A Summer Training Report

Kaira District Co-operative Milk Producers Union Ltd.

Submitted to : Kaira District Co-Operative Milk Producer‟s Union Ltd.

Submitted by : Tushar B. Zala (20721170340)

P.G.I.ABM

P.G. INSITUTE OF AGRI-BUSINESS MANAGEMENT,

(JAU)
Training Period: 2nd July to 30th July, 2018.

1
 INDEX
Sr.No. Content Page No.
1 Acknowledge
2 List of Tables
3 Training Schedule
4 Introduction of company
5 Product range
6 Amul-3 processing plant
7 Amul-2 processing plant
8 Milk pouch & Dahi Section
9 Butter Plant
10 QA Laboratory
11 Amul-3 Powder plant & Packing
12 Ghee section
13 Sterilized Flavour Milk
14 Utilities
15 Conclusion

2
 ACKNOWLEDGEMENT
I sincerely express my deepest sense of hearty gratitude to the following people for supporting and guiding
me ahead in the journey of making the project report of Industrial In-Plant training.
I express my profound gratitude and indebtedness to The Father of “The white Revolution, Dr.
Varghese Kurien” for envisioning this dairy and helping it becomes the stage of learning.
I would like to express my thanks to K.A. Khunt (Principal of P.G. Institute Of Agri-Business
Management, Junagadh.) for permitting me to do my summer training in Amul Dairy, Anand.
I would also like to thank All the professors of our college for supporting & guiding us throughout
our graduation.
I am also thankful to Mr. D. R Sharma (Production Manager), Mr. Mrunal Desai (H.R
Department) without their guidelines and help I was not able to complete my In-Plant training.
I am also thankful to all section In-charges and operators who gave us positive response and guidance
during my training period.
Last but not the least, we express our deep feelings of love and affection to our beloved parents for
providing us valuable opportunities which helped us to stand out on our own feet this stage.

Thank You
Tushar Zala

3
 List of Tables
Table No. Title
i Training schedule
ii Company profile
iii Product Range
1.1 Amul-3 equipment list
1.2 Amul-3 CIP
2.1 Amul-2 Can washing
2.2 Amul-2 equipment list
2.3 Amul-2 CIP
3.1 FFS pouch packaging machine
3.2 Milk pouch standards
4.1 Specification of buttermilk
5.1 Specification of Dahi
5.2 Dahi equipment list
6.1 Specification of powder
6.2 Equipment list (Powder plant)
6.3 Powder packaging
7.1 Specification of butter
7.2 Butter section equipment list
8.1 Chemical composition of ghee
8.2 Ghee section equipment list
8.3 Standards of weight
9.1 Flavoured milk price & shellife
9.2 Specification of Flavoured milk
9.3 Equipment list
9.4 Standards of weight
10.1 Specification of boiler
10.2 Control limit for compressor
11.1.1 Tests done at RMRD lab
11.3.1 Powder analysis
11.3.2 Ghee analysis
11.3.3 Butter analysis
11.3.4 Flavoured milk analysis
11.3.5 Tests for Buttermilk & Dahi
11.3.6 Water analysis
11.3.7 Strength of acid & soda
11.3.8 Packaging material test
11.3.9 Equipment list of central lab
113.4.1 Different microorganisms
11.4.2 Sampling plans for products

4
 Training Schedule
Khaira District Co-operative Milk Producers‟ Union Ltd., Anand AMUL
DAIRY
Name of trainee:-Mr. Zala Tushar B.
Name of the Institute: P.G. Institute Of Agri-Business Management, Junagadh
Training Period :02-07-2018 to 30-07-2018 Training Time : 8:30 am to 12:30
pm
Sr.No Section Training Reporting Officer
Period
1 A-3 Milk process 02-07-2018 to Sh.Rakesh Amin
05-07-2018
2 A-2 Milk process 06-07-2018 to Sh.Chetan Patel
08-07-2018
3 Milk Pouch and Dahi 09-07-2018 to Sh.S.P.Deshmukh
12-07-2018
4 Butter Section 13-07-2018 to Sh.D.R.Patel
15-07-2018
5 QC Lab 16-07-2018 to Sh.Gokul Krishnan/ Sh. Jay Solanki
18-07-2018
6 Amul-3 Powder Plant and 19-07-2018 to Sh.Mayank Patel
Packing 21-07-2018
7 Ghee Section 22-07-2018 to Sh.Ranvijay Singh
23-07-2018
8 Sterilized Flavour Milk 24-07-2018 to Sh. Yogesh Adlakhiya
25-07-2018
9 Utilities 26-07-2018 to Sh. A. V. Zala
2-07-2018
(table no.: i)

5
 INTRODUCTION
AMUL is based in Anand town of Gujarat and has been a sterling example of a Co-operative organization‟s
success in the long term. It is one of the best examples of Co-operative achievement in the developing world.
“Anyone who has seen… the Dairy Co-operatives in the state of Gujarat, especially the highly successful one
known as AMUL, will naturally wonder what combination of influences and incentives is needed to multiply
such a model a thousand times over in developing regions everywhere.” The Amul Pattern has established
itself as a uniquely appropriate model for rural development. Amul has spurred the White Revolution of
India, which has made India the largest producer of milk and milk products in the world. It is also the
world‟s biggest vegetarian cheese brand.

AMUL means „priceless‟ in Sanskrit. The brand name “Amul,” from the Sanskrit word “Amulya” was
suggested by a quality control expert . Amul products have been in use in millions of homes since 1946 and
made Amul a leading food brand in India.

Today Amul is a symbol of many things.

 High-quality products sold at reasonable prices.
 Proven model for dairy development.
 Genesis of a vast co-operative network.

Today,there are twelve dairies producing procucts under the brand name of AMUL. AMUL is now Asia‟s
largest dairy brand and it is the world‟s second largest firm producing dairy products.
80% of profit is divided to farmers according to ratio of milk procured.

Company profile:
Name of plant Kaira district co-operative milk producer‟s
union ltd.

Date of registration 14th December 1946,under cooperative act

Registration no. p.330/1946
Brand Name Amul
Societies 1176 villages co-operative societies with
6,69,566 members
Premises 49.55 acres

Milk procurements 25 lakh liter per day

Plants  Dairy plant – Anand

 Kaira Satellite Dairy – Khatraj
 Food complex – Mogar
 Kanjari Plant – Nadiad
 Amul research & development
association.

(table no: ii)

6
  
History & development of AMUL:
Amul-coperative registered on 14 December 1946 as a response to the exploitation of marginal milk
producers by traders or agents of the only existing dairy, the Polson dairy, in the small city distances to
deliver milk, which often went sour in summer, to Polson. The prices of milk were arbitrarily determined.
Moreover, the government had given monopoly rights to Polson to collect milk from Kaira and supply it
to Bombay city.
Angered by the unfair trade practices, the farmers of Kaira approached Sardar Vallabhbhai Patel under the
leadership of local farmer leader Tribhuvandas K. Patel. He advised them to form a cooperative and supply
milk directly to the Bombay Milk Scheme instead of Polson (who did the same but gave them low
prices). He sent Morarji Desai to organise the farmers. In 1946, the milk farmers of the area went on a strike
which led to the setting up of the cooperative to collect and process milk. Milk collection was decentralized,
as most producers were marginal farmers who could deliver, at most, 1–2 litres of milk per day. Cooperatives
were formed for each village, too.
The cooperative was further developed and managed by Dr.Verghese Kurien with H.M. Dalaya. Dalaya's
innovation of making skim milk powder from buffalo milk (for the first time in the world) and a little later,
with Kurien's help, making it on a commercial scale, led to the first modern dairy of the cooperative at
Anand, which would compete against established players in the market. Kurien's brother-in-law K.M.
Philip sensitized Kurien to the needs of attending to the finer points of marketing, including the creation
and popularization of a brand. This led to the search for an attractive brand name. In a brainstorming
session, a chemist who worked in the dairy laboratory suggested Amul, which came from the Sanskrit word
"amulya", which means "priceless" and "denoted and symbolised the pride of swadeshi production."
The trio's (T. K. Patel, Kurien and Dalaya's) success at the cooperative's dairy soon spread to Anand's
neighbourhood in Gujarat. Within a short span, five unions in other districts – Mehsana, Banaskantha,
Baroda, Sabarkantha and Surat – were set up. To combine forces and expand the market while saving on
advertising and avoid competing against each other, the GCMMF, an apex marketing body of these
district cooperatives, was set up in 1973. The Kaira Union, which had the brand name Amul with it since
1955, transferred it to GCMMF.

Three tier Model of AMUL:

The Amul model of dairy development is a three tiered structure.
1. Dairy Co-operative societies(DCS) at village level. – The role of DCS is to procure & collect
milk from milk producers and transport it to the milk union at district level.
2. Milk union at district level. – The role of MU is processing & value addition in milk and to form
various processed products of milk.
3. State federation(GCMMF) – Selling & marketing of processed products is done only by
state federation.

7
AMUL LOGO
The logo of AMUL is ring of four hands, encircled by the words “KAIRA DISTRICT CO-OPERATIVE
MILK PRODUCER UNION LIMITED”. The essence of this logo is co-ordinate effort of four groups of
people.

First hand is for farmers or producers, without whom the organization would not be existed. Farmers are
the inspiration of the Amul the taste of India.
Second hand is for the representative of processors by whom the raw milk process in to different finished
products.
Third hand is for marketers without whom the products would not been able to reach the consumers.
Fourth hand is for customers without whom the organization could not carry on because they are the
people who consume the products.

Motto of AMUL
The main motto behind the AMUL moment was to help the farmers of Kaira District. The AMUL system
works with the objective of paying highest possible price to the milk supplier and lowest possible price to the
consumers. The farmers supply raw milk for which they are paid cash on daily basis for milk they bring to
milk collection centres. AMUL union is one of the pioneers which started using profit for milk supplier‟s
welfare.

8
ORGANIZATIONAL STRUCTURE OF AMUL

9
PRODUCT RANGE:
Products
Fresh milk Amul shakti (pasteurized standardized milk)
Amul T-special (standardized homogenized milk)
Amul (pasteurized homogenized tonned milk)
Amul Gold (full cream milk)
Amul Lite slim-n-trim milk(Double tonned milk)
Amul Fresh cream
Amul Snowcap softy mix

Fermented Products Amul Masti Dahi (fresh curd)

Amul lite Dahi
Amul Buttermilk
Amul Jeera Butter milk
Amul Lassi

Butter Amul Utterly Butterly delicious

Amul White butter

Bread Spreads Amul delicious

Amul lite

Ghee Amul Pure Ghee

Amul Brown Ghee
Amul Cow Ghee

Milk Powders Amul full Cream milk Powder(WMP)

Amul skimmed milk powder(SMP)
Amulya(Dairy whitener)
AmulSpray(Infant milkfood)
Whey Powder

Flavoured milk Amul kool café

Amul kool koko
Amul shakers ( mango, strawberry, saffron, cardamom, rose)

Cheese Range Amul Cheddar cheese

10
 Amul processed cheese
Cheese spread
Amul Pizza (Mozarella) cheese
Amul ETG(easy to grate) cheese
Amul Emmental cheese
Amul Gouda cheese
Amul malai Paneer

Chocolate & Amul Milk chocolate

Confectionery Amul Dark chocolate
Amul Fruit & Nut chocolate
Amul Bindazz
Amul Chocozoo
Amul ChocoMinis
Energy bar
Almond bar

Mithaee Range (Ethnic Amul shrikhand( Mango, saffron, Almond pistachio, Cardamom)
sweets) Amul Amrakhand
Amul mithaee Gulabjamun mix
Amul mithaee Gulabjamuns
Amul mithaee kulfi mix
Avsar Ladoos
Amul basundi
Amul paysum (Khir)

Sweetened Condenced Amul Mithaimate Sweetened condensed milk

Milk

Amul Ice-creams Royal Treat Range( Butterscotch, Rajbhog, Malai kulfi)

Nut-o-Mania Range (Kaju Draksh, Kesar Pista Royale, Fruit Bonanza,
Roasted Almond)
Nature‟s Treat ( Alphanso mango, Fresh litchi, shahi Anjir, Fresh
Strawberry, Black current, santra mantra, Fresh Pineapple)
Sundae Range (Mango, Black current, sundae Magic, Double sundae)
Assorted Treat ( Chocobar, Dollies, Frostik, Ice Candies, Tricone,
Chococrunch, Megabite, Cassatta)
Utterly Delicious ( Vanilla, Strawberry, Chocolate, Chocochips, Cake
magic)
Amul sugar free ice cream range
11
 Amul prolife proboitic ice cream

Malt based product Amul pro(Whey protein malt beverage)

(table no.: iii)

12
 1.Amul-3 Milk Processing Plant
Reception dock is the very first department of any dairy, where milk is unloaded & simultaneously tested.
Raw milk at Amul-3 is received only through Road tankers coming from different village chilling units &
chilling centers. There are 3 Milk Reception Line (RMRD) each having capacity of 30,000 L/hr. It has
facility of computerized reception.

Process Description:

 As milk tanker arrives in line first agitation is carried out for 15 min by using plunger. QA 
staff/Process Operator after inspection of the integrity of seals; draw a sample to check temperature
and other quality parameters. The results are recorded. The QC officers permit to accept the milk
having acidity up to 0.15% L.A & temperature should  be 10oC. In case of higher acidity, the same
 is reported to in charge (production) for further action.

In case, milk do not confirm to the specification, process staff consults their immediately supervisor
 higher acidity in milk the tanker is sent to Amul-2 dock for unloading
for further action. In case of
and immediate processing.

  storage, processing and dispatch is controlled through PLC
The entire process of milk reception,
(Programmable Logic Controller).

After all tests, the raw milk from tankers after chilling is send to raw milk buffer tank having capacity of
15,000 L. Then this raw milk is sending to clarifier in which the undesirable solid particles are removed
by centrifugation, this particles called as sludge. After every 15min undesirable sludge discharge in
 sludge tank (capacity – 5000 L).Then it sends to sludge treatment tank in which
heat treatment gives to sludge & then it used to produce casein. After clarifier milk is store in raw
milk silos at4oC.There are 5 raw milk silos, 4 silos having 1.5lakh L capacity & 1 having 60,000
 L capacity.

From raw milk silos milk is pumped to Balance Tank of pasteurizer & undergoes pasteurization
(77oC/18 sec). There are 5 Pasteurizers. One is for Cream Pasteurization, rest are for Milk

Pasteurization. Meanwhile after Preheating, milk is separated to Cream & Skim Milk.
  The cream is sent to cream buffer tank & milk is sent to milk silos.

Unit.
The self standardization is done in ALFAST UNIT i.e. Alfa Laval Fat Analyzing Standardization
The separated milk is used for manufacturing powder i.e. WMP, SMP, Amul Spray & Amulya.

13
Process Flow chart:
Raw chilled milk in tankers

Sampling Deaerator Empty tanker

Tankers Pump CIP of tanker

. Grading & Analysis

Acidity test OK Non-return Valve

. (if not ok)
Chiller (25 oC)

Sour Dump tank Buffer tank

Ghee Section Clarifier Sludge Sludge tank

Raw milk silos

(4-5 oC) Sludge treatment tank
PHE
(heating to 60 C,cooling to 10 oC)
o
Balance Tank of Pasteurizer

Pasteurizer Industrial Casein

Regeneration-1(50 oC)
Pre heating (62 oC) Cream Separator Cream

Regeration-2(73 oC) Auto Std. Chilling

Heating (77 oC) Pasteurization

Holding tube (18 sec) Cream silos

Flow diversion Valve Balance tank

Ok if not OK

Chiller (5 oC)

14
 Pasteurized milk silos

Amul-3 Amul-2 Road Tanker Rail Tanker

Equipments:

Equipments Capacity No. of

equipment
Raw milk buffer tank 15000 L 3
Cream buffer tank 15000 L 2
Raw milk chiller 10,000 L/hr 3
Rail tanker chiller 30,000 L/hr 1
Milk clarifier 30,000 L/hr 3
Balance tank 350 L 5
Cream pasteurizer 10,000L/hr 1
Milk pasteurizer 30,000L/hr 4
Homogenizer 10,000 L/hr 1
Cream separator 30,000 L/hr 3
Cream chiller 10,000 L/hr 3
Bactofuge 30,000 L/hr 1
Pasteurized milk buffer 15,000 L 1
tank
CIP tanks 1

Rinse tank

Lye tank 10,000 L

Acid tank 10,000 L

Water tank 8,000 L
CIP tanks for tankers

Rinse tank

Water tank

Lye tank
Sludge tank 5000 L 1
Sludge treatment tank 1000 L 2
Rinse milk collecting (1)15000 L 2
tank (2)2000 L
Raw milk silos 1,50,000 L(4) 5
60,000 L(1)
Butter milk silos 40,000 L 2
Pasteurized milk silos 1,50,000 L(4) 5
40,000 L(1)
Cream silos 60,000 L(2) 5
40,000 L(3)
(table: 1.1)

Standardization in ALFAST UNIT:

1. Density Transmitter

15
 2. Flow Transmitter
3. Control Valve
4. Control Panel
5. Constant Pressure Valve
6. Change over Valve
7. Check Valve

In online standardization cream fat content system works on the basis of Cascade control. A
combination of accurate measurement of fat content and rapid flow metering, known as
Cascade control. In cascade control accurate fat content is measured by density transmitter and
flow transmitters.

In Cascade control, there are mainly 3 flow meters:

1. Density Transmitter:-It senses the density of flowing fluid so it indirectly helps in measuring
flow for standardization.
2. Flow Transmitter:-According to density meter, flow meter adjusts the flow of skim milk
and cream as per the required standardized milk.
3. Control Valve:-It is the heart of ALFAST system. It adjusts its opening according to
required flow for milk.

Auto Standardization in ALFAST UNIT:

Cream Separator

Cream Skim Milk

Density Transducer(to get the amount of fat) Liquid Density Transducer

Flow Meter Flow Meter

Mixing

Final heating section of Pasteurizer

Standardized Pasteurized Milk

Cleaning of Amul-3:
CIP steps Pasteurizer Silo/Tanks Transfer Lines
TIME(min) TEMP(oC) TIME(min) TEMP(oC) TIME(min) TEMP(oC)
Rinsing with 10 Ambient 5 Ambient 5 Ambient
Water
Lye 30 80 20 80 5 80

16
 Circulation
Fresh Water 6 Ambient 7 Ambient 5 Ambient
Circulation
Acid 20 60 15 60 5 60
Circulation
Fresh Water 10 Ambient 7 Ambient 5 Ambient
Circulation
(table: 1.2)

CIP of RMRD:
CIP steps Reception Lines Milk Tankers
TIME(min) TEMP(oC) TIME(min) TEMP(oC)
Rinsing with Water 5 Ambient 1-3 Ambient
Lye Circulation 15-20 80 5 60
Fresh Water 7 Ambient 5 Ambient
Circulation
Acid Circulation 20 60 - -
Fresh Water 10 Ambient - -
Circulation
(table : 1.3)

2.Amul -2 Processing plant

Raw milk at Amul-2 is received mainly through cans but there is one reception line for tankers also. There
are 2 reception lines for unloading milk cans in Amul-2, but recently only 1 is working. About 60% of
reception is Buffalo milk and remaining 40% is cow milk. Raw milk is received in morning and evening
different shift. Milk samples for testing are added with Potassium dichromate for preservation purpose in
case of any dispute. Sour/curdled milk- quality is noted and sent to ghee section to recover fat.

Process Description:

 Milk cans are put on conveyor manually & is tested by the person first. They check the milk by putting
 plunger inside it & organoleptic test is carried out.
  Milk is then dumped in the weighing tank & is weighed &sample is drawn for Fat & SNF testing.
 The milk is collected in collecting tank & cans move to can washer. Can washer has a capacity of 20
 cans/min. The total milk reception in one shift is around 12,000 L by cans.
  There is 1 reception line for tankers in Amul-2.
 Processing plant capacity of Amul-2 is 3, 60,000 L/day for milk. Milk of tanker is also tested by
 person also organoleptic test is carried out. Then it is collected in collecting tank.
 Then raw milk is taken from the raw milk silos, then the milk is standardized & Pasteurized according
 to requirement.
  Then the cream is separated by cream separator and stored in to cream silos.
 The cream is used for butter making, ghee making & standardization of milk. The skim milk is also
 separated & collected in skim milk silos & also used to prepare Skim Milk Powder.
 The butter milk is collected in butter milk silos from the butter section.

17
  Curd is made from Tea special milk, Taaza, skim milk (only Homogenized milk is used).

Flow Chart of Amul-2 RMRD:

Unloading of Cans

Chain conveyor

Removal of Cans lid ghee Section

Physical inspection & Organoleptic grading segregation of sour Milk cans

Empty cans & lids Transfer of milk to dump tank Milk Tanker

Can washer Filter

Weighing

Raw milk collection tank

Pasteurization & Standardization

(At 80 oC+/-3 oC for 15 sec)
Processed Milk Tank

Sent for different product manufacturing & for market milk packing

Routine activities of RMRD:

1) Preparation of RMRD for reception

Dock is thoroughly cleaned after each reception (in afternoon and in night) so that it remains
clean and dry for next reception. Before start of reception, conveyor, moving part of motor and can
washer is lubricated by grease and lubricating oil, all conveyor motors and moving parts are checked
for opened before reception to help up the water and steam valves of can washer are opened before
reception to heat up the water and alkali solution to required temperature.
2) Reception
Milk can truck or milk tankers first report at security gate of premise. Then they come to
gate of RMRD premise having a provision of weighbridge, weight of tanker is recorded and weight
of milk is calculated. The milk cans are unloaded and loaded to twin chain conveyor. Supervisor
performs the organization test with help of plunger after opening the lid by a lid remover and judge
the quality of milk. Sour and curdled milk cans are identified and diverted to another chain conveyor.
3) Sampling
50 ml of milk is taken with the help of a fixed volume sample dipper in a 150 ml plastic
bottle previously filled with 1 ml 10% potassium dichromate. Two sample are taken for each society
one for cow milk and other for buffalo milk. If milk quality from a society is more than 500 lit
weighing is done in parts and a composite sample is taken. The sample from each society is mixed
together and tested in milko-scan for FAT & SNF. The same sample can be tested incase if there is
some kind of dispute.
18
4) Can washing
After reception cans and lids go to can washer. It is a straight through type can washer with
three sections. It has „NO CAN-NO JET‟ system. Total residence time of can washer is 1 minute.

Section Nozzle Medium Temperature Pressure

Pre-rinse section 52 Water 35- 45⁰C 5 kg/cm2
(2)
Detergent section 126 NaOH (0.4%) Min 75⁰C 5 kg/ cm2
(4)

Final rinse section 68 Water Min 75⁰C

(3)
Sterilization (1) - Steam 100⁰C 2 kg/cm2
Drying (1) - Hot air 92⁰C

(table: 2.1)
Acid cleaning is done once in a month using HNO₃ and jet nozzles are cleaned once in a week.

5) Reloading of cans
Washed cans and dried cans are reloaded to the trucks according to the sequence of societies in the
routine.

6) Other activities in RMRD

Can scrubbing – manual cleaning is practiced for cans of four routes. Cheese whey from Khatraj
& colostrums are also received. In the case of incoming of sour milk or curd it is tipped separately and
pumped directly to ghee Section.

Equipments:

Equipments Capacity No. of equipment

Pasteurizer 3
 Milk Pasteurizer 20,000 L/hr
 Cream Pasteurizer 20,000 L/hr
 BM Pasteurizer 10,000 L/hr
Balance Tank 3
 For milk
 For cream
 For Buttermilk
Cream tank 5000 L 1
Sour Buttermilk Tanks 5000 L 7
Cream Separator 20,000 L/hr 1
Homogenizer 10,000 L/hr
Chiller 1
Hot water PHE 1
Butter milk silo 50,000 L 2
Raw Milk silo 1 lakh L(4) 8
1.5 lakh L(2)
19
 25,000 L(2)
Can washer 20 cans/min 2
Can scrubber Manually
Lid Remover Manually
Conveyor 2
 Can loading conveyor 30 feet/min
 Can unloading conveyor 24 feet/min
(table: 2.2)

CIP of AMUL-2:
CIP steps Pasteurizer Silo tanks Transfer lines
Time Temp. Time Temp. ⁰C Time (min) Temp. ⁰C

(min) ⁰C (min)
Rinsing with 5-8 50-55 5-8 50-55 5-8 50-55
water
Lye circulation 40-45 80-85 9-11 80-85 15-20 80-85
(1.5%)
Fresh water 5-8 50-55 5-8 50-55 5-8 50-55
circulation
Acid circulation 40- 45 70-75 9-11 70-75 15-20 70-75
(o.8%)
Fresh water 8-11 50-55 5-8 50-55 8-11 50-55
circulation
(table: 2.3)

3.Pouch packaging section

Flow Chart for Milk pouch packing:

Milk (Amul-2 & Amul-3)

Horizontal milk storage tank

Overhead tank of FFS packing machine

Pouches Milk damaged Pouches

20
 Crates Cut open & Milk Reprocess

Cold storage room (<5⁰C)

Dispatch

FFS machines:
FFS no. Capacity
1 500 ml milk Twin head 75pouches/min/head

2 500 ml milk Vertical sealing temp: 140oC 70pouches/min/head

3 1 L milk Horizontal sealing temp: 160oC 32pouches/min/head
4 500 ml butter milk 60pouches/min/head
(table: 3.1)

Amul pasteurized milk standards:

Sr.No Milk Fat (%) SNF (%)
1 Amul shakti 4.55 – 4.60 8.60 – 8.70
(Pasteurized standardized milk) 4.60 (GCMMF) 8.60 (GCMMF)

2 Tea Special milk 4.55 – 4.60 8.60 -8.70

(Pasteurized, std., homogenized milk)
3 Amul Gold milk 6.05 – 6.10 9.10 – 9.15
(Pasteurized full cream milk)
4 Amul Taaza 3.5 – 3.55 8.60 – 8.65
(Pasteurized Tonned milk
(table: 3.2)

Shelf life: 48hr from the date of packing if kept under refrigeration below 8oC

4.Buttermilk
Buttermilk is a liquid left behind after churning of butter out of cream. It is prepared in Amul-2. It is
standardized & packed in pouch. It has a fat of minimum 1.0%, total solids 6-7% and acidity 0.39 to 0.41%.
21
Operation:
 o
 after pasteurization at 72-75 C for 18sec is sent
Buttermilk from butter section of Amul-3
to buttermilk tanks in Amul-2 Section.
  In buttermilk tank, the standardized & pasteurized mixture is heated 39-41 oC
  DVS Culture is added & is inoculated at 1% buttermilk quantity.



Keep on checking Acidity every 3hrs. Once the Acidity reaches 0.350 %, chilling takes place till
o
  is dropped to 9 C & then sample is tested in quality analysis laboratory for total
the temperature
solids (T.S).

The buttermilk is sent for pouch packing via pipelines. Packing is done at temperature less than 8
o
C. Leaked pouches are stored to temperature less than 5 oC and dispatched after storing for at least

1-2 hours in cold store at minimum 5 oC.

Flow chart for Cultured Buttermilk:

Buttermilk from butter section

Pasteurization (75 – 77 oC, 16 sec)

Buttermilk silos (2 silos, Cap-50,000 L)

Standardization (In silo)

Pasteurization (40oC)
Silos

Culture addition in silo (DVS culture @ 1% of buttermilk)

Acidity maintaining (0.35%)

Chiller (10 oC)
(To chill BM, circulate in silo to chiller till 10oC obtain)

Sampling from silo to check TS

Packaging

Cold storage (<5 oC)

Specification of buttermilk:
Sr.No Parameters Specification
1 Temp. of dispatch Not more than 8 oC
2 Acidity (%) LA 0.35 - 0.45 %
3 Fat (%) Min. 1.00
4 SNF Min 5.5%
5 Total solids Min. 6.5
6 Organoleptic Test (OT) Fresh, free from any off flavour
(table: 4.1)
22
Shelf life: 48hr from the date of packing if kept under refrigeration below 8oC

5.Dahi
Dahi is the fermented milk product produced by bacterial fermented of milk.

Capacity: 6000 kg/day


Masti Dahi:
  Pasteurized homogenized milk having fat 4.5% is taken.
 It is then standardized to 3.2% to 3.3% fat & SNF 11.1% to 11.2% by addition of skimmed milk or
 SMP.
  It is then pasteurized at 90 oC for 10 min.
 Pasteurized mixture is then chilled to 42-44 oC.
 It is then transferred to vat, where DVS culture is added with agitation (15-20 min). DVS culture
 used for making masti dahi is RST 744.90 units and CHN11:10 units per 1000 lit of milk.
  Then it is packed in pouch & cup & put in crate.
  It is then incubated for 42 oC-43 oC for 3hrs.
 Keep on checking acidity every 3hrs. Once the acidity reached to 0.6 – 0.7% LA. It is transferred
 to cold store (8 oC) where it is kept for 24 hrs.
 After 24 hrs acidity reaches to 0.8% - 0.9 % LA & the Masti Dahi is ready for dispach. It is stored in
 cold storage at below 5 oC.
 
 Amul Lite Dahi:
 Amul lite Dahi manufacturing process is same as that of Masti Dahi; the difference is in
 its standardization.
 In case of Amul lite dahi, pasteurized milk is standardized to 0.5% fat.

Flow chart for Dahi:

Milk in to standardize tank

Standardization

Heater

Inoculation tank -1

Circulate in to heater (90oC)

Inoculation tank -2 (for 10min)

Circulate into chiller (42-44oC)

Transfer in vat
23
 Culture addition

Mixing (15-20 min)

Pouch or Cup filling

Incubation room (42-43oC, 3hrs)

Acidity is checked at every 3hrs

(Acidity reached at 0.6 to 0.7% LA)

Transfer to Cold Store (temp-8 oC, 24hrs)

After 24hrs Acidity should be 0.8 – 0.9% LA

Storage (below 5 oC) & Dispatch

Specifications of Dahi:
Sr.No Parameters Specifications
Amul masti Dahi Amul lite Dahi
1 Fat (%) 3.5 0.5
2 SNF (%) 11.5 12.0
3 Acidity (%) as Lactic acid Max. 0.128 0.125
4 Acidity (%) as LA at transfer to cold store Min. 0.500 0.500
5 Acidity (%) as LA at dispatch Max. 1.00 1.00
6 Dispatch temperature Max. 10 oC 10 oC
(table: 5.1)

Equipment of Dahi & Buttermilk section:

Equipments Capacity No. of equipment
Standardization tank 2000 L 1
Inoculation tank 1000 L 2
Chiller
FFS 75 pouches/min 1 (2 head machine)
Cup filling machine 30 cups/min 1
Pasteurizer
Vat 1
(table: 5.2)

Shelf life: Poly pack- 7days, PP cup-15days

24
 6. Powder Plant
Introduction:
L&T stands for Larson & Turbo.

L&T plant is a fully automated Tall Form Drier plant in which two stage drying of standard milk takes place
in Spray Dryer and Vibro Fluidized Bed drier.

The capacity of the plant is 60 MT/day.

Milk is received from processing site is used to make milk powder using different procedures. In the
plant Skimmed milk powder, Whole milk powder, Dairy whitener (Amulya) and Infant milk food (Amul
Spray) are produced.

AmulSpray & Amulya Agglomerated

SMP & WMP Nonagglo OR Agglomerated.

Dryer Principle:
Spray drying operation involves the conversion of concentrated liquid milk to dried powder. This is
carried out by transforming the liquid milk into milk droplets and contacting these droplets with hot air in
a controlled fashion. Due to the enormous area available for heat and mass transfer, the water
evaporation from milk droplets and drying takes place.

Process flowchart:
Standardized milk from silos ( 4-5⁰c ) +Ingredients

Balance tank

Pre heater ( 6 to 1)

Flash vessel (regeneration)

Swirl heater- HHP (90-95⁰C)

CCP
Holding tubes

Flsh vessel (flash cooling)

25
 Calendria1st (70-73⁰c)

Calendria & vapour separator (2 to 5)

Hydro cyclone

Concentrated milk (50% TS) in Concentrate tank

Scrapped surface heat exchanger

Feed pump

Homogenizer (as a high pressure pump)

Atomizer (nozzle) Fines

Nonagglo

Heated Air(1830C) Tall form drier (TFD) Cyclone Exhaust air

Agglo

Vibro fluidizer (12mmWC vacuum) Fines

Vibrating sieve Lumps

Bulk packaging (25kg) Hopper

Dense phase vessel

Pneumatic conveyor

Powder silo

26
 Vibrating tubes

Hopper

Vibrating tubes

Rotary valve &Rotary Sifter

FFS packaging machine

The whole plant is divided in the five sections:

1. Feed Preparation
2. Evaporation system
3. Drying section
4. Powder conveying & storing section
5. Packaging section
1) Feed Preparation:
Milk from milk silos first comes to the section. The section has two milk silos each having 40000 lit. Milk
capacities. In the Dairy Whitener and Infant milk food sugar is added as syrup prepared in sugar Dissolving
tanks having 3000 lit capacity. The tanks are double jacketed for heating. The prepared solution is pumped
into milk silo through inline double filters. Trisodium phosphate (for pH adjustment) and Vitamins (A, D, B,
C) & Mineral mixture ( both for AmulSpray only ) are added in the milk silo.

Preparation of various Additives:

 Addition of BHA (for WMP only) – BHA @ 50g per metric ton of milk powder is added by
 dissolving BHA in 2 -3 L in lukewarm water and is added to milk in silo.
 Addition of TSP – Addition of buffering salt @ 0.2% for SMP, 0.6% for AmulSpray and 0.3 % for
 Amulya. TSP is not added to IMF – 1 and 2 WMP.
  Sugar – Water is taken into sugar vats and heated to 50 - 60⁰ C. Required quantity of sugar is added into sugar vat and dissolved. Sugar solution is pumped to milk silos through filter.
 Vitamins and minerals – Vitamin A + D mix is dissolved in milk and added into sugar solution. Water soluble vitamins and mineral
premix is mixed in lukewarm oil and added to vegetative oil cream. Lecithin is mixed in lukewarm oil/ghee and heated to about 60 -
70⁰c in order to melt lecithin in free flowing form and added into vegetable oil cream mixture.



2) Evaporation section:
Milk is pumped from these silos into a feed balance tank of evaporator. Typically milk is concentrated from
14% solids to 48% solids in evaporator.
Here mechanical arrangement is made such that milk inside tube comes in contact with hot steam
which heats the milk and some of its water parts about 35 %, is evaporated during this section and we get 48
27
% total solid ( TS ) in milk. For concentration of the milk, Multiple Effect Evaporator (5 effect) with
Forward Feed Mode of Evaporation is used. Concentrated milk from evaporator is gathered in Concentrate
tanks. There are three tanks.

3) Drying section:
 The milk concentrate (50% TS/ 500C) is pumped through a scraped surface HE where it is further concentrated and
then to the Spray dryer with the help of a high pressure homogenizer. . Homogenizer has 3 functions, main function
to pump liquid up to the head of the dryer (fifth floor), to raise the temperature of condensed milk to 70⁰c and to
partly homogenize the milk. The Spray dryer is of Tall Form design of 8 nozzle spraying atomizer, which consists
 of Air dispersing system, Electromagnetic hammers, Cyclones, Fire extinguishing system and Vibro fluidizer.
0
 The drying chamber is a cylindrical vessel with 45 conical bottom. The drying process proceeds in a
 co-current mode. Milk is atomized by nozzles at from the top.
 Cyclones are present for collecting fines by centrifugal force. In case of agglomeration these fine
 particles are added back in the dryer along with milk.
 Vibro fluidizer is a vibrating housing which is divided into two parts by a special perforated plate. Air
is blown into lower part which is called Plenum chamber and the powder is fluidized in the upper
vibro shifter. There are three regions in Vibro
1. Initial heating region – 60oC
2. Heating with dehumidified air – 45oC
3. Dehumidified cooling - 40 oC
Vibrator mounted on the lower side produces the vibration. The vibro fluidizer operates at a vacuum of
12mmWC. At the outlet of vibro there is a sieve for removal of lums. Lums are reconstituted into milk.

4) Powder conveying section:

The powder coming out of vibro sieve enters the dense phase conveying unit and from there it is
pneumatically conveyed into powder silos. The powder from the silos is conveyed through vibrating tubes to
packing machine.

5) Packing section:
The powder is packed in pouches. The pouches are inserted in cartons. The cartons are collected & put into
cases. Cases are sealed & conveyed to stores on a belt conveyour.

Specification:
Parameter Amul Spray Amulya SMP WMP
Fat 18.5% min 20.5% min 1.5% max 26% min
Moisture 4% max 4.5% max 4% max 4% max
Protein 22% 20% 35% 15%
Lactose 31% 32% 50% 50%
Sucrose 17% 17-18% - -
Ash 8.5% 5.5% 8.2% 7.3%
(table: 6.1)
Equipment details:
EQUIPMENT CAPACITY
Milk Silos 40,000 lit ×2
Sugar dissolving vats 1000 lit ×2
Evaporator feed handling capacity 22,000 lit/hr
Balance tank for milk condensing plant 150 lit
Concentrate tank 3000 lit ×2
28
 Powder silos 30,000 kg ×2
Homogenizer 6300 lit/hr
Evaporation Capacity 30,000 lit/hr
Dryer Capacity 7400 lit/hr
(table: 6.2)
Packing:
Packaging is done in two ways:
 Manual bagging
 Automatic packaging

Manual bagging:
Powder from vibro sifter is sent to bagging line for bulk packaging of 25kg. Bags are packed manually and
sent to cold storage for Industrial use.

Automatic packaging:
For automatic packing, powder is taken into powder silos. Each silo has 30000 kg capacity. With the help of
dense phase vessel, powder is conveyed through vibrating tubes, rotary valve and rotary shifter and is taken
into packaging machine hoppers. Form, Fill and Seal machine packs 50 gm pouches of Amulya and 1 kg and
½ kg pouches for Amulspray.

Type of Weight of Net Weight Total Approx. M.R.P. Packing

product packaging wt.(gm) Capacity/min
material
1kg 15gm 1000gm 1050gm 1015-1017 340 40 packs
Amulspray,
Amulya
500g 8.5gm 500gm 509gm 509-511 178 60 packs
Amulspray,
Amulya
200g 4.5gm 200gm 205gm 205-207 72 70 packs
Amulspray,
Amulya
27g 2.2gm 27gm 29gm 29-30 10 120 packs
Amulspray,
Amulya
!3.fg 1.7gm 13.5gm 15gm 15-16 5 60 packs
Amulspray,
Amulya
13.5g 1.7gm 13.5gm 15gm 15-16 5 80 packs
Amulspray
(double head,
FFS)
(table: 6.3)

29
 7.Butter Section
Introduction: The utterly butterly delicious butter of Amul is one of the most popular product of Amul
dairy along with the famous butter girl. The Butter section is located in Amul-3 which manufactures Table
butter, White Butter. The section is completely computerized and is equipped with most morden imported
equipments. Amul white and table butter is exported to USA and Gulf countries. Amul Table butter
maintains AGMark standards.
Butter section of Amul-3 has capacity 70 MT per day. The capacity utilization in flush season is 55-60
MT, usually it produces 20 MT per shift.

Process:
The cream for manufacturing Butter is receiving from Amul-3 processes while standardization of milk.
The milk fat will be separated at above 60oC; the centrifugal cream separators in line with milk pasteurizer
separate this as cream.
The cream thus separated is pasteurized and then pumped by positive displacement pump to the cream
buffer tank and then to the cream silo.

After ageing at 8oC for 24 hours cream is pumped to cream chilling unit in the butter section . There the
temperature of cream is adjusted to the required churning temperature (9-11 C) of continuous butter
making machine.
There are three continues butter macking machines.MB05- 2000kg/hr, CBMM1119-5000kg/hr,
HMB-800kg/hr.

Butter milk produced by churning is collected in buttermilk tank. This buttermilk

is used for washing of butter. Excess of buttermilk is stored in silo. A blender of
5 MT capacity is installed which blends butter obtained from the two CBMM.

Salt dosing is done by salt Dozer @ 10-110 lit/hr. Annatto colour is added to
brine @ 2.5%, the strength of brine being 70-80%. This is prepared in a tank and
fed to CBMM using a reciprocating pump. Working of butter is done in blender
under vacumm. Butter is then collected in butter silo of 3.5 MT capacities. Butter
is pumped into hoppers of packaging machines.
The white butter is packed in 15 kg blocks. It is utilized in ghee section for making ghee and also sent to other co-operation for the same purpose.
White butter has a shelf life of 60 days at 0⁰c or below & table butter has a shelf life of 12 months at refrigerated storage. The butter is kept in
cold store for minimum 5 days before dispatch, during which a sample of the lot is analyzed by QC lab.

Process flowchart:
Pasteurized Cream from Silos (20 hr ageing)

Cream Balance Tank (8-9 oC)

Cream Heater PHE (to adjust temp 8-10 oC )

30
 Continuous Butter Making Machine (CBMM)

Churning (500-1200 RPM)

Butter Grain Butter Milk

1st Washing with BM BM Chiller (below 10 oC)

Working (30-70 RPM) BM silos

2nd Washing

Working under Vacuum (450-500 mm Hg)

Blender (17-30 RPM, Vacuum 450-500 mm Hg) Addition of Salt &

Colour Butter Silo

Packing section

10 g Blister Pack 100 g Refill pack 500 g Refill pack 400 g Tin

Butter wrapping (by vegetable parchment paper)

Secondary Packaging

CBX

Storage at below 4 oC

Process flowchart for colour & salt solution:

110 L Pasteurized Water

100 Kg Salt

2000 to 4000 ml Annatto

15min Agitation

Filtration

31
 Add in to Salt dozer

Working Principle of CBMM:

The CBM machine works on the “Frits” process of continues butter manufacture, in the accelerated churning
process, there is a quick fat separation in cream (38 to 42% fat) is affected by high speed beaters followed by
draining of butter milk. In the churning section cream is subjected to high speed beater (variable speed 1200
to 1500 rpm), which guides cream to cylinder walls simultaneously causing foam formation accompanied of
fat globules tale place in cylinder during churning process, formation of pinhead sized butter granules take
place, the mixture of butter granules and butter milk falls into the screw conveyer and then into the rotating
drum where butter granules and butter milk gets separated. The butter granules fall below between a set of
rotating augers (contained chilled water jacket) where the granules are worked upon and then finally
extruded in form of a ribbon directly into butter trolleys.

 
Major section of the CBMM
1. Churning section:
This section has a horizontal cylindrical with the cooling jacket and beater for churning of cream. The
churning process lasts for 2 to 3 sec during which the oil in water emulsion of the cream is broken into
water in oil emulsion existent in butter. The water content of the granules and the fat loss in the
buttermilk depend largely on beater speed and the temperature of cream at the time of churning. The
beater is driven by power transmitted from a motor through a V-belt. The speed of the beater is adjusted
so that butter granules have a suitable size when they press through the separating section.

2. Separating section:
This section has horizontally positioned cylinder resting on rollers and the other supported by a bearing.
The cylinder is fitted with paddles, which stresses the granules suspended in the butter milk to librated
most of their buttermilk content. A draining section is provided where the granules are separated from the
buttermilk and are then passed into the working section. The speed of paddles is 34 rpm.

3. Kneading section:
The kneader consists of two contra rotating augers 40 to 60 rpm that are in mesh with one another. The
front screw ends in perforated discs there are 3 agitating blend per screw operating sequentially between
the perforated discs. Spacer rings ensure the distance between the perforated discs. In the kneader the
gear unit driving the screw is driven by a v-belt through a motor. All parts of beater, draining unit,
washing unit and kneader are made up of high alloy chromium nickel steel
4. Salt dosing unit:

32
 Salting for adjusting the water content or for water content or for salting the butter, water or salt solution
can be added through an opening immediately in front of the perforated plates.
Salting is carried out by injection of 50/50 salt/water slurry into butter early in working stage to avoid color
mottle in the butter a micro fined salt less than 50 micron is used. The salt slurry is loosely filtered through
wire gauze before injection. The slurry is metered to the butter maker by positive displacement pumps. The
dosing system may also be used for adding water to unsalted or slightly salted butter to maximize yield.

SPECIFICATION:
Characteristics FSSAI specification AGMARK specification
Moisture % Max. 16.0 % Max. 16.0 %
Milk fat % Min. 80.0 % Min. 80.0 %
Salt % Max. 3.0 % Max. 0.3 %
Curd SNF % Max. 1.5 % Max. 1.5 %
Acidity % L.A. - Max. 0.15 %
Total plate count Max. 5000 / gm -
Coliform coumt Max. 5 / gm Absent in 0.1 gm
E. coli Absent in 1 gm -
Yeast & mold count Max. 20/gm Max. 20/ gm
Salmonella &shigella Absent in 25 gm -
Staphylococcus aureus Absent in 1 gm -
Anaerobic spore count Absent in 1 gm -
Listeria monocytogenes Absent in 1 gm -
(table: 8.1)

Shelf life: Best before 12 months from packaging when stored refrigerated at 4 oC or below
Storage condition: At 4 oC or below

Equipments:
EQUIPMNTS CAPACITY NO. SPCIAL INFORMATION
NAME
Cream balance tank 350 lit 2
Cream chiller - 2 Temp- 8-10ºc
Plate length- 207-273
Continuous butter 2000kg/hr 3 Made- contimab
making machine 5000 kg/hr Churning speed-500-1200rmp
800kg/hr
Butter blender 1 Vacuum pressure 400-500mm hg
Butter silo 3.5 tones 1
Pasteurized water 5000 lit 1
tank
butter milk buffer 450 lit 1 Temp- 1-2ºc
tank
Wash water tank 500 lit 1 -
Fat rcovery tank 450 lit 2 -
Salt dosing unit - 1 Agitator rmp-1380/min
(table: 8.2)

Packaging machine:
1) SIG machine
33
 500 gm packing – Capacity – 60-62 pack /min
2) BENHIL case packer machine
100 gm packing – Capacity – 150 pack /min

3) HASSIA butter Tub filling machine (Blister pack)

10 gm packing - Capacity – 525 packs /min

4) Tin packing machine

400 gm Tin - Capacity – 36 packs /min

Packaging machine used:

o Parchment paper – used directly for wrapping
o Carton – used for secondary packing,
a. Single laminated foil is used for INDIAN local market.
b. Double laminated is used for EXPORT.
o Tin – used for 400g, Army pack
o Card Board Box – used for tertiary packing.
o Plastic Box – used for school pack

CIP of Butter section :

CIP is done after every 24 hrs (usually in third shift).
Melting of residual butter is done with hot water for 25 min and molten butter is drained into recovery tank.
Degreasing is done for 10 min

8.Ghee Section
Introduction:
Ghee, also known as clarified butter or anhydrous milk fat, is prepared by heating butter or cream to
just over 100°C to remove water content by boiling and evaporation, then filtering out the precipitated milk
solids. Ghee is known as ghrth(commonly spelled ghrita) in Sanskrit. Ayurveda has traditionally considered
ghee to be the healthiest source of edible fat, with many beneficial properties. According to Ayurveda, ghee
promotes longevity and protects the body from various diseases.

Amul has a well laid out Ghee section just behind processing section of Amul – 2. It has got all
facilities of white butter melting, sour cream or curd churning, Ghee processing & storage. Ghee is
manufactures mainly by Pre-stratification method from white butter manufactured in butter section. When
Curd is received in dairy or fat is separated from sour milk or sour cream, it is churned to make butter. This
butter is heat clarified to make Ghee for local market. The Ghee manufactures is also export to gulf
countries USA. In this section AGMARK Special Grade Ghee is prepared. The production Capacity of Ghee
section is 22-24 TPD.

Definition:
According to FSSR-2011, ghee means the pure heat clarified fat derived solely from milk or curd or
from desi (cooking) butter or from cream to which no colouring matter or preservative has been added.
34
Product Description and Chemical Composition of Ghee:
Ghee could be in liquid, semisolid and some time in solid state based on the storage temperature. Ghee
made from buffalo milk is whitish with greenish tinge and that of cow milk is golden yellow colour. It is
usually prepared form cow milk, buffalo milk or mixed milk.

Composition: Ghee is a complex lipid of glycerides (majorly triglycerides), free fatty acids,
phospholipids, sterols, sterol esters, fat soluble vitamins, carbonyls, hydrocarbons, carotenoids, (only in
ghee derived from cow milk). Its detailed chemical composition is given below.

Constituents Cow milk ghee Buffalo milk ghee

Fat (%) 99 – 99.5 99 – 99.5
Moisture (%) <0.5 <0.5
Carotene(mg/g) 3.2-7.4 -
Vitamin A(IU/g) 19-34 17-38
Cholesterol (mg/100g) 302 – 362 209 – 312
Tocopherol(mg/g) 26 – 48 18 – 31
Free fatty acid (%) 2.8 2.8
(table: 9.1)

Milk fat contains at least 500 fatty acids and fatty acid derivatives with 4 – 20 or more carbon atoms in
their chain. The fatty acid may saturated or unsaturated and usually contains an even number of carbon
atoms. Composition of fatty acid also varies between buffalo milk fat and cow milk fat.

Methods for manufacturing Ghee:

Different methods are used for the preparation of ghee. The adoption of a particular method is mainly dependent
on the scale of production. The classification and description of these methods is given as below:

1. Indigenous (Desi) method

2. Direct cream method
3. Creamery butter method
4. Pre-stratification method
5. Continuous method

From these methods Pre-stratification is used in Amul - 2 Ghee section.

Operation:
Butter received from butter section is melted at 95⁰C in an open melting vat having stem coil in its bottom. It is left for about 1 hour in the vat to
separated layer of fat. The melted butter is pumped to pre stratification tank to settle for 2 hours. The serum separated is drained out from bottom of the
tank and is collected in a serum tank. The melted fat is then pumped to ghee kettle where it is heated to 110 - 115⁰C for about 45 minutes. Ghee is allowed
to settle for 1-2 hours in ghee tub. Then ghee is filtered through 100 mesh filter and then clarifier, after clarification again filtered through 300 mesh filter.
After that ghee is stored in storage tanks. From then it is pumped to overheated tank of packing machine. The packing temperature of ghee is 40-45⁰C,
packed at 45 oC in pouch, Tin, & in jar. The serum portion obtained during pre stratification, chilled water is added and churned to recover the fat. Then
after it is pumped in over head tank of packaging machine. Ghee is
35
Flow chart for Ghee:

white butter Sour cream/sour milk/serum/curd/whey fat

Butter churner (45 min, cap – 2000 to 3000 L) buttermilk

Addition of chilled water for washing

Churning (15 min)

Draining of water

Hard grain of fat

Melting vat (95 oC, 1hr) clotting, buttermilk serum

Fat Serum portion

Settling tank (2 hrs) Serum tank

Melting pot Fat recovery

(110 to 115 oC, for brown ghee 143 to 145 oC, for 45 min)

Ghee tub

Filter

Clarifier (in brown ghee clarifier is not used) Ghee residue

Buffer tank Cattle feed

Packaging (packed at 45 oC)

Storage (21 oC)

Equipment:
Equipment Capacity No. of equipment
Melting vat 1)150 blocks of 15kg butter 2
2)100 blocks of 15kg butter
36
 Butter churner Top churn – 2500 L 2
Drum churn – 3000 L
CBMM - 1
Pre-stratification tank 1)2000 L 3
2)2000 L
3)5000 L
Melting pot 1)900 L 4
2)600 L
3)450 L
4)1500 L
Serum tank 2000 kg 1
Fat Recovery Tank 1500 L 1
Ghee tub 1)1 Ton 2
2)1.5 ton
Ghee Buffer tank 3000kg(3) 6
4)20,000 kg
5)15,000 kg
6)15,000 kg
Filter - 2
Clarifier 2000 L 1
(table: 9.2)

Packaging of Ghee:
  Ghee is packed in 200ml, 500ml, and 1000ml pouches by ghee pouch packing machine having two heads.
 
Density :- 0.90 gm/cm2
 
Thickness of packing material- 100µm.

Type of machines:
1.Prepack (pneumatic machine)
  
Make: Samarpan Fabrications, Thane
  
Capacity: 13-14 pouch/min
  
Air consumption: 6kg/cm3
  
Cooling Water: 100litre/hr at 20oC
  
Ghee is also packed in tins in 500ml, 1ltr, 2ltr, 5ltrs, and 15 kg.

2.Gasti Packing Machine
  
Make: Gasti India Ltd.
 
Capacity: 15 tins/min
3.Filling & seaming machine
 
Make: Unitech India ltd.

Standard of weight:
Wt.of product Wt. of packing Net Weight Total Weight
material (gm) (gm)
200 ml 2.5 181 – 183 183 - 185

37
 500 ml 4.9 452 – 456 456 – 459
1 lit 8.0 904 – 908 912 – 916
500 ml tin Empty tin: 58.43 452 – 456 526 – 530
Bottom: 16.5
1 L tin Empty tin: 97.325 904 – 908 1018 – 1022
Bottom:16.5
2 L tin Empty tin: 168 1810 – 1814 2009 – 2013
Bottom:30.58
5L tin Empty tin:344.5 4528 – 4532 4932 – 4936
Bottom:59.11
15 kg Empty tin:932.5 14.998 – 15.662 15.962 – 15.966
Bottom:30.5 (kg) (kg)
(table: 9.3)
CIP of ghee plant:
  After use of every melting system hot water of 70 - 75 oC is filled up & flushed.

 
Then it is cleaned with 0.2 – 1% of lye solution at temperature 70 oC & circulation & drained.

with hot water of 70 - 75 oC without lye. The system is
After this the cleaning procedure is carried out
washed third time with water for 25 – 30 min.
 
Finally rinsing is done.

CIP of clarifier:
 o
Detergent solution, hand brush cleaning with hot water having temperature of 40 - 45 C is used
for cleaning after every use.
Shelf life: Pouch packing- 9 months
Tin packing- 12 months
Jar packing- 6 months
Bulk packing- 12 months

9.Sterilized Flavoured Milk

Amul kool is refreshing milk with test. It is an easy to use delicious drink that refreshes you immediately
with goodness of milk. Available in easy to use glass bottles & metal cans. Coffee & Coco flavours are
available in glass bottles. Metal can is used for all flavour.

 Products :
  
Coffee Flavoured Milk
  
Coco Flavoured Milk
  
Rose Flavoured Milk
 
Milk Shakers (Strawberry, Mango, Almond )

Sr. Product Type Prize(200ml) Shelf life

38
No Can Glass Can Glass
bottle bottle
1 Coffee Flavoured Milk 40 22 270 days 180 days
2 Coco Flavoured Milk 30 22 270 days 180 days
3 Rose Flavoured Milk 30 22 270 days 180 days
4 Milk Shakers (Strawberry, Mango, 30 22 270 days 180 days
Almond )
(table: 10.1)


Specification:
Characteristics Specification
Fat Min 3%
SNF Min 9%
Added Sugar 7-8 %
TS Min 20 %
Acidity Max 0.13 % L.A
Alcohol test Should be –ve
Flavour As required
Colour Artificial max 100ppm
Organoleptic Evaluation No Abnormality
(table: 10.2)

Flow chart for Amul kool koko:

Milk from A2 & A3 to storage tank

(Min 2.1 % fat, Min 8.7% SNF)

Slurry tank
+Cocoa powder
+Cocoa extender
+ Dark Chocomass
+Milk Chocomass
Heated to 80-85oC
Provat
+Sugar 8-10 %
+Stabilizer

(Fat, SNF, Protein, Lactose test)

PHE (60-65oC)

Homogenizer
1st stage: - 180 to 200 kg/cm2
2nd stage: -80 to 100 kg/cm2

39
 Chiller (Below 10oC)

Bulk Milk Cooler

(Cream Index, T.S, pH, Acidity Test)

Filling Machine (Can Filling / Glass Bottle Filling)

Sterilizer (121 oC for 21 min at 1.5 Kg/cm2) CCP

Cooling (through cooling fans)

Flow chart for Amul Kool cafe:

Milk from A2 & A3 to storage tank

(Min 4.9 %fat, Min 8.7% SNF)

Provat
+Sugar 8-10 %
+Stabilizer
(Fat, SNF, Protein, Lactose test)

PHE (60-65oC)

Homogenizer
1st stage: - 180 to 200 kg/cm2
2nd stage: -80 to 100 kg/cm2

Bru Coffee (0.8%) Chiller (Below 10oC)

Coffee Blender Bulk Milk Cooler

(Cream Index, T.S, pH, Acidity Test)

Filling Machine (Can Filling / Glass Bottle Filling)

Sterilizer (121 oC for 21 min at 1.5 Kg/cm2) CCP

Cooling (through cooling fans)

40
Flow chart for Amul shakers:

Milk from A2 & A3 to storage tank

(Min 5.2 %fat, Min 8.7% SNF)

Provat
+Sugar 8-10 %
+Stabilizer
+SMP
(Fat, SNF, Protein, Lactose test)

PHE (60-65oC)

Homogenizer
1st stage: - 180 to 200 kg/cm2
2nd stage: -80 to 100 kg/cm2

Chiller (Below 10oC)

Bulk Milk Cooler (Flavour Slurry)

(Cream Index, T.S, pH, Acidity Test)

Filling Machine (Can Filling / Glass Bottle Filling)

Sterilizer (121 oC for 21 min at 1.5 Kg/cm2) CCP

Cooling (through cooling fans)

Equipment:
Equipment Capacity No. of Equipment
Milk tank 10,000 L 3
Process vat(Provat) (1)2500 L 2
(2)5000 L
Slurry tank 15000 L 1
Pasteurizer 10,000 L 1
Homogenizer 5000 L 1
Chiller 10,000 L 1
Bulk Milk Cooler (1)5000 L 3
(2)2500 L
(3)2500 L
41
 Metal Can filling 100 cans/min 1
Machine
Glass bottles Filling 80 cans/min 1
Machine
(table:10.3)

Standards of weight:-
Product name Specific Gravity Wt.of packaging Net wt Gross Approx.
material (g) wt (g) wt
(g) (gm)
Empty Bottom
can / Crown
/Bottle
Koko Can 1.069 32 5.4 214 251 251 - 253
Coffee Can 1.058 32 5.4 212 250 250 - 252
Milk shakes/badam 1.066 32 5.4 213 250 250 - 252
Can
Koko bottle 1.069 150 2.2 214 366 366 - 368
Coffee bottle 1.058 150 2.2 212 364 364 - 366
(table: 10.4)
 
CIP (Cleaning In Process)
CIP for process vats, storage vats, PHE, bulk chiller, Homogenizer and pipelines:
CIP steps Time (min) Temperature (oC)
Rinsing with water 20 60
Lye circulation (0.8 %) 40 80
Fresh water circulation 20 60
Acid circulation 30 70
Fresh water circulation 20 60
(table: 10.5)

CIP for can filling machine, overhead tank/bottle filling machine:

CIP steps Time (min) Temperature (oC)
Rinsing with water 5-10 50-55
Lye circulation (0.5-0.8%) 20-30 75-80
Hot water circulation 15 50-55
Acid circulation (0.4-0.6%) 15-20 72-75
Hot water circulation 15 50-55
Lye circulation 5-10 75-80
Hot water flushing 20 50-55
(table: 10.6)

Cleaning of Sterilizer:
All sterilizers are cleaned manually from inside daily.

42
 10. Utilities
Introduction:
The whole section has look of a mechanical workshop. Sections involved in engineering are as follows:

 Boiler Section:
The Boiler section is located at Amul - 2 and the steam generated is used for heating work in different
sections of dairy plant. In AMUL, there are 2 boilers & Economizers, both boilers are fire tube
horizontal boiler. The function of steam boiler is to convert chemical energy of fuel by combustion into
heat and to transfer this heat to water to produce steam. All the boilers have forced draught system for air
combustion and removal of flue gas.

Specification of Boilers:
Boiler Capacity Feed Temperature
Forbs Marshall, 12 ton/hr Natural gas/ furnace oil 1000 oC
pune
Thermax India 10 ton/hr Natural gas/ furnace oil 1000 oC
Ltd.
(table: 12.1)
COMBIMAX STEAM BOILER
It is twin drum 3 pass fire tube horizontal, fully wet back packaged boiler with corrugated furnace. The
water pressure required at the inlet of water softener is 2.5 - 3.5 Kg/cm2. There are 212 tubes in each
fire tube horizontal boiler. Steam out put at 100 OC is 10000 Kg/hr.
 Make: Thermax
 Heating area: 225 m2
 Burner: Thermax
 Fuel: Oil / Gas
 Steam pressure: 12.8 Kg/cm2
  Design pressure: 17.5 Kg/cm2
  Operating pressure: 13.2 Kg/cm2
  Safety Valve set pressure: 17.5 Kg/cm2
 Design temperature: 250°C
 Thermal efficiency: 92%
 Fuel Consumption: Natural gas - 835 N
m3/H LSHS – 640 kg/hr
Furnace oil – 603 kg/hr
  Temperature in combustion chamber: 1100 OC
  Chimney diameter: 950mm
 Velocity of flew gas in chimney: 10m/sec

MARSHALL BOILER
• Make: Forbs Marshall Private Ltd.
• Fuel: Oil / gas
43
• Set point pressure: 11.5 bar
• Set point temperature: 187°C
• Evaporation: 12000 Kg /L
• Thermal efficiency: 72.2%
• Steam flow rate: 2900 -3100 Kg / Hr
• Chimney gas temperature: 185°C
• Blow down interval: 30 min

The feed water used for boiler should fulfill the following conditions.
i. pH of water :8.3 to 9.2
ii. Hardness :<10 ppm
iii. Silica :<1ppm
iv. Total dissolved solid :<5ppm
v. Total alkality :<10ppm

Blow down water standards

i. pH of water :7.8 – 11.4
ii. Silica :< 52 ppm
iii. Total dissolved solid :< 3000ppm
iv. Total alkality :< 350ppm

 RO water system:

Raw water

Multi grade filter

Cartridge filter

High Pressure pump

Membrane tube (Two stage RO system)

Permeate water

Degasser

pH corrector

UV light

RO water storage tank

 Refrigeration section:
44
Refrigeration is essential for preserving the dairy products. Butter is stored in cold storage. Additionally
chilled water is required to chill the pasteurized milk & refrigeration is also required to cool packaging
room & laboratories.

The Refrigeration Plant of Amul is situated in Amul - 3. It is a fully automated plant which has the
facility of automatic turn off of compressor when maximum demand is met. The entire such automation
of each & every department of dairy industry is taken care of in this department. It has facility for
controlling the discharge temperature of ammonia gas which is based on automatic turn on and off of
cooling tower & condenser. In Amul plant refrigeration system with a capacity of 1500 TR/hour.

The plant is divided in to 3 different sections

1. -2° C system: used for chilling the water.

2. -10 ° C system: used for maintaining the temperature of Ice silos.

3. -30 ° C system: used for cold storage & deep freezer.

  -2° C system has three horizontal compressors & two oil separators.
  
-10 ° C system & -30 ° C system each are having two compressors and two oil separators
  
In the entire three system screw type compressor are used.
  
There are two liquid ammonia receiver tanks, each having capacity of 10000 L
  
There are two ice silos of 1, 25,000 L capacity in which water is chilled by liquid ammonia.
 
There are 5 water cooled condensers

Control limit for Ammonia gas Compressor:

Conditions Low Normal High

Discharge pressure (bar) - 11.5 12.5
Condensed temperature (oC) - 32 35
Discharge gas temperature (oC) - 80 85
Compressor oil pressure (bar) 3 4 -
Oil temperature (oC) 40 55 60
Differential pressure across Duplex Filters - 0.2 0.8
(bar)
(table: 12.2)

45
Flow chart:
Refrigerant Receiver

Expansion Valve

Surge Drum

Liquid Vapour

Through pump
Goes to cold storage
Evaporator

Compressor

Evaporative condenser

Receiver

Water chilling system:

Balance tank

Chiller

Water ammonia

Chilled water

Ice silo
(Ammonia is circulated through coil in ice silo)

Chilled water

Used in plant

46
 Water returns to balance tank

13. Q C LABORATORY
Introduction:
Quality Control (QC) is a way of preventing mistakes or defects in manufactured products and avoiding
problems when delivering solutions or services to customers. Which ISO 9000 defines as “part of quality
management focused on providing confidence that quality requirements will be fulfilled”.

This Department in the dairy plant has to perform multifarious activities and keep track of different aspects
while maintaining a strict vigil on the quality of every packet of every product originating from the dairy. In
laboratories all the raw material, ingredients, products in progress, finished products as well as packaging
materials are tested for their physical, chemical and microbiological quality to maintain hygienic condition in
the production area.

There are FOUR main quality control /assurances laboratory at Amul dairy as follows:

1. Milk reception Laboratory at Amul-3

2. Milk reception Laboratory at Amul-2
3. Central laboratory
4. Microbiology laboratory
The tests done in the Reception lab of Amul – 3 include the analysis of Raw milk as well as Pasteurized
milk.

In the Reception lab of Amul – 2, mainly the quality of Raw milk, Flavored milk and Dried milks are tested.

In Microbiology lab the microbial analysis of product is done.

The Central Laboratory is the main lab where all the in process checks, finished product analysis, packaging
tests, water analysis are done.

1. Milk reception laboratory at Amul-3

Amul-3 testing lab is a reception laboratory; therefore platform tests are performed here to for acceptance or
rejection of the raw milk. In addition with that the adequacy of pasteurization of pasteurized milk is also
checked here.

After arrival of milk tanker first of sampling is done & following parameters are checked for acceptance or
rejection:

 Temperature: using digital thermometer it should be below 10oC.

  Smell: should be free from taints or abnormal smell.
 Visual inspection: should be absence of abnormality
 Taste: pleasant.
47
Then sample is taken to reception lab for following tests:

Sr. Test Procedure Interpretation

No.
1 Acidity 10 ml milk + 5 drops of phenolphthalein It should not exceed 0.14% for
indicator. & Titrate against N/9 NaOH till cow milk & 0.17% for Buffalo
faint pink colour appears. milk.
Acidity = Titre value×0.1 % as lactic acid
2 MBRT test Take 10 ml milk + 1 ml methylene blue This test is used to check the
dye in a test tube. Close it with rubber cock bacterial load in the milk. If milk
& put it into water bath at 37oC. Check at is having high bacterial count the
15 min intervals & note down the time dye will reduce in lesser time &
taken to reduce the dye. vice versa.

3 Phosphatase test Take 1 ml milk + 5 ml test solution in a This test is used to check the
test tube, put it in water bath at 370C for adequacy of pasteurization in
30min. milk.
If yellow colour appeares this test is +ve &
white colour remains means test is –ve.
4 COB Approx 5 ml milk sample taken in test tubeIt is a quick test to determine
& boiled for 2 min in a water bath. Then it
developed acidity and suitability
is observer for any precipitated particles.
of milk for processing. Milk
should not be curdle upon heating.
5 Alcohol test Take 2 ml milk + 2ml alcohol (68% conc.). If there is no flakes of curd the
Mix vigorously & check the curdling on test is –ve. The milk that is used
the test tube. to make flavour milk should be
alcohol –ve.
6 Fat(gerber Take a butyrometer add 10 ml H2SO4 (92% It should be around 4% for cow
method) conc.) + Few drops of water + 10.75 ml mil & 6% for buffalo milk.
milk + 1ml amyl alcohol. This method is also used to
Stoppered & centrifuge at 1100 rpm for standardize the milkoscan.
5min.
7 SNF It is measured by gravimetric method. It is around 9%.
SNF% = TS% – Fat%
(table: 13.1.1)
The constituents of milk can directly know by using Milcoscan like fat, SNF, Lactose, sucrose, FPD, etc.

There is a Bactoscane also. Bactoscane is used to determine the total bacterial load in the raw milk sample.
It employs the use of ethlyidene bromide red dye (fluorescent dye) to stain or highlight the bacteria the filler
used top allows the bacterial cell (0.2-10 micron size) to pass through and all other cells are filtered. The
highlighted bacterial cells are thus obtained in the filtrate and the amount of light (blue) scattered from their
cell gives the bacterial load. The count is obtained as individual bacterial count (IBC) can be considered as
colony forming unit.

2. Milk reception Laboratory at Amul-2

This lab is mainly used for the pricing of milk. Every village society sent a sample of their milk with the milk
tanker. These samples are tested here for fat & SNF using milkoscane & on that basis pricing is done. A
SMS showing % fat & SNF & amount of their milk is sent to that village society immediately after testing. If
they have any doubt regarding to their sample they can report within 24 hrs. After 24 hrs samples will be
discarded.
48
 Other activities:
 In this lab they also keep the records of average weight of milk pouches & flavor milk cans.
 pH of flavour milk is checked using the pH meter.
  Acidity & alcohol test is done of milk sample from the batch taken for preparation of flavor milk.
  Moisture of powder checked using Moisture analyzer.
 Clarity of ghee is observed after melting on hot plate. If there is any ghee residue that batch will be
reprocessed.

3. Central laboratory:
In the central lab all the finished products are tested for their parameters using different methods. In addition
to that water analysis, strength of soda & acid, packaging material tests are also done.

 Tests done for Powder:

Sr.No Tests Procedure Observation &
Interpretation
1 Grading For reconstituting any powder 200 ml water The black particles denote
is used. Into it SMP- 20gm, Amulspray - burnt particles. After
28g,Amulya – 28g,WMP – 26g are added filtration if wt. of burnt
and dissolved with the help of a flat blade particles are
disc blender for 90 sec with 4000rpm.After 0-7mg - A grade.
the reconstitution grading is done by looking 7-15mg – B grade
at the top and bottom of the beaker. The Above 15mg – C grade
grade is given according to number of C grade should be
scorched black particles. reprocessed.

2 Insolubility index 50 ml of reconstituted milk is taken in an After centrifuging, the

It is volume in milliliter Insolubility index tube up to 50 ml mark and insoluble powder settles
of sediment obtained centrifuged at 1100 rpm for 5min. down. The volume of this
when a dried milk or powder should be less
dried milk product is than 1.5 ml, else the CIP
reconstituted. of system is required as
drying may be
incomplete.
3 Moisture 2 -2.5 gm of powder is taken in the The moisture content
Automatic Moisture Analyzer. The meter should be between 2.6 –
gives reading in 5 min. 3.3%. If it is more, the
batch is rejected and test
is done for condensed
milk and the flow rate of
milk to the dryer is
reduced.
4 Fat content Take 10ml conc.H2SO4 (92%) + 2.5g SMP – 0.5 to 1%
powder + 1ml Iso Amyl Alcohol + 1ml WMP – 26 %
distilled water into 36%butyrometer. Rubber Amulspray – min 18%
stopper it & centrifuge it at 1100rpm for Amulya – min 20%
5min.
5 Coffee Test 150ml distilled water is heated to 90oC & Observe bottom & Upper
To check heat stability 1.5g of coffee powder is dissolved. When layer, if there is any clots
o
it‟s temp. reaches 80 C, 5g of powder is coffee test is negative.
49
 added and stirred with a spoon for 15 sec in Take 50ml solution, put it
clockwise & anticlockwise direction. in centrifuge & observe
sediment layer.
6 Acidity The No. of ml of 0.1N NaOH solution Acidity should be up to
required to neutralize a quantity of 1.5%.
reconstituted milk. Until pink colour
obtained in the presence of phenolphthalein
indicator.
7 Wettability test Take 13g powder sample, and then add this For Agglo powder 19 to
Wettability is the ability, powder in 100ml water at 45oC. Temp of 20 sec
expressed as the time in powder is 35oC. Then note down time.
seconds, necessary for a For non-Agglo powder
given amount of powder max 40sec
to penetrate the quiet
surface of the water
8 Bulk density Take 10 gm of powder & tape 100 times in Up to 0.6
Bulk density depends on stampf-volumeter & note down volume.
water content & particle BD = Mass/ Volume
size in measuring
cylinder.
9 % Agglomerate This test is done for Amulya & Amul spray. The mass of powder
Powder 50g powder is sieved manually on retained on sieve
sieve(250µ) mesh for 5min. multiplied by 2, gives %
agglomerate. It should be
around 36-38%.
10 Total solids of Milk Take 2g of milk concentrate in a disc. Put it 45 to 50%
concentrate on a boiling water to evaporate moisture.
Then Place it in Oven maintained at 98-
100oC, 3hrs. Weigh the dish at hourly
interval until constant weight attain.
TS%=( wt of residue/sample wt.) *100
11 Ash Take 3g of powder in crucible & put it in a Max 8.5%
muffle furnace at 550oC for 5-6 hrs.
Ash = (wt. of sample after drying/before
drying)*100
12 Presence of vitamin 50 ml reconstituted milk+2-3 drops of Blue colour appears
indophenols blue vitamins are present
13 Presence of Iron 10 ml reconstituted milk + Ammonium Formation of red
thiocyanate + conc.HCl precipitate shows
presence of iron
(table: 13.3.1)

 Ghee Analysis:
Sr.No Tests Procedure Interpretation
1 Baudine test Take 5ml ghee in test tube. Add equal This test should be –ve.
quantity of concentrated HCl. Add furfural
solution, Mix it well. Observe.
2 FFA Take 9.4 ml ghee in conical flask. Special grade: 1.4%
Add 50 ml neutralized spirit & plug it by
50
 cotton. FFA(max)
Put on hot place / boiling.
Cool at room temperature. General Grade: 2.5%
Titration against 0.1 N NaOH & Observe FFA(max)
light pink colour and note the reading. Standard Grade : 3.0%
FFA % = Titrate value × 0.3 FFA(max)

3 RM value Take 5gm sample in polenske flask. Add Should be 28(min)

20ml glycerine + 2ml 50% NaOH solution.
Heat the flask over a flame until mixture
become perfectly clear. Cover the flask with
watch glass & cool. Add 93ml boiling
distilled water slowly drop by drop + 50 ml
dil.H2SO4 (2.5 N). Connect the flask with
distilled unit. Heat the flask until insoluble
acids are completely melted (without
boiling). Collect the distillate at 19-21 min
(100-110ml). At 110ml remove the flame,
cool it. Immerse in water at 15oC. Take 100
ml filtrate, add 1ml phenolphthalein
indicator. Titrate it with 0.1 N NaOH
solution, Light pink colour appear.
RM Value = (Burette reading – Blank
reading) * 1.1
4 Polenske value Wash the condenser with the 45ml portions 1.0 to 2.0
of cold distilled water passing each washing
separately through the 25ml, cylinder the
110ml flask. Dissolve the insoluble acids by
three similar washings of the condenser with
45ml of neutralized Alcohol & titrate it.
Filter it. In filtrate add 1ml phenolphthalein
indicator & titrate with 0.1 N NaOH solution.
Polenske Value = (Burette reading – Blank
reading)
5 Peroxide value Take 10gm of sample in 250ml conical flask, 0.55
add 30ml Acetic acid-chloroform solution.
Swirl the flask until sample is dissolved
+0.5ml of saturated KI soln, allow the soln to
stand for 1min. 30ml distilled water, shake
well. Add starch as indicator. Titrate with
0.01N sodium thiosulphate soln till yellow
colour disappears.
PV = (vol.of sodium thiosulphate * No.of
sodium thiosulphate*1000) / wt. of sample
(table: 13.3.2)

 Butter Analysis:
51
Sr.No. Tests Procedure Interpretation
1 Moisture Take 10g of butter in aluminum dish. Heat 16%(max)
the dish on electric hot plate with constant
strring. Curd at the bottom has attained the
characteristics slightly brown colour. Allow
the cup to cool in desiccator. When cooled
place the cup on the balance
Moisture content = (wt before heating – wt
a after heating) /(wt a
a before heating)
2 Salt Take 10 g of sample in a beaker.100 ml 3%(max)
distilled water, heat it. Add into sample &
mix it well. Take 10ml sample & titrate with
0.1N AgNO3 with K2CrO4 indicator.
Salt = titre value*mol.wt of AgNO3*100/ wt
of butter

3 Curd Take 10gm sample. Melt it. Give 3 wash of 1.5%(max)

petroleum ether. Dry it in oven 1 hr &
weigh.
4 Fat Fat =100 – Moisture – Salt - Curd 80%(min)
(table: 13.3.3)

 Flavour milk analysis:

Sr.No Tests Procedure Interpretation
1 Alcohol test Take 2 ml milk + 2ml alcohol (68% conc.). The raw milk used for
For Raw milk Mix vigorously & check the curdling on the flavoured milk should be
test tube. alcohol –ve.
2 pH Using pH meter. 6.3 to 6.5
3 Fat Take 10ml conc.H2SO4 (92%) + 2.5g Koko- 2.4 to 2.5
Gerber method powder + 1ml Iso Amyl Alcohol + 1ml Kafe- 4.85 to 4.90
distilled water into 10%butyrometer. Rubber Shakers- 3.4 to 3.5
stopper it & centrifuge it at 1100rpm for
5min.
4 SNF SNF% = TS% – Fat% 8.6 to 8.8
5 Cream Index(CI) Cool the milk sample at 20oC & take 50 ml It should be <10%
Used to check the in each of the 2 centrifuge tubes. Centrifuge
efficiency of the tubes at 1000 rpm for 15 min. Using fine
homogenization pointed pipette take 5ml upper part of the
layer & collect in a beaker. Then collect the
remaining milk in another beaker.
Determine fat content of A & B.
CI = (A-B)/B*100%
(table: 13.3.4)

 Tests for Buttermilk & Dahi:

Sr.No Tests Procedure Interpretation
52
1 TS Take 10 gm of Buttermilk in a plate & place Buttermilk - 5.5-6%
it in a Hot air oven at 100oC until constant
wait attains.
2 Acidity 10 ml Buttermilk/Dahi + 5 drops of Buttermilk - 0.35 to 0.40
phenolphthalein indicator. & Titrate against Dahi - 0.8 to 0.9
N/9 NaOH till faint pink colour appears.
Acidity = Titre value×0.1 % as lactic acid
3 Fat Gerber method Butter milk – 1.0 to 1.1%
Dahi – 3.3 to 3.3
4 SNF SNF% = TS%-Fat% Butter milk – 4.5 to 5%
Dahi – 11 10 12%
(table: 13.3.5)

 Water analysis:
Sr.No. Tests Procedure Calculation
1 Hardness Pipette 100ml water into a conical flask. Total Hardness (as mg/lit of
CaCO3) = Reading X 10 ppm
Add 2 drops ammonia buffer solution (ph
10) followed b) 3 drops of Eriochrome
Black T indicator solution.

Titrate with 0.02 M EDTA until the

solution turns from wine red to sky blue
with no hint of red.

2 Chloride Pipette 10ml water into a conical flask. Chloride = (Reading X N X

35.45 X 1000)/V = Cl ppm
Add 2 drops of 5% K2CrO4 solution as
indicator.

Titrate with 0.1 N AgNO3 until the

solution turns from yellow to brie red
colour.
3 Alkalinity Take 20.0 ml water sample and add 2-3 1) Phenolphthalein
drops phenolphthalein indicator and titrate Alkalinity (AS mg/lit
with 0.1 N H2SO4. of CaCO3) = A*N *
50000 / V
Note down the reading as a reading (A). 2) Total Alkalinity (AS
(Pink to colourless is end point). mg/lit of CaCO3) =
Then add 2-3 drops mix indicator and ((A+B)* N * 50000) /
V
titrate with 0.IN H2SO4.
Light green to pink Colour is end point. Where, N= Normality of
Note down reading as (B). H2SO4
A = Reading of
Phenolphthalein indicator
titration (1st Titration)

53
 B = Reading of Mix indicator
titration (2nd Titration)
V = Volume of water = 0.108
3) Alkalinity (As mg/lit
of NA2CO3) = (1.06 X
Total Alkalinity) -
Total hardness

(table: 13.3.6)

 Strength of Acid & soda:

Sr.No. Tests Procedure Calculation
1 Caustic Soda Take 10ml dist. Water in 250ml conical flask Strength of Caustic soda
and weight 0.5g caustic soda in 250ml % = (Reading X N x 40) /
conical flask. (Weight of caustic soda X
10)
Add 2-3 drops phenolphthalein indicator and
titrate with 0.5N HCl. Pink to colourless is
end point.

2 Nitric Acid Take 10ml dist. Water in 250ml conical flask Strength of Nitric Acid %
and weight 0.5g Nitric Acid in 250ml conical = (Reading X N x 63) /
flask. (Weight of Nitric Acid X
10)
Add 2-3 drops phenolphthalein indicator and Where, N = Normality of
titrate with 0.5N NaOH. Colourless to pink is HCI or NaOH
end point.

(table: 13.3.7)

 Packaging material tests:

Sr.No Packaging material Tests Procedure Interpretation/

& its characteristics Calculation
1 Card board Box Weight test weigh the entire package in box form -
(CBX) without cutting any part of it on a
5 ply sensitive balance.
(12×1kg Box) Dimensions Measure the inner dimensions of the L*b*h
folded box with an accurate cm scale
Bursting Using digital bursting strength The brusting
Strength apparatus. strength should be
12 kg/ Cm2 .
Grammage A 10×10 cm specimen is cut from the The resultant
(GSM) CBX and then put it on boiling water weight is multiplied
for 10min so that starch based adhesive by 10 to give GSM.
54
 melts and the ply layers get separated.
The individual layers allowed to dry at
room temp for 30 min & the oven dried
for 10 min. then each layer weigh
separately.
Outer printing The card board random sample is Correct details
of CBX chosen & viewed for its outer printings. regarding title of
manufacturer,
weight of product,
stackability, etc.
2 Milk pouch & Ghee Grammage A 10×10 cm square is cut and weighed. It represents Grams
Pouch per square meter.
(LDPE+LLDPE) Thickness Using micrometer Milk pouch-55
micron
Ghee pouch- 100
micron
Outer printing A random sample is picked up and all All the details
printed features such as Principle should be correct.
display panel, Manufacturer detail,
Product detail, Nutritional facts,
Address of Company, etc.
3 Tin containers Lacquering
(table: 13.3.8)
 
Equipments present at central lab:
Sr. Equipments / Instruments Purpose
No.

1. Milkoscan Fat, SNF, Protein, Lactose

Determination

2. Food scan Fat, moisture, Protein, Lactose

of butter, cheese

3. Auto Titrators Acidity Determination

4. Conductivity Meters Conductivity of CIP Chemicals

5. Microwave Moisture Analyzer Moisture Detection

6. IR Moisture Analyzer Moisture Detection

7. Stamp Volumeter Density of Powder

8. Bursting Strength Analyzer For Packaging Material

9. pH Meter pH Measurement

10. Solubility Index Mixer Solubility Index of Powder

55
 11. Electronic Weighing Balance For Weighing Purpose

12. Gerber Centrifuge For Determination of Fat

13. Muffle Furnaces For Ash

14. Spectronic 20 For colour determination

15. Oxygene analyzer For determination of Oxygen

content in packages

16. Bulk Density Apparatus For determining Bulk density

17. Electric Hot Plate For heating purpose

18. Remi centrifuge For determination of

insolubility index

19. Refractometer For determination of

Refractive Index

20 Food Scan For chemical analysis of butter

& powder

(table: 13.3.9)

4. Microbiology laboratory:
Since milk and milk products are extremely susceptible to microbial contamination during their
production and processing, it becomes a necessary to assess the microbiological quality of this products in a
quality control lab. as bacterial load is the function of the species of bacteria as well as their number, a
program for controlling the total bacterial load of milk and dairy products must include metabolic activity
test (indirect test) as well as test involving the enumeration of bacteria or test for the presence and absence of
specific pathogenic organism(direct test). The routinely used method in quality control laboratories are:

One random sample of every product is analyzed daily for SPC, Coliforms and Yeast & mold using
readymade dehydrated petrifilms. Pathogen tests are done weekly or once in two weeks.
 
Different microorganisms:
TYPE OF MEDIA Ph OF THE APPEARANCE OF THE
MICROORGANISM MEDIUM COLONY

Total viable count Plate count agar 7.0 +/-0.2 -------

Coliforms Violet red bile agar 7.4+/-0.2 Red/ Purple colony

Yeast & mold count Potato dextrose agar 5.6+/-0.2 White/grey/yellow/ black
colony formed

56
 E.Coli Eosin methylene blue 6.8+/-0.2 Green metallic sheen, black
agar centered colony

Salmonella Bismuth sulphite agar 7.6+/-0.2 Black metallic sheen

Shigella Brilliant green agar 6.9+/-0.2 Pink coloration

S. aureus Baird parker agar 6.8+/-0.2 Black colony surrounded by

clear zone

B. cereus Bacillus cereus agar 7.2+/-0.2 Pink/ white colony

Listeria Listeria agar 7.2+/-0.2 Black colony

Monocytogenes

Feacal Streptococci Mac Conkey‟s agar 7.4+/-0.2 Pink colony

Vibrio Cholera Thiosulphate citrate bile 8.2+/-0.2 Yellow colony

salt sucrose agar

Anaerobic Spores Liver meat infusion agar 6.9+/-0.2 ----------

(table: 13.4.1)
 
Sampling plans for analysis of products:

PRODUCT PARAMETERS FREQUENCY REJECTION CRITERIA

Raw milk Plate Count 2 Tankers/ day >5000000 cfu/ml

Pasteurized Milk Plate Count, Coliform 1 sample /day >30,000 cfu/ml

from running Count
Present in 0.01ml
Pasteurizer
Pathogen Test 5 samples /month Present

Railway tanker Plate Count, Coliform Every tanker >30,000 cfu/ml

milk Count
Present in 0.01ml

Sterilized Plate Count, Coliform 1 sample / shift

Flavoured milk Count
> 5 / ml
Spore Count

Various milk Plate Count Composite sample of > 40000 / g

57
 powders Coliform Count two / shift Present in 0.1 g

Pathogen Present

Butter Plate Count 2 samples / line / shift >5000 / g

Coliform Count >5/g

Yeast & Mold Count >5/g

Pathogen Weekly- 7 days Present

composite

Export Butter Plate Count 100 g – every 50th >5000 / g

case of each
consignment.

500 g – every 100th

case. Composite
sample for each
Coliform Count consignment >5/g

Yeast & Mold Count >5/g

Pathogen Present

Raw materials- Coliform Count Each consignment or Present in 1 g

Maltodextrin ,
Salt, Annato, Yeast & Mold Count Twice in a month Present in 1 g
Vitamins , Corn Pathogen Present
oils, Colour

Raw materials – Coliform Count Twice in a month Present in 1 g

Sugar , TSP
Yeast & Mold Count

(Table: 13.4.2)

58
 CONCLUSION
 Amul spurred India‟s White Revolution, which made the country the world‟s largest producer of milk
& milk products. In the process Amul become the largest food brand in India and has ventured in

to markets overseas.
 Amul committed produce safe and wholesome food to continually remain as the market leader by
 the providing the food product delight customer expectation & best of safety.
 Here in Amul learned about the practical working at the Industrial level. The various problems
 that can occur & the different ways to shoot them.
 The important of working environment and how to generate highly professional work environment.
We also learnt about how to manage the available resources to extract maximum production and
 the handling of manpower to get the professional work experience.
 Working in any industry is difficult without mutual understanding, co-operate nature and team work.
 Here in Amul learned about all these things. To learn all the above things the historic unit of Amul
is one of the best place in the World.

Thank you………..

59