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INTRODUCTION

The Kaira Distt. Cooperative Milk Producers Union selected the brand name AMUL for its product range in 1955.

It is derived from the Sanskrit word "AMULYA", which means Priceless / Precious.

AMUL is a successful cooperative sector & proud of INDIA & also of whole world.

General Information

Full Name Kaira Distt. Cooperative Milk Producers Union ltd.

Date of registration December 14, 1946

Different units of AMUL Dairy plant- Anand

Kaira Satellite Dairy-Khatraj

Food Complex- Mogar

Amul Satellite Dairy, Pune.

Chilling centers Balasinor, kapadwanj,

Khambhat, Khatraj. Total no. of society 1085 Average collection of milk 10-12 LLPD – Lean season 12-15 LLPD – Flush season Installed Capacity 15 LLPD Awards of AMUL

Best Productivity Award – 1987, 1988, & 1989. Indian Merchants Chamber Award for outstanding contribution towards Food Processing

Industry – 1989. Special Award for sustaining Productivity Performance – 1990 & 1996. ICA Memento Award toward genuine & self substaining cooperative world wide – 1992. GD Birla Award for outstanding contribution in Rural Upliftment – 1996. Shahakari Vikas Ratna Award – 2005.

HISTORY AND DEVELOPMENT 1929 : Shri Pestonji Edulji Polson established Polson Model Dairy at Anand to manufacture butter, ghee and casein. 1944 : Inauguration of Bombay Municipal Corporation Milk

Supply. Monopoly rights were awarded to Polson for Procuring milk from Kheda.

01-04-1945 : Government of Bombay took over the Administrative control of milk supply scheme and established the Bombay Milk scheme.

04-01-1946 : Meeting of milk producers of Kheda District at village Samarkha precided over by Shri Morarjibhai Desai who Decided to organize Co-operative Societies.

26-10-1946 : Collection of milk started and supplied to Polson Model

Dairy for processing.

14-12-1946 : The Union gets registered (Certificate no.P-330/1946)

31-10-1949 : Local sale of milk started by the Union through milk Consumers co-operative society, Anand.

01-01-1952 : Government cancelled contract with Polson Dairy. Work was given to the Kaira Union.

14-10-1952 : Rajendra Prasad, President of India inaugurated the first . mobile dispensary of the Union for treatment of animals.

15-11-1954 : Foundation stone laying ceremony was performed by Dr. Rajendra Prasad for construction of Dairy. 31-10-1955 : Opening ceremony of the dairy was performed by P.M. of India, Shri Jawaharlal Nehru. 31-10-1960 : Opening ceremony of the extension wing of Dairy was performed by Shri Morarjibhai Desai. 31-10-1964 : Opening ceremony of cattlefeed factory was performed by Shri Lal Bahadur Shastri. 31-10-1971 : 25th Annual Day was celebrated under the president ship of Morarji Desai and Governor of Gujarat.

October 1973 : Production of high protein food and chocolate started at Mogar Complex.

31-10-1973 : 27th Annual Day was celebrated, A farewell to Shri Tribhuvandas and Dr. V. Kurien was also arranged on the Same day.

Feb. 1976 : Production of Nutramul started at Mogar Complex. 03-09-1981 : 2nd plant of cattlefeed factory at Kanjari was started. 11-09-1985 : Successful completion of the co-generation project when 2 gas turbins generators of 1.5 MV each, based on Nutramul gas was commissioned. 22-03-1986 : Shri Rajiv Gandhi, Prime Minister of India visited the Union the flagged off the special milk train to Calcutta. 31-10-1992 : The foundation stone of the New Dairy Plant (Amul III) was laid by Dr. V.K. Kurien, Chairman, NDDB. 02-02-1994 : The foundation stone laying ceremony of Cheese Manufacturing PPlant was performed by Dr. V. Kurien. 1996 : GD Birla Award for outstanding contribution to Rural up liftmen by Birla Academy of Art & Culture given by Shri K.R. Narayan, Vice President of India. 23-11-1996 : Special award for sustaining productivity performance awarded to Kaira Union by Shri H.D. Deva Gowda, Prime Minister of India.

AMUL SYSTEM

WHY DID THE AMUL SYSTEM SUCCEED?In the old system of middlemen the guiding principles were: lowest possible price to the milk producer, highest possible price to consumer, and lowest possible quality of milk and milk product for sale. The middlemen pocketed the profits.

Under the Amul system the reverse held well: highest possible price to the milk producers, lowest possible price for the consumer and highest possible quality of milk & milk products for sale. The profits were used for the milk producers' welfare.

The system was a two-tier one. The village society was concerned mainly with the purchase of milk from producers; it also acted as a channel for milk production enhancement schemes.

The District Union looked after policy formulation, processing and marketing of milk and provision of technical inputs to enhance milk production in animals like artificial insemination service, veterinary care, better feeds, etc.

The system is same now, except for a third tier: a Federation: an apex co-operative of district unions for marketing.

ORGANIZATION STRUCTURE

MANAGING DIRECTOR

↓GENERAL MANAGER

↓ASST. GENERAL MANAGER

↓MANAGER

↓DY. MANAGER

↓SUPERINTENDENT

↓DY. SUPERINTENDENT

↓SENIOR OFFICER

↓ASSISTANT

↓JR. ASSISTANT

CERTIFICATIONHACCP and ISO

Amul has achieved HACCP and ISO22000-9001 certifications. These standards are basically implemented at each and every stage of processing from farm to home. The uses of these standards are as follows –

1) The standards protect the consumers from the hazards of adulteration and help the industry to produce safe, hygienic and healthy products.2) The standard in manufacturing promotes efficiency and quality assurance, minimizes wastage, increase production and profitability.3) Standards ensure optimum utilization of scarce resources.

HACCP

HACCP (Hazard Analysis Critical Control Point) systems are a systematic approach in preventing hazards that may harm a consumer, from occurring or developing during the course of food production.

Role of HACCP

HACCP was originally developed during NASA's Apollo programme in the early sixties. The objectives was to ensure that astronauts who spent extended periods in space would not be exposed to any food borne hazards especially microbiological, thereby jeopardizing their personal safety as well as the success of the space programme. HACCP implemented first time in food products on 1971.

ISO Certifications

The international organization for standardization (ISO) is a worldwide federation of national standards bodies from some 140 countries, one from each country.

ISO is non-governmental organization established in 1947. The mission of ISO is to promote the development of standardization and related activities in the world with a view to facilitating the international exchange of goods and services, and to developing cooperation in the spheres of intellectual, scientific, technological and economic activity.

It also defines basic and fundamental terms relating to quality concepts applicable to production and services.

"ISO" is a word, derived from the Greek word "ISOS", meaning, "equal". ISO organization is a company, firm, and institution, corporation that has its own functions and administration.

Amul is India's most successful & first cooperative movement who has achieved ISO-22000:2005 certification that is highly recognized achievement for any unit in term of quality assurance & food safety.

Amul has introduced a changed management process where field staffs are encouraged to become consultants rather than supervisors, facilitators rather than decision-makers, trainers rather than doers.Because of this research and developing units of Amul that has made it comply all the regulations of the ISO certifications.

INTRODUCTION TO ISO22000:2005

As ISO 22000:2005, food safety management system- Requirement for any organization in the food chain is an industry standard which, for the first time:

1. Is internationally formulated & will be internationally recognized;

2. Is application for all organization through & and across the food supply chain;

3. Embodies and maintains the codex Alimentarius HACCP principle;

4. Is a full food safety management system – Exceeding the requirement of HACCP

ISO22000 is the first in a series, or family, of standards that will include the following;

ISO/TS 22003, FSMS- Requirement for bodies providing audit & certification of FSMS will give harmonized guidance for the accreditation (approval) of ISO 22000 certification bodies & define the rules for auditing a FSMS as conforming to standards.

ISO/TS 22004, FSMS-Guidance on the application of ISO 22000:2005, provides important guidance that can assist organization including small & medium size enterprises around the world.

ISO 22005, Traceability in the feed & food chain – General principles and guidance for system design & development.

ISO 22000 Structures:

The following diagram broadly identifies the concept covered in ISO 22000.

Management System Elements↓

HACCP Principle (Codex Alimentarius)↓

Good Manufacturing Practices

CONCEPT OF AUTOMATION

Automation means that all action required operating a process with optimal efficiency are ordered by a control system on the basis of instructions that have been fed into it in the form of a control programmed.

Programmable logic control (PLC) The PLC which controls the automated operation of plant areas, with sequence control

and process regulation programmes written and stored in the PLC's. The PLC's operate only as actuators of programme sequences. Initiation and co-ordination of operations are managed either at operator level or by upper levels of the central management system.

Principles of automation Automation refers to actions which are carried out automatically rather than by human agent. Automation implies some decision making as well as the per formation of physical tasks.

Automated control may be divided into two categories

1. Sequence or logic control

2. Process regulation

Automated control may be limited to Sequence control of a simple operation such as filling of silo or regulation of a continuous process such as pasteurization, where operating parameters must be monitored and adjusted continuously.

In Process Regulation the objective of controller is to regulate a characteristic of a system which is subject to disturbances. The controller counteracts the disturbances to keep the characteristic close to constant. The controller has a set point for a parameter under its control which is the required value for proper operation of the plant. It's aim is to keep conditions close to this set point by manipulating other process variables.

Sequence control is only concerned with whether equipment is activated or not. Digital computer equipment lends itself very well to this type of control. Sequence control by a PLC system involves the activating and de-activating valves, pumps and other equipments according to a pre-determined sequence. This sequence is written in a code or language, which the computer can read and use. The use of computer system to control a CIP sequence is a good example of the application of sequence control rather than process regulation.

Modern systems are capable to perform both sequence control and process regulation. In this way they can control all aspects of manufacturing process, including cleaning and sanitation.

Controllers

Controllers are microprocessors which receive inputs or messages from sensors on the plant and sends outputs or instructions to actuators which activate the plant. Computer based controller must deal with two types of inputs/outputs (I/O's), analog and digital. Analog signals may continuously vary for example temperature or pressure. Digital signals are only of the "on or off" type. The difference between the two is that digital signals can only take one of two possible values. Analog signals can take any value within a continuous range.

A microprocessor is programmable which means that the rules which govern what it does at any particular time are defined in a set of instructions written for the particular application. The instructions are read in sequence by the microprocessor as digital signals.

The order of steps written in the programme is important. The way the PLC operates is to scan the programme repeatedly, starting at the top, reading each step in turn, until it reaches the bottom and then starting at the top again. As it comes to each step of the programme the PLC compares the actual situation to the instruction to decide whether any action is necessary. All possible data is read by the controller before it starts each scan of the programme and the values of this inputs is used to evaluate each step during the scan. A change in an input variable would not be detected until the next scan begins. The time taken to scan a complete programme depend on the size of the programme but is usually a small fraction of a second. Once a scan is completed any actions arising out of the evaluation of the situation at each step are done before the next scan commences. The speed of modern systems means that they can be used to control even the most critical processes.

Sensors

To ensure good performance from automated control systems it is essential to have accurate measurement of process conditions. Sensors have developed to a sophisticated level and may be constructed in a hygienic manner for food processing plant applications. Examples of sensors which may be used on the process and service equipments of a dairy industry include:

Pressure sensorPhoto cellTemperature sensor (thermocouples, thermostats)Flow rate sensorConductivity sensorProximity sensor (infra red magnetic flux etc.)Level sensor (pressure actuated)pH probeViscosity sensorMoisture sensorDensity sensor (with flow sensor can measure mass)Infra red radiation sensor (flame detection).

Signals transmitted from sensors may be converted to digital signals before entering the controller. They may also be conditioned that is transformed into another form of signal or filtered to eliminate extraneous interference with the signal called "noise".

Actuators On the basis of input signals received from sensors, the controller may decide to adjust the process operating conditions in order to compensate for a disturbance or alternatively to activate a process element to move on to the next stage of an operating sequence.The output signals from the controller activate an actuator on the control element of process equipment to bring about the required change to the operating conditions. The actuator is the converter of the control signal into action on the control element.

Pid control In process regulation the task of the controller is to adjust the process so that a controller variable remains close to a pre-defined set point. Adjusting manipulated variable in response to disturbance in the system does this. To do this effectively the controller must be tuned. In other words, it must be able to manipulate variable which will affect the variables to be controlled.

A number of types of control action are available:-

On off Control: It is a simple type of control which may be used in Electrical systems e.g. an electric water heater. When the temperature reaches a certain level the electricity is switched off and temperature will start to fall. At the lower temperature the electricity is turned on again to once more heat the water. This type of control creates oscillation in the controlled variable and has limited use for manufacturing processes.

Proportional Control : It responds to the current value of the error (the difference between the actual and set point). A large error will result in a large correction being made and as the error reduces the correction applied will reduce. The correction is proportional to error. Because there must be an error to cause a correction, proportional control alone can never return the controlled variable to the set point value when a disturbance occurs. The difference between the new actual value and the set point is called the offset.

Derivative Control: It acts on a rate of change of the error. It anticipates that the error may worsen. It does not assume that the error is constant. If the difference between the actual and the set point values is increasing rapidly, the correction due to derivative control will be strong. As the rate at which values are moving apart is reduced the derivative correction will diminish thus smoothing out response to the control action. If the difference between the actual and the set point values is constant there will be derivative correction and it can not be used to correct offset.

Integral Control: It acts on the cumulative error over time. The longer an error has existed, the stronger will be the corrective action due to integral control. Thus, if there is an offset between the actual and set point values, the integral control will exert a stronger correction according to the time which the error persists. This will correct the offset.

The best controller will use a combination of these control techniques to bring about a smooth and rapid correction of any deviation of the controlled variables.

User interfaces

Modern process control systems usually allow the operator to interact with the process through a computer system. The computer display will usually consist of a number of "screens" which may mimic the process, display process conditions, display alarms, log process variables, show trends and any other information useful to the operator. Some of the screens may be animated to give a better simulation of the process operation. The operator may use a computer keyboard or more usually a specially protected key pad which is simplified too suit the particular task without having the full range of keyboard functions.

A printer may also be provided to allow the production of reports, print outs of alarm conditions and a log of the process operation.

………………………….

AMUL-2 RAW MILK RECEPTION DOCK AND PROCESS SECTION

The RMRD at AMUL-2 receives cow milk and buffalo milk in separate cans. The milk

is received in the morning and evening shift from different societies. The milk is collected from 1092+5 societies on 93 routs by trucks and is brought to the dairy. The total milk reception in first shift is around 170000 liters and in second shift is around 150000. This milk is than standardized to prepared standardized milk or is homogenized (in Amul-3 Process section) which is sent to Bombay, Calcutta etc and cow milk is collected separately for the preparation of cow milk. The surplus milk is sent to AMUL-3, where it is standardized to make different milk products.

Total milk collection: 3.2 - 3.5 lakhsFlush season: 1.91 lakhs (per shift)Lean season: less than 1.51 lakhs

Milk collection from different chilling centers S.NO. NAME OF CENTER TOTAL ROUTES TOTAL SOCIETIES

1. Khatrej 23 204 2. Khambhat 12 96 3. Balasinor 18 184+154. Kapadvanj 17 1415. Anand 32 300+56. V.C.U. 23 - TOTAL 93 1092+5 Milk reception For reception of milk there are two reception lines. When the cans come, they are manually put on the conveyor. Firstly, when the milk cans is put on the conveyor is tested by the person. The person checks the milk by putting plunger inside it and also smells the milk to segregate the sour milk and curdled milk. Milk is then dumped in the weighing tank and is weighed and sample is drawn for Fat & SNF testing. Then the weighing tank valve opens automatically and the milk is collected in the collecting tank and cans move to can washer. On each line there is a can washer and each can washer has a capacity of 12-15 cans/minutes (presently) Equipments:1. Weighing balance tank Capacity – 500 kg2. Collecting tank (Dump tank) Capacity – 5000 liters3. Milk storage tank

No. - 10 Capacity – 35000 liters4. Milk pasteurizer No. – 3 Capacity – P1 (Cream pasteurizer) = 3000 liters P2 (Skim milk pasteurizer) = 25000 liters P3 (High fat milk pasteurizer) = 15000 liters5. Can washer No. – 2 Capacity – 12-13 cans/minutes Total number of nozzles in each can washer=246 6. Cream separator (Westfalia Separator) No. – 1 R.P.M- 4500 No. of Disc-108 Model no-

7. Cream pasteurizer No. – 1 Capacity – 3000 liters/hrs

8. Buttermilk tanks No-10 Capacity – 5000 liters 9. Milk Silo No. - 4 Capacity-1 lakh litres

Can washer

1. It has a drive sever, 2 pre-rinse sections in which water at 50°C is sprayed.2. There are four chemical sections in which lye solution [0.4% to 0.5%] at 85 °C is

sprayed.3. Then hot water at 80 °C is sprayed in three sections.4. Finally cans are sterilized by steam at 2kg/sq.cm. In last section, lids are also given the

same treatment.5. The pressure of lye and water spray is 5kg/sq.cm.6. There are total 246 nozzles in each can washer.

The samples from each society is mixed together and than tested in milko scan for Fat & SNF.The same sample can be stored for 3 days by adding Potassium dichromate and can be tested incase if there is some kind of dispute.

Detergent mixtures used in can washing

Composition kgs

Sodium meta silicate 4.7Sodium sulphate 2.1 Washing soda 1.9 Tri-sodium phosphate 0.6 Sodium hexa-metaphosphate 0.6

---10 kg mixture to be used in 250 ml of water ( 0.8% strength)---10 kg mixture to be used in 350 ml of water (0.6% strength) Flow chart of Amul-2 process

Unloading of cans

↓Chain conveyor

↓Removal of cans lid

↓Physical inspection & organoleptic grading

(If milk is found to be sour, it is sent to Ghee section)

↓ Transfer of milk in Dump tank

↓Filter

↓Weighing

↓Raw milk collecting tank

↓Chilling

↓Raw chilled milk storage tank

↓

Pasteurization & standardization (at 78°C±3°C for 15 seconds)

↓Processed milk tank

↓Sent for different product manufacturing and for market milk packing.

*Cow milk is pasteurized separately and is sent to market milk pouch for the packing of cow milk.

Buttermilk processing: Butter milk is prepared in AMUL-2. It is standardized and packed in pouches .It has a fat of minimum 0.5% and total solids 6 to 7% and acidity is 0.2 to 0.3 %.

Raw buttermilk from AMUL-3(Acidity-0.138% L.A)

↓Pasteurization (77°C for 15-16seconds)

↓Storage tank

↓Buttermilk tank

↓Heating (37 °C)

↓Addition of Butter culture (1%)

↓Incubation till acidity reaches 0.3%

↓Chilling (9°C)

↓Packing

Pasteurized milk processing:

Pasteurized high fat milk

Raw chilled milk (7°C)

↓Balance tank

↓Centrifugal pump

↓Regeneration-1(65 °C)

↓ Heating (77±5 °C)

↓Holding (15 sec)

↓Partial cooling by incoming raw milk

↓Cooling (7°C)

↓Storage tank

.

Pasteurized skim milk

Raw chilled milk (7°C)

↓Balance tank

↓Centrifugal pump

↓Regeneration-1(65 °C)

↓

Simplex filter

↓Cream separator

↓Skim milk

↓

Heating (80-82°C)

↓Holding (15 sec)

↓Partial cooling by incoming raw milk

↓Cooling (7°C)

↓Storage tank

Cleaning of AMUL – 2 Process

CIP STEPS PASTEURIZER SILO/TANK TRANSFER LINESTIME [MIN]

TEMP[°C]

TIME[MIN]

TEMP[°C] TIME[MIN]

TEMP[°C]

Rinsing with water

5-7 50-55 5-7 50-55 5-7 50-55

Lye solution 40-45 80-85 5-10 80-85 5-10 80-85Fresh water 5-7 50-55 5-7 50-55 5-7 50-55Acid circulation

45 70-75 5-10 70-75 5-10 70-75

Fresh water 5-7 50-55 7 50-55 5-7 50-55

*Acid solution is having 0.4 to 0.6% strength*Lye solution is having 0.6 to 0.8% strength

Fluid milk packing Pouch packing section deals with packing of milk into pouches. There are three packing machine. Each machines consists of two identical heads for packing, each head draws heat sealable polyethyelene sheet from a separate roll and is fed with milk to be packed from the overhead tank by gravity. The material moved continuously in a strip, the film is folded longitudinally. Firstly vertical sealing occurs, as continuous cylinder moves downwards transverse heat seals are made by jaws which have the effect of closing the bottom of pouch, so that measured volume of milk is filled into the space above a seal. Milk pouch specification Two types of milk are packed in this section.A] Cow milk Fat = 4% SNF = 9%B] Standardized milk Fat = 4.5% SNF = 8.5% The milk is packed under the brand name of AMUL SHAKTI. The Butter milk is also prepared and packed.

Liquid milk pouch packing standards Net volume Max. Permissible limit 500ml ±10ml 1000ml ±10ml 5000ml ±10ml For Butter milk 500ml ±10ml

MASTI DAHI

Flow process chart Milk (Fat: 4.5%, SNF: 10.5)

↓Pasteurization (90o C for10 minutes)

↓

Homogenization (Ist Stage-50kg/cm2 , IInd Stage-150kg/cm2)

↓ Separated in five lots

↓ Maintain Temperature (37-39o C)

↓ Culture addition @ 2 %

↓ Ageing (15-20 minutes)

↓ Pouch filling

↓ Incubation ( 37-420C)

↓ Acidity is checked after every 3.30 hrs

↓ Final acidity 0.8-0.95 % L.A.(After 24 hrs).

↓ Transfer To Cold Store (50C or below) Pack size – 200 ml. & 500 ml.NOTE – Manufacturing of Dahi – 1200 liters/day. Acidity at transfer to cold storage (% lactic acid 0.45-0.55% LA) Acidity at time of dispatch (% lactic acid 0.80-0.95 % LA) Sealing temperature – above 1000C for pouch packing. Culture – DVS (RST 744 + CHN 11) Skim milk powder – 42 kg/1200 liters PFA specification for Masti dahi

Constituents PercentagesFat 4.5% Min.SNF 10.5% Min.Acidity 0.80-0.90% lactic acidTotal plate count 1000000/g Min.Coliform Not more than 10/gE.coli Absent in 1g

Salmonella Absent in 25gShigella Absent in 25gStaphylococcus aureus Not more than 100/gListeria monocytogenes Absent in 1g

Cleaning In PlaceSr. No. Process Temperature Time

1. Water rinse 55-55OC 15 min2. Lye circulation (0.5-0.8%) 80-85OC 40-45 min3. Fresh water 50-55OC 20 min4. Acid (0.4-0.6% HNO3) 72-75OC 30 min5. Fresh water 50-55OC 20 min.

Operation of the machineStarting of the machine

Load of packing film on the idler roller with the free hand of the film hanging towards back of the machine.

Pass the film through dancing roller, U.V.tube, forming plate injection tube, vertical sealing jaw, nip roller and horizontal sealing jaw.

Switch on main switch and heater switches. Operate manual press switch and check if all the cylinders work properly and all the

heaters are sealing. Operate manual injection ON-OFF switch to check if the injection system is working. Put the auto A & auto B, switched on. Takeout the filled sealed empty pouches to ensure

quality of sale. Put the injection switch ON select the filling quantity, adjust the quantity selector. The

machine will begin automatic operation. Now make final adjustment to- 1. the filling accuracy2. the pouch length3. the seal strength

Shutting down

1. Turn off switches in the following order.- Injection- Auto- Horizontal seal- Vertical seal.

2. Shutt off the milk supply to the header tank.3. Place the ends of the film tubes in a can or crates in front of the machine to collect milk from the head tank.4. Turn ON manual injection switch to empty header tank.5. When flow stops, turn all in following order

- Manual injection

- Vertical seal- General switch

Check list in prepack section

1. Check U.V.light2. Check oil level and air pressure in FRL. If water then drain.3. To open electrode and clean it.4. To check back up sealing rub box.5. To check temperature and flow of cooling water.6. To check machine and cleaning of the filter.7. To check Teflon cloth and tape.8. To check the condition of air compressor and drier.9. To clean all rollers and lubricant it.10. Before start the machine, check nip rollers.11. To check filling valve and tube.12. Check the cleaning of buffer tank and line filter and overhead tank.13. In condition of cylinder operate; keep attention on aie pressure on each machine.

Specification of machine Make - "Prepac IS – 5"Manufacturing – Samarpan fabricators limited.Operational speed – 5000 pouches to 1liters/hrs 5140 pouches to ½ liters/hrs 5260 pouches to ¼ liters/hrs 5580 pouches to 1/8 liters/hrsElectricity – 380 or 415 V, 3 phasePeak power rating – 8kwPower assumption – 2kw/hrsCompressed air - 1) Pressure – 6kg/cm2

2) Consumption – 50m3/hrs 3) Water consumption – 200 liters/hr at 20°C. 4) Head capacity – 2500 liters/hrs

NOTE – Filpack is same as Prepac, but it is electronic system; therefore air pressure is not required. Specification of polyfilm Quality – Natural milky colored, transparentCore size – 70mm.Film thickness – 65 to 140 micronsWidth – 130 to 140 mm.R.H. – 60%

Strength of film – should not stretched easily under normal condition. Squeeze test There are different ways of testing pouches.

1. Standing on them with 1 foot, throwing them against a wall or tossing them high in the air to drop on the ground etc. That may be impressive but is hardly a proper a testing method.2. The correct method of testing horizontally seals is to grip the pouch in its centre with both hands, then squeeze slowly until the film begins to stertche. If the pouch can be ballooned in this way the seals are ground.

………………………………………………

AMUL-3 RAW MILK RECEPTION DOCK AND PROCESS SECTION

Introduction This is the very first department of any dairy where tankers loaded with milk are unloaded and simultaneously the milk is tested and processed further in other departments. Raw milk at Amul-3 is received only through road milk tankers. There are 3 bays for unloading milk tankers.

Features

Storage/handling capacity- 12 lakhs litres/day

Milk sent to- Larsen & Toubro (L&T) powder plant-4.5 lakhs litres

Calcutta - 40000 litres

Pune - 30000 litres

Market milk - 30000 litres

F-60 Powder plant - 3.6 lakhs litres

Total receiving

Khatrej- 1.55 lakh liters/day

Kapadvanj-1.8-1.9 lakh liters/day

Khambhat-1.7 lakh liters/day

Balasinor- 1.7 lakh liters/day

V.C.U- 3.5 lakh liters/day

Process flow chart

Raw chilled milk in tankers

Deaeration

Filter

NRV (Non Reversible valve)

Pasilac Continuous Mass Meter (PCMM)

Buffer tank

Milk clarifier

Sludge tank

Raw milk silo (4-5°c)

Balance tank of pasteurizer

1 s t Regeneration section of milk Pasteurizer (50-55°C)

2n dregeneration section of milk Pasteurizer (65-70°C)

Homogenizer (1 s tstage-2500psi, 2 n dstage-500psi)

Cream separator

Skim milk Cream balance tank

↓ ↓

Pasteurizer Cream pasteurizer (90 oc)

↓

Milk storage tank/silo Cream storage tank (14 oC)

↓ ↓ Issued to powder section issued to butter sec.

Standardization (ALFAST UNIT)

↓

Pasteurizer 1 Pasteurizer 2

(Skimmed milk) (Whole milk)

↓ ↓ Pasteurization Pasteurization

↓ Pasteurized standardized milk F60 powder L & T Amul-2 Road Rail Tanker tanker

Equipment specifications

Each reception line is equipped with following:-

1). Centrifugal pumps each of capacity 30,000 LPH 2). De-aerator to remove air from the milk3). Auto sampler to take the uniform sample4). Pasilac Continuous Mass Meter (PCMM) for the measure of quantity of milk unloaded in kilograms. It has five modules.

a). Vortex generator for uniform flow.

b). Density transmitter: It is having artificial radioactive substance called Americium (Y-RAY). The attenuation of Y-Ray in the medium currently in the metering section. The non-attenuated Y-Ray are converted and counted and then becomes an expression of the density of the product.c). Flow transmitter: It is inductive type. A potential difference is depends upon the velocity of the medium is induced between two electrodes in the metering pipe. A built computer converts the recorded signals into pulses which finally becomes the expression of the flow.d). Non-reversible valve (NRV): For security i.e. one direction flow of product.e). Display unit/Control Unit: Receive pulse a signal from the density transducer and flow transmitter and on that basis calculates the mass in kilogram and displays it.

5). Duplex filters - A separate room is provided with four duplex filters, one for each line.6). Plate Heat Exchanger (Chiller) - One PHE after each filter.7). Raw milk silo (RMS) - All unloaded milk is finally stored into the Raw Milk Silos.

Process

Milk from various villages is collected in chilling centers and from there the milk is out to the dairy in tankers by road or by railways routes. After that the sample is tested/analyzed in the reception lab, by milko-scan the corresponding fat, SNF (solid not fat), protein, lactose readings are recorded and the most important factors. On the basis of acidity and temperature milk is unloaded or rejected is also performed in the reception lab. The tanker with acidity less than 0.15of Lactic acid and temperature less than 10 are unloaded and rests are rejected.

This unloading is done in a milk buffer tank with storage capacity 15,000 liters. The processing of milk starts now. The milk is chilled to 4oC and then is sent for clarification.

Clarification – This is very important process in which the dust, dirt or any kind of milk impurity is removed in a clarifier. From the clarifier the milk is sent to raw milk silo and stored temporarily. Clarifier has centrifugal force 2000 rpm. Therefore the milk is unloaded and is sent for pasteurization.

Pasteurization is a process whereby the germs pathogens are killed. In this process the milk from raw milk silo is heated up to 78±3oC for 16 seconds and then is cooled to 4oC. Simultaneously after heating milk is separated in a separator to milk and cream. Milk contains 5-6 % fat and cream contains 40 % fat. The surplus cream is sent to cream buffer. This is standardization. It is done in ALFAST UNIT i.e. Alfa Laval Fat Analyzing Standardization Unit.

The separated milk is used for manufacturing powder i.e. WMP, ASP (Amulspray-Infant food), Amulya (Dairy whitener), and sent in the market for sale (in purchase).

The separated cream is further pasteurized to make it human consumption capable. The process includes heating of cream at 90oC and then cooling to 8oC. After that it is stored in cream buffer tank with capacity 2 lakh. From this cream buffer tank the cream is used in manufacturing butter.

The various sections under the process control are:-

A. Reception

B. Milk Standardizing and Processing

C. Cream processing

D. Dispatch

Control room

For the successful operation of these activities a control room is provided. The operators at the control room continuously monitor all the process activities. All the operation in the Dairy is PLC (Programmable Logic Controller) controlled. A set of logical programmes through a programmer on PC is prepared and stored in the memory (RAM) of the CPU of the PLC. This is possible because of microprocessor based technology. Whenever the operator performs the operation, these programmes are recalled and executes according to the programme prepared and signals for activating/ deactivating of solenoid valve, thereby opening and closing of pneumatic valves and start and stop of pumps are affected.

There is one PLC in the control room. All valves, transmitters, PLC etc. run on 24V DC supply which is converted from 220V AC supply by transformer in each unit of PLC. Incase of power breakdown the PLC continues to get power supply of 24V DC through dedicated UPS (Uninterrupted Power Supply) system.

Management Information System (MIS)

For proper monitoring and management control MIS is a very effective tool. The control room also has information system for updation of production data of milk, cream, raw milk intake, center wise milk reception and dispatch record, inventories, CIP programming and its timing, trend charts, consumption of steam, electricity, air water etc. in which data are transferred from the PLCs. Along with this various log sheets are also maintained by the operator of all of the above listed production data.

Reception lab

All the incoming milk is tested for its acceptance and rejection at the reception lab. Following facilities are provided at reception lab for testing milk:

Milko scan for the estimation of Fat % and SNF %.

pH meter and temperature recorder.

Water bath

Refrigerator

Gerber centrifuge

Oven

Computers and printer

Operation

As the tanker arrives at the Reception bay, Sample of the milk is taken by lab analyst after plunging. The temperature is recorded as the sample is taken. Then the milk is tested for its quality by reception lab analyst. Firstly organoleptic test is done. If the temperature of milk is below 10oC and it's acidity is less than 0.136 % of L.A. and the fat and SNF percent matches with delivery channel sent by the center which is automatically updated by the computer as the analyst measures these parameters on the instruments whose terminals are connected to the main computer, the computer "Accepts" the milk. The lab analyst enters the password in the computer and gives signal "READY" for unloading of tanker at bay. RAM is selected by shift in-charge from Control Room. After connecting the hose pipe and checking that the manhole of tanker is slightly open. Signal is accepted by reception in-charge from local panel and unloading of milk from tanker starts. The milk unloaded at the bay is pumped through a de-aerator, centrifugal pump, NRV, vortex generator, density meter and flow transmitter (which is then converted into kilogram by PCMM display unit), then through duplex filter and to chiller where the temperature is reduced below 4oC, then finally stored into the RMS.

Note - As there are three bays (RL1, RL2 and RL3) for unloading milk tankers all four can be used at a time i.e. milk is unloaded at the rate of 3 x 30,000 LPH in any of the four RMS. However, combination of other bays can not be used to unload milk in the same RMS.

It is having following sections:-

Raw cream chiller - Some quantity of the raw milk coming from the RMS is utilized for the chilling of the raw cream which is separated from the separator.

Regeneration II - Here the heat of out going milk is utilized to heat incoming milk.Regeneration I - Here the standardized milk is further heated before going to heating section by the milk coming from the holding tube.Heating section - Here the milk from regeneration II is heated to pasteurization temperature by the hot water.Holding tube - Pasteurized milk is hold in the holding tube which is 42 m long with 72 mm diameter.Water heating section - Here steam is used to heat the water which is further used to the heat the milk in heating section.

Equipments

1). Raw milk buffer tankCapacity - 15000 lit.Nos: Two2). Cream buffer tankCapacity - 15000 lit.Nos: Two3). Balance tank

Capacity - 350 lit.Make – ALFA-LAVALNos: Three4). Cream pasteurizerType - PHEMake – ALFA-LAVALCapacity - 10000 lit.Number of plates – 222Number: One5). Milk pasteurizerType – PHEMake – ALFA-LAVALCapacity - 30000 lit./HNumber: TwoNumber of plates – 4126). CIP tanksLye tank capacity - 10000 lit.Acid tank capacity – 10000 lit.Water tank capacity – 8000 lit.7). CIP tanks for tankerWater tank - 8000 lit. CapacityLye tank - 8000 lit. Capacity8). Cream separatorType – Automatic self-desludgingCapacity - 30000 lit. /hMake - ALFA-LAVALNumber of Discs – 265Number – Two9). Milk clarifierMake - ALFA-LAVALCapacity - 30000 lit.10). Butter milk storage tanksNumber - TwoCapacity – 40000 lit.11). Raw milk silosNumber - FourCapacity – 150000 lit.12). Pasteurized milk silosNumber - FourCapacity – 150000 lit.

13).Raw Milk Silo Agitator Kilowatt: 5.5 14). Clarifier feed pump Kilowatt: 7.5 15). Tanker unloading pump Kilowatt: 7.5

16). CIP conc. Lye circulation pump Kilowatt: 7.5 17). Valves - Pneumatically operated Sanitary milk-proof valve Cleaning of Amul-3 process

CIP stepsPasteurizer

Silo/Tanks Transfer lines

Time (Min.)

Temp. (oC)

Time (Min.)

Temp. (oC)

Time (Min.)

Temp. (oC)

Rinsing with water10

Ambient7

Ambient5

Ambient

Lye circulation (1.5%) 30

8020

805

80

Fresh water circulation 5

Ambient7

Ambient5

Ambient

Acid circulation (0.8%) 20

6015

605

60

Fresh water circulation 10

Ambient7

Ambient5

Ambient

C I P (Cleaning in place)

CIP stepsReception lines

Milk tankers

Time (Min.)

Temp. (oC)

Time (Min.)

Temp. (oC)

Rinsing with water5

Ambient1-3

Ambient

Lye circulation (1.5%)15-20

805

60

Fresh water circulation7

Ambient5

Ambient

Acid circulation (0.8%)20

60-

-

Fresh water circulation10

Ambient-

-

Preventive maintenance of valves

A faulty seal normally starts leaking slowly. It's therefore often possible to continue production until the end of the day before repairing the valve.

Valves in plants are not all used to the same extent and not under the same conditions. Consequently, the exact life of the seals etc. can not be stated.

Regular inspection of valves for -Product leakageAir leakage

……………………

BUTTER SECTION

The cream obtained from process section is fully utilized for butter making. Butter section is very important as it handles fat, which is the costliest constituent. It sold under the brand name of "AMUL". The total capacity of this section is 70 tones/day. Cream Reception

The cream for manufacturing butter in AMUL-3 is to be received from following sources:1) Cream obtained in AMUL-3 while standardization of milk.2) Cream to be pumped from AMUL-2

In AMUL-3 the milk fat will be separated at above 60O C, the centrifugal separators inline with milk pasteurizer separate this as cream. The cream thus separated is pumped to the cream buffer tanks for further processing. Cream from AMUL-2 is pumped to AMUL-3 at low temperature. (About 6O C) by a positive displacement pump equipment for water purging and returning CIP solution is provided in AMUL-2, this cream can be taken to the cream Pasteurizer without starting it in the cream piping tanks.

Starting Operation of Continuous Butter Making Machine (CBMM)

The start up sequence comprises.1) Start cooling water to the separation reaction jacket.2) Start the churning motor.3) Start cream feed to CBMM.4) Start working motor.5) Start cooling water-recovering pump.6) Start vacuum pump.7) Start wash water/ buttermilk pump.

Stopping operation of CBMM

1) Stop cooling water to separated section jacket.2) Stop cooling re-injected of buttermilk.3) Stop working motor.4) Stop cream pump.5) Stop churning motor.6) Stop all other pump.

Flow process chart (Butter)

Raw cream ↓ Pasteurizer (90-95°C)

↓ Cooling (9-12°C)

↓ Aging (8-9°C /12-13hrs)

↓ Cream balance tank

↓PHE (For temperature adjustment at 6-8°C)

↓ Churning

Butter grains Butter milk↓ ↓

1st washing with butter milk Butter milk balance tank↓ ↓

Working (40-50 rpm) Chiller↓ ↓

2nd washing with butter milk Butter milk storage silo

↓ ↓ used end product Working under vacuum

(400-500 mmHg)

Unsalted butter (white butter) Salting ↓ ↓

↓ ↓ Used for Ghee Manufacturing Grinding ↓ Brine & color addition ↓

Blender (25-30 rpm) ↓

Butter silo ↓

Packing line

↓ 8g blister pack

10g chiplet

100g refill pack

500g refill pack

15kg bulk 400gm tin

Composition

Constituent Contents (%)Fat Min80%

Moisture Max15.8%Salt Max2.0%Curd Max1.5%

Butter packing

From the butter silo butter distribute for packing line. Finally packing of butter is carried out in different size like.

1 8gm blister pack2 10 gm chip let3 100 gm refill pack4 500 gm refill pack

5 15 kg bulk pack 6 400 gm Tin (For Defence Service only)

Packing material used is follows

Parchment paper-use directly for wrapping.Laminated foil-use for secondary packing, single laminated foil is used for INDIAN local market while double laminated is used for EXPORT.Aluminum foil- use for chiplet.Aluminum tin – use for EXPORT.

Detail about packing machine

1) SIG machine

Use for 100 gm packing, capacity 90-92packets/min & 500 gm packing ,capacity 60-62packets/min.

2) Case packer machine

Case packer machine is manufacture by BENHIL, As total 150 no. of 100 gm packed in a carton and similarly 30 packets of 500 gm is filled in a carton & rated capacity of the machine is 150pack/min.

3) Chiplet packing machine

It has capacity of packing 97 packets/min, per chip net wt. is 10 gm & one box contains 110 chiplet.

4) Butter tub filling machine (Blister pack)

Butter tub filling machine is manufacture by HASSIA. The capacity of this machine is 800-900pack/min, & each box contains 125 packs.

CIP for butter section

Hot water flushing for 25 minutes at 80°C(Melted fat goes to fat recovery tank).

Degreasing (hot water flushing for 10 min).

Detergent solution circulation for 25min at 85°C (1% concentration).

Hot water flushing for 15 minutes at 80°C.

Sanitization by using Iodophor (150-200 ppm) and circulate for 15 min.

GHEE SECTION

Ghee may be defined as clarified butter prepared chiefly from cow & buffalo milk. To clarify means to make clear a liquid or something liquefied, by removing unwanted solid matters or impurities. Section specification

In this section Agmark special grade (Green) ghee is prepared.Creamery Butter method of ghee manufacturing is followed.The surplus cream from AMUL-3 is converted into white butter, which is packed in 15kg boxes, & then utilized for ghee manufacturing. The ghee manufacture by white butter is only preferred for export purpose, to the gulf countries &.USA.The ghee prepared from the curd, sour cream, & whey is used for domestic purpose, village mandalis.The production capacity of ghee section is 6-7 TPD.In this section, PFA & Agmark standard is followed.

Standards of ghee

Characteristics RequirementFat 99.7 %( min.)Moisture 0.3 %( max.)Free Fatty Acid (as oleic acid) 0.75%(max)Organoleptic evaluation No abnormality, free from any foreign

flavours or off flavours. Flow process chart of ghee manufacturing Curd from chilling Cream White Butter Centers/ societies/KSD

Curd pump Churning Melting vat (Temp.-110°C) Serum Portion Pre-stratification Serum tank Ghee kettle Boiled for 45mins at 115°C Filtration Clarification (at 60-65°C) Buffer tank Sent to QC lab for testing Packing line (at 40-45°C)

Pouch packing Tin packing Bucket packing

(200ml, 500ml, 1000ml) (500g, 1 lit, 5 lit, 15 litres) (10 litres) Equipments

Top churn Make: Silkeborg Capacity: 3000 kg of cream / batch Drum churn:

Capacity: 3000 kg of cream / batch Pre stratification tank/ Settling tank:

Make: Grasim Ind. Ltd., Birlagram Nagda No-2 Capacity: 2000 Liters.

Ghee Pots / kettles Nos – 4 Capacity: 1) 1.0 tonne 2) 0.6 tonne 3) 0.5 tonne 4) 1.5 tonne

Ghee Balance TanksNos – 3Make – L&T Ltd., BombayCapacity – 3000 Liters

Ghee melting vatCapacity - 1tons

Serum tankCapacity – 2 tons

Ghee ClarifierCapacity -0.45-0.5tons/hr.Rpm-1400No. of disc- 49

Ghee packing

Ghee is packed in 200 ml. 500 ml, 1000ml pouches by ghee pouch packing machine having two heads. It is driven by pneumatic gear box and its capacity is 13-14 pouch / min.

Specification

Type: PrepacMake: Samarpan Fabricators, ThanePower Consumption: 4Kw / Hr.Air Consumption: 6 Kg / sq. cm.Cooling water: 100 Ltrs. / Hr. at 20 CGhee is then packed in tins in 1/2lit., 1 lit., 5 lit and 15 kgs. by Gasti packing machine.SpecificationMake: Gasti India LtdCapacity: 15 Tins / min.

CIP of Butter Churn

After removing butter from churn flush with well waterThen take 500 – 600 litres. water at 80 – 85 C and add 10 liters. LyeRotate the churn for 30 mins.Drain the lyeAdd hot water and rotate for 30 mins.Drain the hot waterFill fresh water and rotate it for 10-15 mins.Drain the water

…………………………..

FLAVOURED MILK

Introduction

It is produced at AMUL-2. There are 6 types of flavoured milk/drink produced. Kesar Flavoured milk Elaichi Flavoured milk Rose Flavoured milk Kool cafe Kool koko Nutramul energy drink

Common Name : Sterilized flavoured milk.Usage : Chilled Drink.Pack size : 200 ml glass bottles & 250 ml cans.Shelf life : 120 to 180 days at cool and dry place.Specific Controls : Product to be stored in crates as it is packed in glass bottles.

Specifications

Characteristics SpecificationFat min 3.0%SNF Min 9.0%Added Sugar 7-8%TS Min 20.0%Acidity Max 0.13%LAAlcohol test (-)veFlavour As requiredColour Artificial max 100ppmOrganoleptic Evaluation No abnormality

Flow process chart of Flavoured milk

Pasteurized milk (3.80 to 4.5% fat, min. 8.5% SNF)

Addition of SM P(),TSP, Sugar in the process vat.

Pass the milk through PHE (Heating to 65-70°C) to completely dissolve sugar.

Homogenize the milk mix at 2nd stage (80-100 kg / sq.cm) and 1st stage

(180 – 200 kg / sq.cm Chilling in bulk milk cooler (8°C)

Addition of Colour and flavour

Mixing

On line filtration

Overhead tank

Glass Bottles Automatic washing, filling and corking machine

Placing filled bottles in the metal crates

Sterilization at 121° C / 1.1 – 1.2 kg / sq. cm pressure for 15 minutes.

Cooling by fans in the cooling rooms / incubation rooms

Holding for 7 days at ambient temperature to watch for quality defects such as curdling, leakage and discoloration in the bottles .

Labeling & Shrink wrapping

Storage at ambient temperature

Note: 1) Analyze the sample for Total solids, pH, acidity test and creaming index. 2) Care should be taken that chilling is to be done within 1 hour of completion of heating inorder to prevent development of acidity. 3) Sterilizer has PID controller in which time settings are done and steam inlet is controlled for the required temperature.

Nutramul energy drink

Pasteurized milk (3.5% fat min. 8.5% SNF)

40 litres Slurry+ 40ml Caramel in 1000 litres milk Addition of Chocolate Slurry

Heating to 65-70°C in process vat

Addition of Sugar* (8.5%)

Heating of milk in PHE (65°C)

Homogenize the milk mix at 2nd stage (80-100 kg / sq.cm) and 1st

stage

(180 – 200 kg / sq.cm)

Bulk milk cooler (Cooling at 8°C)

Overhead tank

Glass Bottles Automatic washing, filling and corking machine

Placing filled bottles in the metal crates



Holding for 7 days at ambient temperature to watch for quality defects such as curdling, leakage and discoloration in the bottles

Labeling & Shrink wrapping


Amul cool cafe

Homogenized and Pasteurization milk (4.5% fat min.)

Addition of Sugar (12%), TSP ()

Heating in PHE (65-70°C)

Bulk milk cooler (Addition of Coffee after blending in Coffee blender

Can filling and Sealing



Holding for 7 days at ambient temperature to watch for quality defects such as curdling, leakageand discoloration in the bottles


Bottle filling

SHRIYAN is the name of the bottle filling machine with capacity 112 bottles/min. It involves 6 processes. Receiving bottles, checking for damages, cleaning bottles, filling, cap closing, handling of finished bottles. Bottles taken in trays are unpacked and fed in the rotating table. Diverting rods over the tables; feeds the bottles into belt conveyer. Checking is done in magnascope with lighting and magnifying lens arrangement. Cleaning of bottles is done by a chamber with 20 nozzles arranged in rotating table. It takes the bottles up, down when the nozzle sprays high pressure water into the bottles. Filling is done by an Overhead tank with nozzles over a table. This table is rise up in it circular rotation over a cam at bottle. The nozzle is pushed by the bottle mouth during which filling is done Caps are fed in a hopper at the cap closing section. It has electromagnetic cap holders which receives caps with a pressure of Ksc, the caps are closed over the bottles. Passing through a counter it reaches a receiving table from where it is taken in tray.

Can filling

With an overhead tank (OHT) of 50 litres capacity, maintaining a constant head filling is done. The conveyer has short valves to carry the cans. It makes a circular with this OHT where filling is done. Foam removal and addition of product on compensation and cap feeding are done on conveyance. These filled cans are then taken to can seamer. The end product is taken on tray for further processing

Features:

♦ Tin cans are imported from Singapore ♦ Product exported to Australia, Gulf countries ♦ Empty cans cost Rs. 6 ♦ Can printing area- head on M/C, video jet printing ♦ Lamination at 210°C ♦ Sterilizing holding time- 21 minutes

List of equipments

Type Description

1 PHE (Chiller) Make – Alfa LavalNo. of plates – 96Capacity – 5000 lits / hr

2 PHE (Heater) - do -3 Homogeniser Make – Manton Gaulin

Capacity – 2500 lits / hr

4 Bulk milk coolerNos. – 3

Capacity – 2500 litres5 Process vat Nos- 2

Make – Dalal Eng. Pvt. Ltd.Capacity – 1200&1400 lit. / hr

6 Over head tank Capacity – 1100 / lit / hr7 Continous bottle filler Make – Shriyan, Pune

No. of cans / min -60 No. of bottles / min- 112 Washing – 1 bottle / sec at 1 kg pr. Filling – 12 heads at 1 kg pressure Corking – 6 heads at 7 kg pressure

8 Sterilizer Nos-3Stationary (not more than 2250 bottles / batch)Working pressure – 1.13 to 1.3Kg / sq.cm

9 Sealing machineType – Shrink wrapping

Temperature – 160 to 165°CMake – SilvaModel – AHL – 300 / HL2/HL3/400

10 Printing machine Type – Inkjet labelingMake – Video jet

11 Metal crates As requirement

List of additives added for making flavoured milk

CIP programme for flavored milk section

Pre-rinse for 15-20 minutes (normal water)

Soda circulation at 82-85°C for 45 min. (0.6-0.7%concentration)

Hot water circulation for 20min (85°C)

S.N. Type Description1 Skimmed milk powder From the powder section in 25 kg bags as per

requirement2 Sugar Sugar % in the final product is 7-8%.3 Elaichi additives(Cardamom) Colour – 0.275 g / lit of Bush brand

flavor – 0.25 ml / lit. of spice drops4 Kesar Additives Colour – 0.20 g/ lit. Of type

Flavour– 0.50 ml / lit. Of spice drops5 Rose additives Color – 0.025 g / lit of Amerind Erythrosine

Supra Flavor – 0.18 ml / lit of Sonarex

6 Coffee additives Bru Coffee powder

Citric acid circulation at 75°Cfor 25-30 min (0.4-0.5% concentration)

t water flushing (80°C) for 15 min

Sanitization by using Iodophor (150-200 ppm)

F-35 SPRAY DRYING PLANT

Introduction

It is situated in north east and also called Amul-2. It was inaugurated by Pt. J. L. Nehru on 31st August, 1955. This plant is used for manufacturing of cheese whey powder (CWP). Standard of Cheese whey powder

Particulars ContentsMoisture Max 3.5%Fat Max 2.0%Milk protein Min 10%Total ash Max 9.5%Ph Min 5.1Lactose content(anhydrous lactose) Min 61%Total plate count Max 50000/gmColiform count Abs in 0.1gmE. Coli Abs in 0.1gmSalmonella Abs in 25 gmShigella Abs in 25 gmStaphylococcus aureus Abs in 0.1 gm Y&M count Abs in 0.1 gmAerobic spore count Abs in 0.1 gmListeria monocytogens Abs in 0.1 gmInsolubility index Max 3ml

Particulars of the F-35 Drying Plant:

Particulars SpecificationsMake StaincoCode F-35

Type 2 fluid type spray dryer, vertical chamberYear Installed 1978System of air flow, and milk with blow back system

Co-current

Installed Cap. 35 tons/dayActual Cap. 9-10 tons/dayChamber height 100 feet

Process flow chart (f - 35) Cheese whey ↓ Balance tank ↓ Preheater 1st to 7th ↓ Low heat pasteurizer (85°C) ↓ High heat pasteurizer (85-95°C) ↓ Hot well (75°C) ↓ Calendria 1st (75°C) ↓

Calendria 2nd (71°C) ↓ Calendria 3A & 3B (68°C) ↓ Calendria 4A & 4B (64°C) ↓

Calendria 5 (56°Css) ↓ Finisher ↓ Concentrate tank ↓ Feed pump ↓ Atomizer (Nozzle) ↓ Spray drier ↓ Powder

↓ Bulk packing (25 kg.)

General Creation InstructionsThe spray drier comprises mainly of 3 units.

1. Primary fan and air heating system2. Concentrated feed system3. Drying system

1. Primary fan and air heating system

a). This primary air system involves the use of primary fans which are being run by 125 HP motors directly coupled to the fan shaft. Since the fan is rotating at 2900 rpm, care should be taken in the centering and alignment of fan and motor shafts.b). The heating system involves the following.

i). Air heater chamber and heating elementsii). Flame exhaust and recirculation fans iii). Hot air valvesiv). Hot air ducting

2. Concentrate Feed System

The system involves the following a. Feed pump with motor

The Rotary pump, which is a positive displacement single screw pump directly, coupled to D.C. motors. This D.C. motor is a variable speed motor with 0 to 1500 rpm controlled directly from the panel by adjusting the knob of diameter stat of three-phase silicon rectifier control panel. The pump can run in either direction with equal efficiency, which is maintained over a wide range of speed and pressure. Since the motor is a unidirectional, care should be taken for deciding outlet and inlet connection of pump.

b. Concentrate pre-heaterThis is a tubular pre-heater with shell and tube design. Steam is the

heating medium. This is a double barrel type with two barrels. c. S.S. feed line and sprays nozzles

The inter connections of pre-heater, balance tank and pump is made by S.S. tubes of 38 mm diameter, whereas the nozzles are connected with 28mm tubes.

3. Drying system

This covers the following items. a. Drying Chamber

The most important of all points, which should be taken care of during fabrication and installation, is the concentricity of top and bottom openings. All

openings viz. chamber door, top platform, and blow back duct connections flexible connections between power and cyclone etc. should be airtight. The surface of drying chamber should be smooth and without any dents etc. which would be otherwise obstruct electric vibrations fitted on the drying chamber should have minimum amplitudes of vibrations.

The star valve fitted at the bottom of drying chamber helps I regular discharge of powder to the conveying system, which ensures a proper and uniform cooling of the powder. The rotor running should not scratch the body; this should be ensured after each run when the rotor is reassembled after cleaning.

b. Cyclone separators and Powder return system:Cyclone separators are the most critical part of the spray drier. To have

minimum losses separator leveling and concinnity of basket is most important. The fine powders separated by cyclone are discharged into a screw conveyer.

A special fan is attached to each nozzle for supplying the air which passes through the steam heater and gets hot. The steam heater is connected with steam and condensate is drained off through steam trap cum strainer. The flexible connection between the screw conveyer and the nozzle should not be air tight and that small quantity of air should be allowed to be sucked in through the opening.

c. Powder conveying system:

This involves the use of cooling filter, conveying duct and conveying cycle and exhaust fan. Cooling filter supported on three legs has a woolen filter cloth trapped between two wire mesh, which are clamped to the filter frame with quick release clamps. The filtered air, sucked through the filter carries the powder discharged by the star valve to cyclone separators through S.S. ducting.

The S.S. ducting has male-female type points, which are machined for easy fittings. The powder is bagged off at the bottom of cyclone where a rotary valve is fitted. Separator leveling and concentricity of basket should be properly done.

Cleaning Of Plant

Chamber is opened and is manually scrapped and cleaned when felt necessary. Actual operational parametersParameter ValueConcentration of condensed milk 45-48% TSNo. of nozzle jet 16Angle of jet 10°CDiameter of jet 1.8mmHot air nozzle size 610x72 mmSecondary air opening FullCooling air temperature 5°C

Temperature of outgoing powder 40 °CLiquid spraying temperature 48° CVacuum in chamber -8mmHgInlet air temperature 270-280°COutlet air temperature 85-90°CFurnace temperature 690-710°CFlue gas temperature 168-170°C

Note1). The powder manufactured is filled directly into the bags at collecting cyclone/bagging cyclone. CWP is packed into 25 kg bags.2). The outlet temperature of air is maintained and regulated by feed rate of condensed milk, which is controlled by speed variable pump. When we increase feed, then decrease outlet temperature and vice versa.

NIRO F-60 DRYING PLANT

IntroductionIt is an old and the largest plant of this type in Asia. It is used for manufacturing of SMP.

This is a two stage drying plant. Second stage drying takes place in the vibro fluidizer.

Grades of PowderSr.No. Description SMP WMP

1. Moisture% 3.2 3.22. Fat % 1.0 26.53. Protein 35 264. T.S.% 96.8 96.85. Total ash % 8.2 7.36. Insolubility index (ml) 0.5 0.57. Titrable acidity % LA 1.5 1.08. SPC/gm 30000 300009. Coliform/0.1gm Nil Nil10. Staph. aureus/0.1gm Nil Nil

11. Salmonella/25gm Nil Nil12. Shigella/25gm Nil Nil13. Lactate content mg/gm 1.5 -14. Heat stability grading - -15. High heat :WPNI mg 1.5 -

16. Medium heat: WPNI mg ≥1.5 to ≤6 -

17. Low heat : WPNI mg 6 -

SpecificationsParticulars DataMake Niro atomizer, Copenhagen, Denmark.Model Niro atomizer, Copenhagen, Denmark.Type Spray dryer with centrifugal spinning disc

type atomizer with vertical camber and Co-current system with gas.

Installed Capacity 60 TPD Plant DetailsParticulars DataNo. of Stages 2 stagesChamber diameter(outer) 8.8 mChamber cylindrical height 2.5 mChamber conical height 7.5 mDiameter of conical bed 1.1 m

Make Niro, DenmarkType Rotary, centrifugal spinning disc, sealed

vans, with 16 slots

Speed 15000-24000 rpmFeed Single and double tube with distributorType of feed pump Centrifugal pumpHot air source Direct gas fired air heater

.Process DataParticulars DataFeed rate 500 kg/hrFeed Concentration 45%TSFeed Temperature 48-50° CMoisture of Powder 3-4%

Process flow chart (f - 60) Standardized milk ↓ Condensing plant unit ↓ Preheater 1st to 7th ↓ Low heat pasteurizer (85°C) ↓ High heat pasteurizer – 1st (85-95°C) ↓ Hot well (75°C) ↓ Calendria 1st (75°C) ↓

Calendria 2nd (71°C) ↓ Calendria 3A & 3B (68°C) ↓ Calendria 4A & 4B (64°C) ↓

Calendria 5 (56°Css) ↓ Finisher ↓ Concentrate tank ↓ Feed pump ↓ Atomizer (Rotary) ↓ Spray drier ↓ Vibrofluidzer ↓

Bulk packing (25kg bags) Equipment Associated

1). Exhaust fan motor, 120 HP, 1460 rpm, Crompton Greaves, Capacity= 78000m³/hr

2). Powder conveying fan, 30 HP, 2390 rpm, GSF.3). Air supply fan, 60 HP, 1410 rpm, 28000 m³/hr.

4). Vibrators and electrical hammers5). Air cooling system with fan and chilled water6). Damper and hot air inlet duct7). Air heater 3 Nos.8). Cyclone separators 6 Nos.9). Storage tank for condensed milk No. 2, Make L&T, BombayCapacity 10,000 lit each.

Technical Operational DetailsParameter ValueCondensed Milk Feed Temperature 50°CInlet Air Temperature 212-217°COutlet Air Temperature 85-89°CLoad On Atomizer 75-80AmpFinal Product Temperature. 45-48°CVacuum In Chamber 12mm WCLoad On Conveying Fan 40 AmpLoad On Exhaust Fan 178-180 AmpChilled Water In Coils 4-6°CAir Supply Fan No.1No.2No.3

76-77 Amp""

Air Pressure In Hot Air Line 50mm WCChilled Water Inlet Temperature. 5-6°CChilled Water Outlet Temperature. 7-8°CVibro Heating Zone Air Pressure, Kg/ Cm² 90/100Vibro Heating One Temperature. 77°CVibro Cooling Zone Temperature. 30°C Air Heater of F-60 PlantParticulars DataNo. 3Make DERTLI, GAS BERNERMethod of heating air Indirect heat exchangeFilter Woolen clothTemperature. of furnace 530-540°C

Hot air temperature. at outlet of furnace

230-240°C

Air Flow

Air suction by primary fan↓

Preheating of air to 60°C through hot water from heat recovery system↓

Heated by gas in chamber↓

Drier Note

1. When there is no need of hot air, it is diverted to atmosphere.2. Oil can be use when natural gas is not available.3. Other details same as that of F-35 plant air heaters.

Starting of Plant

1). Start in sequence the following.a). Exhaust fanb). Atomizer cooling fanc). Supply fan 1 and 2d) Exhaust fan with cyclonee). Supply fan 3f). Air cooling fang). Electrical hammers.

2) When temperature reaches start atomizer3 Divert hot air supply into chamber4) Feed water to atomizer5 At 50°C feed concentrate into atomizer. Stopping of plant

1). Stop the dryer as usual2). After cooling down the system, separate the dryer and vibro.3). Run the vibro for some time to get the powder out and stop4). See that chilled water and steam valves are stopped.

Operating instructions for starting and stopping

A). Check all the dampers settingB). Check all rotary valvesC). Start vibro keeping plate below chamberD). Heat the vibro system For ASP 55 to 60°C on heating and 52-55°C in cooling zoneE). Remove the plate from chamber bottom and start Niro dryer after fixing flexible joint (Canvas belt) to vibro. Check accumulation is there or not, push in manually.F). Start air heater and heat the drying system. Running with water to maintain outlet temperature 100°C for 20 min.

G). Start concentrate in dryer. Keep parameters as followsa). Keep inlet temp. 170°Cb). Vacuum in chamber 8 to 10 mm WCc). Load on vibro exhaust fan 45 Ampd). Damper position, hot and cold air fan as required

H). Start chilled water in air cooler. Cool air temp. should be maintained to 35-40 °C. it should not be less than 2°C in any case.I). Initially collect fines in bags from last cyclone.J). Blowback blower must be started when water is started to atomizer and it must be stopped when water is stopped to atomizer. It should not be started before taking water in atomizer.

Drying Plant Cleaning and Maintenance

1). F-60 atomizer can run safely for 72 hours, under normal running conditions. At the time of atomizer change following jobs are to be carried out.

a). Changing of suction air filter(woolen and muslin)b). Atomizer feed line chemical cleaningc). Chamber come drying cleaningd). Conveying line and rotary lock cleaninge). Checking of the fan belts, bearing and electrical installation.

2). Complete drying system is to be dry cleaned every after 15 days and wet cleaning to be done once in a month3). Concentrate chiller and pre heaters must be chemically cleaned at the time of CIP and through chemical cleaning of anhydrous condensing plant with soda-acid. Recommended strength is 0.8 to 1% for 30 min. sanitization to be done by Polyson-D solution.4) . F-60 atomizer can run safely for 48-54 hours under normal running conditions. It is cooled and lubricated continuously while working.

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L & T POWDER PLANT

Process

Standard milk is received from processing site and it is send to milk silos for temporary storage. Each milk silo has 40,000 lit milk capacities. This milk is then used to make milk powder using different procedures.

Process flow chart (L& T)

Standardized milk inlet at (4-5°C) ↓ Balance tank ↓ Preheater 6th ↓ Preheater 5th to 1st ↓ High heat Pasteurizer (90-95°C) ↓ Flash vessel 1st ↓ Flash vessel 2nd ↓ Holding tubes ↓ Calendria 1st

↓ Vapour from vapour separator 1st

Calendria 2nd ↓ Vapour from vapour

Separator 2nd Calendria 3rd ↓ Vapour from vapour separator 3rd Calendria 4th ↓ Vapour from vapour separator 4th Calendria 5th ↓ Duplex filter ↓ Concentrate tank ↓

Scrapped surface heater ↓ Piston pump ↓ Homogenizer ↓ Atomizer (Nozzle) ↓ Tall form dryer (TFD) ↓ Vibrofluidizer ↓ Vibrating sieves Bulk packing Hopper ↓ Dense phase vessel ↓ Powder silo 1 Pneumatic conveyor line ↓ Powder silo 2 Diverter valve Vibrating tubes ↓ Hopper ↓ Vibrating tubes ↓ Rotary valve ↓ Rotary sifter ↓ Diverter valve ↓ Vibrating valve ↓ Packing tubes ↓ Packing Hopper ↓ Packing machine

Specification of Amulspray

Sr.No.

Description Specification

1. Moisture % (max.) 3.22. Fat % (min) 18.53. Total ash % (max) 8.54. Acid insoluble ash % (max) 0.15. Insolubility index ml (max) 0.56. Milk protein % (min) 127. Sucrose % (max) -8. Coffee test Pass9. SPC/gm (max) 3000010. Coliform/0.1gm Absent11. Staph. Aureus/0.1gm Absent12. Salmonella and Shigella /0.1gm Absent13. Wettability at (45°C) (max) 35 sec14. Scorched particles (max) 15 mg, disc B15. Vitamins and minerals as per BIS,PFA -

This whole process is divided into following sections:-

1. Evaporator

2. Concentration tanks

3. Packing

1) Evaporator

Milk from milk silos first comes to this section. 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 part about 35%, is evaporated during this section and we get 48% total solid (TS) in milk. Evaporator has following components:-

1. Balance tank

2. Six pre-heat3. Flash vessel

4. Holding tube

5. Calendria

6. Vapour separator

7. Vacuum system

8. Thermo compressor

A) Balance tank: Milk from silo comes to it, the level and flow is controlled in the balance tank.

B) Pre-heater: From balance tank milk goes to pre-heater. Here milk is heated step by step in different pre-heaters. It is heated up to 55oC.

C) Flash vessel: It has two components

D) Regeneration: Here milk is heated up to 95°C.

E) Cooling: Here milk heated during regeneration process is cooled.

F) Holding tubes: Here, milk is heated up to 95oC to kill bacteria in standard milk.

I. Calandria: It is shell and tube type heat exchanger. Inside the shells, milk is dropped while steam comes in contacts with shell and milk is heated.

II. Vapour separator: Vapour which is produced in calendria is separated here and condensed milk is added in transfer pump.

III. Vacuum systems: There are two stages to get vacuum.

A. Barometric condenser

B. Vacuum pumps

IV. Thermo compressor: Steam is added in calendria shell side by thermo

compressor to get required set point density.

2) Concentrate tanks

Milk from evaporator is gathered and concentrated here. There are 3 conc. tanks. Two having capacity of 3,000 lit. & one having capacity of 5,000 lit.

Plant operating parameters1). Evaporation flow rate kg/hr. : Min. 22000 lit/hrs2). Shell temperature of 1 s t calandria : Max. 82 oC3). Evaporator vacuum : Up to 140 mm Hg4). T.S. : 42 – 48%5). Thermo compressor : 6-8.5 kg/cm 2

6). Pasteurization temperature (HHP) : 87-94 oC7). Vapour separator 3 temperature : 70oC8). Vapour separator 4 temperature : 65oC9) Vapour separator 5 temperature : 55-60 oC

Preparation of various additives

1. Addition of BHA (for WMP only): BHA @ 50 g per metric ton of milk powder is added by dissolving BHA in 2-3 lit. Lukewarm water added to milk in silo/tank

2. Addition of TSP: Addition of buffering salt @ 0.2% for SMP, @ 0.6% for Amulspray and 0.3% for Amulya. No TSP is added to IMF –1 and 2 and WMP.

3. Sugar: Water is taken ion sugar vats and heated to 50-60oC. Required quantity of sugar is added into sugar vat and dissolved. Sugar solution is pumped to milk silos through filter.

4. Vitamins and Minerals: Vitamin A + D mix is dissolved in milk and added into sugar solution. Water soluble vitamins and mineral premise is mixed in lukewarm oil and added to vegetative oil cream. Lecithin is mixed in lukewarm oil/ghee and heated to about 60-70oC in order to melt lecithin in free flowing form and added into vegetable oil cream mixture.

C I P (Cleaning in place)Normal CIPEvery 24 hours of cont. operation:-a. Soft water flushing is done at ambient temp. for 20 min.b. Chemical cleaning with soda at 70oC for 40 min(soda concentration-1.5-2%)c. Hot water flushing at 60oC for20 min Extended CIP after maximum four normal CIP cycles

In this kind of CIP in addition to above 3 steps chemical cleaning with acid at 60oC/60 min. followed by hot water flushing at 60/35-40 min.The vitamin pre-mix is added @ 1.58 kg/2 tons of final product.

CIP tank – CIP time schedule

Sr.No.

CIP Code CIP typeTime

(min.)Lye

conc.Acid conc.

Temp. (oC)

1 Milk silo Normal 25 0.6-0.8 - 55-60 Milk silo

Extended

2 EvaporatorRinse with lye

1.30 hr. 0.9-1.1 - 60-65

Rinse with acid

1.15 hr. - 0.45-0.6 60-65

Normal 2.3 hr. - - 60-65 Extended 4.3 hr. - 100-110 60-653 Feed line Normal 60 - - 55-60 Extended 1.20 - 100-105 55-60

PackingPacking is done in two ways:-a) Manual baggingb) Automatic packing

A. Manual bagging

Powder from powder shifter is send to bagging line. Here it is bagged manually and bags are sending to cold storage via conveyers.B. Automatic packing

For automatic packing powder is taken into powder silos. Each silo has 50,000 capacity with the help of dense face vessel powder is conveyed through vibrating tubes and rotary valve and rotary shifter powder is taken into packing machine hoppers. We can do manual bagging here also. Powder is packed into bags and sends to cold storage by conveyer. Equipments

1) HomogenizerMake Niro Soavi (member of Niro group), Parma, ItalyCapacity: 63000 lit/hrLubrication oil pr. 5.5kg/cm²Pr. Gauge range 0-800 bar

2) Milk silosNo.s 2Make IDMCCapacity 40,000 lit. 3) Concentrate tanksNo.s 2Capacity 3000 lit.

4) CIP tanksNo.s 3Capacity 10,000 lit. 5) Lye/sanitizer tanksNo.s 2Capacity 1500 lit. 6) Air heatersNo.s 2 7) Balance tank for milk (condensing plant)

Capacity 150 lit. 8) Sugar dissolving tanksNo.s 2Capacity 3000 lit. 9). Powder pouch packing machineMax. Capacity 65 packs/minMake Rovema, Germany

10). Powder siloNo.s 2Capacity 50,000

11) Pneumatic valvesMake APV RESISTA-8700 HORSENS, DenmarkMax. Air pressure 608kP/cm² 12). MotorAgitator fan feed conc. Tank - 1.5 KWVacuum pump - 11.0 KWMilk fed pump to evaporator - 2.2 KW

Powder plant process parameters Parameter ValueEvaporator vacuum 110-140 mm Hg

CAL-1 Temp. 72-74°CHHP Temp. 92-95°CFlash vessel II 153.5°C approx.Flash vessel I 90°C approx.Separator no. 5 temp. 57.9°CBaum reading 1125-1130 kg/cm²Concentrate density 1172.8 kg/cm²Chamber vacuum 8-14mm WCThermo compressor pressure 6.5 – 7.5 kg/cm²Concentrate TS 40-48%Feed pressure 175-190 bars

L&T packing machine

Powder comes in auger from the hopper through the vibrating tube. On the top of the auger one high level sensor is located which sense quality of powder. Then powder enters or stopped accordingly in auger. Nitrogen pipe also fitted in auger. Powder flows down by the steel tubes where pouch film folds in round closed shape that moves between tube and rubber belt. Here both edges of film heat sealed but only inner side due to inner part is laminated of the film. Where tube keeps spiral ring inner side which is maintained in specific angle according to quality of pouch for export. For 1/2 kg dosage angle is 114°, where as for 1 kg it is 160°. When pouch moves downward, there is one set of jaw (called front jaw and rear jaw) and heat seal at the bottom of the pouch besides jaw keeps one knife which cuts the pouch in the bottom when this process continue, then automatically pack of pouches make. The pouches falls in the conveyer belt and the pouches reaches for continuous weighting which is pre set, and there is one sensor located which senses the weight. If the weight is below to the pre set weight, then pouch pushes out side and except it other pouches move to case packer through the conveyer belt. There are three sensors in the pouch film side. One is for sensing availability of film (if film is unavailable, machine will be stopped). Second sensor senses black rectangle of the film by which coding is possible (date, price etc.). Third sensor also senses the black rectangle, but it works for cutting the pouches. Another sensor is located in the machine which sense the door situation (if door will be open, then machine will be stopped). Specification of packaging Capacity - 65-130 Bags/min (according to quantity of powder)Density - Should be 0.400 g/cm³Volume of powder (in auger) - 150 cm³Weight of powder - 1000 g for pouchWeight of empty pouch - 13gTotal weight of filled pouch - 1013g

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QUALITY CONTROL LAB (AMUL 3) All products manufactured by dairy must comply with the legal standard and should be

acceptable by the consumers. To ensure this a quality control laboratory has been constituted. The product must be safe for the consumers and follow BIS and PFA standard. Also GCMMF has let down its own requirements for all the products.

In laboratory all the raw material, ingredients, products in progress, finished products as well as packaging materials are tested for their physical as well as chemical characteristics. In addition, the finished products and ingredients are checked for their microbiological quality to maintain hygienic condition in the production area. To ensure all the appropriate processing and processing parameters are followed, quality assurance personnel take a round in dairy plant and rectify any anomalies.

Lab technician collects product sample in the sample containers from each section mostly for various products. The sample is analyzed for various tests and result obtained is communicated to respective laboratory for reference. Sample meeting the desired standard of a particular batch that is passed for further packaging. Packaging material is also tested for required strength and leakage and graded accordingly. The products are graded according to PFA. Various tests conducted for different products are as follows

A) For Raw Milk - Amul dairy receives raw milk from village chilling units and other chilling centers, such as Kapadvanj, Khambat, Balasinor and Khatraj.Milk when received from different chilling units & societies is measured & sample is drawn for quality testing. The temp. Of milk should not exceed 8-10OC. A small bottle of milk is also given by the centers along with the Chelan data to compare the result of fat, SNF, acidity. This helps in determine whether adulteration has takes place or not during transportation. Following test are performed for raw milk;

1). Titratable acidity2). Clot on boiling3). Alcohol test4) Methylene Blue Reduction Test5) Fat test6). Determination of phosphatase activity

1) Determination of Titrable Acidity

Procedure - Thoroughly mix the milk sample & pipette out 10ml of milk in 100 ml beaker & add equal amount of water, & 1 ml phenolphthalein indicator. Rapidly titrate against N/9 Sodium hydroxide till pink colour comes which remains for 10-15 sec. NOTE- Acidity of raw milk should be between 0.12-0.14 % LA.

2) Clot on boiling - This is quick test to determine developed acidity & suitability of milk for processing.

Procedure - Transfer 5 ml of milk sample to the test tube & place it in boiling water bath for 5 min. Remove the tube & note it in an almost horizontal position & pour the content in a clean petri dish & examine for any precipitated particles.

Result - The formation of clot is indicative of positive test. 3) Alcohol test

Principle - The alcohol test is used for rapid assessment of stability of milk to processing particularly for condensing & sterilization. The test aids in detecting abnormal milk such as colostrums milk, mastatic milk, & milk in which the mineral balance has been altered.Procedure - Place 5 ml of milk in a test tube & add equal amount of ethyl alcohol (68% w/v). Mix the contents of the test tube inverting several times. Not any flakes or clot.

Result - The presence of clot or flakes denotes positive test. 4) Methylene Blue Reduction Test (MBRT)

Principle - This test is based on the oxidation-reduction potential. The speed of the reduction of the stain is an indication of rate of taking place.Procedure - Take 10 ml milk in test tube & add 1 ml of methylene blue solution & cork it. Incubate at 37 OC in water bath & observe the milk, colour at every half an hour till the blue colour of the dye in the milk decolourises. Note the time.

Result - Standard MBR time min. is 5 hours.

5) Fat test - The Fat content of raw milk is estimated with the help of an instrument known as milkoscan, which also gives the estimation of protein, lactose, SNF.The milkoscan is standardized in morning in term of fat & SNF content present in the milk sample, which has been gravimetrically tested for fat & TS.Procedure - The fat is tested by Gerber method. In this method, 10.75 ml of milk is taken in butyrometer & add 10 ml of Gerber sulphuric acid then add 1 ml of amyl alcohol & shake the content properly. Than centrifuge for 5 mins & note down the reading. Testing of adulterants of raw milk1). Urea Detection2). Ammonia Fertilizer detection 3). Nitrate Fertilizer / pond water test4). Starch & Cereal flour detection test5). Sugar / Sucrose detection 6). Glucose detection7). Salt detection8). Neutralizer detection 9). Hydrogen peroxide test10). Formalin detection 11). Test of ammonia compound12). Test of ammonia sulphate

B) For Table Butter1) Moisture content 2) Salt content 3) Curd (SNF) content

1) Moisture content Procedure

Weight a clean & dried flat bottomed dish, which is preweighed. Transfer of 10 ml sample into the dish & note the weight. Heat butter on a hot plate, rotate the dish while heating so as to aid the moisture to escape. Heat till light to dark brown colour appears, this will indicate that all the moisture is driven off. Cool the dish & contents to the room temp. & weighed the cool dish immediately. The percent of moisture is calculated from the loss in weight.

Calculation - wt. of moisture / wt. of butter × 100. Where, wt. of moisture = (wt. of dish + butter) – (wt. of cool dish) Wt. of butter = (wt. of dish + butter) – (wt. of empty dish)

2) Salt content Procedure

Firstly perform the moisture test. Add 100 ml of distilled water to the dish with residue.

Shake the contents thoroughly, so as to distribute the salt evenly through out the solution.

Pour the solution into a separating funnel.

Remove the brine solution, pipette out 10 ml of brine solution.

Add 4-5 drops of 5% potassium chromate solution, a lemon yellow colour is imparted.

Titrate with N/10 silver nitrate solution. The end point is indicated by the appearance of brown colour.

Calculation Salt % = ml of N/10 silver nitrate × 0.0585 × 100 /wt. of butter.

3) SNF (Curd) content Procedure

Firstly perform the moisture test.

Add 10-20 ml of petroleum ether to the residue.

Slowly heats until the sediment get dried.

Cool & weight.

Add 100 ml of water at 60 OC to the sediment & run the salt test.Calculation

Curd % = wt. of residue / wt. of butter × 100 Where, wt. of residue = wt. of sediment dish – wt. of empty dish

This gives total of curd & salt percentage. Subtracts salt % from the total %, this gives the curd %.

Result

Table butter content = 0.8- 0.9 % White butter content = 1.1- 1.3 % C) For Ghee1). Organoleptic grading test2). Moisture test3). Free fatty acid test

1). Organoleptic grading test - In this, ghee is taken & smell for any off flavour, uniformity of colour etc. Good quality ghee must be free from any off flavours & must contents pleasant nutty flavour & granular size.

2). Moisture test Procedure

Weight a clean & dried flat bottomed dish, which is preweighed.

Transfer of 10 ml sample into the dish & note the weight.

Heat the ghee in hot plate until appearance of dark brown colour & cool.

Wt. the cooled dish immediately.Calculation Moisture % = wt. of moisture / wt. of ghee × 100

where, wt. of moisture = wt. of moisture = (wt. of dish + ghee) – (wt. of cool dish)

3). Free fatty acidReagent - Nutrized spirit – Take 100 ml spirit & add 2-3 drops of phenolphthalein indicator, then titrate it with N/10 NaOH till light pink colour appears.Procedure

Take 9.4 ml of ghee in conical flask.

Add 50 ml neutralize spirit & put a cotton plug.

Place it on the hot plate till boiling.

Cool it at room temp.

Titrate with 0.1N NaOH solution using phenolphthalein as a indicator. Light pink colour appears.

Calculation Free fatty acid % =Titrate value × 0.3 D) For Flavoured milk1) pH reading2) Acidity3) TS4) Alcohol test5) Creaming Index

1). pH reading - measured by pH meter, it should be between 7-7.2.

2). AcidityProcedure

Take 10 ml of flavoured milk in 100 ml beaker. Add few drops of phenolphthalein indicator.

Titrate with N/9 NaOH solution, till light pink colour appears.

3). Total solids Procedure

Weight a clean & dried flat bottomed dish, which is preweighed.

Transfer of 2 ml sample into the dish & note the weight.

Heat till all moisture evaporates.

Cool the dish to bring down the temp. at room temp.

Again wt.. the dish.

Difference the wt. gives the % of TS

4) Alcohol testProcedure - Place 10 ml of milk in a test tube & add equal amount of ethyle alcohol (70 % w/v). Mix the contents of the test tube inverting several times. Not any flakes or clot.

Result - The presence of clot or flakes denotes positive test.

5) Creaming Index - It is one of the most important test by this, we can come to know the % of cream present in the sample. The creaming index should be less than 10.

ProcedureTake the milk & heat upto 21 °C, then transfer 50 ml of milk in two separate in round bottom tube.

Centrifuge 1100 rpm for 15 mins.

The fat – cream layer & non fat portion separate out.

Take out the fat- cream layer portion from both tube & assign it as (A).

Mix the non fat portion or the portion containing less fat assign it as (B).

Now both test tube portion A & B for fat content & note down the reading.

Calculation % creaming index = A-B / B × 100

E) For Milk Powder1) Moisture2) Reconstitution test3) Sieve test4) Coffee test5) Insolubility index6) Fat test7) Wettability test8) Bulk Density 9) pH10) Titrable acidity11) Grade test 12) Leakage test13) Nitrogen content test

Main Instruments in Laboratory

Sr.No. Equipments/ Instruments Test Carried1. Milkoscan Fat, Snf, Protein, Lactose

2. Flurophase Alkaline Phosphatase Activity

3. Biocounter For Swab Test

4. Auto Titrators Acidity

5. Conductivity Meters Conductivityof Cip Chemicals

6. Microwave Moisture Analyzer Moisture Detection

7. Ir Moisture Analyzer Moisture Detection

8. Stamp Volumeter Density Of Powder

9. Bursting Strength Analyzer For Packaging Material

10. Ph Meter Ph Measurement11. Solubility Index Mixer Solubility Index Of Powder

12. Laminar Air Flow Chamber For Microbiological Tests

13. Electronic Weighing Balance For Weighing Purpose14. Gerber Centrifuge For Determination Of Fat

15. Muffle Furnaces For Ash

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Microbial Analysis

Standard plate count (SPC) Procedure

Mix the sample thoroughly & transfer 10 ml of sample in 99ml of dilution blank in a UV chamber (Laminar Air Flow Chamber).

Water bath at 44°C.

Take 1 ml of sample & transfer second tube blank. Mark the dilution 1.

Take 0.1 ml from dilution (which is equal to 1 ml of third dilution & transfer to petri dish).

Pour 10-15 ml of standssd plate agar on a petri dish.

Mix the agar with inoculum gently by rotating the plates in opposite direction.

Allow the agar to set in about 5-10 mins, invert & incubate at 37°C for 48 hrs.

Name of organism Media used for cultivation

pH of the medium Appearance of the colony

Total viable count (SPC)

Plate count agar 7.0±0.2 --

Coli forms Violet red bile agar 7.4 0.2 Red / purple colonyY&M count Potato dextrose agar 5.6 0.2 White /grey

/yellow /black colony formed

E. Coli Eosine methylene blue agar

6.8 0.2 Green metallic sheene black centered colony

Salmonella Bismuth sulphite agar

7.6 0.2 Black metallic sheene

Shigella Brilliant green agar 6.9 0.2 Pink colorationStaphylococcus aureus

Baired parker agar 6.8 0.2 Black colony surrounded by clear zone

Bacillus cereus Bacillius cereus agar

7.2 0.2 Pink /white colony

Listeria monocytogens

Listeria agar 7.2 0.2 Black colony

Fecal streptococci MacConkeys agar 7.4 0.2 Pink colonyVibrio cholera Thiosulphite citrate

bile salt sucrose agar

8.2 0.2 Yellow colony

Anaerobic spores Liver meat infusion agar

6.9 0.2

ResultSPC per ml =no. of colonies × 103

(dilution factor) . Coliform Procedure



Take 1 ml of sample & transfer second tube blank. Mark the dilution 1.

Pour 10-15 ml of Violet Red Bile Agar (VRBA) on a petri dish.

Mix the agar with inoculum gently by rotating the plates in opposite direction.

Allow the agar to set in about 5-10 mins , invert & incubate at 37°C for 24 hrs.

ResultColiform per ml = no. of coliform × 102

Yeast & mould count Procedure



Transfer 1 ml of sample in a petri dish.

Add 10-15 ml of Potato Dextrose Agar (pH adjust to 3.5) & mix the sample.

Invert & incubate the plate at 21-25°C for 5 days.

Note the growth formation.

Result hite /grey /yellow /black colony formed. Shelmonella & Shigella Procedure



Taken 1 ml of sample in Petri dish & add 0.5 % of Brilliant green agar.

Incubate at 37°C for 20 hrs.

Taken 1 ml in 10 ml Selanight Broth.

Incubate at 37°C for 24 hrs.

Streak a loop ful of Bismuth Sulphite Agar spread on Petri dish by help of inoculation needle.

Incubate at 37°C for 24-48 hrs.

Result - Pinkish white colony with or without black centre.

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Agmark Analysis RM Value (Reichert - Meissl value): Principle: It is defined as no. of ml of 0.1 N aqueous alkali solution required to nutralised steam volatile water soluble fatty acid distilled from 5 g of fat. It is measure of butyric & caproic acid.

Procedure:

Weight 5 g Ghee in a 300 ml RM flask.

Add 22 ml glycerin & 2 ml of 50 % NaOH solution.

Heat the flask in a Bunsen Burner until the ghee is saponified & the liquid becomes perfectly clear & transparently.

Add 93 ml of boiled water ( boiled+ 5 min.) distilled water to the saponified ghee.

Add 50 ml of dilute sulphuric acid solution & add 5-6 glass beads.

Distilled it on a standard distillation apparatus. The distillation should take 20 min to get 100 ml of distillate in a standard 110 ml marked sugar flask.

Cool it to 15°C by help of chilled water.

Filtrate through Whatman filter paper.

Take 100 ml filtrate & titrate against 0.1N NaOH (V1).

Repeat the same procedure with blank (V2) without addition of ghee. Result

RM Value = V1 – V2 × 1.1 P value (Polanski value) Principle - It is defined as no. of ml of 0.1 N alkali solution required to neutralized steam volatile water insoluble fatty acid distilled from 5 g of fat. P value is the measure at caprylic & capric acid which are volatile & insoluble fatty acid.

ProcedureWeight 5 g Ghee in a 300 ml RM flask.

Add 22 ml glycerin & 2 ml of 50 % NaOH solution.

Heat the flask in a Bunsen Burner until the ghee is saponified & the liquid becomes perfectly clear & transparently.

Add 93 ml of boiled water (boiled+ 5 min.) distilled water to the saponified ghee.

Add 50 ml of dilute sulphuric acid solution & add 5-6 glass beads.

Distilled it on a standard distillation apparatus. The distillation should take 20 min to get 100 ml of distillate in a standard 110 ml marked sugar flask.

Cool it to 15°C by help of chilled water.

Filtrate through Whatman filter paper.

Wash the filter paper by 3 times with 15 ml cool distilled water. First pass water through condenser then through filter paper. Discard the filtrate.

Similarly wash the condenser & filter paper 3 times with 15 ml of neutralized rectified spirit.

Collect 45 ml of filtrate & titrate against 0.1 N NaOH solution (V1).

Repeat the procedure with blank (V2).

Result P value = V1 – V2.

Boudouin Test Principle - Vanaspati contains 5 % Sesame oil by weight. If ghee is adulterated with vanaspati, it can be detected as sesame oil, those gives crimson colour with furfural in the presence of conc. HCL. Procedure

Taken 10 ml of melted ghee in a test tube.

In another test tube mix 0.1 ml of furfural solution with 10 ml of conc. HCL (2 ml of furfural in 100 ml of 95 % alcohol is furfural solution).

Mix the melted ghee with furfural solution.

Shake well & allow it 10 mins. & observe the colour.

Result Presence of crimson colour indication of adultration of ghee with vanaspati.

BR Reading (Butyro – Refractometer Reading) Procedure

Clean the butyro-refratctometer with ether & dry.

Place 2-3 drops of melted & filtrate ghee on the sample of lower prism & enclosed it.

Maintain temperature around the 40°C by circulation of hot water.

Take the B.R. reading at 40°C.

Ghee (Agmark Special)Sr.No. Description Specification

1. Moisture % (Max) 0.3

2. FFA % (Oleic Acid) (Max) 0.753. B.R.Reading At 40 O C 40-434. P Value (Max) 1.0-2.05. R.M.Value NLT28

……………………….

Effluent Treatment Plant (ETP)

Introduction - For any industry ETP is very important as water of industry is recycle & then is used as the industry is having effluent treatment plant is so called environmental friendly industry. If effluent is not treated then will pollute the environment. As in this unit waste water of the whole units accumulated & is tried to be converted to the normal water, which can be safely use for irrigation purpose. As now-a-days the environmental load is very active & that check every month for the control of the pollution & if the industry effluent plant is found not proper grade than the board has full right to shut off the plant. Method of treatment Raw effluent - It is effluent of all production section including wash water.

Channel - It is small settlement tank which settles heavy materials. Gate valve - To pass or obstruct effluent to the next channel. Equalization tank - the effluent is collected in equalization tank through screens filter & oil trap. Air blowers are provided to maintain its uniformity. Normalization tank - If pH is less than 6 then 10 % solution of lime is added to maintain the pH 7-8. Fat separation tank - To separate the fat of effluent which come on top due to density differences. Aeration tank - Treatment to wash water is done at aeration tank. Oxygen to washes water is supplied by surface aerators. Clarifier - Effluent from aeration tank after treatment flows by gravity to clarifier where the sludge settles at the bottom end treated effluent over flows into the next clarifiers. It is tested one for pH, BOD, oil content & COD. The settle sludge is pumped brake to aeration tank. Excess sludge is pump to drying bed. Drying bed - The excess sludge gets dried by filtration & evaporation in drying beds. The filtered effluent goes by gravity to equalization tank.

Analysis procedure for industrial effluent Chemical oxygen demand (COD) Biochemical oxygen demand (BOD) Oil content pH suspended solid

The prescribed limit given by Gujarat Pollution Control Board (GPCB) Test Limit

Chemical oxygen demand (COD)

250 mg/l

Biochemical oxygen demand (BOD)

100 mg/l

Oil content 100 mg/lpH

6.5-8.5

suspended solid

100 mg/l

Chemical Oxygen Demand Principle - The organic matter of the sample is oxidized water, CO2, & ammonia by refluxion with a known excess of potassium dichromate in 50 % sulphuric acid solution. The excess di chromate is titrate with standard solution of ferrous ammonium sulphate solution. Usually silver sulphate is added as a catalase to promote oxidation of certain classes of organic compound as acetic acid, amino acids etc. mercury sulphate is added to eliminate the interference due to chlorides.

ProcedureTake 2 ml of sample in 18 ml distilled water.

Add 10 ml of 0.025 N potassium dichromate (K2Cr2O7) solutions.

Keep it for refluxing for 152°C for 2 hrs.

Add 70 ml of distilled water.

Cooling at room temp.

Add 3-4 drops of ferroin indicator.

Then titrate against 0.1N ferrous ammonium sulphate (FAS) solution.

The end point is sharp colour change from blue green to reddish brown.

Calculation (Blank reading – sample reading) × 8000 × N of FAS solution

COD mg/ l = ------------------------------------------------------------------------------ Ml of sample taken (20 ml)

…………………………

UTILITIES SECTION Refrigeration section

Introduction

Refrigeration is essential for preserving the dairy product such as butter, cheese. Butter & cheese are stored in cold storage. Additionally chilled water is required to chill the pasteurized milk & to store in the tankers are load it in milk tankers to be dispatch to the other places. Refrigeration is also required to cool packaging room & central laboratories.

Refrigeration is measured in tonne of refrigeration. It is amount of heat absorbed by melting 1 tonne of ice at 0°C into water at 0°C in 24 hrs. It is equal to 3000 kcal/ hrs, 50 kcal/ min, 200 btu/ min. Capacity of refrigeration plant is 1500 TR. Automation system

This system has facility that if maximum demand of energy crosses then the compressor automatically turns off. The entire such automation of each & every department of dairy industry is taken care of in this department. Additionally, it has facility for the discharge temp. of ammonia gas that is sets of cooling tower & condenser set on & off automatically. Refrigeration system

In AMUL plant we have ABB (Asea Brown Boveri) stal refrigeration section which is divided in 3 different sections:-

1) -2°C system: used for chilling the water.2) -10°C system: used for maintaining the temp. for ice silo.3) -30°C system: used for cold storage & deep freezer.

-2°C system has three compressor & three oil separators. -10°C system & - 30°C system each are having two compressors & two oil separators.

In all the three system screw type compressor are used.There are two liquid ammonia receiver tanks, each having capacity of 10,000 lit.There are two ice silos of 1.5 lakhs lit capacity in which water is chilled by liquid ammonia.There are 5 cooling tower & 5 condensers.

Control limit for ammonia gas compressor Condition Low Normal High Discharge pressure (bar)

----- 11.5 12.5

Condensed temp. (°C)

----- 32.0 35.0

Discharge gas temp. (°C)

------ 80.0 85.0

Compressor oil pressure (bar)

3.0 4.0 -----

Oil temp. (°C) 40 55.2 60.0Differential pressure across Duplex filters

------ 0.2 0.8

……………………..

Boiler section Introduction - Boiler is a closed vessel, constructed of steel in which steam is generated from water by application of heat.

The steam generated is used for producing power & for heating work in different section of dairy plant.

The function of steam boiler is to convert chemical energy of fuel by combustion into heat & to transfer this heat to water in produce steam. Types of BoilerIn AMUL, there are 4 boilers & 1 economizer. 3 boilers are fire tube horizontal boiler & 1 is driven by turbine.Type- COMBIMEX STEAM BOILER. It is twin drum fire tube horizontal boiler. Boiler specification

Boiler code no.

Heating surface area(m2)

Operating pressure( kg/cm2)

Capacity (ton)

GT/1673 350 12.9 13GT/1725 350 13.2 13GT/1674 350 12.4 13GT/3524 225 13.2 10GT/E-416 152 ----- ----- Note - 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. The boiler firing system is desire to operate on two fuels;

1). Natural gas2). Furnace oil

The water used for boiler it should be fulfill the following condition;

1). The pH of water is 8.5 – 9.5.2). Hardness 10 – 40 ppm.3). Chloride content 400-800 ppm.4). Total solid 300- 4500 ppm.5). Total alkalify 400 -1000 ppm.

The distribution of steam in different section

Boiler mounting The main function is to protection of boiler.

Safety valve Water level indicator Fisible plug Feed check valve Blow of check valve

Boiler accessoriesThe main function is to increase the efficiency of boiler & help in smooth working.

Feed water pump Injector Super heater Air preheater Economizer

Economizer - Main loss of boiler plant is heat carried away by fuel gases. The function is heat recovery appliance. Placed between boiler & chimney & path of feul gases to preheat feed water before it supplied to boiler, so it is increasing heating surface & also increase life & efficiency of boiler. ………………………….

Section Steam RateAmul-3 445Laboratory 452F-35 powder plant 524F-60 powder plant 457L & T powder plant 454ETP 461Flavoured milk 410

CHEESE PLANT, KHATRAJ

IntroductionKheda Satellite Dairy – Khatraj, inaugurated in 1996, by Prof. Madhu Dandvate, Deputy

Chairman- Planning Commission. Product manufacturing in KSD

1. Cheddar cheese (Raw cheese for Process cheese)2. Process cheese3. Emmental cheese

Uniqueness of KSD KSD is the largest cheese plant of Asia. In KSD, 50 % of Buffalo milk is utilized for manufacturing of cheese.

RMRD (Raw Milk Receiving Dock)

Milk Reception

Milk is collected at village societies (mandalis) and from there transported by trucks to the Dairy Plant in cans. In all 168-village societies supplies milk to Kheda Satellite Dairy (KSD). 19 routes are identified; mandalis on the same route bring milk in the same truck. Each route is given a specific time for the delivery of milk at the Dairy.

Each reception line is provided with a chain conveyer and a can washer. Cans are manually loaded on the conveyers from the trucks. The can lids are opened and the inside contents (milk) is agitated. The milk inside the cans is observed for any curd formation, and examined for other organoleptic tests. The name of the society from which milk is received is painted on the cans. The cans are conveyed to the tipping point where they are inverted manually and milk is taken in the weighing tank. A filter cloth is applied to the inlet duct of the weigh tank to remove any suspended foreign matter from the milk.

Milk from each society is weighted separately, for which cans from each society are emptied in weigh tank, the reading of the weight is recorded in the computer by the operator. Then the operator opens the pneumatic valve beneath the weight tank is opened and the milk is dispensed to the dump tank by gravity.

Two valves are there on the base of weighing tank, one opening in the buffalo milk dump tank and another in cow milk dump tank, which are opened according to the milk tipped in the tank (whether cow or buffalo).

Sampling of the raw milk is done from the weighing tank, which is taken to the laboratory for further analysis.

Different routes are identified for milk collection. The milk cans from societies lying on the same route are brought in the same truck. Trucks are loaded with the can in a specific sequence and unloaded on the Raw Milk Receiving Dock in synchronization with the sequence of list of societies in the computer.

The cans and the lid are placed (in inverted position) on the conveyer, which carries it through the straight through can washer. A drip saver is placed beneath the conveyer leading to can washer, to recover the residual milk dripping down the inverted cans.

After passing of milk to the dump tank the operator tares the digital weight indicator. Now the can from another society are emptied in the weight tank and so on.

Based on the weight of the milk received, each society is given the receipt of receiving milk.

There are in all three-dump tanks, two for buffalo milk and one for cow milk. For identification of cow milk and buffalo milk, the necks of cow milk cans are painted with red or green strips.The capacity of weight tank is 500 Kg and dump tank is:

Buffalo milk dump tank = 5000 liters (2 no.s ) Cow milk dump tank = 5000 liters (1 no.s)

From dump tank milk is pumped to the chiller (in processing section) via filter filters. Two separate duplex filters are installed for cow and buffalo milk. Filtration is carried in order to remove any foreign particles suspended in raw milk.

Tanker Bay Besides receiving milk in cans, milk is also received in tankers (skim milk for standardization). Skim milk is received in tankers which are utilized in standardization of cheese milk.

Tankers are filled and emptied at a site called "Tanker Bay." It has a plane horizontal cemented surface where the tankers are halted. Ata time four tankers can stand on the Bay. it also has a raised platform with stairs, having height justifying the height of a tanker so as to reach the top of the tankers ( for sampling cleaning etc.). Before arrival of the tanker at the tanker bay it is first weighted at the Weight Bridge. The weight of the incoming tanker is recorded and for empting of tanker a hose pipe is connected to the outlet of the tanker and the other end is connected to the inlet pipe of the filter (2 nos). A centrifugal pump then pumps the milk to the RMRD section. The pipe carrying milk is connected to the suction pipe of the centrifugal pump at RMRD (which is used for pumping raw milk to processing section). The milk is then pumped via buffalo milk filter to the processing section for pasteurization and then to silo number 5 or 6 for standardization of cheese milk.

PROCESSING SECTION

The underlying operations of processing section are Pasteurization

Standardization.

Whey processing (RO Plant).

Tanker loading and unloading.

Overview of Operations

Chilling of the milk received from R.M.R.D. marks the initialization of operations in the processing section. Chilling of raw milk is necessary to address the growth of microorganisms present in milk and thereby preventing its deterioration. Cow milk and buffalo milk is separately pumped from the dump tank via respective filters and are chilled in cow milk and buffalo milk chillers respectively.

Both the chillers are Plate Heat Exchanger type with a capacity of 30 KLPH the cooling medium used is chilled water. Milk is chilled to a temperature of 50C and transferred to intermediate tank, Cow milk and buffalo milk is pumped cow milk intermediate tank (CMIT) and buffalo milk intermediate tank (BMIT) each having a capacity of 20,000 Ltr. The milk and chilled water flow in a counter current fashion, which ensures maximum heat transfer.

The chilled milk is stored in buffalo milk intermediate tank and cow milk intermediate tank and then pumped to pasteurizer via a balance tank. The pasteurizer is again a Plate Heat Exchanger with a capacity of 30,000 LPH.

The pasteurized milk is then pumped to silo no. 5 and 6 (for cheese making), Silo no. 1 and 2 (for tanker filing). Pasteurization Pasteurization performed at 78±3°C.Importance of pasteurization from cheese making point of view:

1. To destroy all the pathogenic microorganisms and spoilage agent.2. To ensure uniformity of product

PHE Technical DetailsMake : Alfa Laval Capacity : 30,000 Ltr/ Hour Maximum working pressure : 6 kg/cm2

Material of construction : Stainless steel

Maximum working temperature : 1100CNo. of plates : 303

Sr. No. Section No. of plates 1. Chilling 512. Regeneration I 1383. Regeneration II 584. Regeneration III 275. Heating 296. Total 303

CIP of Pasteurizer & Milk Silo

CIP Steps Pasteurizer Milk SiloTemperature 0C

Time Min

Conc. ms

Temperature. 0C

Time Min

Conc.ms

Rinse Water

Ambient 15 - Ambient 5 -

Lye circulation

80 60 75 75 10 50

Hot water circulation

- 10 - - 10 -

Acid circulation

60 30 65 - - -


- 15 - - - -

Water rinse

- 10 - - 10 -

CIP of Storage Tank and Pipe Lines

CIP Steps Storage Tank Pipe Line Temperature. 0C

Time Min

Conc.ms

Temperature. 0C

Time Min

Conc.ms

Rinse Water

Ambient 5 - Ambient 5 -

Lye circulation

70 10 50 75 10 50


- 10 - - 10 -

Acid circulation

- - - - - -


- - - - - -

Water rinse

- 10 - - 10 -

Note - For pasteurizer : Lye conc. 0.75

For pipe line : Lye concentration 0.50 StandardizationCasein/Fat ratio = 0.7

Unlike other dairy product milk for cheese making is not standardized simply by adjusting the fat %, instead standardization of cheese milk is carried out by adjusting the casein /fat ratio of milk which must be 0.7

Significance

(1). To regulate the fat in the dry matter of cheese.(2. To producer the maximum amount of cheese per kg. of fat in cheese milk.(3). To ensure desirable body and texture characteristic in the finished product.

Approach

The % fat and % protein of milk estimated by the milkoscan. This gives rapid results as compared to other methods of estimation.

As it is known that 80% of milk proteins are casein, there fore the total casein % of milk is calculated by multiplying the % protein by 0.8 (80/100) which gives the % casein in milk. Now % casein is divided by %. Fat in milk. The resulted value is the C/F ratio of non standardized milk.

For a given % of casein, % fat is calculated which will give C/F = 0.7. Now the difference between this fat % and fat % of non-standardized milk is calculated, and fat % is reduced by adding proportionate quantity of skim milk.

Whey ProcessingIntroduction

Whey is the by product obtained during the manufacture of cheese, paneer Composition

Sr.No. Constituents Percentage (%)1. Water 93.12. Fat 0.33. Protein 0.94. Lactose 4.9

5. Ash 0.6

Whey has always been a bugbear for cheese manufacturers. The quantity produced is approx. 88% of the milk taken for cheese making, which itself poses a problem in handling of whey. Further, the low TS content and high acidity hinders the efficient utilization of whey.

Traditionally, whey was drained and no sort of commercial utilization technique was practiced. This is obviously undesirable both from economic point of view, and environmental aspect, as well.

Membrane Processing

Dairy industry witnessed a real break through in the whey processing with the advent of Membrane Processing Technology.

The membrane separation processes are based on the ability of semi-permeable membranes to discriminate between molecules on the basis of size, shape & chemical composition. The role of a membrane is to act as a selective barrier. It permits the passage of certain components, referred to as 'permeate' and retains certain other components concentrate or 'retenate' of a fluid mixture.

Ultra Filtration (UF) is a fractionation process separating molecular species on the basis of size, using a membrane, which retains the large molecules and allows water and other molecules to pass. Thus from milk, some water, salts and lactose can be filtered out, leaving a concentrate richer in protein and fat. Reverse Osmosis (RO) is similar in operation to UF. But employs a tighter membrane able to pass water only. The RO is therefore, concentration process. In the UF & RO processes, the solution is forced through the membrane under pressure and particles with a sufficiently high molecular weight are separated.

Permeability of milk and/or whey components through different membrane systems

Milk/Whey components Type of membrane system RO NF UF MFWater P P P PMinerals R P P PLactose, AA & NPN R R P PProteins R R R RFat and bacteria R R R R RO - Reverse osmosis; NF: Nanofiltration: UF: Ultra filtration; MF: Microfiltration; AA Amino acids; NPN: Non protein nitrogen, P: Pass through the membrane into permeates; R: Rejected by the membrane and retained in the retentate; Flow process chart

Whey (6% TS)

Whey tank (No. A (Balance Tank A)

Feed Pump

Filter

Damper (For removal of air)

High Pr Pump (Reciprocating)

Dampener HPA-I Water (Concentrate from HPA-1)

Whey tank B

Feed Pump

Filter

Dampener

High pressure Pump

Dampener

HPA II

Water Whey concentrate (16% TS) Tank C

Pumping

Chiller HMST (Capacity 15 KL- 15000 L Make: Grasim Industries)

Tanker

To Anand Whey powder (at F- 35)

RO Plant at Kheda Satellite Dairy

Whey produced during cheese manufacturing is separated and whey fat is removed. The whey is then chilled (upto 7-80C) and then pumped to silo no. 3 or 4. From whey silo it is pumped to balance tank (Tank A). Tank A is fitted internally with coils, in which hot water is circulated through a hot water set & pump assembly. The temperature of whey is brought upto 18-250C .A feed pump then pumps the whey to the micro filter module at a pressure of 3-4 kg/cm2 which is a type of duplex filter. The fat residues in the whey are separated and the whey is passed to the dampener. A pressure drop of 0.5 to 1 kg/cm2 occurs in the microfilteration module and the outlet pressure is the range of 2.5- 3.00 Kg/cm2 The dampener removes the air bubbles from the whey if any.

The whey is then pumped by a high pressure reciprocating pump (Triplex Plunger Pump) to the 1st stage of the NF set (HPA-I). The inlet pressure must be in the range of 11-15.5 kg/cm2.

Filtration of whey is carried out. Only water is permeable through the nanofilters &the rest solids are retained back in the concentrate which respectively constitute the permeate and retentate. The whey concentrate (retentate of HPA-I) is led to the tank B and water (permeate) is used for irrigation purpose.

The whey, after passing through the HPA-I, NF modules has a TS content of 12-13%. The partially concentrated whey is now pumped by the feed pump to another set of micro filters and to Dampener. A high pressure reciprocating pump then pumps the whey to the HPA-II .NF modules at the pressure of 12-18kg/cm2 .Water is further removed from the whey and thus the latter is concentrated to about 16%TS. A pressure drop of 1-1.5 kg/cm2 will occur in the HPA-II and outlet pressure will be 11-17 kg/2 . This concentrate is passed to tank-C. From Tank-C it is passed to a chiller (PHE type) so that outlet temperature is about 5-60C. They chilled concentrated whey is stored in Horizontal Milk Storage Tank (HMST). From where it is filled in tanker and transported to Anand (AMUL) for whey powder manufacture.

Standard operating parameters

HPA-1Inlet

Temp.Micro filters

pressure (kg/ cm2)

Nano filtration pressure (kg/ cm2)

Flow (m3/ hr)

Inlet Outlet Inlet Outlet Concentrate Concentrate Retentate

Permeate

18-25 3.0-4.0 2.5-3.0 11-13.5 9-12 2-3 9-11 2-3

HPA-IIOutlet Temp.

Micro filters pressure (kg/ cm2)

Nano filtration pressure (kg/ cm2)

Flow (m3/ hr)

Inlet Outlet Inlet Outlet Concentrate Concentrate Retentate

Permeate

5-6 3.0-4.0 2.5-3.5 12-17 11-15 1.5-2.5 5-7 05.-1.0

System Details Make : Permionics Year of Installation : Jan-2005System : Two a stage HPA membrane No. Of membrane modules : 1st stage-12 2nd stage-6 Size of membrane modules : 8" Diameter x 40" long (each) Module specification - HPA 250Limiting conditions of whey solution to micron filter Oil & Grease NilTS 5-6.5%FAT < 0.5%Free organics Nil Free chlorine NilTemperature Max 15-200CIron as Fe3+ Less than 0.1 ppmS.S.Load Less then 5 ppm Operating Parameters1st Stage HPA system 1 Feed quality - as mentioned in (above) Table-12 Permeate quality - Clear water with salt3 Feed flow rate - 83.3 LPM (i.e. 5000 LPH)4 Permeate flow rate - 41.67 LPM (i.e. 2500 LPH)5 Concentrate flow rate - 41.67 LPM (i.e. 2500 LPH)6 Concentrate recycle - 136.67 L PM (i.e. 8200 LPH) 7 System recovery - 50% + 2%8 Operating pressure - 400 PSI9 Operating temperature - 15-200 C 2nd Stage HPA system 1 Feed Quality - Reject of 1st stage system2 Permeate quality - clear water 3 Feed Flow rate - 41.67 LPM (i.e. 2500 LPH)4 Permeate flow rate - 16.67 LPM (i.e. 1000 LPH)5 Concentrate flow rate - 25.00 LPM (i.e. 1500 LPH)6 Concentrate recycle flow rate - 78.33 LPM (i.e. 4700 LPH)7 System recovery - 40% + 2 %8 Operating Pressure - 400 PSI9 Operating temperature - 15-200 C

10 Overall Recovery - 70%11 Overall permeate flow - 58.33 LPM (i.e. 3500 LPH)12 Over all concentrate flow 25.00 LPM (i.e. 1500 LPH) - Composition of whey concentrate

Constituents PercentagesWater 83-84

Fat 0.5-0.6SNF 16-16.5

Lactose 14-14.5Proteins 2.3-2.5

CIP of NF Plant

(1). Balance tank A is filled with water at the ambient temperature & is circulated for 30 minutes.

(2). Meanwhile, CIP solution is prepared in a separate tank, provided in the plant. The contents of the CIP solution are:

EDTA (Ethylene Di-amine Tetra Acetate)-2kgSLS(Sodium Lauryl Sulphate)-250gramLye-3 litersSMBS(Sodium Metabisulphate)- 3kgWater-200 liters

(3). After circulation of water, CIP solution is circulated for 20 minutes.(4). Then, normal water is circulated for about 30 minutes, till clear water is achieved at the outlet of NO plant.Note: pH of CIP solution should be 11.0-12.0.

Cheese Manufacturing Section

Introduction

This section involves manufacturing of cheddar cheese from standardized milk (C/F = 0.7). Mechanization of cheddar cheese manufacture involves State of the art technology with highly sophisticated equipments coupled with PLC control. CheesePFA Definition

(Hard) Cheese means the product obtained by draining after the coagulation of milk with a harmless milk coagulating agent, under the influence of harmless bacterial cultures. It shall not contain any ingredients not found in milk, except coagulating agent, sodium chloride, calcium

chloride (anhydrous salt) not exceeding 0.02 % by weight, annatto or carotene colour, and may contain certain emulsifiers and / or stabilizers, namely citric acid, sodium citrate or sodium salts of orthophosphoric acid and polyphosphoric acid not exceeding 0.2% by weight; wax used for covering the outer surface should not contain anything harmful to the health. In case the wax is coloured, only permitted food colours, may be used. Hard cheese shall contain not more than 43.0% moisture and not less than 42.0% milk fat of the dry matter. Hard cheese may contain 0.1 % of sorbic acid or its sodium, potassium or calcium salts or 0.1% of nisin.

Principle of Cheese Making

Cheese making involves coagulation of milk protein (casein) by the action of rennet. Before addition of rennet, starter cultures (LAB) are added to provide congenial conditions for the activity of rennet. Starter culture is rightly called "Heart of the Cheese" as it is heart not only furnishes favorable conditions for rennet activity but also aids in flavor development during ripening and generation of special features in some varieties. (Such as eye formation in Swiss cheese).

The coagulation of milk protein is carried out by milk coagulation rennet, which is basically a combination of enzymes rennin (Chymosin) pepsin, principally the former being responsible for milk clotting and the later for proteolysis. Principle of Rennet Action / Mechanism

Rennet contains enzyme rennin (80%) and pepsin (20%). Rennet brings about clotting as well as proteolysis in milk during cheese making. (A) Clotting Action

Clotting process occurs in two stages: First, a specific action of rennin on the caseinate and second coagulation or clotting of the product under the influence of calcium salts in the milk. It is easy to separate the two stages by manipulating the temperature or the calcium content. First Stage (Destabilizing Stage):

In this stage it appears that rennin induces a specific irreversible change in the casein. This change is only very slight since the altered product (often called as "paracasein") does not differ detectably from the original case in most properties. In this step casein micelle is destabilized by disturbance of its colloidal nature as a result of action of rennin on K-casein fraction of casein, as indicated below. RenninCasein micelle Para K-casein + Glycomacropeptide(K-casein)

The above reaction is due to the cleavage of peptide linkage between amino acids at 105 and 106 positions in the peptide chain of K-casein, which has a total length of 169 amino acids.

K – Casein

Pyroglutamyl ----- Phe Net ----- Valine 105 106 169Para K – casein K – caseinomacropeptide

Rennet

(B) Second Stage (Coagulation Step)

The paracasein obtained after destabilizing of K-casein is almost similar in properties to the original casein fraction, of milk. However, the most spectacular difference in properties between the intact casein and rennet treated case in is the sensitivity to precipitation by divalent cations, such as calcium. Rennet treated casein (para casein) gets quickly coagulated in presence of calcium ions. The reaction takes place as follows. Para K-casein + Ca2+ Calcium para K-caseinate

(Clot) (C) Proteolytic Action

Milk proteins are broken down to peptides of varying lengths due to rennet activity mainly during ripening of cheese. The primary action consists of a mild proteolysis of the case in involving the liberation of small amount of a peptide or more than one peptide from the molecule. Rennin has been found to have this action on -casein but not on - or - casein. About 2% of the total nitrogen of -casein is thus liberated in the form of low molecular weight peptides. Before the product is rendered coagulable with calcium. Rennin Protein Peptides

(-casein)

Process flow chart (Cheddar cheese)

Receiving Cheese milk (C/F – 0.7, Fat/SNF – 4.5/9.5 acidity 0.12 - 0.13%)

Balance Tank PHE (31-35°C, Capacity 18000 L/h) Milk is taken in Vat (capacity- 15000 ltr.) Culture Addition (@ 1.5 % at 31°C)

Acidity development (0.02 % LA) Renneting (@ 1.2-1.4%, Chymex)

Setting (1 hour) Cutting (10 min) Cooking (36-400C for 30-40Minutes)

Stirring of curd (15 min)

Transferring to cheese master Drainage of whey Cheddaring Milling

Salting (@ 2%) Mixing with Agar

Transferred to cheese tower

Hooping (Get its final shape and 20 kg blocks are made) Pressing of blocks

Coating in barrier bags

Sealing (applying vacuum)

Blast store (10-12°C) Cold store (5-6°C)

Details of Manufacturing1. Receiving cheese milkCheese milk is received from processing section where it is pasteurized and standardized

(for C/F = 0.7) cheese milk is stored in Silo No. 5 and 6 in manufacturing section. Milk from silos is sampled and sent to laboratory for checking the C/F ratio and for alkaline phosphatase test etc.

2. PreheatingCheese milk is pumped from silo to a pre-heater (plate heat exchanger) via a Balance Tank

where it is preheated to a temperature of 310C.Purpose: To provide optimum condition for culture and rennet activity.

3. Receiving Milk In VatThe preheated milk is then pumped to the "Double O" Vat. About 15000 ltr. milk is taken

for one batch. The milk is continuously agitated in the vat.

4. Starter Culture AdditionPurpose

1. The basic purpose of addition of starter culture is to increase the acidity and decrease the pH so as to furnish congenial condition for rennet activity.2. To produce flavour compounds during ripening of cheese.Starter Culture is prepared in a separate room. For culture preparation, the freeze dried mesophilic homo-fermentative culture preparation is added to 1000 lit of milk which is first preheated to 900C and then cooled to 35-400C, followed by incubation for 8 hr. The final acidity of culture is about 0.5-0.6 % LA..Starter culture is added to vat @ 1-1.5% of milk. The acidity is allowed to develop for 30 min to the extent of 0.02% from the initial level of acidity of milk.

5. RennetingPurpose - The purpose of rennet addition is to coagulate milk protein (casein) and formation of a firm curd.Approach - After proper development of acidity renneting is carried out. The commercial rennet preparation "Chymax", prepared from Aspergillus Niger var. awameri by recombinant technology (supplied by Chr. Hansen) is used for carring out the coagulation of milk. This preparation is in granular form and is added with 20 to 30 times its weight of potable water having neutral pH. This solution is then added to cheese milk in the vat. Stirring is continuously carried out for mixing of the rennet.

6. Setting

Purpose - The purpose of setting is to give sufficient time for rennet action which will result in a firm curd.Setting is done by leaving the milk in vat undisturbed for 1 hour.

7. Cutting

Purpose: - The basic purpose of cutting is to increase the rate of whey expulsion from the curd by increasing the surface area for removal of whey.Cutting is carried out by rotating blades for 10 min after cutting.

8. Cooking

Purpose – cooking aims at further contracting of the curd particles and expulsion of whey. These changes are manipulated by temperature and agitation during cooking.

Approach - cooking is done by circulation of steam in the jacket of the double O vat. Cooking temperature vary in the range of 36 to 400C for 30 min. Acidity of the curd drops down during cooking due to continuous expulsion of whey (syneresis) from curd pieces and attains a final value of approximately 0.09 to 0.1. After the cooking is completed a sample is drawn out of the vat and tested for acidity and pH. After cooking is completed the curd mass is stirred for 15 min.

9. Transferring To Cheese MasterThe curd whey mixture is then transferred from the vat to the top of the cheese machine

(also called cheese master) where it falls on the first belt. The curd whey mixture is uniformly distributed on the belt where most of the whey is removed which is collected in the whey sump. The curd pieces moves with the belt and passes through stirrers which adds in further whey drainage. Here matting and fusing of the curd is done. It is then transferred to the second belt where the mat is inverted and cheddaring takes place at the end of second belt the curd is milled to chips of uniform size which falls on the third belt. After milling dry salt is sprinkled on the curd pieces. Further stirring is carried out for efficient mixing of the salt. On the first belt the acidity of the curd is about 0.118% LA and it increases gradually as the curd moves forward on the belt and is reaches to final value 0.68 to 0.70 %LA on the third belt.

Due to salting of the curd further whey removal occurs this salted whey is collected in a separate sump from where it is pumped to salted whey tank. In salted whey tank gravity separation is carried out which results in separation of fat which is recovered and filled in cans. The remaining salted whey is drained out.

The whey collected in the sump of first and second belt is pumped to a fine siever where by the application of the centrifugal force suspended curd particles and whey is separated. The whey is then transferred to a whey intermediate tank. From this tank it is passed on to a separator where fat is centrifugally separated from the whey The fat is transferred to a whey fat tank and the defatted whey is transferred to silo 3 and 4 via a chiller (plate heat exchanger). From where it is transferred for membrane processing. The fat is taken in cans from the whey fat tank and is transferred to Anand for Ghee making.

10. Transfer To Cheese TowerThe milled and salted chips (curd pieces) are drawn by vacuum to the top of the cheese

tower. The tower is filled; curd begins to fuse into a continuous columnar mass. Regular blocks of identical size weighing 20 kg are automatically guillotined (G-cut), then pressing of each block is carried out at a pressure of 6 kg / cm2 for 39 sec. during pressing some whey is remove from the block which is removed and transferred to tower whey tank.

Multilayer cryovac barrier bags are applied to the door of the tower. The block is ejected and bagged which is manually pulled out and put on the conveyor.

11. Vacuum Packaging Of Blocks

Purpose1. To protect the cheese from attack by molds, insects and fault inducing microorganisms.2. To prevent moisture loss from cheese blocks during ripening.

In the vacuum packing machine first of all the air inside the bag is evacuated and the open ends of the bag are sealed.One of the major advantage of vacuum packing is that it eliminates the requirement of humidity control in ripening room.

12. Weighing Of BlocksAfter the vacuum packing of blocks each block is weighed on the weighing machine and

its weight is recorded.

13. Transfer To Blast RoomBlocks are kept in crates which are then transferred to the blast room. In blast room cooled air at about 80C is circulated at high velocity. Blocks are kept in blast room for 8 hours.

Purpose1. To reduce the temperature of cheese blocks to arrest microbial activity. 2. To reduce the heat load in the cold storage.

14. Curing Of Cheese

The curing or ripening of cheese involves storage of green cheese for two months or more according to requirements of processed cheese, for a temperature about 5-6 0C. Profound changes occurs in the physical, chemical, and bacteriological properties of cheese due to activity of starter organisms and enzymes as a result of which protein breakdown, fat hydrolysis etc. occurs, which results in the production of flavour compound and imparts desirable body and texture characteristics. Description of Equipments

(A). Double O vatThis type of cheese vat resembles an open figure of eight, and can be used for production of

curd for majority of cheese varieties. The capacity of vat is 15000 lit. The vat is totally enclosed. Double blades operate in one direction for stirring and reverse for cutting. Cheese making operation starting from addition of culture to the cooking of curd is carried out in the double O vat. The local PLC system attached with the vat helps in carrying out various operations with efficient control. The construction the vat offers improve cheese yields production of consistent high quality cheese and minimizes fat and curd fines loses in the whey. There are 4 such vats in the manufacturing section.

(B). Cheese MachineCheese machine is also called as cheese master (Make: Wincanton Engineering). It is

highly advanced mechanized cheddaring machine. In this, the curd whey mixture is uniformly distributed on a special drainage screen where most of the whey is removed. The curd then falls in the first belt, which has stirrers for further whey drainage. In cheese machine, there are in all 3 belts each of which made of Teflon and perforated for removal of whey. The top and bottom belt moves in same direction while the middle one moves in opposite direction. The belts complete

one rotation in 30 min . matting and fusing begins in the first belt itself. It is then transferred to the second belt where the mat is inverted through angle of 900 which results in cheddaring of curd in due course. At the end of second belt the curd is milled into chips of uniform size which falls on the third belt. The milled curd is salted by the to and fro motion of the sprinkler. Stirring is carried out for proper mixing of salt.

(C). Cheese Tower (The block former system)Critical problem in cheddar cheese making has long been that of producing well formed

uniform blocks. The block former, utilizing a basically simple system of vacuum treatment and gravity feed solves this problem. The continuous block former has eliminated the use of moulds.

The milled and salted chips are drawn by vacuum to the top of the tower. The tower is filled and the curd begins to fuse into a continuous columnar mass. Vacuum is applied to the column throughout its height to deliver a uniform product, free from whey and air, at the base of machine. Regular blocks of identical size, having a weight of 20 kg, are automatically guillotined (G-cut) i.e. they are cut from the continuous column. The blocks are then pressed to a pressure of 6 kg / cm3 and then automatically ejected and bagged by opening the door of the tower.

High capacity is achieved by linking all the three towers together.

CIP of Cheese Tower, Cheese Vat and Cheese Machine

Rinse

TimeLye Hot

waterAcid Hot

waterRinse waterTime

minTemperature 0C

Conc. Ms

Time min

Temperature 0C

Conc. MS

Cheese Vat

5 10 700 50 10 -- -- -- -- --

Cheese machine

3X7 6X7 85 75 6X7 -- -- -- -- 6X7

Cheese tower

5 15 75 55 15 -- -- -- -- 15

Manufacturing of Processed Cheese

Selection of raw material (75% young cheese & 25% old cheese)

Computation of ingredients

Cutting

Taken in Stephan coocker

Addition of other ingredients & water

Blending

Thermal Processing [850C for 3-5 min] Packing

Storage (5-100C) Ingredients used in processed cheese

In manufacturing of processed cheese following ingredients are added to raw cheese and each ingredient plays very important role in body, texture, appearance, taste and keeping quality of final processed cheese. These ingredients are;

i). Waterii). Salt iii). Sodium Citrateiv). Citric acidv). Tricalcium phosphatevi). Sodium hexameta phosphate, vii). Sorbic acid and Nisin

Besides these basic ingredients other optional ingredients can also used for their specific utilities viz. skim milk powder and / or whey powder DSP (Di sodium phosphate), butter etc.

Function / Role of Basic Ingredients in Processed Cheese1. Water - To maintain the moisture and body of final product as per its packaging requirements.2. Salt - It enhances sensory attributes in processed cheese and complements the final taste of the product. It also acts as a preservative.3. Sodium Citrate - It regulates the body and texture of processed cheese. It gives specific soft and smooth body and texture characteristics in finished product. It also produces desirable melting and slicing properties in the finished cheese.Sodium citrate acts as a emulsifier and it binds calcium which is necessary to stabilize the cheese, so that it will not release moisture or fat during heating.4. Citric Acid: - It acts mainly as a acidifying agent and regulates the pH of final cheese.5. Tri calcium phosphate (TCP) - Tri calcium phosphate is added to the processed cheese batch only when slice is prepared. The basic purpose of TCP is to provide a shining appearance to cheese slices.6. Sodium Hexametaphosphate - Sodium Hexametaphosphate is added to the processed cheese when intended for chiplet form of packing. Sodium hexameta phosphate impart specific anti threading property, which is important during filling of the cheese through nozzle in the cup formed by the body foil.

7. Sorbic acid and Nisin - These acts as a preservative and enhances the shelf life of the product. Sorbic acid is a antifungal agent and nisin is particularly effective against the Gram positive bacteria.

Procedure1. Selection of Raw (Natural) Cheese

Selection of raw cheese mainly depends upon the desired flavour, body and texture and end use of final product. Raw cheese is selected under the criteria of type, flavour, maturity, texture composition and pH.

Relatively young cheese produces mild flavour, smooth texture, firm body and has good slicing properties, while older well cured cheese produces a strong flavour, grainy texture, weak body and has poor slicing properties. Highly acid cheese tends to produce a grainy texture.

2. Computation of Ingredients

After selection of raw cheese for blending, ingredients are divided and their amounts are calculated. It varies according to final a body and texture characteristic requirement which mainly depends upon its packaging form. For example in the chiplet packing, the mechanism needs to avoid thread formation in processed cheese which is normal characteristic of a normal composition of processed cheese hence for this requirement we have to add. The anti threading agent "sodium hexameta phosphate" to the processed cheese and similarly in slice packing, the cheese requires soft body and shining surface with some sweetness in taste. Hence here the ingredients are changed rather than the ingredients of chiplet form of cheese. Hence computation of ingredients is done for following purposes.

1. To achieve desired body and texture characteristic in final cheese2. To achieve legal standards in quality of cheese.

Quantity of ingredients is calculated for 66 kg of raw cheese while during calculation the quality standards are kept in mind.

Raw cheese is tested regularly for fat salt, moisture and pH, and a quality standard is prepared previously for each packing form of processed cheese in which required maximum level of fat salt, moisture and pH are described.

Quality Standard for Processed Cheese Processed cheese for Chiplet, Tin and Refill packing

Moisture 44 - 46.5%Salt 1.9 – 2.1%Fat 28 – 30%PH 5.4 – 5.6

Processed Cheese for Slice PackingMoisture 46-48%

Salt 1.8-20%Fat 28-30%PH 5.6-5.8

Major ingredients like water, salt and citric acid are calculated to achieve the above quality standard in final processed cheese while some essential ingredients like raw cheese, TCP, sodium hexameta phosphate and preservatives are added in fixed quantity to each batch.

Ingredients QuantityRaw cheese 66 kg

TCP250 gm

Sodium Hexameta phosphate 400 gmPreservative 70-100 gm *Sodium citrate 1800-2000 gm*

* Varying according to form of packaging of processed cheese. ssssssssssss

3. Blending Blending is the operation of bringing together for processing cheese of different age groups.

Purpose1. To prepare a separate batch for processing2. To facilitate subsequent operationsAfter selection of raw cheese they are arranged in a batch. Each batch contains 10 blocks of

raw cheese and each block having average weight of 20 kg. Blending is done 24 hours before processing. In the mean time tempering of cheese block is carried out.

Advantages

1. It makes a separate batch of raw cheese being special formulae for a special quality of processed cheese.2. It facilitates subsequent operations.3. Makes easier to handle the batch and programme planning for production of processed cheese.

4. Tempering And Cleaning

Tempering of cheese refers to brining it to proper consistency or hardness and cleaning refers to the removal of inedible portion of cheese before processing. Tempering Purpose:-To bring the cheese to proper consistency or hardness that facilitates subsequent cutting process.

Before blending the cheese blocks are stored in curing room at about 9 – 100C at this stage it is very hard and difficult to cut into pieces. Hence after blending the cheese blocks are brought to blending room from the curing room where it is kept for about 24 hr during this time the

cheese blocks attains a temperature of about 210C. Now the tempered cheesed blocks have achieved proper consistency and hardness and are ready for cutting. CleaningPurpose - 1. To remove inedible portion from cheese.

2. To prepare the raw cheese for processing Before cutting the multilayer plastic bag is teared off and any undesirable portion of cheese

is scarped off.

5. CuttingBefore processing each block of tempered cheese is cut into 12 pieces.

Purpose:-1. To facilitate subsequent processing operation.2. To facilitate dividing each batch of raw cheese into 3 lots for processing.

For cutting of raw cheese it is first cleaned and then feed into a machine called cheese cutting machine or cheese cutter. In the machine two pushers are assembled perpendicular to each other which work in synchronization with each other. Machine is operated automatically. The cheese block is cut into four pieces and then it pushes across 2 wires by next pusher and each quarter of one block is cut into 3 small pieces consequently one block of 20 kg of cheese is cut into 12 pieces of equal size and shape.

After cutting one batch of raw cheese having total weight of 200 kg is divided into 3 lots hence each lot of cheese will contain 66 kg of raw cheese. During dividing into 3 lots precaution should be kept in mind that equal portion of each cheese block should be distributed into each lot. For this 4 pieces out of 12 pieces of one block are taken in each lot. Therefore 3 lots are prepared for processing to processed cheese.

6. Addition of Water And Other IngredientsAfter preparation of lots, one lot of 66 kg of raw cheese is fed into a Stephan cooker also

called kettle for cooking of cheese. Before cooking of cheese the calculated amount of water, salt and other essential ingredients are added to the batch and then it is processed in the kettle.

7. Thermal Processing / Cooking of cheeseThe mixture is heated in steam-jacketed kettle at a temperature of 850C. Agitators in the

kettle constantly agitate the mixture during heating to avoid scorching. The cooking process takes place under vacuum which offers advantage from the point of view of heating and emulsification. Vacuum decreases the boiling point of mixture which prevents heat damage to the product and also it removes undesirable odors and flavours and makes it easier to regulate the moisture content.

Due to heating processed cheese mass acquires more plastic, homogeneous smooth and glossy characteristics.

Three different speed options are provided in the kettle, viz. slow, middle and fast. During start of the batch, the agitator is run in slow mode with steam circulation in the jacket. When a temperature of 700C is achieved, the speed is turned on to middle, and is maintained to a temperature of 850C. This takes around 3-5 mins after which steam supply is cut off and agitation is stopped and the bleeder valve is opened to release the vacuum. The lid of the kettle is opened and the processed cheese is transferred to a pan by inverting the kettle.

8. PackagingIt is very essential that packaging of processed cheese is carried out when it is hot;

otherwise it gets solidified on cooling and will not be able to pack in any form. Hence as soon as the processed cheese is obtained in pan it is pumped to the hopper of packaging machines. Processed cheese is packed in four different forms viz.

Chiplet Slice Tin Block (or refill) Each packaging form have a specific machine which utilizes special mechanism for forming

of package filling of processed cheese and sealing. Packets / Tins of processed cheese are weighted and are arranged conveniently in cartons, which are sealed with tapes. Packaging Forms and Machines

(1). ChipletChiplet is cuboids in shape and weights 25 gram.Make: Sapal (Switzerland)Capacity: 500 chiplets / min (max.)Packaging material used: Aluminium foil.

Operation

Body foil roll and lid foil roll is loaded in the machine. Body foil is cut into octagonal shaped pieces. Four pieces are made at a time. The product is then intermittently filled in the body foil of chiplets four at a time. The top lid also made up of aluminium foil is cut in square shape and put on the top of body foil that covers the product. The sides of chiplets are then folded in a folder machine. The folded ends of chiplets are sealed by heat sealers. The chiplet is then taken out of the cup by lifting the table. Now the chiplets are placed on the conveyer belt where they are manually picked, kept in cardboard boxes to which stickers are applied and placed on a conveyer. The conveyer carries the boxes beneath a printing machine where batch no, date of manufacture and MRP is printed.

(2) SliceMake: Green Bay Machinery (GBM), USA

Capacity: 600 Slices / MinPacking material used: LDPE

The mechanism of slice making of GBM closes resembles the form fill seal (FFS) machine. In GBM machine the product is pumped from a balance tank and filled in a continuous film of LDPE which is vertically sealed just before filling of the product. This continuous film is sprinkled with coldwater. The film then passes through a bath of potassium sorbate, which acts as a antifungal agent. The film then passes through a roller which creates the final shape of the slice. The gaps generated by the rollers are sealed by horizontal scalers and witting is done from same position. The cut slices are arranged in 3 stacks each having 10 slices.

The GBM machine is coupled with Hayseen RT 1000 (modified atmospheric packaging machine).

The roll of Biaxial Oriented Polypropylene (BOPP) is loaded in machine.As the roll moves forward the batch no., date of manufacturing and MRP is printed.Further it comes on a belt conveyor on other hand lots of 10 slices are arranged manually in chain conveyor that carries the slices to the belt conveyor on the package. The package is then sealed vertically which makes an enclosed chamber.The mixture of N2 and CO2 in ratio of 3:1 is forced in the enclosed film which removes the oxygen.The packets are then sealed, cut and weighted and packed in cartons.

(3) Tin

Make of machine: - GastiPackaging material used: - Tin (Coated internally with food grade epoxy phenolic lacquer)Final Weight: - 400 gm

Operation

The machine consists of a long conveyor on which tin cans are placed upside down after passing over a vacuum pump, which removes adhering dust inside the can.The can then moves through conveyor and is filled with processed cheese which is being pumped from the kettle assembly to the hopper of filling unit.The bottom of hopper is fitted with an arrangement (piston and cylinder) which allows intermittent filling of the product.The can moves below of the hopper and is filled with the product.After some length, bottoms are placed manually on the tins and they are allowed to move to the sealing machine.The sealing machine presses the bottom on the can and seals themThe cans are then cleaned for any product residues which may be sticking to the outside surface.The cans are now dropped from chain conveyor to belt conveyor. The belt conveyor moves the bottom can surface beneath the printing machine which prints the batch no., date of manufacture, and MRP.Plastic lids are applied manually on the top of the can and then they are loaded in crates. One crate contains 45 cans. The cans are then placed in cartons, one carton contains 36 cans.

(4) Block Packing

Processed cheese is packed in 200,400 gram and 1Kg.blocks.The machine consists of a hopper in which processed cheese is fed from the kettle.Cartons of 25 gram are placed on the platform, with the top side opened. The box is lined internally with Aluminium foil.A motor operated filling system is used to fill the boxes with fixed quantity of product.

……………………..

Quality Control in KSD

Quality

Quality is defined as desirable attributes of a product which are liked by the consumer. Quality embraces many characteristics such as chemical, bacteriological, physical, nutritional, sensory, and aesthetic. It is a combination of characteristics that have significance in determining the degree of acceptability of the product to a consumer.

Quality AssuranceAccording to ISO 9000 quality assurance is defined as "All those planned and systematic

actions necessary to provide adequate confidence that a product or service will satisfy given requirements for quality."

Buyers specificationQuality control station

Quality ChartQuality Specification

Solution

Activities of QC LabAssessment of the quality of the raw material and finalizing its acceptance or rejection.Checking the operational parameters (example pH, temperatureerature, acidity etc.) during manufacturing process. And furnishing the results to the concerned section.Assessing the quality of finished product for various parameters and taking necessary actions, if deviations occur.Monitor sanitary conditions and applications of HACCP during manufacturing.

Routine Tests at QC Laboratory, KSD

(A). Raw milk1. Organoleptic test2. Fat3. SNF4. Temperature5. Acidity

(B). Pasteurized milk1. Alkaline phosphatase test2. Methylene blue reduction time test

(C). Cheese milk1. Fat and casein ratio

(D). Cheddar Cheese

1. Moisture2. pH 3. Salt 4. Fat

(D). Cheese whey

1. Acidity2. Temperature3. Fat

(E). Concentrated whey

1. TS2. Acidity

(F). Paneer whey

1. Fat2. SNF3. pH 4. Acidity

(G). Processed cheese

1. Moisture2. Salt3. pH 4. Fat5. Grading

(H). Blow down water (From Boiler)

1. pH 2. TS3. TDS (Total dissolved solids)4. Hardness

(I). E.T.P.

1. BOD2. COD3. TDS (total dissolved solids)4. SS (Suspended solids)

(J) CIP Solutions (Acid and Alkali)

1. Strength2. Temperature

(K) Water softening plant1. Hardness2. pH

List of Laboratory Equipments

SrNo.

Equipment Function Make Nos.

1. Milko Scan Estimation of fat, lactose protein

N.Foss Electric Denmark

2

2. Weighing Machine Weighing of samples Mettler 23. MBR water bath For MBRT Test Zebra instruments, 14. Autoclave For sterilization 25. pH meter Determing pH IQ scientific

instruments2

6. Incubator Incubation Remi instruments 17. Oven Heating Temperature

instruments3

8. Refrigerator For cooling and storage Godrej 19. Foot pump For leak test Vinod instruments 110. UV Chamber sterile environment for

microbial testKlenzoid 1

11. Density meter Determines density AP Paar (Austria) 112. Microscope Microbial examination 113. Centrifuge Centrifugal separation 114. Scientific calculator Arithmetic calculations Casio 1

15. Computer Record maintenance 3

…………....................Refrigeration Section of KSD

DefinitionThe term 'REFRIGERATION' may be defined as the process of removing heat from a

substance under controlled conditions. It also includes the process of reducing and maintaining the temperature of a body below the general temperature of its surroundings. In other words the refrigeration means a continued extraction of heat from a body whose temperature is already below the temperature of its surroundings. Introduction

Refrigeration is one of the prime utilities in a dairy plant. Milk and milk products being extremely perishable in nature, requires to be kept under refrigerated storage. Also, it is required for maintaining comfort conditions in offices and labs. (A.C.).etc. Mechanical Vapour Recompression system is the most feasible refrigeration system for large size plants. Refrigeration System

The refrigeration system installed at AMUL is a mechanical vapour recompression system, with ammonia (R-717) (NH3) as the primary refrigerant. This system works on the principle of vapour recompression cycle. Water is used as the secondary refrigerant by chilling it to about 00C by the primary refrigerant ammonia. The chilled water is then circulated through a network of pipelines in the plant according to the need. This type of refrigeration system is called as indirect refrigeration system. In such system evaporator is conveniently called as Ice Bank Tank. Basic Components

1. CompressorCompressor sucks the vapour at low temperature and low pressure from the evaporator and

discharges at high temperature and pressure to condenser. The compressor compresses the vapour refrigerant and raises its pressure so that the corresponding saturation temperature is higher than that of the cooling medium. It also continually circulates the refrigerant through the refrigerating system.

2. CondenserThe Condenser is an important device used in high pressure side of refrigerating system. It

consists of coils of pipe in which the high pressure and temperatureerature vapour refrigerant is cooled and condensed. The refrigerant while passing through the condenser gives up its latent heat to the surrounding condensing medium and changes its phase from vapour to liquid state.

3. ReceiverReceiver is a vessel in which the condensed liquid refrigerant is stored and from where it is

supplied to evaporation through expansion.

4. Expansion device

Also called throttling device or metering device, is an important component of a refrigerating system. The function of expansion device is to allow the liquid refrigerant under high pressure and temperature to pass at a controlled rate after reducing its pressure and temperature. Some of liquid refrigerant evaporates as it passes through the expansion device but greater portion is vaporized in the evaporator at low pressure and temperature.

5. EvaporatorIt consists of coils of pipe and is used in the low pressure side of refrigeration system. The

liquid refrigerant at low pressure and temperatureerature enters into evaporator from expansion valve where it takes heat from the surrounding of the evaporator coils and change into vapour.

In evaporating, the liquid refrigerant absorbs its latent heat of vaporization from the medium, which is to be cooled. Refrigeration Process

One cycle of mechanical vapour recompression system is completed by four basic processes.1. Compression2. Condensation3. Expansion and 4. Evaporation

Vapor refrigerant at low pressure and temperature from evaporator is sucked by the compressor and discharged at high pressure and temperature, by mechanical work of compressor. The lubricating oil used in compressor gets mixed with refrigerant which is removed in a oil separator. The high pressure and high temperature vapour refrigerant from compressor enters into the condenser where it losses its latent heat and acquire liquid phase, but the pressure and temperature remains unchanged.

The condenser is a shell and tube type, water cooled condenser. The cooling medium (water) extracts latent heat from the vapour refrigerant and gets partially heated. It is collected in sump at the bottom of condenser and from where it is pumped to the cooling tower. It is a induced draft type cooling tower in which the water from condenser is cooled and pumped back to condenser top.

The liquid refrigerant is collected in receiver from where it passes to the expansion device. A capillary tube is used as expansion device. Due to the frictional resistance offered by small diameter capillary tube, the pressure of refrigerant drops and the temperature as well. The refrigerant is introduced in the economizer where due to sudden pressure drop some part of liquid refrigerant acquires vapour state, which is passed to the compressor. The liquid refrigerant is now passed to the accumulator, from where it is pumped to the Ice Bank Tank. The IBT contains, coils submerged in water. the liquid refrigerant extracts latent heat of vaporization from water and gets evaporated. The temperature of water drops down and it is continuously agitated to avoid form of ice. The chilled water is circulated through pumps in different sections as per requirements. The vapors from IBT coils enters into the accumulator top from where it sucked by the compressor.

Specification Type of refrigeration : MVRCTon of Refrigeration : 400 TRRefrigerant used : R – 717 (NH3)Material of Constructionfor pipe lines : MS (Mild Steel)Compressor Type : Rotory Screw compressor No. : 3 (2 in use 1 in stand by)Make : Frick Horse Power (H.P) : 330 Max. Design pr : 350 PSIGMax. Speed (RPM) : 4500Suction Pressure : 3 barDischarge Pressure : 12-17 bar Condenser Type : Shell and tube condenser water cooled type : Make : Aerotherm productNo. of tubes : 257No. : 2 Expansion Device : Capillary Tube Evaporator : (Ice Bank Tank)Total No. of IBT : 4Capacity : 10000 Lit. Water (each)Total Capacity : 40000 Lit.Cooling Tower : Induced Draft Type

………………………

Boiler section of KSDSpecification

Number of boiler: 2 Type : Three pass fire tube type boiler Type (Based on heating medium) : Oil fired Type (Based on arrangement of tubes): Horizontal smoke tube Fuel used : Furnace oil Make : J.N.Marshall Capacity : 5 Ton steam per hour Furnace oil tank capacity: 1 Lakh lit. Height of chimney : 100 feet

Steam pressure : 9 kg / cm2

Required pressure in plant : 6 kg / cm2

(Pressure reduced through pressure release valve) Specifications for BoilerDescription SpecificationSteam output from air at 100o C 10000kg/hrSafety valve set pressure 17.5 kg/cm2.sDesign pressure 17.5 kg/cm2.sDesign temperature 250O CCode IBR-1950Fuel oil consumption LDO (based on LCV 10200 kcal/hr)

602 kg/hr

Fuel oil consumption LSHS(based on LCV 9600 kcal/hr)

640 kg/hr

Fuel oil consumption natural gas ( LCV 7350 kcal/hr)

831 kg/hr

Turn down 1:4Thermal efficiency 92%Feed water pump suction size 80mmFeed water pump inlet size 50mmSteam outlet size 150mmAir vent outlet size 50mmSafety valve discharge size 80mmBlow down size 50mm

Heat Absorption Efficiency

For improving the heat absorption efficiency it is important to ensure that heat transfer surfaces both on fuel gas and water side are clean. These are fouling deposits and salt due to bad water on water side and bad and bad quality of oil gives soot and sublimed and condensed salts on the gas side.

Measurement of stack temperature gives an indication of absorption efficiency.

Safety

1. The most important in the operation of boiler is that it is the presence of water on the heating surfaces which prevents the buckling oof pressure parts taking point of safety. The water inside boiler is really to cool the boiler to prevent heat damage to the flame swept area rather than producing steam. 2. Flame temperature us 1100o C. It is important to put water level above the combustion chamber. Achieved by designing of automatic water level controller.3. A mechanical relief of pressure in case everything fails is to be provided, open at combustion pressure.

Description of Boilers1. Registry number: GT-1673 Boiler rating: 350 m2

Type of boiler: PACKAGEYear of mfg.:1973The boiler can be worked at maximum pressure of13.35kgm/cm2

2. Registry number: GT-1725 Boiler rating: 350.2 m2


3. Registry number: GT-1674 Boiler rating: 350.2 m2


…………………………

FOOD COMPLEX MOGAR

MALTED MILK PRODUCT [NUTRAMUL]

Definition According to the PFA rules (1976), malted milk food is the product obtained by

mixing whole milk or partially skimmed milk or milk powder with malt extract and cereal grain flour in such a manner as to secure complete hydrolysis of the starchy material. It should not contain added sugars, foreign fat and added colors and preservatives. It may contain cocoa powder. Malted milk food should be in the form of a powder.

The process of manufacture of manufacture of malted milk powder was invented by William Horlick of the USA in 1883 and the product was first placed on the market in 1887.

Malted milk plant at Mogar established in 1976. Specification Constituents SpecificationMoisture (%) Max. 4.0Protein (%) Min. 11.5Fat (%) Min. 6.0Total ash (%) Max. 5.0Acid insoluble ash (%) Max. 0.1Solubility (%) Min. 90.0Cocoa powder (%) Min. 5.0Total bacterial count cfu/g Max. 50,000Coliform count in 1g product Max. 10Organoleptic evaluation No abnormality, Off taste, Flavour Analysis of above parameters is carried out as per the scheme of testing and inspection (STI) of IS : 1547 1985OF THE Bureau of Indian Standards. Nutritional facts Malted milk powder is high in protein and very high in sugar, both of which are present in readily digestible form. It has a pleasant flavour and is used for feeding children, invalids and convalescents. 100g of Nutramul contains [Amount/100g]Calories - - Protein - 11.5gFat - 6.0gCarbohydrates - 70.0g Usage – Nutramul is also excellent as an icecream topping or as cake flavouring. Intended use – 1. Flavouring agent. 2. Hot or cold beverage. 3. Ingrident in varity of food. Pack size – 1. 500g Jar 2. 500g Refill 3. 50g pouch. Shelf life – Best before 12 months when stored in cool and dry place.

Ingredients – Malt extract, milk solids, cocoa powder, natural color (E- 150d), Emulsifier (E-322), Acidity regulator (E-500), & Natural and nature identical flavouring substance.

Contains essential minerals1. Sodium2. Potassium3. Calcium4. Phosphorus5. Chloride6. Magnesium7. Iron8. Manganese9. Rich in natural Vitamins of milk.

Reprocess/rework Non confirming products are reprocessed. Flow process chart

Raw material from store

↓ Stacking on pallets Addition of malt extracts, Addition of water, milk powder, Cocoa powder, SBC in SBC, salt & reprocess powder in Kettle no. 1. [CCP–01cooking temperature] kettle no. 2 ↓ ↓Cooking at 95±5°C/1 hrs Milk powder reconstitution ↓ (50 to55°C)Addition of sugar/ceramal/ Malt extract/lecithin/anyReprocess powder ↓Filteration (Balance tank) ↓Vacuum evaporation Temperature – 70 to 80°CVacuum – 720 to 760 mmHg

↓Solids checking Collection in kettle/vats ↓Spreading on trays ↓

Oven dryingTemperature – 70 to 80°CVacuum – 720 to 760 mmHg ↓Cooling at room temperature (35-40°C) ↓ [CCP 02 A monitoring magnetScrapping/Grinding sensitivity]

↓ Magnet [CP 01 moisture determination] ↓ Nutramul powder ↓Silo/Bags/Drums filling Rework to kettle ↓ Storage

CIP (Cleaning in place) In malted plant chemical cleaning of evaporators is done once a week or before 25 batches. The procedure includes washing of evaporators with hot water. Then lye solution of about 1.0 to 1.5% in hot water at 85±5° is used to clean the evaporator. After the lye cleaning it is flushed with normal water till no residual lye appears in water. Name of machine Cleaning procedure FrequencyCooking kettle Hand brushing & Cleaning

with waterDaily

Evaporators Hand brushing & Cleaning with water

Weekly

Vats Hand brushing & Cleaning with water

Weekly

Spreading machine Hand brushing & Cleaning with water

Daily

Ovens Cleaning through scrapping or washing

Monthly

Scrapping table Hand brushing & Cleaning with water

Daily

Scrapping conveyor & grinder

Hand brushing & Cleaning with water

Weekly

Packing conveyors & silo Hand brushing & dry cleaning

Monthly

Product drums Hand brushing & cleaning with water

Fortnightly

Packing machine Hand brushing & cleaning with water

Daily

Tray cleaning

Regular cleaning of trays is done by scrapping the material. Trays are washed weekly.

Waste disposal system Malted milk food plant generates two type of waste.

1. Solid waste2. Liquid waste

Emergency preparedness plans for MMF unit

A. Natural calamitiesEarth quakeFlood

B. Energy failureElectricityBoilerSteam

C. Fire

NUTRAMUL SLURRY

Intended use – Product is intended for consumption by the flavoured milk section of Amul dairy for the Nutramul flavoured milk. Pack size – 20/40 kg in cans.

Specification

Constituents PercentagesTotal solids% 72-77pH 6.5-6.7Cocoa powder% 1.0Organoleptic evalution No abnormality,

Off taste,Flavour

Flow process chart

Raw material from store ↓ Stacking on pallets ↓ Addition of M.E./CP/Caramel/ lecithin/TSP in kettle no. 1 ↓ Mixing for 1 hrs ↓ Addition of vanilla & malt flavour ↓ TS & pH checking ↓ Emptying into cans and weighing

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CHOCOLATEIntroduction

It is defined as a product which contain high amount of sugar & oil. The

ingredients are cocoa solid (cocoa butter, cocoa liquor & permitted emulsifiers &

added flavours.

Milk chocolate was first invented by Danial Pitter in 1876.

Chocolate plat established in 1974.

Chemical composition of Cocoa Bean

Constituents Cocoa beanNib (%) Shell (%)

Water 2-5 4-11

Fat (cocoa butter & shell fat) 48-57 2-6

Protein 11-24 13-16

Starch 6-9 -

Fibre 2-3 13-19

Ash 2.5-4 6-21

Theobromine 0.8-1.4 0.2-1.3

Caffeine 0.1-0.7 0.05-0.3

Variety of chocolates

Amul bindaaz (Rich dark chocolate)

Amul fundoo (Milk chocolate)

Amul chocozoo (Chocobite in fun animal forms)

Amul Almondbar

Milk chocolate

Fruit-n-nut

Amul Almonds (Enrobed in chocolate)

Amul chef's premium cooking chocolate

Amul Rejoice Assorted Chocolates

Sugar free chocominis (India's first specially created Diabetic Delight)]

Equipments

1. Cleaner2. Roaster3. Winnower4. Cocoa mass making machine5. Cocoa press6. Mixer/grinder7. Refiner8. Conches (No. – 3)

a.) 1st – 1.5 tonnes capacity b) .2nd – 1.5 tonnes capacity c.) 3rd – 2.5 tonnes capacity 9. Tempering machine 10. Chocolate moldling machine. 11. Chocolate wrapping and packing machine Mfg by – SIG, Switzerland. 12. Sifting machine Flow process chart (Cocoa Bean) Cocoa tree ↓ Mature pod (Contains 25-30 beans) ↓ Cocoa bean with pulp ↓ Fermentation (In wooden box for 5 days) Natural yeast & bacteria multiply in pulp Breakdown of sugar & mucilage Drain of pulp as a liquid Removal of bean from wooden box ↓ Drying (Sun drying – To achieve 7to 8% moisture) ↓ Cocoa bean for chocolate ↓ Storage & transportation (Covered with Jute)

NOTE – If fresh bean are dried without any fermentation, the nibs will be a sleety, gray color rather than the brown are purple color of fermented dried cocoa bean. Cocoa flavour is due to Cotyledons (nibs). Cotyledons are consists of two types cell.

1. Storage cell (fat & protein)2. Pigment cell (Phenolic compound & Xanthines )

Fermentation & drying are Post harvesting process. Fermentation may be two types such as Natural and artificial (Improved fermentation process). Flow process chart

Storage tank (cocoa liquor) ↓ Cocoa Bean (5-6%moisture) ↓ Dumping ↓ Bucket elevator ↓ Cleaner (removal of dust & foreign matters) ↓ Roasting (120±5°C at 30-40 mins/ 4-6 kg / cm2

Moisture-2.5%) ↓ Silo (through bucket elevator) ↓ Winnower ↓ Nib (50% cocoa butter) ↓ Pin mill/Cocoa mass making machine (Crushing & Grinding) ↓ Hydraulic press ↓ Cocoa cake ↓ Grinder ↓ Cocoa powder ↓

Silo (Milk powder, sugar, cocoa powder, cocoa butter) ↓ Mixer (Homogeneous mass) ↓ Refiner (For smooth & refined mass – 30µ) ↓ Conch (45-65°C /for min. 8 hrs, addition of lecithin – 0.4665%, ) ↓ Storage tank (40±2°C) ↓ Tempering (30-32°C) ↓ Moulding line ↓ Depositor ↓ Tray (through nozzle) ↓ Vibrator ↓ Cooling box (10±2°C for 20-22 mins) ↓ Demoulding ↓ Final metal detector (if more than 1mm metal) ↓ Packing Specifications (Chocolate)

Constituents Percentages

Total fat Min 25%

Milk fat Min 2%

Cocoa solids Min 2.5%

Milk solids Min 10.5%

Total ash Max 5%

Acid insoluble ash Max 0.2%

Quality criteria for cocoa powder

Quality criteria for cocoa butter

Particulars Pure pressed cocoa butterFree fatty acids (% max.) 1.75Unsaponifiable (% max.) 0.35Moisture & volatiles (% max.) 0.2Iodine value (% max.) 33-42Blue value (% max.) 0.05Residue solvent (mg/kg) -

Process details The fermented and dried cocoa bean are purchased by the department:- A. Fermentation and drying

A good flavour in the final cocoa or chocolate due to fermentation and drying.During fermentation and drying process, the unfermented wet beans taken from the pod lose about 65% of their weight assuming the final optimum moisture content of 6% is attained.

B. Cleaning

To remove foreign matters.To remove adhesive matters stones.There is vibrating action so adhesive matter can be separated.Air is blown forcely to remove light material.

C. Roasting

Roasting is done to eliminate the moisture.To produce the special chocolate flavour and aroma.Roasting is done at 120-1300 C with the help of steam at 5-6 kg/cm2 .

Specification PercentagesFat 10-24%Moisture Max 4.5%pH 4.8-8Total plate count (per g) Max. 5000Molds (per g) Max. 50Yeasts (per g) Max. 10

Roasting procedure reduces the moisture level below to 2.5%.After roasting cocoa beans are cooled for 10 min. and transferred to winnower.

D. Winnowing

Winnowing machine crushes beans into smaller pieces and separates the shells from nibs. (i.e. the Cotyledon). Shells or husks are separated by vibrating and shaking action and also beans are broken by rollers. Husk are transferred to cattle feed factory.The separated nibs are transferred to cocoa mass making machine.

E. Cocoa mass making machine

In this machine, there are three rollers. There is breaking knife to obtain mass. Pressure maintained is 40-50 bars and temperature is 30-400 C. Mass is heated and agitated and collected in tanks. Magnet is present in the machine to remove metal pieces.Cocoa mass is stored at 900 C.

F. Hydraulic pressing

Pressing is done to separate the cocoa butter from the cocoa liquor and to get the cocoa cake.Cocoa cake is made for making cocoa powder.Cocoa powder is used in chocolate & malted milk food manufacturing.Pressure is 400 kg/sq.cm. at 700 to 1400 rpm.The end of we get cocoa butter & 5 cocoa cakes.

G. Grinding

The cocoa cake is then ground to make cocoa butter.Cocoa cake is broken into small pieces, then put into cake breaker to get small pieces & then put into Pin mill.Cocoa powder is collected into drums and packed.

H. Mixing For milk chocolate mass, cocoa liquor is to be taken first and then icing sugar or milk powder and finally cocoa butter is mixed into the mixer.

For dark chocolate mass, first cocoa liquor then icing sugar.For compound coating mass, first vegetable fat and icing sugar, milk powder, cocoa powder and lecithin.For chocopaste, first vegetable fat and then icing sugar and cocoa powder is mixed into the mixer.

I. Refining

The mixed mass is allowed to refine and reduced in the particle size to get the smooth mass.

The rollers rotate in opposite direction.It has 5 rollers, each roller has different pressure.

1st Roller 2 – 3 kg/cm2 26-280 C2nd Roller 3 – 4 kg/cm2 28-300 C3rd Roller 4 – 5 kg/cm2 28-300 C4th Roller 4-5 kg/cm2 38-400 C5th Roller 2 kg/cm2 28-300 C J. Conching

There are three conches having different capacities.The refined mass is than subjected to the conching operation for flavour development.To attain the required moisture content.To get smooth texture & body of chocolate.First dry conching is carried out by adding emulsifier and flavours for 2 hrs.Then wet conching is done by adding remaining cocoa butter for 20 hrs & temperature is < 550C.For milk chocolate mass max. temp. is 550C & dark chocolate mass max. temp. is 750C.After conching moisture of chocolate should be less than 1.5%.

K. Tempering

There are two sectors in tempering machine.The temp. is maintained at 26-28 0 C in 1st sector and 28-300 C in 2nd sector.It is done to get good consistency .Tempering is done for attaining the proper or stable crystallization.Tempering converts all the unstable forms into the stable form.If stable form of crystallization has not been achieved, the chocolate will not leave the mould surface.Shining property of chocolate.

Note – Four forms of crystals are found in cocoa butter viz. alpha, beta, beta prime and gamma. The beta prime is the more stable form. Moreover the property of chocolate is to shrink when cooled and leave the the surface of the mould when demoulding is done. L. Moulding

After tempering chocolate is poured through depositor into suitable moulds to get the desired shape and structure.

M. Vibrating belt

After moulding moulds are transferred on conveyor and simultaneously vibrated by vibrator so chocolate is properly disturbed.

N. Cooling

It is cooled at temperature 8-10 0C for 20-22 mins. and then demoulded by 2-3 stroking action and then transferred on conveyor for packing.

Packaging and storage

Chocolate is wrapped in aluminium foil and then by paper.The packets are sealed and chocolate are packed in paper boxes.Then chocolates boxes are packed in big cartons and stored in cold storage.Three SIG packing machines.80 gm ,40 gm and 35gm,18gm are provided for packing chocolate and then chocolate is stored at 150C-200C.

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BREAD SPREAD History

The food complex at Mogar, a plant 8 km. away from Anand facilitates to manufacture malted milk foods, Chocolate, Bread spread (Delicious, Amullite) and ready to eat extruded food products. It was a humble effort by Amul to prove the world that a farmer's co-operative can also manufacture Chocolates. DefinitionMargarine or fat spread – Margarine or fat spread are product made from emulsion of fat/oil and water/milk solids dissolved in water. Water or aqueous phase is dispersed/mixed in fat/oil phase (continuous phase) after adding emulsifier to get emulsion. The emulsion is then chilled to get margarine. Bread spread – Bread spread is a water-in-oil emulsion consisting of continuous phase (aqueous phase) finely dispersed in the oil phase. The oil phase contains fat crystals, which give body to the product. Bread spread is a type of fat spread or margarine. Usage – 1.Consumed with bread and bun. 2. Used in bakery. Intended use – The product is intended for consumption by general population, which will include children and the elderly.

Pack size 1. 200g Amullite in food grade poly \propylene cups and heat sealed on top with aluminium

foil.2. 100g & 500g Delicious wrapped in VPP paper roll and inner cartons and 8g in tubs.3. 100g & 500g Amullite wrapped in VPP paper roll and inner cartons and 8g in tubs.

Shelf life – Best before 6 months when stored at below 100C. Ingredients – Hydrogenated & unhydrogenated refined vegetable oil, common salt, skimmed milk powder, emulsifier, permitted class two preservatives, sequesterant & antioxidants, vitamin A not less than 30IU/g and vitamin D is 2IU/g. Specification – Amullite (Medium fat spread) Description Amul PFA AgmarkMoisture (% by mass) 25-28 16-56 16-36Fat (% by mass) Max. 65-75 40-80 60.1-80Salt % 1.6-1.8 Max. 2.0 Max. 2.0Acid value of the extracted fat %

Max. 0.5 Max. 0.5 Max. 0.5

Unsaponifiable matter %

Max. 1.0 Max. 1.0 Max. 1.0

Melting point of extracted fat %

Not greater than 370C Not greater than 370C Not greater than 370C

Colour count 34-38 by MINOLTA reading or H1, H2 by shade card.

- -

Sensory parameters No abnormality like Off or rancid taste

No abnormality like Off or rancid taste


Total plate count 20000/g max. - -Coliform 5/g max. - -Yeast & mould 5/g max. - -Pathogen Nil/0.1g Nil/0.1g -Reference – Agmark and PFA specification for medium fat spread.

Specification – Amullite (Low fat spread) Description Amul PFA AgmarkMoisture (% by mass) 37.8-38.2 16-56 36.1-56Fat (% by mass) Max. 58-59.9 40-80 40-60Salt % 1.6-1.8 Max. 2.0 Max. 2.0Acid value of the extracted fat %

Max. 0.5 Max. 0.5 Max. 0.5

Unsaponifiable matter %

Max. 1.0 Max. 1.0 Max. 1.0

Melting point of extracted fat %

Not greater than 370C Not greater than 370C Not greater than 370C


- -




Total plate count 20000/g max. - -Coliform 5/g max. - -Yeast & mould 5/g max. - -Pathogen Nil/0.1g Nil/0.1g -

Reference – Agmark and PFA specification for medium fat spread. Specification – Amul Delicious (Table margarine) Description Amul PFAMoisture (% by mass) 12-16 12-16Fat (% by mass) Max. More than 80 More than 80Salt % 2.0-2.5 Max. 2.5Acid value of the extracted fat %

Max. 0.5 Max. 0.5

Unsaponifiable matter % Max. 1.0 Max. 1.0Melting point of extracted fat %

Not greater than 370C Not greater than 370C


-



Total plate count 20000/g max. -Coliform 5/g max. -Yeast & mould 5/g max. -

Pathogen Nil/0.1g Nil/0.1g IBT – Intermediate batch tankBMV – Butter melting vatHSBT – Hard & soft batch vatSSHE – Scrapped surface heat exchangerAHU – Agitated holding unit Oil phase preparation

Palm oil, soya oil, til oil, are used to prepare oil phase. The melted oil is dumped in balance tank and transferred to hot and soft vats. Emulsifiers are added along with melted oil in mixing kettle at 80-850 C.Butter is added as milk fat (@10%) in Amul Lit and no milk fat is added in Delicious (Table margarine). Aqueous phase

It is prepared by adding hot water, SMP, starch and salt in line venture hopper and then pasteurized and transferred to HSBT. Mixing and standardization

The above phases are mixed and the temp. of emulsion is kept 55-65 c. emulsion is transferred to IBT, where all additive and flavours are added. Class II preservatives such as citric acid and TBHQ are added. Moisture, fat, salt and pH are the parameters to be standardized.

Reprocess/rework – Non confirming products are reprocessed (Refer procedure for N.C. product). Records are maintained in the department. Note – The hazard identification, risk assessment and hazard analysis of the product is carried out as FEMA (FAILUER MODE EFFECTIVE ANALYSIS). Manual cleaning & cleaning in place (CIP) All tanks and pipelines that are used to prepare the bread spread are thoroughly cleaned after the batch operation is over by hot water flushing.Water in CIP tanks is heated to 85±5°C for supplying the hot water to the respective tanks and pipelines. When the batch process is over, tanks are rinsed for 5 min. with clean water. After rinsing; hot water circulation through CIP tanks is done for 10 mins. After two week of production or before starting production, when processing is stopped for more than 2 days, up at the tanks and pipelines is carried out as follows; Sequence Minutes Temperature (°C)Water prerinse 2 AmbientHot lye cleaning (1.0-1.5%) 5 85±5Hot water rinse 10 85±5Pause 2 -Cold water rinse Till lye disappear in water

rinse Process monitoring Process activity Monitoring Amullite Delicious

Acceptance criteria Acceptance criteriaFat phase heating Temperature 85±5°C 85±5°CPasteurization of aqueous phase

Temperature 85±5°C 85±5°C

Standardization of emulsion

pHMoisture%Fat%Salt%

5.2-5.637.5-3858-591.8-2.0

5.2-5.612-1680-832.3-2.5

Packing of bread spread

Hygienic handling of bread spread.Packing integrity

No packing defect No packing defect

Product storage Temperature of cold stores

Below 10°C Below 10°C

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GANTHIA Intended use – Product Amul ganthia is for general population that includes elders and children. Pack size – 20g printed laminates 35g printed laminates Shelf life – Best before 4 months. Plant capacity – Ingredients – Basen, wheat flour, rice flour, potato flour, corn, salt, turmeric, cotton seed oil. Flavours – 1. Magic masala 2. Pickup masala 3. Podina masala 4. Tomato masala Equipments – 1. Raw material mixture

2. Preconditioner3. Spicing machine4. Wenger drier5. Feeder motor6. Rotameter7. Extruder

Flow process chart

Raw material

Mixture

Drum

Conveyor through preconditioner

Extruder

Conveyor through drier [120°C/20 min]

Cooling

Sent to spicing machine(Cotton seed oil – 20%, masala – 8%)

Packaging

QUALITY ASSURANCE LABORATORY Quality is all those planned and systematic action necessary to provide adequate confidence that a product or service will satisfy given request for quality. The following test performed to monitoring measurement of products, from each unit.

1. Incoming material2. In process product3. Finished product4. Microbial testing of finish product.

Equipments

1. Oven2. Incubator (No. - 2)3. Soxhlet apparatus4. Centrifuge5. Muffle furnace6. Vacuum oven7. Hobart mixture8. Tinto meter 9. Infra red10. pH meter11. Projecto meter12. Melting point meter

Raw material analysis for Chocolate

1. Sugar2. Choco whip3. Milk powder4. Lecithin5. Vanilla6. Vanillin7. Orange flavour8. Almonds9. Raisins10. Vegetable fat11. Liquid glucose

In line & on line process analysis A. Cocoa bean processingB. Chocolate manufacturing

1. Cocoa powder/cocoa cake

Fat –By Soxhlet methodMoisture – By air oven methodParticle size – By sieving it through 100 mesh.

2. Moisture determination in cake/powder3. Determination of cocoa powder (Fat)4. Determination of lactose & sucrose in milk chocolate

Finished product analysis for Malted milk food

1. Determination of moisture2. Determination of protein3. Determination of Acid insoluble ash4. Determination of fat5. Determination of total ash6. Determination of solubility%7. Determination of residue8. Determination of density

Finished product analysis for Bread spread

1. Determination of fat2. Determination of moisture3. Determination of melting point of fat4. Determination of unsaponifiable matter5. Determination of Free fatty acid6. Determination of salt7. Determination of acid value

Packaging material analysis

1. Grammage determination(For outer boxes, cardboard boxes or any paper)

2. GSM or Lacquering(For printed foils such as Amullite foil, chocolate labels, BOPP/Polyester film/refill packs)

3. Foil thickness (Gauge) (For aluminium foil in chocolate unit)

4. Separation of polyester layer on card board (For presentation pack, stiffeners, refill carton etc).

5. Separation of foil, paper & poly paper(For 40g labels, 18g film, refill pack, amulya film etc)

Checking of lye concentration in CIP solution

Take 10 ml. of alkali solution in a conical flask. Add few drops of phenolphthalein indicator. Titrate against N/10 H2SO4 till the colourless liquid is obtained.

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