Mechanized Production of Traditional Indian Dairy Products:

Present Status, Opportunities and Challenges

Sunil Patel and A. G. Bhadania
Department of Dairy Engineering, SMC College of Dairy Science, AAU, Anand-388110.
Email: drsunilpatel.de.dsc@gmail.com

India is number one producer of milk in the It is high time that concerned efforts are made by
world, with an average production of 128 Million the experts and scientists to formulate value added
Tones per annum in 2012; out of this about 50- dairy products with engineering interventions
55% of the total milk production is converted of innovative design of equipment to produce
into traditional milk products, which is mainly hygienic products with economy of processing.
confined to the cottage scale in the non-organized The commercial large scale production of Value
sector. With the rapid growth of dairy industry in added dairy products with very good hygienic and
our country, the technology and design of process sensory properties has necessitated sincere efforts
equipment has also undergone needed changes for innovations in the designing of equipment for
and equipment for making indigenous products the manufacture of Value Added Dairy Products.
are no exception. The small-scale technology for
With the rapid growth of dairy industry in our
the preparation of indigenous products cannot be
country, the technology and design of process
exploited for industrial production.
equipment is also undergoing changes. The small-
Technical Articles

India has made substantial growth of urban and scale technology for the preparation of indigenous
semi-urban areas. As a result, increasing number products cannot be exploited for industrial
of persons in the cities is desirous of purchasing production, therefore innovations in the designing
quality milk products and milk-based sweets. of equipment for the manufacture of value added
The small scale techniques used at present for dairy products is the need to have premium
the preparation of value added Traditional Indian prices for the locally produced high quality value
Dairy Products (TIDP) can not be adopted for added dairy products. One of the strategies to
industrial production. The current method for enhance our presence in world dairy market is
the manufacture of indigenous dairy products are to promote R & D of value added quality dairy
based on the techniques that remained unchanged products besides improving the traditional dairy
over ages. Regardless of the volume of the products by innovative techniques, designing of
production, they are manufactured primarily in equipment and mechanization for the manufacture
jacketed kettles, which inherently suffers from of value added dairy products. India also needs to
several disadvantages, where possibilities to develop innovative dairy products and modernize
control and optimize heat treatment processes manufacturing of traditional dairy products. The
are very limited. The equipment employed at the value addition of milk is an important aspect to
cottage level is enlarged for the industrial level of be looked into by the dairy engineers, scientists
operation. Consequently inefficient use of energy, and technologists. India has developed various
poor hygiene, sanitation and non-uniform product innovative indigenous technologies over the
quality associated with rural scale operation centuries, to preserve milk in the form of value
crept into large-scale manufacture due to the added products. India can be a lead player to
non-existence of processing equipment based on command the value added dairy products in the
advanced techniques of production and sound global market by introducing innovations in the
engineering principles. This has necessitated the designing of equipment for manufacture of value
need for innovations in designing of equipment added dairy products. It also helps in opening new
for the manufacture of value added dairy products. frontiers for indigenous dairy products through

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mechanization and innovations in designing of of a steam jacketed S.S. conical vat with a cone
equipment to have exciting opportunities for angle of 60 degree. More (1987) developed an
development of the rural economy of India. equipment which consists of a stationary jacketed
drum having steam inlet, condensate outlet through
Present Status of Mechanized Manufacture steam trap and pressure gauge. A prototype khoa
of Traditional Indian Dairy Products making machine of mild steel working on the
principle of SSHE has been successfully developed
A variety of traditional milk products are by Christie and Shah (1988). Sunil Patel (1990)
manufactured in India with most of them are region has studied heat transfer performance of scraped
specific. The making of traditional milk products surface heat exchanger during khoa making.
has essentially been a cottage scale enterprise
within the basic process of their production, In order to overcome drawbacks of traditional
variations exist from one unit to another that give method of khoa making, such as limited capacity,
products their distinctive touch, taste and flavour. lot of time and labour requirement and necessity
Now, technologies for mechanized production to clean pan between batches, Banerjee et al.
of these products on industrial scale are being (1968) designed and developed an equipment for
standardized. continuous khoa making. The method for production
of khoa with this machine was standardized by
Conventional methods of manufacture of De and Singh (1970). Rajorhia and Srinivasan
Traditional Indian Dairy Products has inherent (1975) made improvements in the design of this
disadvantages such as inefficient use of energy, plant by replacing mild steel with stainless steel.
poor hygiene, fatigue on the operator, non-uniform Punjrath et al. (1990) have developed an inclined
product quality etc. In order to overcome these scraped surface heat exchanger for continuous
inherent disadvantages, attempt have been made khoa making. Dodeja et al. (1990) have described

Technical Articles
for mechanization of the process to develop batch, a continuous khoa making equipment operating
semi-continuous, and continuous equipments on the principle of thin film scraped surface heat
for manufacture of these products on large and exchanger. Christie and Shah (1992) studied the
commercial scale. feasibility of manufacturing khoa using scraped
Khoa is an indigenous milk product prepared by surface heat exchanger. Dodeja et al. (1992)
concentration of milk and is widely used in India developed a continuous khoa making system
and in neighboring countries as a base material for which consists of two SSHE equipped with scraper
preparation of numerous sweets like penda, burfi, assembly. Bhadania (1998) has developed three
gulabjamun, kalakand, etc. Generally three main stage continuous khoa making machine based
types of khoa namely pindi, dhap and danedar on principle of scraped surface heat exchanger
are recognized which differ mainly in body and and has studied heat transfer performance of the
texture characteristics and are required for specific machine.
types of sweets. Mechanization of manufacture of khoa based
Rajorhia (1971) attempted a semi-commercial sweets like penda, halwa (Gajar Halwa, Dudhi
process of khoa making using jacketed steam Halwa) is tried using Batch type Stainless Steel
heated stainless steel kettle with built-in-stirrer. Version of SSHE developed at SMC College of
Khoa making unit suitable for village level Dairy Science, Anand Agricultural University,
operation has been developed by Sawhney et al. Anand. The process parameters are optimized for
(1980) to overcome some of the problems faced in and the product was compared favourably with
traditional method of khoa making. More (1983) products made by conventional method in the
developed a prototype khoa making machine sensory and rheological profile, with better score
working on the principle of SSHE and it has been and colour (Upadhyay et al., 1993). Jain (2010)
claimed to perform satisfactorily on small and manufactured ‘Lauki Halwa’ & ‘Carrot Halwa’
medium scale production. Agrawala et al. (1987) using batch type multi purpose SSHE developed
developed a conical process vat which consists at SMC College of Dairy Science, AAU, Anand,

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215
 and studied its heat transfer performance. A tried at NDRI, Karnal, using conical process vat
mechanized method of manufacture of burfi was and two-stage thin film SSHE with standardized
developed by Palit and Pal (2005). Khojare and buffalo milk. ‘Basundi’ prepared in conical process
Kumar (2003) standardized the parameters for vat, was good in body, texture, appearance and
Burfi making in Conical Process Vat (CPV) from overall acceptability for processing time between
Khoa. Pre-weight khoa obtained from Thin Film 80 to 100 min. (Agrawala et al., 1987a, More,
SSHE was loaded in the CPV. 1987, Ranjeet, 2003, Dodeja et al., 2004). Patel
et al, (2007) developed a mechanized system for
A mechanized semi-continuos system is adopted
Continuous Basundi Machine (CBM) based on the
for the manufacture of gulabjamun from khoa at
principle of thin film SSHE. Batch type Halwasan
Sugam Dairy, Baroda (Banerjee, 1997). Efforts
makimg Machine (BHM) is designed at SMC
have been made to develop a commercial method
College of Dairy Science, Anand Agricultural
for manufacture of Rabri employing SSHE for
University, Anand.
concentration of buffalo milk, and addition of
shredded chhana/paneer in place of clotted cream Panner and Chhana are two prominent traditional
to provide the desirable texture to the final heat and acid coagulated milk products of India.
product (Gayen and Pal, 1991 b). Pal, et al., Mechanized processes for industrial production of
(2005) successfully developed a technology for these products has been developed. Significant R &
the large scale production of Rabri using thin film D at National Dairy Development Board (NDDB),
scraped surface heat exchanger (TSSHE). Jain National Dairy Research Institute (NDRI) and
(2010) manufactured ‘Kheer’’ using batch type several agricultural universities has resulted in to
multi purpose SSHE, and studied its heat transfer optimization of processing variable for mechanized
performance. The Industrial mechanized method production. Different workers made successful
of converting khoa into Kesar Peda had been attempts to mechanize the production process of
Technical Articles

developed at National Dairy Development Board rasogolla. Choudhury et al. (2002) developed
(NDDB), Anand. a prototype mechanized unit for kneading of
chhana and chhana ball-forming in a continuous
Patel et al. (2005) made Basundi by open pan
manner. Recently, Karunanithy et al. (2007a,b &
concentration using steam jacketed kettle and
c) also tried to mechanize these unit operations
products were evaluated for their proximate
in rasogolla making for its continuous production.
composition, physico-chemical properties and
Kumar and Das (2003) optimized the processing
sensory attributes. Three pilot models viz.
parameters viz. mixing, kneading and cooking of
cylindrical type, conical type, and Karahi type were
chhana and sugar mixture for the mechanized
developed for Basundi making on the principle
production of sandesh from cow milk. Kumar and
of scraped surface heat exchanger (SSHE). All
Das (2007) subsequently developed a single-screw
the models were tested for Basundi making and
vented extruder for cooking of chhana and sugar
their heat transfer behaviour at different operating
mixture that can be integrated with the mechanized
conditions. Heat transfer and energy consumption
method for the continuous production of sandesh
were estimated for design optimization and to
from cow milk.
generate information for optimum operating
conditions of the machine (Rajasekhar, 2001). Fermented milk constitutes a vital component of
Mechanization of manufacture of Basundi is human diet in many regions of the world. In the
tried using Batch type Stainless Steel Version Indian sub-continent also, fermented milk products
of SSHE developed at SMC College of Dairy such as dahi (curd), lassi and butter milk figure
Science, Anand Agricultural University, Anand. prominently in people’s diet. Many organized dairies
The process parameters are optimized for and the are now preparing dahi adopting mechanized and
product was compared favourably with products standardized method (Singh, 2005). Kumar and Pal
made by conventional method in the sensory and (1994b) studied the suitability of reverse osmosis
rheological profile, with better score and colour (RO) concentrates for the manufacture of dahi
(Patel, 2006). Manufacture of ‘Basundi’ was and reported that the quality of dahi made from

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216 216
1.5-fold RO concentrates was highly satisfactory. Design and Development of Equipments
The technology for the manufacture of misti dahi for Value Added Traditional Indian Dairy
in an organized manner was developed by Ghosh Products at SMC College of Dairy Science,
and Rajorhia (1990). Industrial process with AAU, Anand
mechanization is developed for manufacture of
Lassi. Extension of shelf life of lassi is achieved SMC College of Dairy science, Anand Agricultural
by ultra high temperature (UHT) processing University, Anand has designed and developed
of product after fermentation and packaging several equipments for mechanized production
it aseptically. Aneja et al. (1989) developed a of value added Traditional Indian Dairy Products
method for manufacture of long-life lassi that does (TIDP), like Basundi, Kulfi mix, Kheer, Khoa,
not settle down over extended storage in aseptic Peda, Thabdi, Burfi, Gajar Halwa, Dudhi Halwa,
packs. Kumar (2000) developed lassi for calorie- Halwasan etc. with better hygienic, rheological
conscious and diabetic people using an artificial qualities and improved shelf-life at lower cost of
sweeteners. Recently, Khurana (2006) developed processing. The mechanized production of value
suitable technologies for the manufacture of added dairy products will give the following
advantageslike (i) Economic production (ii)
mango, banana and pineapple lassi along with
Uniform quality of the product (iii) Hygienic
their low-calorie counterparts using artificial
production and better keeping quality (iv) Scale-
sweeteners. A fully mechanized/continuous process
up production (v) Less laborious process (vi)
has also been developed for industrial production
Less energy consumption (vii) Better control over
of Shrikhandd (Aneja and Vyas, 1983). Dhotre
the process parameters to maintain rheological
(2006) developed and studied the performance of
and sensory attribute (viii) Promotes export of
SSHE for continuous thermization of Shrikhand.
traditional Indian products like Basundi, Kulfi mix,
Shrikhand was thermized at different operating
Kheer, Khoa, Peda, Thabdi, Burfi, Gajar Halwa,
conditions like temperature, scraper speed, and TS

Technical Articles
Dudhi Halwa, Halwasan etc. through small and
level in Chakka.
medium entrepreneurs. These innovations in
Punjrath (1974) developed a prototype continuous designing of equipment for the manufacture of
ghee making plant of 100 kg/h capacity on the value added TIDP will help in commercialization
principle of flash evaporation using butter as base and to promote small entrepreneurship through
material. In another process Abichandani et al., Public Private Partnership (PPP), for the benefit of
(1995) a thin film scraped surface heat exchanger the society to get hygienic and best quality value
(TFSSHE) attached with a butter melter for added dairy products.
continuous manufacture of ghee. Recently, Patel
et al. (2006) developed an industrial method (A) Continuos Basundi Making Machine
of ghee making with an aim to reduce fat and
‘Continuous Basundi Making Machine (CBM)’
SNF losses by inclusion of serum separator and
is designed at SMC College of Dairy Science,
a spiroheater. NDRI has perfected continuous
Anand Agricultural University, Anand, based on
equipment for manufacture of 500 kg ghee per
the principle of Scrap Surface Heat Exchanger
hour (Abhichandani, 1997). This equipment is
(SSHE). It is consists of concentration unit of
integrated with an efficient butter melter developed three SSHEs and chilling units of two SSHEs with
at NDRI. specially designed scrapers, Variable Frequency
Indian Kulfi is a popular frozen dessert of Indian Drive (VFD) to facilitate variation of speed of
origin produced by freezing a mix obtained from scrapers, Resistance Temperature Detector (RTD)
concentration of milk and sugar (like Basundi). sensors and other controls to optimize processing
Patel (2013) has developed batch type basundi parameters, which results in to better quality
kettle and integrated plant for Traditional Indian product in terms of sensory and rheological
Dairy Products and has prepared basic Indian attributes. Standardization of mechanized
Kulfi mix using both and prepared Indian Kulfi production of ‘Basundi’’ in terms of manufacturing
with better Rheological and sensory quality. techniques, sensory profiles, and compositional and
physico-chemical attributes is done for attaining a

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217
 product of uniform standard and assured quality. This integrated plant is suitable for mechanized
The method of hi tech production of ‘Basundi’, production of value added Traditional Indian Dairy
using ‘Standard Process’ and ‘Continuous Basundi Products like Kulfi mix, Basundi, Kheer, Khoa,
Making Machine’ offers several advantages over Peda, Thabdi, Burfi, Gajar Halwa, Dudhi Halwa,
traditional method of Basundi making. Halwasan etc. The mechanized production of TIDP
has better control over the processing parameters
(ii) Batch type Halwasan making Machine to have hygienic production with better rheological
quality of processed product. It also helps to
‘Batch type Halwasan makimg Machine (BHM)’ overcome the limitation of traditional method of
is designed at SMC College of Dairy Science, manufacture like inefficient use of energy, poor
Anand Agricultural University, Anand, with hygienic conditions, non-uniform product quality,
funding support of ‘Business Planning and intensive labour, small scale production etc. The
Development Unit-Anand Agricultural University. processing cost of mechanized production of TIDP
Standardization of mechanized production of using this plant is almost half than the cost of
‘Halwasan’’ in terms of manufacturing techniques, processing of conventional method of production.
sensory profiles, and compositional and physico- The mechanized production of such TIDP, will
chemical attributes is done for attaining a product help in commercialization and to promote small
of uniform standard and assured quality. Halwasan entrepreneurship through Public Private Partnership
prepared by using Batch type of Halwasan making (PPP) to improve the socio-economical status of
Machine (BHM), is very good in hygienic quality milk producing farmers. The technology develop
as well as rheological attributes, having average with mechanization would benefit both the
sensory score of 92/100 as compared to sensory milk producer and consumers and will promote
score 88/100 of Halwasan made by traditional/ entrepreneurial development by fetching the higher
Technical Articles

conventional method. The cost of processing in price of value added products.

BHM is almost half than conventional method. The
keeping quality at room temperature of Halwasan Commercialization of Machines Developed
made by using BHM is 20-22 days compared to
AAU BPD Unit is commercializing equipments
keeping quality of 8-10 days of Halwasan made developed to promote small entrepreneurship
by conventional method. The profit margin is through Public Private Partnership (PPP).
around 90-100%. Continuous Basundi making Machine and Batch
type of Halwasan making machine is kept in AAU
(iii) Integrated Plant for Traditional Indian BPD Unit basket for its commercialization. MoU
Dairy Products is also signed with ‘Panchamrut Dairy, Godhara,
for mechanized production of khoa using
Integrated Plant for ‘Traditional Indian Dairy
the machines developed at Dairy Engineering
Products’ is designed and developed at Dairy
Department, SMC College of Dairy Science,
Engineering Department, SMC College of Dairy
AAU, Anand, resembling taste of khoa made
Science, AAU, Anand, under AAU-BPD Unit-
by traditional method in karahi. We have also
ICAR-NAIP-I Project. The Plant is designed for
received many inquiries from the entrepreneurs
mechanized production of TIDP, having capacity
for mechanized production of Halwasan, Burfi,
of handling 250 kg of milk per hour. The plant
khoa & Kulfi mix.
is consisting of three basic units (i) Plate Heat
Exchanger (PHE), (ii) Twin Cylinder Thin Film
Scraped Surface Heat Exchanger (Twin SSHE) Opportunities
and (iii) Batch type Steam Jacketed Kettle. India’s traditional dairy sector is poised to have
Patent filing for the plant and standard process rapid expansion hopefully with the innovations in
of mechanized production of Basundi, Halwasan, technology, equipments for mechanized production,
Kulfi mix and Sandesh using this integrated plant packaging and storage. The major strength of the
is in process. TIDP is the mass appeal enjoyed by such a wide

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218 218
variety of products. The operating margins are also to develop energy efficient new equipment for
much higher, mainly due to lower raw material manufacture of various TIDP. The possibilities
cost. They can do wonders for organized sector to of utilizing alternative sources of energy in
have better financial stability and steady growth manufacture of TIDP should be exploited, wherever
possible. Great scope also exist for improving the
Challenges shelf life of TIDP by employing newer preservation
techniques. Industry and R & D organizations
In spite of several innovative efforts made in links need to be strengthened. Collaborative
the mechanization of manufacture of indigenous efforts of industry, unorganized sector, equipment
dairy products, adoption of these innovations manufacturer and R & D institutions are required
by the industry is very limited. Development for all round development of this sector.
of new equipments for a variety of traditional
milk products is a time consuming exercise
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Technical Articles
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 Sector” oral presentation in National Seminar for Sustainable Rural Development’
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India Under Changing Global Economic Engineers, at Tamilnadu Agricultural
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K. Nagar, Gujarat.
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Sunil Patel; Bhadania, AG.; Shah, BP.; Rajsekhar,
Shah, US. (1993). Manufacture of khoa
T; and Solanki, MJ. (2006). Engineering
based sweets and other food products on
Intervention in Economical Production of
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the Souvenir on 40th Annual Convention & encouraging experience. Indian Dairyman,
symposium of Indian Society of Agricultural 45(6):224- 227.
Engineers (ISAE), on ‘Energy Management www.nddb.org
Technical Articles

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