INTERNSHIP REPORT

AT

(THE PONDICHERRY COOPERATIVE MILK PRODUCERS UNION LTD)

Vazhudavoor Road, Kurumampet, Pondicherry – 605009

(DURATION: 15th February 2023 to 21th February 2023)

SUBMITTED BY
ARTHI DHANISHA.D (21TF0002)
ASHITHA WINSLIN .W (21TF0003)
DJEOCIKA LIZY.D (21TF0005)
MAHALAKSHMI.T (21TF0016)
PADMAJA.G (21TF0019)

MANAKULA VINAYAGAR INSTITUTE OF TECHNOLOGY

B.Tech DEPARTMENT OF FOOD TECHNOLOGY
BATCH 2021-2025
KalitheerthalKuppam, Madagadipet Commune, Puducherry.
 ACKNOWLEDGEMENT

First and foremost, praises and thanks to the God, almighty for
providing us this distinctive opportunity and for the showers of blessing that he
bestowed upon us during our internship.
The successful completion of internship would be incomplete without
mentioning the person who helped to make it possible.
It is our great privilege and honour to have our internship training
from your esteemed company PONLAIT,
We would like to express our sincere gratitude to Mr.S.Murali
(Managing director, PONLAIT) for giving us the opportunity to do an
internship within the organization and we like to thank
Mr.S.Preumal(Deputy manager) and Mr.Sam Densly(Assistant
manager)
We convey our thanks to Mr.N.Parthasarathy (Technical
superintendent) and Mrs.Nirmala Devi (Lab Assistant) and other Lab assistant
for their patience and openness with which they created an enjoyable working
environment. We thank all employees for their valuable knowledge, guidance
and support.
We heartily thank our college Professors, Department of food technology
Dr.D.Tiroutchelvame (Head of the department) and Dr.Bhagya Nisha
(Assistant Professor) who motivated all the students in successful completion of
this internship.
We thank our parents who raised us with love and supported us
throughout our internship.

ABSTRACT
 PONLAIT is a Pondicherry's very own co-operative milk society comprising an
impressive range of variety in milk and milk products. Ponlait is the first registered
Co-operative Society under Pondicherry Co-operative Societies Act, 1972.

The average milk procurement by Ponlait from the Milk Producers’ Co-op.
Societies every day is 1,00,000 litres and the same is collected through 25+ Bulk Milk
Cooling Centres installed across Pondicherry Region. It produces 3 varieties of milk
namely Toned milk (Blue packet), Special Toned milk (Green packet) and
standardized milk (Orange packet) which provide premium milk as per the consumers
requirement. Toned milk contains 3.0% fat and 8.5% SNF, Special toned milk
contains 3.5% fat and 8.5% SNF, and Standardized milk contains 4.5% fat and 8.5%
SNF.

DAIRY PLANT:
The Milk procurement is directly from the farm and they are chilled and
storage. Milk chilling is necessary after receiving milk from the society. Then milk is
tested for its quality and then stored in the BMC (Bulk Milk Cooler) further it is
cooled below 50C . The milk producers are paid for their milk at the collection centres
or co-operative societies on the basis of Fat and SNF content of milk.
Milk is pasteurized with the help of batch milk pasteurizer. Then they
standardize the milk fat with the help of cream separator. Pasteurized milk is packed
on the same day to improve the shelf life. Here they use plate heat exchanger method
and high temperature short time pasteurisation.
Milk is standardised and pre heated and sent to a homogenizer. For the
homogenization of milk , milk is passed through the homogeniser which make the fat
molecule very small under heavy pressure, Milk is homogenized to break all fat
particles into even size thus form a white creamy layer and later milk is stored in
pasteurized milk storage tank. In pasteurizer the cream is also separated from milk
using separator.
The collected cream is then sent further for the processing of products such as
ghee, ice cream and the skim milk is transferred to storage tanks via pipeline. The
storage unit consists of six storage tanks with 5000 litres capacity where the skim milk
is collected. It is further tested in the lab. Once it is approved it is allowed for
packaging and is stored in cold storage room then dispatched.

DAIRY PRODUCTS:
The various by products are:

 Ice cream,
 Ice candy,
  Milk peda,
 Kulfi,
 Paneer,
 Flavoured milk,
 Sweet lassi,
 Badam mix powder,
 buttermilk,
 Curd,
 Ghee,
 Bread

Learning Objectives/Internship Objectives

 Internships are generally thought to be reserved for college students looking

to gain experience in a particular field. However, a wide array of people can
benefit from Internships training in order to receive real world experience
and develop their skills.

 An objective for this position should emphasize the skills you already
possess in the area and your interest in learning more

 Internships are utilized by a number of different fields, including

architecture, engineering, healthcare, economics, advertising and many
more.

 Some internship allows the individual to perform scientific research while

others are specifically designed to allow people to gain first-hand experience
working.

 Utilizing internships is a great way to build your resume and develop skills
that can be emphasized in your resume for future jobs. When you are
applying for a Training Internship, make sure to highlight any special skills
or talents that can make you stand apart from the rest of the applicants so
that you have an improved chance of landing the position.
 CONTENT
S.NO TITLE PAGE NO.
.

1. Introduction
6

2. Dairy plant
8

3. Dairy Maintenance
15

4. Boiler and condenser

16

5. Milk products
18

6. Effluent treatment plant

34
7. Laboratory test
36

INTRODUCTION:
Ponlait is Pondicherry's very own co-operative milk society comprising an
impressive range of variety in milk and milk products. The importance of diary
development cannot be over emphasize in our country where the main contribution
of growth and strength for a bulk of population are derived from milk and it’s
products. The word PONLAIT refers to ‘PON means Pondicherry and LAIT means
milk’.
India’s modern dairy sector has expanded rapidly. It has been biggest and
fastest growing market in the world of milk and milk products. On an average the
liquid milk marketed by Ponlait in Pondicherry is 1.0 lakhs litres per day which
includes sale to the General Public, supply to Hospitals, Hostels, Educational
Institutions, etc.
In the year 1955, the first co-operative milk society in union territory was
registered. The Union started procuring milk from the village producers on quality
basis from 1970 onwards. To keep pace with the milk production, the Milk Union
has also set up a Dairy Plant with 10,000 Liters capacity for processing on 1971.
The average milk procurement by Ponlait from the Milk Producers’ Co-op.
Societies every day is 1,10,000 litres and the same is collected through 25+ Bulk Milk
Cooling Centres installed across Pondicherry Region after subjecting the milk for
instant chilling to maintain quality. About 40,000 litres per day additionally is out
sourced from the neighbouring states to meet the market demand.
There are 10,000 cattle owners who become members in the Dairy
Cooperative societies at villages and supplying milk to Pondicherry Cooperative milk
producers’ union. The present handling capacity of the Dairy is 50,000 litres per day
which support 75,000 to 1,10,000 litres of milk is handled per day. About 1,00,000
litres of milk is used for packaging of the milk and remaining 10,000 litres of milk is
used for products.
It produces 3 varieties of milk namely Toned milk (Blue), Special Toned milk
(Green) and standardized milk (Orange) with provide premium milk as per the
consumers requirement. They comes from the premium package packets like blue,
green and orange packets based on consumer’s satisfaction.
Toned milk contains 3.0% fat and 8.5% SNF, Special toned milk contains 3.5%
fat and 8.5% SNF, and Standardized milk contains 4.5% fat and 8.5% SNF.
The varies by products which include ghee, khoa, flavoured milk, paneer, curd,
buttermilk, milk, bread, milk peda, Badam mix, Ice cream.

OBJECTIVE OF PONDICHERRY MILK CO OPERATIVES:

The dairy cooperatives in Pondicherry have some of the basic objectives
towards the achievement of which they have to work constantly. They are:
 To ensure supply of good quality milk and milk products to the consumers at
fair prices.
 To offer remunerative prices to the dairy farmers for their better living
standards.
 To ensure the development of mulch cattle.

LIST OF PONDICHERRY MILK CO-OPERATION SOCIETY:

Some of the well-known milk co-operatives in Pondicherry are:
 Abishegapakkam Co-operative Milk Producer’s Society Ltd.
 Anandapuram Co-operative Milk Producer’s Society Ltd.
 Ariyankuppam Women Co-operative Milk Producer’s Society Ltd.
 Bahour Co-operative Milk Producer’s Society Ltd.
 Aranganur Co-operative Milk Producer’s Society Ltd.
 Andiatpalayam Co-operative Milk Producer’s Society Ltd.
 Embalam Co-operative Milk Producer’s Society Ltd.
 Alankuppam Sanjeevi Co-operative Milk Producer’s Society Ltd.
 Ganapathichettikulam Women Co-operative Milk Producer’s Society Ltd.
 Kriyamanickam Co-operative Milk Producer’s Society Ltd.
  Karikalampakkam Co-operative Milk Producer’s Society Ltd.
 Keezhagraharam Co-operative Milk Producer’s Society Ltd.
 Kodathur Co-operative Milk Producer’s Society Ltd.
 Lingareddipalayam Co-operative Milk Producer’s Society Ltd.
 T.N. Palayam Co-operative Milk Producer’s Society Ltd.
 Sellipet Co-operative Milk Producer’s Society Ltd.
 Ramanathapuram Co-operative Milk Producer’s Society Ltd.
 Nallur Co-operative Milk Producer’s Society Ltd.
 Manamedu Women Co-operative Milk Producer’s Society Ltd.
 Thirukanji Co-operative Milk Producer’s Society Ltd.
 Villanur Co-operative Milk Producer’s Society Ltd.

DAIRY PLANT:

MILK PROCUREMENT:
Ponlait has about 110 societies from which 60,000 litres of milk are
collected on daily bases.
The Milk collection in Ponlait is through co-operative organization. In this
system of milk collection, producers living in villages join together to form a co-
operative society for procuring and supplying milk to co-operative dairy plants. These
members’ producers get the maximum remuneration for their milk through this
method.
Normally cows are milked twice a day; first, in the early morning and the
second, in the late afternoon or evening. This milk is brought in small quantities at the
collection centres in the producers own utensils. It is then measured, sampled and
transferred to aluminium cans where it is mixed with other producer’s milk. The milk
producers are paid for their milk at the collection centres or co-operative societies on
the basis of Fat and SNF content of milk. The pay scale is
SECTOR FAT SNF TOTAL AMOUNT PAID PER AMOUNT PAID
SOLID LITRE OF MILK PER kg
Private 4.0% 8.0% 12.0% Rs. 42 Rs. 354
Society 4.2% 8.3% 12.5% Rs. 36.87 Rs. 295
 Milk procurement starts directly from the farm and they are chilled and stored.
Milk chilling is necessary after receiving milk from the society. Chilling is done in
order to retard the growth of microbes. Then milk is tested for its quality and then
stored in the BMC (Bulk Milk Cooler) where it is cooled below 5oC.

BULK MILK COOLER (BMC):

BMC is a large storage tank that holds milk at a cold temperature. The
extracted milk is around 37OC. When the Milk remains at room temperature after
extraction, bacterial growth will take place immediately after milking. In order to
retard the growth of microorganisms and to maintain the quality of milk it is chilled
below 50C.
Ponlait has 25+ BMC’s located in areas in and around Pondicherry .About 9
BMC has 5000 litres capacity , 12 BMC has 1000 litres capacity , 1 BMC have 3000
litres capacity and 1 BMC have 500 litres capacity
From BMCs’, milk is transported to the company by means of tankers . After
milk is received, with the help of plunger milk is mixed well in order to evenly
distribute the fat and SNF in the milk and the sample is used for testing. The milk
from the BMC is called as Raw Chilled Milk.

Flow chart:
Milk in cans

Weighing the milk

Pouring and filtration in dump tank

Milk pumped to BMC

Chilling at 5 C

PASTEURIZER:
 High temperature short time pasteurisation(HTST) is an effective method of
making milk safer for consumption, without changing its sensory quality because
heating the milk at short time only targets the pathogenic bacteria and the nutrients
will not get lost. The milk pasteurizer can be operated in auto mode and manual mode.
Milk is pasteurized with the help of batch milk pasteurizer, and then it is
standardized with the help of cream separator. Pasteurized milk is packed on the same
day to improve the shelf life. In pasteurizer the cream is also separated from the milk
using cream separator.
For the standardization of milk, Cream is added to increase the fat ratio and to reduce
the fat ratio skim milk is added. To increase the SNF skim milk powder is added. This
helps to maintain the fat ratio and SNF ratio

There are various section. They are:

Regeneration section, Heating section, Holding section and Cooling section.

Regeneration section:
Raw Chilled milk first enters the regeneration section and the temperature of
the milk is raised to 400C. In this section the outgoing pasteurized milk heats the raw
milk.

Heating section:
Immediately after regeneration section the milk is passed to heating section.
Here the milk is heated to 80oC. The heating takes place by passing hot water at 95 oC
between the tubes. The milk and hot water circulation will be in the ratio of 1:3.

Holding section:
Milk enters the holding section, where the holding time is 15 seconds which
is found to be optimum. In modern practice milk is passed through a pipe and the flow
is arranged in such a way to achieve correct time at 72oC.
Cooling section:
Milk is sent to cooling section where the temperature is gradually reduced to
24 C and then finally temperature is reduced to 5oC.
o

PLATE HEAT EXCHANGER METHOD:

This method mainly regulates fluid temperatures in the process to meet the
requirements of pasteurization and food safety. The main aim of heat exchanger is to
reduce or to arrest microbial growth to make the products safe for consumption and to
prevent spoilage. Due to the high and sudden lower of temperature the pathogens are
arrested. It is cooled under 35o C and the nutritive value of milk is maintained.

HOMOGENIZER:
First milk is standardised and pre heated and send to a homogenizer. During
homogenization, milk is passed through the homogeniser which breaks the fat
globules under heavy pressure. Here a piston is used to break the fat molecule.

The process has specific function of reducing size of fat globules of milk
to less than 2 microns size. It is used to produce thick milk by mixing the fat globules
evenly. This milk is mainly used for the production of curd, ice cream, ghee etc…
 Milk is homogenized to break all fat particles into even size thus form a
white creamy layer and later milk is stored in pasteurized milk storage tank.

SEPARATOR:
The milk flows through the distributor through the distribution holes of
discs. The separation takes places in spaces between the discs. That part which is
discharged as cream is pressed towards the bowl centre along the top sides of discs
and flows out. The discharged skim milk which flows along the upper side of top disc
and leaves the bowl via the outlet sleeve.

Through this process we get two outputs cream and skim milk. The collected
cream is used in product processing such as ghee, ice cream and the skim milk is
transferred to storage tanks via pipeline.
The storage unit consists of six storage tanks with 5000 litres capacity where
the skim milk collected from the separator is stored at 6-7 oC. After storage the milk
goes to lab for testing, then it is approved for packaging. If it is not approved it is
further allowed for processing.

PACKAGING OF MILK:
First the printed milk packets are loaded on a cylindrical roller. It is an
automated machine. The rolled sheets are moved in roller, they opened as v-shaped
and it is sealed vertically with a vertical sealer and then it is sealed horizontally by
horizontal sealer and using the injection needle the milk is filled in the packets to the
required amount and temperature .
 Then it is further sealed horizontally and cut. It is manually placed in tray
containing 25 packets in one tray and are stored in cold storage room at the
temperature of 5-8oC, then it is dispatched.

PROCESSING OF MILK:

Fresh quality milk is received.

Then the milk is sent through stainless steel pipes to large refrigerated vats, then
stored at 5°c or less.
Pasteurisation: This technique heats milk to 72°c for no less than 15 seconds, the
cooled immediately to destroy microorganisms.
Homogenisation: Milk is put under pressure through fine nozzles, which evenly
disperses fat globules.
Centrifugal separation: This removes some or all of the fat cream to make reduced
fat, low fat or skim milk.
Chilling: In chilling process the temperature of milk should be less than 10°c ,
preferably 3 to 4°c.
Skim milk powder: Skim milk is obtained by removing water from pasteurised skim
milk by spray drying.
Finishing storage: The milk were stored in the storage room for some time.
Packing: The milk is sold in flexible packages like pouches.
Cold room: After packaging the milk is stored in the cold room for below 5°c (1 or 2
hours).
Despatch: The milk is ready to sold after stored in the cold room for 1 or 2 hours.

Nutritional values:
Calories - 42 g
Saturated fat - 0.6g
Cholesterol - 5mg
Sodium - 44mg
Potassium - 150mg
Total carbohydrate - 5g
Dietary fibre - 0g
Sugar - 5g
Protein - 3.4g
Vitamin c - 0g
Calcium - 12%
Cobalamin - 8%
Magnesium - 2%

CIP CLEANING:
To use CIP (cleaning in place) there is a condition that the scaling on the plates
is soluble. All materials in the whole circulation system of course have to be resistant
to the cleaning material. The total cleaning time takes around 3 hours.
The cleaning materials should be in such a way that the scaling on the plates
should be removed without damaging plates and gasket. Generally cleaning materials
are: caustic soda and Nitric acid (HNO3).
MILK STORAGE TANK CLEANING PROCEDURE:
STEP 1: Wash the interior of the tank using raw water and after completely cleaned
the washed water is released out.

STEP 2: Now, clean the internal area of the tank with the detergent or caustic soda
using Nylon brush.

STEP 3: Allow the water to enter the tank continuously till the applied detergent is
completely washed out.

STEP 4: Again wash the tank with hot water and release it out.
STEP 5: Apply Chlorine or Iodobar or Nitric acid to the internal surface area of tank
and wash it with water.

STEP 6: After these successive steps fill the tank completely with milk.

DAIRY MAINTENANCE:
Maintenance is a planned service programme. This helps in minimizing major
break down, to operate the plant at design efficiency and also to save energy. This
maintenance work is done by a well experienced serviceman.
 Periodical Inspection and service – Ensure that oil level in the compressor is
proper. Drain oil from the system.
  Check the various pressure, temperature and current drawn by the motors,
analysis the reading if some malfunctioning is indicated, investigate and rectify
the faults.
 Carry out a thorough test for refrigerant leak
 Check operation of all safety and operating controls.
 Check belt tension and adjust. Replace worn out belts.
 Check alignment of belts and drives and rectify where found necessary.
 Check all bearing surface for abnormal heating, check drains for free flow and
clean wherever necessary.
 Check abnormal vibration and noise. Check for tightness of all fastening bolts.
 Check condenser coil for dirt accumulation. Clean if found necessary.
 Check that electrical connections are tight.
 Lubricate all moving parts. The compressor oil however need be changed only
if the condition of oil is bad.
 Check and clean contacts in starters/contactors.
 Cleaning and painting the pipes and equipments.
DAILY AND WEEKLY MAINTENANCE:
 Running and operating maintenance
 Water level in condenser sump and ice bank tank
 Oil level in compressor, log book
 Leak testing for refrigerant leak
 Water pump glands
 Belt tension of belt drives
 Clean water strainers
 Pressure gauge and thermometer
 Check the spray of condenser spray headers
 Clean, refill the sump

BOILER:
Here they use fire tube boiler in which hot gas from a fire through one or
more tubes running through a sealed container of water. The heat of the fire tube is
circulated to the walls of the tubes containing water by thermal conduction, heating
the water and creating steam. It is fully automated and the steam is used for dairy
plant. They have two boiler with 2 ton capacity. In between the two tubes of water the
centre heat is placed.
Fuel used to heat the water is furnace oil. Here ,only soft water is used to avoid
the scale formation. In addition it has PH balancer used to maintain the PH of water.
CONDENSER:
A condenser’s function is to allow high pressure and temperature refrigerant
vapour (Ammonia gas) to condense and eject heat and leads to formation of liquid
during the phase change. By ammonia refrigeration system the water is cooled to 1-
5OC .It is used for washing tank and it is used for pasteurisation purpose as a chilling
section.
There are various tubes in the condenser. To identify it easily yellow tube carries
fluid, the red tube carries gas and the green tube carries water.
MILK PRODUCTS:
The various by products like ice cream, ice candy, milk peda, kulfi, paneer,
flavoured milk, sweet lassi, badam mix powder, buttermilk, curd, ghee, bread and so
on to shine in the competitive market. The processed / manufactured milk & milk
products are stored at required temperature at Dairy and transported to sale points
across Puducherry. The milk and milk products are sold to the consumers around 200
Agents and through 70 Ponlait owned Parlous. For distribution, vehicles are engaged
around ponchicherry. Ponlait kulfi is one of the best product manufactured by
PONLAIT.

KHOA:

For making khoa whole milk is used. The whole milk is transferred in a khoa
plant with 120 liters capacity where it is heated continuously with constant stirring.
The milk is allowed to boil, 60 liters capacity of water present in milk gets evaporated
and remaining solid residue (i.e.) fats are coagulated then sugar is added and leads to
milk peda.
 Then it is transferred in trays and dried at 370C and then packed, stored and
dispatch. In ponlait, khoa is available in 50g, 100g, and 250g. For one batch 60 liters
milk is mixed with 4kg of sugar and gives 14kg of khoa.

Flow chart

60 L Whole milk

Dehydration

Sugar addition (3-4 kg sugar) Sugarless khoa

Drying in trays 37OC Drying in trays

Packaging Packaging

Storage Storage

Dispatch Dispatch

Nutritional value of khoa

Energy value -551.50kcals

Carbohydrates-56.00gms
Fat-26.50gms

Protein-11.00gms

Added sugar-28.00gms

PANEER:

Whole milk is first heated in paneer plant at 80 O C, and then it is brought to 75 O

C.The boiled milk is then filtered in cans by filter cloth , the milk is coagulated by
adding citric acid with a required amount it is mixed using a plunger and whey water
is removed from coagulum and it is placed in a paneer mold and with the help of
hydraulic press it is pressed for 10-20 mins. It is stored , packed and dispatched.

Flow chart

Raw whole milk

Heating to 80 C

Cooled to 75 C
 Filling in cans

Citric acid added (Coagulation)

Filtration Whey separation

Hydraulic press

Packaging

Storage

Dispatch

Process of paneer:

1. Milk standardization: For commercial manufacture of paneer milk is

standardized to 5.8% fat having 9.5% SNF.

2. Heat treatment: After standardization of milk, it is heated to 90°c

without holding in a jacketed closed vessel known as paneer vat.

3. Coagulation and Draining of whey: Coagulation is done at above 70°c

by slowly pouring 1% hot citric acid solution with constant stirring till
clean whey is separated.

Coagulum is allowed to settle for 5minutes after which the whey is drained
off.

4. Hooping: The curd so obtained is filled into hoops lined with cloth.
5. Pressing: Pressure is applied on top of the hoop at a rate of 0.5 to 1
kg/cm2. The surface of hoops must contain holes to facilitate whey
expulsion.

6. Dipping in chilled water: The pressed bocks of paneer are removed

from the hoops and immersed in chilled water for 2-3 hrs. The chilled
paneer is then removed from water to drain out.

7. Packing: Finally paneer blocks are wrapped in parchment paper /

polythene bags and placed in cold room at about 5 to 10°c.

Nutritional values:

Total Fat - 25g

Saturated Fat - 16g

Cholesterol - 88mg

Sodium - 18mg

Total carbohydrate - 4g

Dietary fiber - 0g

Included 0g Added sugars.

FLAVOURED MILK:

Homogenized milk is used to prevent lump formation. First the homogenized milk is
heated and collected in a service tank at 35 o C and there is addition of sugar, colour
and essence like strawberry, pista, badam, it is mixed thoroughly. Now the milk is
ready to be filled in bottles.

Before filling, the bottles are cleaned by jet air pump to remove the dust particles in
bottle then it is passed to conveyer, then it is automatically filled one by one.
Manually the bottles are closed with caps and are pressed by hydraulic press to seal
completely. Then the bottles are sterilized at 105-115 o C for 15-30 mins. This is done
to improve the quality of milk, free from microbes then it is labeled, stored at 37 o C
and dispatched.

The various flavored milk are:

1. Chocolate
2. Strawberry
3. Elaichi
4. Pistachio
5. Badam
6. Rosemilk

FLAVOURED MILK PROCESSING:

SORTING OF MILK: The good quality of milk is used for making flavored milk.

HOMOGENIZATION: This process is done for even distribution of fat globules at

350C and to prevent the formation of lumps. It is collected and stored in service tanks.

ADDITION OF FLAVORS: The addition of sugar, color, and essence like

strawberry, pista, badam are mixed thoroughly with the milk.

BOTTLE FILLING (200ml): The mixed flavored milk is ready for bottle filling.
The bottles are cleaned by jet air pump to remove dust particles. Then passed to
conveyer and it is filled one by one. Manually the bottles are closed with caps.

HYDRAULIC PRESS: The closed bottles are pressed by using hydraulic press at
high pressure.

SEALING: The filled bottles are sealed completely.

STERILIZATION: The sealed bottles are sterilized at 105 0c -115 0c for 15 -30
minutes. This process is done to improve the quality of milk, to prevent the microbial
contamination.

COOLING: The filled bottles are cooled to retain the freshness of milk.

LABELLING: They are labeled with Ponlait logo with nutritive contents.
STORAGE: They are stored at 370C and dispatched.

Flow chart:

Homogenized milk

Addition of flavor, sugar, colour

Bottle filling(200 ml)

Sealing

Hydraulic press

Sterilization at 105-115oC for 15-30 mins

Cooled

Labeling

Storage
 Dispatch

GHEE:

The whole milk is passed into separator where whole milk is separated into skim milk
and cream. The separated skim milk is then dried by spray drying method and made
into SMP- skim milk powder.

The cream is pump to ghee tank (i.e.) kettle at 50-60o C for 4-5 hrs. The cream is
heated continuously with constant stirring at 110-120o C with blender, after it is stirred
the cream melts and ghee is made. They have 1000 liter capacity ghee plant; it is
filtered by sieve filtrate and stored at 37 0C then dispatched. In ponlait, ghee is
available in 100 ml, 200 ml, 500 ml, 1 liter, 15 liter.

CURD:

First the milk is heated at 85-95 o C for 10-15 mins and then cooled to 40-45 o C then
milk is transferred to tanks where it is stored. Addition of culture takes places such as
lactobacillus and streptococcus species at 39-40o C, then it is filled in cups and packets
by automated machine, then it is allowed to ferment in incubation room for 6-7 hrs.
The incubation room consists of heater and room is warm.
Curd processing :
Sorting of milk: Fresh and good quality milk is received and analyzed.

Pre- heating: Done at 30- 40 °C

Standardization of milk: 3% to 5% fat and 10% milk solids are standardized.

Homogenization: Milk is subjected to high pressure for even distribution of fat

globules.

Pasteurization: Milk is heated to 85-90°C for 15 to 30 mins and temperature is

bought down to 3-4 °C.

Pre - heating: Pasteurized milk is preheated to 40-45°C and transferred to inoculation

tank.

Inoculation: Milk is inoculated with 1-2% of starter culture at 37°C. The inoculation
tanks are insulated to maintain constant temperature.

pH: Used to check the development of acidity .

Packaging: The inoculated milk is then packed in separate packets.

Incubation: Milk is incubated at 30-420C for around 4- 5 hrs.

Cooling: Now the curd is cooled for 3-40C with proper settings.

Storage: curd is stored below 60C

Nutritional value of curd :

Calories - 61 kcal

Carbohydrates - 4.7 g
Proteins - 5.1 g

Fats - 3.5 g

Calcium - 121 mg

Iron - 0.1 mg

Phosphorus - 141 mg

Magnesium - 12 mg

Zinc - 0.6 mg

Potassium - 155 mg

Sodium - 46 mg

Vitamin C - 0.5 mg

Vitamin K - 0.2 mg

Vitamin D - 0.1 mg

Flavoring agents of curd :

Lactic acid, acetaldehyde , diacetyl , acetoin , acetone .

Flow chart

Toned milk
 Heating at 80-82o C for 30 mins

Cooled to 40-45o C

Addition of culture strain

Filling in cans

Packaging

Fermentation

Storage

Dispatch

BUTTERMILK:

Processing of Butter Milk :

Sorting: Fresh and good quality milk is received and analyzed.

Starter culture: Starter culture such as lactic acid bacteria is prepared

and added.

Standardization of milk: Helps to standardize solid fat contents.

Heat treatment: This process is to ensure the destruction of pathogens

and to make the product safe for human consumption. Milk is heated
above 88°C.
 Cooling: Milk is cooled for 22- 25°C. It must be cooled down to
inoculation temperature.

Inoculation: Milk must be inoculated with appropriate starter culture.

Inoculation rate varies from 0.5 - 2.0 %.

Incubation: The typical incubation temperature of milk is 21.6°C .

Agitation: Gentle agitation is required to break curd and to have efficient

and quick cooling.

Dilution: Dilution is done to adjust the solid level to desired level.

Packaging: The resultant butter milk is packed in separate packets. Bottle

or carton packaging material is used.

Storage: Butter milk is stored in such a way to avoid the microbial

growth.

Nutritional value of Butter Milk :

Calories - 40 kcal

Fat - 0.9 g

Cholesterol - 4 mg

Proteins - 3.3 g

Sodium - 105 mg
Potassium - 151 mg

Magnesium - 2 %

Calcium - 4%

Vitamin C - 2 %

Riboflavin – 29%

Flavoring agents of Butter Milk : Lactic acid and diacetyl .

Flow chart

Toned milk

Heating at 80 C

Cooled to 40-45 C

Addition of culture strain

Fermentation
 Storage

10 L curd +200 ml extract+ 200 g salt+ 30L chilled water

Mixed with plunger

Filtration

Filling

Packaging

Storage

Dispatch

KULFI:

Whole milk is transferred in kova plant where it is heated and condensed to 60 liters.
Now 37 kg sugar, 3kg kova and 1kg cashew, 20g badam mix powder is added to milk
and completely mixed and is transferred into cans, and then aging is done. The
mixture is poured into molds and sticks are inserted followed by freezing, storing and
dispatch.
ICE CREAM:

In mix preparation tank cream and pasteurized toned milk (250 ml) is heated to 50 o C
for 5 mins. Then addition of 62kg sugar, 90 kg skim milk powder at 60 o C , stabilizer
powder at 70o C, 70 kg cream is added and then chilled at 6 oC. Aging is done, then
transferred to flavoring tank where addition of color and flavor takes place , it is
freezed at -28o C and stored at -18o C and dispatch.

Flow chart

Cream + Pasteurised toned milk

Heating

Addition of sugar+ SMP+ Stabilizer

Mixing

Chilling at 6 C

Aging

Flavoring tank

Addition of colour and flavor

Freezing
 Ice cream extrution at -3 to -5 C

Packaging

Storage at -18 C

Dispatch

AMUL ICE CREAM PRODUCTION:

The majority production in ponlait industry is Amul ice-creams. They

are prepared in certain amount of ratios and proportions. Here they are
manufacturing eight variants of ice-creams with different flavors. The main
ingredients used are water, sugar, glucose, corn syrup. The different types of
ice-creams include candies, kulfi, Choco bar, stick varieties. Gravitation and
injection method of fillings are used to fill the ice-creams. Gravitation method
is used to fill candies, Injection method is used for filling Choco bar and kulfi.
The processed ice-creams are then moved to a stick injector and microfilling
process. The production of ice-cream per hour is 2600 pcs. For completion of
one round it takes 8 minutes. In Choco bar processing the ingredients such as
dark chocolate, milk chocolate, Choco butter, Choco soya, and coconut oil are
used. The ice-creams are labeled and packed. They are stored in cold room at -
5 0c and dispatched.

BADAM MIX POWDER:

The badam mix powder is prepared by addition of 48kg sugar, 4.5kg badam and nuts,
6.5kg milk powder, 600g cardamom, 1.5kg corn flour powder, 0.35g of yellow color
and mix it well and are filled in a container, packed , storage and dispatch.

Nutritional value of badam mix:

1. Fat - 4.0

2. Protein - 5.5

3. Carbohydrate- 67

4. Sugar

Ingredients of badam mix:

Sugar -48kg

Nuts-4.5kg

Milk powder -6.5kg

Cardamom-600g

Corn flour powder - 1.5kg

Yellow colour- 0.35g

TRAY WASHING UNIT:

There are two types of tray washing unit one is for milk packet tray and
another is for ice cream basket tray. Ice cream and other products are collected in
large trays and stored; these trays are washed in series of process in different machine
whereas small trays used for storing milk, curd are washed separately. The series of
steps include:

 Pre rinse
 First rinse
 Hot detergent rinse
 Hot water rinse

EFFLUENT TREATMENT PLANT (ETP) :

ETP (Effluent Treatment Plant) is a process design for treating the industrial
waste water for its reuse or safe disposal to the environment, it is used for removal of
high amounts of organic compound, debris, dirt, toxic, non-toxic material, polymers
etc. The chemical process involves the addition of certain chemicals to improve the
quality of wastewater

COLLECTION TANK- It collects effluent water from screening chamber, stores

and then pumps it to the equalization tank.

AEROBIC DIGESTER- It is a process of degradation of organic sludge in presence

of oxygen, where the sand, fat separates down and water is separated.

PRE-AERATION TANK- It helps in soften the water.

AIR BLOWER AERATION TANK- In this process where the enzymes, sugar are
added. If the bacteria are died there is a change in color
TREATED WATER- After all these process the water is collected to the treated tank
where the treated water is present, this treated water is used for irrigation of plants,
and also for animals.

ETP PLANT LAYOUT:

Dairy effluent Equalisation Scum removal

Dairy Effluent
tank tank

Aerobic Collection Oil skimmer tank

Digester tank

Air blower Aeration Sludge Drying

Pre aeration tank
Tank Bed

Multi Media Treated water

Settling Tank
Filter Tank

TREATED WATER

LABORATORY TESTS:
There are various steps involved in testing of milk and milk products. The samples are
collected from the raw chilled milk tank and were tested, and stored in the storage
tank. The steps include:

 Temperature
 COB Test (clot on boiling)
 MBRT Test (Methylene Blur Reduction Test)
 Acidity
 Fat
 PH
 SNF
 Alcohol Test
 Heat Stability
 Adulteration
 Preservation
 Aflatoxin & Antimicrobial agent

COB Test:

COB test is done to check the heat stability of milk during processing. It is used
to determine if sample tested is too acidic or not.

COB test is done by taking 5ml of milk sample in test tube and place it in
boiling water bath for 5 min, remove the test tube from water bath. Note the smell,
observe and record the sample. If the sample is positive(+) then such milk is
rejected, if the sample of milk is negative (-) it is good and suitable for further
processing.

MBRT (Methylene Blue Reduction Test):

MBRT test is used as a quick method to assess the microbiological quality of

raw and pasteurized milk. This test is that the quality of the milk is determined by
observing the color that appears in the milk after addition of dye like methylene blue.
Because methylene blue is a redox indicator, which loses its color when it comes
under the effect of lack of oxygen.
 The test has to be done under sterile conditions. Take 10 ml milk sample in
sterile MBRT test tube. Add 1 ml MBRT dye solution, Stopper the tubes with
sterilized rubber stopper and carefully place them in a test tube stand dipped in a
serological water bath maintained at 37⁰C. If color changes from blue to colorless,
time taken to change the color are noted, the change is color is due to the microbes
present in the milk.

Using lactometer it is used to detect the density or thickness of milk.

ACIDITY:

PH level is below neutral at about 6.7 to 6.9. This is because it contains lactic
acid.

10ml of milk is taken and add 1.0 ml of the phenolphthalein indicator using
1ml pipette. Titrate the contents with sodium hydroxide (NaOH) solution stirring the
contents. Observe occurrence of pink color as end point for the titration.

HEAT STABILITY:

10 ml of milk and 0.5ml of HCL for whole milk and 0.6 ml of HCL for
sterilized milk, 5th should be negative, here water is heated at 80-90O C. Acid is used
to check the heat stability.

ALCOHOL TEST:

5 ml of milk 68% ethanol and are freezing point depression should be 500 it
indicates water is added. If the tested milk is of good quality, there will be no
coagulation, clotting or precipitation. Presence of flakes or clots indicates poor quality
milk.

ADULTERATION:
 Some of the adulteration added in milk like sucrose, salt, urea, milk powder,
maltose, starch, ammonia sulphate. To detect the adulteration in milk Lactoscope FT-
A is used to detect adulterants in Raw chilled milk. Some of the major adulterants in
milk having serious adverse health effect are urea, formalin, detergents, ammonium
sulphate, boric acid, caustic soda, benzoic acid, salicylic acid, hydrogen peroxide,
sugars and melamine.

Neutralizers are chemical substances, which are alkaline in nature. They are
added to milk in order to regulate the acidity of milk. In milk, sodium hydroxide,
sodium carbonate and sodium bicarbonate are added by adulterators to neutralize the
developed acidity in milk. It decreases the acidity in milk.

AFLATOXIN:

Aflatoxins are mycotoxins produced by some species of Aspergillus. In dairy

cows, ingested AF is metabolized into carcinogenic, which is eliminated through milk,
thus posing a risk for consumer health. Molds growing on agricultural products
produce toxic substances, generally called mycotoxins, some have mutagenic or
carcinogenic effects, others are toxic for specific organs, and others still pose health
risks owing to the effects they can have on an organism.

Some preservative are added like hydrogen peroxide (H 2O2 ) is widely used to
inhibit microbial growth and milk spoilage. It is been evaporated during processing.

SNF (Solid not fat):

To find SNF by using a Richmond’s formula:

SNF = CLR / 4 + 0.2 X fat + 0.36

CLR – Correct lactometer reading

SNF – solid not fat

EXAMPLE FOR CALCULATE THE SNF :

Toned milk contain 3.0% fat and 8.5% SNF

Whole milk contain 4.0% fat and 8.5% SNF

To find the skim milk content:

5000 X 3.0 / 4.0 = 3750 kg of whole milk

5000 – 3750 = 1250 kg skim milk

To find the percentage of cream:

1250 X 4.0 / 70 % = 71.4 kg cream