Hot Filtered Air

Spray drying

Filtrated cool air conveyer fan .

Testing Moisture

Packaging 10kg tin/ 25kg Bags

storage at room temperature .

Critical Control Milk Powder :

Pasteurization –75-80C

Temp to Chilled milk temp -5C

Pre Heating temp -86C

Cool Air – Absence of foreign Particles -

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SPICED LASSI

Lassi is a drink from cultured standardized milk by 50.50 dilution with water

Flow chart for lassi Making :-

Receiving Milk

Standardization (45 % fat 85% SNP)

Heating of Milk to 85C /5Min

Cooling of Milk to 40 C

Inoculation with culture @ 1% at 40 C

Incubation at 40 C (till acidity reaches 0.67%)

Addition of pasteurized chilled water (2:1)

Breaking of Coagulation (Acidity 0.54 %)

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Packaging in Pouches

INGREDIENTS OF SPICES : For (40 liters)

Common salt - 100 gm

Black salt - 100 gm

Roasted Jeera Powder - 15 gm

Black pepper - 5 gm

QUALITY CONTROL

Quality control is the maintenance of quality at level of tolerance acceptable by the

buyer with minimizing cost for seller.

Objective of quality control :-

1. To establish the desired standard which are acceptable to the consumer .

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2. To discover variation in raw material and manufacturing process in order to ensure

smooth and uninterrupted production .

3. Evaluate methods are processing production and suggest further improvement in their

functioning .

4. To study and determine the extent of quality deviation in product during

manufacturing process.

5. To analyze in detail the causes responsible for such deviation .

CHEMICAL ANALYSIS

DETECTION OF MAJOR ADULTERANTS

1. Salt

Take 5 ml silver nitrate solution (AgNo3) 0.1341 % in test tube

Add 2drops of potassium chloride (Kcl) 1% solution

Add 1ml milk.

Yellow coloration shows presence of salt.

2. Cane Sugar

1) Take 15 ml of milk

2) Add 1ml of conc. HCL acid & mix.

3) Add 0.1 gm of resorcinol powder and mix thoroughly.

4) Place the tube in a boiling water bath for 5 min & observe the colour.

Red colour obtained indicates the presence of cane sugar.

3. Urea .

Take 2ml of milk and 2ml of Bench reagent (1.6 gm 4-dimethyl amino benzaldehyde in

100ml of distilled ethyl alcohol +10 ml conc .HCL & mix.

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Yellow colour indicates urea

DETECTION OF NITRATES

Take milk sample in test tube

Discard the sample

Add to the rinsd tube from the corner 2% diphenylamine in conc. HCL .

Blue Colour Indicates Nitrates

Detection of Starch & Cereal Flours

1. Take 3 ml of well mixed milk in a test tube

2. Boil the milk

3. Cool to room temperatures and add 1 drop of 1% iodine solution and observe the

colour .

Blue Colour that disappear on boiling and reappear on cooling shows presence of starch.

DETECTION OF PRESERVATIVES : (FORMALIN – HEHNER

TEST )

1. Take about 10 ml of milk in a test tube and add 0.5 ml of 10% ferric chloride

solution.

2. Add carefully about 5ml of concentrated sulphuric acid down the side of the test tube

in such a way that it forms a separate layer at the bottom without mixing with two

milk

Observe the colour of the ring formed at junction of 2 liquids . Development of violet

coloured ring indicates presence of formaldehyde as preservatives.

METHYLENE BLUE REDUCTION TEST (MBRT)

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1. Thoroughly mix the milk sample and transfer 10ml of each sample into separately

identified sterile test tube.

2. Add 1 ml of the bench methylene blue solution to the milk in each of the test tube to

get a concentration of 1 part of dye to 300000 parts of milk replace the cotton plugs

with sterile rubber bungs.

3. Mix the dye and milk by inverting the tubes twice.

4. Place the tubes in the water bath , Maintained at 37+0.5 C.

5. The tubes should be observed & inverted initially at half an hour.If milk begins to

decolorize the tubes should not be inverted . Tubes shall be incubated until milk is

completely decolorized .

6. Note the time after which the milk decolorizes.

Standards

Sr.No MBR Time (hours) Quality of Milk

1. 5 hrs or above Very Good

2. 3-4 hours Good

3. 1-2 hours Fair

4. ½ hour or less Poor

MOISTURE TEST

Milk Contain Solid 12-14 %

Water 86-88 %

PROCEDURE 1. Take Petri dish and weight it (w1)

2. Add some sample & weight it (w2)

3. Now put . It in microwave oven & set for 2 min.

4. Cool the dish & weight it (w3)

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% moisture = W2-W3 X 100

W2-W1

ACIDITY TEST

Titration of milk sample (10ml) against N/10 Na OH Sol. using phenolphthalein as

indicator. The end point is pink colour . The acidly of milk should not be more than 0.14%.

CLR (Correct lactometer Reading)

1. Take raw milk sample . heat to 45C & Cool to 15 C

2. Dip lactometer into milk taken in measuring cylinder .

3. Note the Reading.

SNF (SOLID NOT FAT) :

CLR

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FAT TEST : (Gerber Method )

1. Take 10 ml of H2 SO4 in butyrometer .

2. Add 10.75 ml of milk sample followed by 1ml of amyl alcohol .

3. Close it with cork and shake well .

4. Centrifuge at 1200 Rpm for 3 min .

5. Note the reading .

REICHERT – MEISSL TEST (FOR GHEE)

5g Ghee +20ml glycerol +2ml 50% NaoH + Glass Beads

Clear by heating

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+ 0.2 R % fat + 0.29 .%SNF =

Saponification

Add 93 ml distilled water +50ml H2SO4(IN)

White colour appears and fat forms a scum at the top

At receiver end collect upto mark when first drop falls , in 2 mins it falls.

Filter in using whattman filter paper

Put the filterate in flask with phenolphthalein as indicator and titrate with N/10 NaoH

R.M value (T.V - B.V.)x 110100

T.V = Titre Value

B.V = Blank value i.e. when only H2O + Phenolphthalein is titrated against N/10 NaOH R.M. value should be around 32.

COB : (Clot on Boil ) :- This is a quick test to determine the developed acidity and

suitability of milk for processing.

1. Heat about 5 ml of milk in test tube

2. Observe the Change .

Milk with high acidity clots on boiling due to poor keeping quality .

RAW MILK FROM CHILLING CENTRES IN TANKERS

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The milk received in each tanker from chilling centers is tested for :-

1. Temperature 2. Organoleptic Quality 3. Acidity 4. Fat 5. SNF6. MBRT7. Preservative on Daily Basis

Milk from MPC’s is tested for extraneous matter (ppm per ltr) . The sample from tanker is kept in cold room after adding formalin as preservative for 48

TEST FOR PASTEURIZED MILK

Sample size : - From storage tank and milk pouches from cold store .Frequency :- Once a day (STS-ST 10 twice a day)

TESTS Describe Norms

1. Fat and SNF Maintain the legal standard 2. Salt ammonia compound , Neutralizer Nagative

3. Phosphates Negative 4. PCP Negative5. Temperature Not more than 7° C6. Acidity 0.12-0.14 %LA7. MBRT 5.30 Hr Test for curd

1. Sample size Finished product in Cup 2. Frequency One sample per lot of finished product

TEST Desirable Norms 1. Fat Not less than 3.10 % 2. Total solids Not less than 12.20 % 3. Acidity 0.70 to 0.85% LA .

TESTS OF PANEER

Sample Size : (i) Sample after packaging , ready for storage or marketing

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(ii) Sample form cold store for temperature & Organoleptic tests.

Frequency One sample per lot of finished product

Tests Desirable Norms

1. FAT Not less than 50 % on dry basis 2. Moisture 48-56%3. Total Solid 44-52% 4. Organoleptic Tests Normal 5. Temperature of Dispatch Not more than 5.0 C 6. Shelf Life 4 day at 5-7 C

TESTS OF CREAM/BUTTER

Sample size : (i) Cream daily vat wise , one sample form vat at morning (ii) One butter sample of each lot form butter churn.

Tests Desirable Norms

1. Cream Acidity 0.1% max (0.08-0.10 %) 2. Cream Temperature Not more than 12 C3. FAT Around 40%4. Acidity in Butter (%FFA) 0.27 %

TESTS OF GHEE

Sample Size : (i) Ghee settling tank /vat/packed ghee

Frequency : One sample from each tank at 9.00am and packed sample (packet/tin)

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Tests Desirable Norms

1. Moisture Not more than 0.30%2. Acidity (% FFA) Not more than 0.30%3. RM Value 28-33

TESTS OF PANEER WHEY

Sample size : Paneer whey form paneer vat before drainage Frequency : One composite sample of each lot of raw cheese and paneer manufactured on daily basis .

Desirable % FAT (Max) % TS (Max)Paneer Whey 0.36 7.0

MICROBIOLOGICAL ANALYSIS

Microbiological analysis of the product is very vital for the product to be consumed .

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The product consumed by the consumer should be free from the pathgens and other harmful microbes . In these analysis it is made sure that the product is safe for consumption and also it is good for its shelf life .

MICROBIOLOGICAL ANALYSIS OF MILK

SPC (STANDARD PLATE COUNT )

PROCEDURE :-

1. Melt required quantity of plate count agar media mainly used is potato dextrose agar, by boiling & cool to 44 -45° C

2. Add 1ml of thoroughly mixed and appropriate dilution of sample aseptically in sterile labeled Petri dish in duplicates.

3. Pour medium to the plates 4. Rotate and tilt the dish to spread the medium uniformly .5. After solidification , invert the plate and promptly place in the incubator6. Run agar medium black as well as dilution water blank .7. Incubate at 37°C for two days .

Standards : Acc.to BIS

Type of Milk Colony count Quality of Milk Raw Milk Upto 2,00,000/ ml

2,00,000 -10,00,000 10,00,000-50,00,000Above 50,00,000

Very Good GoodFair Poor

Pasteurized Milk Not more than 30,000 /ml

INTERPRETATION Count the colonies and compute the number of Bacterial colonies per ml.

FREQUENCY :- Every Day

COLIFORM COUNT

Presumptive test with solid media

Testing Procedure 1. Introduce 1ml of sample or decimal volumes intosterile plates .

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2. Add to each plate ten to fifteen ml of violet red bile agar , previously melted and cooled medium at 42-44° C.

3. Mixed the contents thoroughly by tilting and rotating the dish .4. After the mixture has solidified , distribute 3-4 ml of medium completely over the

surface of the solidified medium for inhibiting surface colonies formation. 5. Allow to solidify .6. Invert and incubate the plates at 37° C. for 18 to 24 hours .

Standards :-

Raw milk – Absence of coliform in 1:100 dilution of raw milk is considered satisfactory

Pasteurized Milk – Coliform should be absent infirst dilution 1:10 .

INTERPRETATION

Presence of dark pink / red colonies measuring at least 0.5 mm in diameter constitutes a positive presumptive test

FREQUENCY : Every Day

BACTERIOLOGY Of PANEER SPC OF PANEER MATERIAL:_

Incubator (37˚ C)

Bacteriological delivery pipettes (1ml)

Petridishes

Plate count agar

Crusher

Test tubes

Sterile spatula

PROCEDURE

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1. Taje a crusher.Sterlize it with spirit and crush 11 gms of paneer.

2. Put 11gms of paneer into dilution tube and mix it . Allow it to stand for 1-2 min.

3. Use a sterile pipette of 1ml and transfer dilution into sterile Petri dishes .Add 10-15 ml of

plate count agar .

4. Mix the contents of plates thoroughly while the medium is still liquid by gently rotating

and fitting the Petri plates and allow the contents to cool and set .

5. Invert the plates and incubate it at 37° C for 24 hours

6. Remove the plates after 24 hours and count the colonies .

PRECAUTIONS

1. Apparatus should be clean

2. Proper sterile conditions should be maintained

3. Measurements should be accurate,

EFFLUENT TREATMENT PLANT :

ETP (effluent treatment plant ) means treating industrial wastewater to make it pollution free

material before it is drained . During wastewater treatment organic compounds are transformed into

inorganic compounds with the help of biomass .

Main Aim of Etp Plant

To render sewage inoffensive so that it causes no odorous nuisance

To reduce or eliminate danger to public health be possible contamination of H2O Supplies &

bathing areas .

To prevent destruction of risk and aquatic life .

In this ETP plant water is treated by activated sludge process . The wastewater form plant is

stored in storage tanks when quantity of H2O is sufficient then it is sent to ETP plant . In ETP

plant it is received in tank fitted with air blowing pipe .Sewage is first filled in this tank lime is

mixed in this tank and then air is blown through water to remove the dissolved gases and

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facilitate sludge formation . then this water is pumped to clarifloculator . This arrangement

consist of two deep cylinders, first cylinder is sealed to the bottom . The internal cylinder is not

connected to bottom and is uplifted form bottom at a distance of one foot . Agitators are fitted in

internal cylinder one rotates at high speed and other at a quite slow speed . Sludge being lighter

comes to top form where it is removed and sent to bed containing sand and rocks and adsorbs

sludge . The water is then goes to aeration lagoon where I is aerated by two surface aerator .

Oxidation reaction take place . It can be aerobic or anaerobic or anaerobic.

This process is carried for 4-6 hours . After aeration effluent is sent to setting or sedimentation

sedimentation tanks where suspended particles are clean water is obtained .

And the treated water is drained through v-notch to the city sewage . V-notch is used to measure

on the flow rate treated water. Urea & DAP is used (2:1) in the water tank to maintain the level

of MLSS.

The treated water is tested for :

PH, suspended solids , oil & grease Once a day

COD Once a week

BOD Once a fortnight

Standard of treated water :

Sampling point V-notch

Colour Clear

PH 6.5-8.5

Suspended solids <150 ppm

Oil and grease <10 ppm

COD <100 ppm

BOD <30 ppm

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