Koyana report

Koyana Sahakari Dudh Utpadak sangh Ltd. Khodashi. Industrial Training Report.

History of the company –

To meet the demand of milk in urban area and to provide the complementary and joint business to farmer. The Koyana Co-Operative Dudh sangh was established by late Raghunathrao Daulatrao Patil and his colleagues on 1 oct. 1957. That was first Co-Operative dairy Maharashtra established was during second five years plan finance was made available of about 1 lakh from 5 years plan by State Govt. at first dairy was starting working in hired trend in shaniwar peth Karad.

The plant was built on the land of 16 acres i.e. donated by Khodshi Grampanchyat and 6 acres purchased from private owners.

The machinery and mechanical devices was made available by Alfalaval and the building constructed to M/S New Triyo Builders.

The plant was completed in the end of years 1964 milk co-operative societies and 84 persons together with share capital Rs. 5370 was only the Koyana Dairy.

Mokashi College Of Food Technology Rajmachi, Karad.


1. Infrastructure for procurement of milk. In rural areas of

Maharashtra & to ensure on assured market for milk producers

throughout the year, as well as the best remunerative prices.

2. Fulfill the growing needs for milk & milk products of the

consumers in the Maharashtra & elsewhere.

3. Organize the co-operative structure of milk at the villages level.

4. Supplement of programme extension input, with particular

reference to feed & fodder production & implements an

intensive breeding programme for milchy animal to increase

milk production.

5. Imparting training for developing human recourses at rural level

for effective leadership, management skills & improvement of

services to rural milk producers.

6. The Koyana sahakari dudh utpadak prakriya sangh Ltd. Karad.

Are aim to get the ISO 9001:2008 Certified company in this

year.

7. Running co-operative development cell to increase awareness &

active women participation for better management &

their positive role.



PRODUCT OF THE COMPANYPRODUCT OF THE COMPANY:- :-

1.1. MILK:-MILK:-

Pasteurized Full Cream MilkPasteurized Full Cream Milk

Pasteurized Homogenized cow milk Pasteurized Homogenized cow milk

Pasteurized Toned MilkPasteurized Toned Milk

Pasteurized Double Toned MilkPasteurized Double Toned Milk

Flavoured Milk ( Sugandhi Dudh)Flavoured Milk ( Sugandhi Dudh)

2.2. PEDHAPEDHA

3.3. DAHIDAHI

4.4. LASSIELASSIE



5.5. BASUNDIBASUNDI

6.6. SHRIKHANDSHRIKHAND

7.7. AMRAKHANDAMRAKHAND

INTRODUCTION:-INTRODUCTION:-

The RMRD is the section where unloading, weighing, testing The RMRD is the section where unloading, weighing, testing

of raw milk takes place. RMRD at Koyana dairy is well equipped of raw milk takes place. RMRD at Koyana dairy is well equipped

with the advanced equipment like computers and electronic with the advanced equipment like computers and electronic

weighing system, milk testing machinates. There is spacious areaweighing system, milk testing machinates. There is spacious area

in front of the dock to park the vehicles. The dock having two ranin front of the dock to park the vehicles. The dock having two ran

reception lines, so has two units of each equipment like can reception lines, so has two units of each equipment like can

opener, weighing tank Dump Tank, can washer, and crate washer.opener, weighing tank Dump Tank, can washer, and crate washer.

In Koyana dairy raw milk is received by cans & tankers from In Koyana dairy raw milk is received by cans & tankers from

various societies and chilling centers. Tankers from chilling various societies and chilling centers. Tankers from chilling

centers generally receive the milk which is away from 150 K.M. Itcenters generally receive the milk which is away from 150 K.M. It

has already weighed sampled and cooled. This raw milk is again has already weighed sampled and cooled. This raw milk is again

tested for SNF, Protein, C.O.B., Acidity & adulteration test.tested for SNF, Protein, C.O.B., Acidity & adulteration test.

The process on RMRD starts from unloading the tempos. The process on RMRD starts from unloading the tempos.

The cans are conveyed on chain conveyer. The cow milk and The cans are conveyed on chain conveyer. The cow milk and



buffalo milk is collected separately on RMRD. On the way to buffalo milk is collected separately on RMRD. On the way to

tilting point lid opener to opens the can lids and organoleptic teststilting point lid opener to opens the can lids and organoleptic tests

are conducted. If anything wrong with can then it is detected andare conducted. If anything wrong with can then it is detected and

such can is taken out form conveyer. Then these cans are such can is taken out form conveyer. Then these cans are

unloaded / emptied in dump tank manually at tilting point. The unloaded / emptied in dump tank manually at tilting point. The

suspected / sour milk is not allowed to mix with good / fresh milk. suspected / sour milk is not allowed to mix with good / fresh milk.

It is diverted from that line and conveyed to sour milk is collected It is diverted from that line and conveyed to sour milk is collected

separately on RMRD. A lab person or chemist analyses the separately on RMRD. A lab person or chemist analyses the

sample for platform tests such as Fat, SNF, CLR, Acidity, Heat sample for platform tests such as Fat, SNF, CLR, Acidity, Heat

stability of Milk, etc. stability of Milk, etc.

After preliminary testing Milk is poured into the weight After preliminary testing Milk is poured into the weight

scale and note down on the computer as the using society scale and note down on the computer as the using society

number codes for simplenumber codes for simple for create data. for create data. Here the two Here the two

parameters like quantitative and qualitative parameters of parameters like quantitative and qualitative parameters of

incoming milk from the societies. These parameters are Fat, CLR incoming milk from the societies. These parameters are Fat, CLR

and quantity of milk. These parameters are used to calculate the and quantity of milk. These parameters are used to calculate the

price of milk per liter. The same time agitate milk for 1 to 2 price of milk per liter. The same time agitate milk for 1 to 2

stroke of plunger for well mix milk and correct sample for testing stroke of plunger for well mix milk and correct sample for testing

is taken from the weigh tank. Milk is then transferred to the two is taken from the weigh tank. Milk is then transferred to the two

dump tank of 1000 Liter capacity. Nylon filters do filtration at dump tank of 1000 Liter capacity. Nylon filters do filtration at

weigh tank and dump tank. The two 5 HP centrifugal pumps are weigh tank and dump tank. The two 5 HP centrifugal pumps are

transferred the milk dump tank to processing section.The cans, transferred the milk dump tank to processing section.The cans,

which are not properly cleaned, are taken to can scrubber and which are not properly cleaned, are taken to can scrubber and

again loaded to can washing for reclining. again loaded to can washing for reclining.

TANKER RECEPTIONTANKER RECEPTION:- :-



The milk from the various chilling centers as 1} Dabane The milk from the various chilling centers as 1} Dabane

Milk dairy, (Kasegaon), Tal.- Walawa, Dist.- Sangali. 2} Jagtap Milk dairy, (Kasegaon), Tal.- Walawa, Dist.- Sangali. 2} Jagtap

Milk dairy Vai, Dist.- Satara. 3} Gyaneshwari dairy Parkhandi. 4} Milk dairy Vai, Dist.- Satara. 3} Gyaneshwari dairy Parkhandi. 4}

M/S Dhaphalapure dairy & Agro products At.- Mugalkhod, Tal.- M/S Dhaphalapure dairy & Agro products At.- Mugalkhod, Tal.-

Raibag, Dist.- Belgaon. 6} Prithviraj Milk & Food Processing, Raibag, Dist.- Belgaon. 6} Prithviraj Milk & Food Processing,

Banpuri Tal.- Khatav, Dist.- Satara. Etc. is transported by road Banpuri Tal.- Khatav, Dist.- Satara. Etc. is transported by road

tankers. These tankers are on hire basis as add when required tankers. These tankers are on hire basis as add when required

subjected to procurement of milk.subjected to procurement of milk.

As soon as the tanker arrives at the dock containing As soon as the tanker arrives at the dock containing

processed or chilled milk it is being tested for organoleptic tests processed or chilled milk it is being tested for organoleptic tests

and labtests. After analyzing its quality, it is accepted for further and labtests. After analyzing its quality, it is accepted for further

processiong and production. processiong and production.

The reception starts from 9.00 a.m. during morning and The reception starts from 9.00 a.m. during morning and

6.00 p.m. at evening and continues till all the expected milk is 6.00 p.m. at evening and continues till all the expected milk is

received. The milk handling capacity of KOYANA dairy is around received. The milk handling capacity of KOYANA dairy is around

1.5 lakh Lit. / day. 1.5 lakh Lit. / day.



MILK RECEPTION FLOW LINE:-

Reception of cans on platform

Can conveyor

Manual can Opening

Organoleptic Testing

(If doubt then COB testing)

Tilting of Cans

Sour Milk

Weighing

Sample (Testing CLR and Fat )

Processing Dump tank

Reception of milk

Empty can from tankers

Milk Draining



Can Washer Can Scrubbing

Dispatch

RMRD EQUIPMENT DETAILS: -

1. Can : -

Material of construction = Aluminium & Fibers

Capacity = 40 Liters.

2. Can Conveyor :-

Type = Chain conveyor

3. Organoloeptic Testing :-

At first, milk is well mixed with the help of plunger and

following testes are carried out by experienced persons.

a) Colour b) Smell c) Taste

d ) Temperature by touch to cans.

4. Tilting of cans :-

Mode of operation - Manual

5. Weighing :- Weighing Balance



Operation - Electricity operated

6. Milk Samplers :-

Amount of sample drawn from each lot - 100

ml

7.RMRD Lab :-

Tests are conducted by advanced machines (EKO

MILK). These tests are for Fat, SNF, Protein, which are

conducted on the platform.

8. Screens & Filters :-

Small Pore Size Screens are used to efficiently remove

the sediments from the milk. These are present at weighing

tank and dump tank.

9. Can Washer :-

Can Washing by manually by using hot water.

10. Can Scrubber:-

Shape = Semi cylindrical open

Brushes = Nylon hairs

No. of Brushes = 2



CLEANING OF CANS:-

The empty cans are washed in a straight through can washer daily. Once in a week the cans should be washed

manually with schedule programme.

Can Washing Programme: =

1. First washing using can scrubber with solution of hot water and detergent and pass to this cans to manually washing.

2. Then can washing by using iron strip brush and detergent and then wash to clean by using hot water.

3. Drain down the water and used to next operation.

CRATE RECEPTION DOCK: -

The crates returned from distributors are received here and washed out in crate washer. This section is located at side to the RMRD.

Crates washing by using hot steam and hot water.

Crate Washing Programme:-

1. Pre-rinse with normal water at 40˚C.

2. Drain.

3. Jetting with caustic solution at 75°C, of strength 0.6=0.8% NaOH, pressure = 0.75 kg/cm square and drain.

4. Hot water heated by steam at 80°C & drain water.



TANKER CLEANING:-

After every Emptying & before every filling.

1. Pre-rinse with water.

2. Manual cleaning with hot water, detergent & pads.

3. Final rinse with hot water.

4. Sterilization with chlorine 150-220 ppm i. e. 150ml in 40 liters of water solution.

5. Man whole cover, gaskets, air vents: Brushing with liquid detergent, flushing.

6. with hot water & sterilization with chlorine.

7. Valve box steam union Open valve body, union & clean them with detergent & hot water.

Organoloeptic Test:-

The milk is tested organoloeptically for smell, colour

appearance, taste & temperature by touching after

mixing with plunger, If the milk is suspected then C. O.

B. (clot in boiling) is carried out.

Dock Lab Test:-



1} Clot in Boiling:-

This test is carried out for checking the heat stability of milk.

Procedure:-

1. Pipette out 2ml milk sample in test tube.

2. Kept the test tube on burner for boiling of milk.

3. After boiling of test tube is washed with water & checked for clots on bottom of test tube.

4. If clots are is observed this milk is not suitable for further processing a so makes as it may spoil the entire batch of

milk.

2} Acidity Test for milk :-

Procedure :-

1. Pipette out 10ml of milk sample in beaker.

2. Add 30 ml of distilled water in it.

3. Add 3-4 drops of phenolphthalein indicator.

4. Titrate against 0.1 N. NaOH solution.

5. End point is colorless to faint pink.

Calculation : - B.R. X 0.09

The acidity of milk should not more than 0.14 in terms of lactic

acid.

3} Fat Test of Milk (Gerber Method) :-

Procedure :-



1. Take 10 ml Gerber sulphuric acid in milk butyrometer by tilt

measure.

2. Add 10.75 ml milk in it using 10.75 ml pipette by sanding manner.

3. Add 1 ml of amyl alcohol in butyrometer.

4. Lock the butyrometer by lock stopper.

5. Shake the butyrometer at 45° angle for dissolve the curd.

6. Centrifuge for 5 min. at 1100=1200 R.P.M.

7. Read the reading on fat column & not down fat % in milk.

Detection of Adulteration in Milk :-

1} Detection of Suger :-

Procedure :-

1. Pipette out 10 ml milk sample in test tube.

2. Add 1 ml conc. Hydrochloric acid.

3. Add 1 gm resorcinol powder in it.

4. Properly mix the content in test tube.

5. Keep the test tube in water bath for 5 min.

Observation: - Red color indicate the test is positive. And sugar is present in milk sample.

2} Detection of Starch :-

Procedure :-

1. Take 5ml milk in test tube.



2. Boil the sample on hot plate.

3. Immediately cool the sample.

4. Add 2 drops of Iodine solution & Shake the test tube properly.

Obeservation :- Sky blue color indicates starch is test positive.

3} Detection of Urea :=

Procedure :=

1. Take 5ml milk in test tube.

2. Add 5ml of 1.6% of DMAB solution and observe color.

Observation := Yellow color indicate presence of urea, while yellowish white color gives negative test.

4} Detection of Common Salt :=

Procedure :=

1. Take 5ml of 0.1341% AgNO3.

2. Add 2 drops of 10% potassium chromate.

3. Which gives brick red color.

4. Add 1.0ml of milk and mix, and observe the color.

Observation := Yellow color obtained indicates presence of salt. Brick red color remains indicates negative test.

5} Detection of Soda ( Neutralizer test ) :=

Procedure :=

1. Take 5ml milk sample in test tube.



2. Add 5ml pure ethyl alcohol in it.

3. Add 4 drop rosalic acid, and observe the color.

Observation :=Rose red color gives +ve & Light brownish color –ve test.

6} Detection of Phosphatase :=

Procedure:-

1. Take 5ml Phosphatase sodium salt buffer sub substrate solution in test tube.

2. Add 1ml milk sample in it.

3. Shake well & incubate at 37±0.5°C for ½ hour.

4. Compare yellow color on standard disc & determine efficiency of pasteurization.

Observation: - Yellow color gives +ve test.

7} Detection of Maltose :=

Procedure :=

1. Take 25ml of milk in beaker.

2. Add 1ml HCL in beaker.

3. Filter the sample.

4. Take 5ml sample in test tube.

5. Add 2 drops of Iodine solution.

Observation := Brown color gives +ve & Yellow color gives =ve test.

8} Detection of Cellulose ( CMC ) :=



Procedure :=

1. Take 10 ml of milk in 100ml beaker.

2. Add 50ml hot water & stir for 2 minutes.

3. Filter through a fine mesh nylon cloth.

4. Wash residue on cloth with 50ml hot water twice.

5. Scrap the residue with a spatula & place it in a spotting plate.

6. Stain a part of residue with iodine – zinc chlorides reagent and another part with iodine solution and observe the colour.

Observation: = Development of blue color with iodine=zinc chloride reagent and absence of blue color with iodine solution confirms presence of cellulose.

9} Detection of Skim Milk Powder :=

Procedure:-

1. Centrifuge about 50ml of milk at 3000rpm for 30 min.

2. Decant the supernatant liquid carefully.

3. Dissolve the residue in 2.5ml conc. HNO3.

4. Dilute the solution with 5ml distilled water.

5. Add 2.5ml liquid ammonia and observe the color.

Observation: = Development of orange or yellow color indicates addition of SMP in sample.

10} Detection of Added Natural Water & Pond Water: =

Procedure: =



1. Take 5ml of milk in test tube.

2. Add 6 to 7 drops of 10% lactic acid and shake for 2min.

3. Take 2ml of diphenylamine reagent in another test tube.

4. Filter the content of the sample tube.

5. Collect about 1ml of filtrate over diphenylamine reagent & observe the color.

Observation: = Development of blue color indicates presence of nitrate in milk and thus of added natural water.

INTRODUCTION: =

Milk Processing Section is the heart of dairy industry. The milk received from the RMRD cannot the instantly processed. So it is first chilled and stored in silo tanks. Consequently processing is carried out in this section are, pasteurization, cream separation, filtration, clarification, homogenization, standardization, reconstitution, chilling storage.

Milk Process: =

The equipment in this section is HTST Pasteurizers, Duplex filters, Clarifier cum separators, Homogenizer, Balance tank, Cream separator, Chillers & Storage tank.



Processes carried out in this section are as below: =

Pasteurization:-

Pasteurization is critical control point in processing of milk. Such heat treatment destroys nearly all pathogenic micro-organism including most heat resistance. Mycobacterium tuberculosis, E=monocytogens without seriously affecting composition & properties of milk.

First the milk is pumped out from dump tank & tankers by using 5HP pumps to the pasteurizer. The four section of the milk pasteurizer are first the Heating section, second is holding section, third is Regeneration section & fourth is Cooling section. The first raw milk in to the heating section and the holding section for the holding purpose at temperature of 78 +/- 2°C for 15 sec. And pass the hot milk in regeneration section in this section temp. Increased in steps as 35°C, 47°C, 65°C, 80°C hence milk can be sent to separation, homogenization between the regeneration sections. Pasteurizers are connected to Duplex filter, Cream separator and Homogenizer. Flow diversion valve is attached after the holding section. After pasteurization of milk is instantly cooled to 3°= 5°C and stored in storage tanks.

Cream separation:-

Centrifugal cream separator used for cream separation. Which function based on the centrifugal force.

Basic Principle of cream separator: -

Separation of cream from milk is possible because of a difference in specific gravity between the fat & liquid portion. Whether separation is accomplished by gravity or centrifugal



method. The result is depending upon this difference. The skimmed milk possesses on average a specific gravity is 1.032 while that of milk is about 0.93.

Cream is separated for several purpose. The most important is to obtained a product from which butter may be changed more economically than from whole milk. Cream also provides a richer product than milk for certain manufacturing purposes, more especially for ice-cream making and milk standardization.

Homogenization: =

A three stage homogenizer is installed in processing section, which is used homogenizing whole milk and it is connected in between regeneration 1 & 2 heating section. The main principle of homogenization is the milk fat in milk is dispersed in the milk for small size for 0.1-2 µ for the purpose of good flavor for milk and increase the quality of milk.

Chilling of Milk: =

After milk has been subjected to the temperature of pasteurization the product is chilled by the using chilled water to temp. of 3°-5°C. And the chilled milk is passing to storage tank.

FLOW CHART OF MILK PASTEURIZATION: =



Milk from dump tank`s & Tanker`s

Filter Regeneration 1 (Milk inlet temp 10-15°C)

(Milk outlet temp. 45°C)

Cream Separator

Cream Skim milk Regeneration 2 (Milk inlet temp.45°C)

(Milk outlet temp. 55=60°C)

Homogenizer

Regeneration 3 (Milk inlet temp. 60°C)


Hot Water (85°C) Heating Section (Milk inlet temp. 65°c)

(Milk outlet temp. 78±2°C)

Holding tubes or Holding plates (for 15 seconds)

Regeneration 3 (Milk inlet temp.) 78±2°C)




Regeneration 2 (Milk inlet temp.) 65°C)


Regeneration 1 (Milk inlet temp.) 45°C)


Chilled Water (1=2°C) Chilling section (Milk inlet temp.) 25°C)

(Milk outlet temp. 3=5°C)

Pasteurized Chilled Milk

Storage Tank



Standardization is an important procedure for the adjustment of fat and SNF as per the specified standard. The standardization is done by Skim milk or Reconstituted milk for buffalo milk while buffalo milk for cow milk. The tanks are provided agitators inside for through mixing continuously. There are different ratios for standardized milk whole milk.

Operating parameters for Standardization: -

Product Fat (%) SNF (%)

Standardized Milk 4.5 8.5

Whole Milk 6 9



Cow Milk 4 8.5

Flow Diagram of Reconstituted Milk: -

Skim milk powder

Hopper

Addition of water

Mixing in tank

Agitator (for well mixing)

Pasteurization & Homogenization

Reconstituted Milk

BULK MILK DISPATCH THROUGH TANKER

Daily near about 60,000 lit. Processed milk is sent to Washi

& Amul dairy for packaging. Before the milk is dispatched

through tankers, the tankers are cleaned properly as per

schedule given previously in the RMRD section. The

Pasteurized Whole Milk and Standardized milk is chilled at

1.5=2°C and filled in tankers and after filling, the sample is

given for analysis. After satisfactory analysis report, the



tankers are permitted for transportation to Washi & Amul for

packaging. This is carried out with Glycol chiller. The cooling

medium used in this chilling is Glycol.



INTRODUCTION: =

This section is very important as it gives the protection to

the product and improves its attractiveness i.e. contributing for

enhancing the acceptance.

This section is located just behind the RMRD. It is in

between RMRD & process section. The washed creates are

received in pre=pack, section for placing the pouch of milk and

then shifted to cold storage. In this section, there are five

fill=pack machines. This section is laterally connected with

cold storage.

The milk, which is pasteurized, homogenized or

standardized, is received from storage tanks in overhead

balance tank of fill=pack machine at 4°C. This flows from

overhead balance tank into the pouch by gravity. Machine

operates one electronic and pneumatic principle. Laboratory

takes sample for each size sample for each of pack and after

clearance regarding chemical analysis, weight and length of

pouch, from quality control laboratory; machine is run for

regular production.



Flow Diagram of Pouch Filling: =

Milk from storage tank (4°C)

Over head balance tank

Filling cylinder

Vertical sealing and pouch formation

Filling of milk and Horizontal sealing

Milk pouch

Weighing & leakage testing of pouch

Filling in crates

Crate convey to cold storage



Cold storage (0.5=1°C)

Dispatch

DETAILS OF PACKING MACHINE: -

In this section, three packaging machines are working.

Packaging material is polythene film. Roll is fixed on the

backside of the machine and it is carried out to the top of front

side mechanically by the nib rollers. Vertical edges of material

are sealed to each other by vertical Teflon coated electrode rod

at a temperature of 60°C. Then the material comes down and

sealed by horizontal electrode rod at 90°C. The horizontal rod

seals first lower end of pouch horizontally and after filling

adjusted amount of milk with the help of pneumatically

operated pistons having adjustable stroke volume, the pouch

slips down a specified distance and the its upper edge is

sealed. Horizontal sealing of upper side of one pouch and lower

side of next pouch & horizontally cutting of filled pouch is

carried out in single stroke of horizontal sealer. Packaging

machine and quantity of milk to be packed without leakage.



Parameters of Packaging Machines: =

No. of Units

1. Power saver (Nichrome)

2. Nichrome

The milk, which is collected from leaked pouches, is sent

for reprocessing. Average milk loss during adjustment & due to

leakage is around 6 liters per hour. Air is used as lubricant in

pulling cylinder.

Storage of film: =

1. At dry cool & dust free area.

2. Keep wrapped until taken for use.

3. Stacking on wooden pallets/racks.

PRODUCT LINE: -

1.1. PEDHAPEDHA

2.2. DAHIDAHI

3.3. LASSIELASSIE

4.4. BASUNDIBASUNDI



5.5. SHRIKHAND & AMRAKHANDSHRIKHAND & AMRAKHAND

6. FLAVOURED MILK 6. FLAVOURED MILK

1. PEDHA: - 1. PEDHA: -

Raw milk Raw milk

Filtration Filtration

Pasteurization (78°C for 15 sec.) Pasteurization (78°C for 15 sec.)

Homogenization Homogenization

Standardization (6% Fat & 9% SNF) Standardization (6% Fat & 9% SNF)

Chilling Chilling

Fill milk in Khoa machine bowl (80 lit.) Fill milk in Khoa machine bowl (80 lit.)

Heating of milk Heating of milk

Semisolid Mass (Khoa stage occurred) Semisolid Mass (Khoa stage occurred)

Addition of (Sugar 6.4 kg &) Addition of (Sugar 6.4 kg &)



(Spices 60gm/20kg of Khoa) (Spices 60gm/20kg of Khoa)

Spread on table for cooling Spread on table for cooling

Make desired shape ball Make desired shape ball

Prepared Pedha Prepared Pedha

Packaging Packaging

Storage Storage

2. DAHI2. DAHI: : - - Take raw milk Take raw milk

Pasteurization 78±2°C for 15sec. Pasteurization 78±2°C for 15sec.



Spices = Nutmeg 100gm + Cardamom 100gm & it grind

well & mix well.


Batch Pasteurization 80-85°C for 20 min. Batch Pasteurization 80-85°C for 20 min.

Drop temp. 38-40°C Drop temp. 38-40°C

Addition of 1% lactic culture Addition of 1% lactic culture

Storage of milk in inoculation tank Storage of milk in inoculation tank

Packaging in PET Packaging in PET

Storage in Incubation chamber Storage in Incubation chamber

(8 hrs. 40±2°C & Acidity 0.7- (8 hrs. 40±2°C & Acidity 0.7-

0.8%)0.8%)

Take to Deep Freezer for Blast cooling Take to Deep Freezer for Blast cooling

Storage in cold room Storage in cold room

LASSI: -

Take raw milk Take raw milk











0.8%)0.8%)

Addition of same quantity of water Addition of same quantity of water

Addition of Sugar (16.5 kg for 100lit.) Addition of Sugar (16.5 kg for 100lit.)

Grinding for well mixing Grinding for well mixing



Batch Pasteurization Batch Pasteurization

Addition Iodized Salt (150gm/100lit. during heating) Addition Iodized Salt (150gm/100lit. during heating)

Addition of Cardamom (110gm /100lit.) Addition of Cardamom (110gm /100lit.)

Chilling Chilling


Storage (2-4°) Storage (2-4°)

4. BASUNDI: -

Raw milk Raw milk







Chilling Chilling

Fill milk in Khoa machine bowl (80 lit.) Fill milk in Khoa machine bowl (80 lit.)

Heating of milk Heating of milk

Semi Liquid Mass (Basundi stage occurred) Semi Liquid Mass (Basundi stage occurred)

Addition of (Sugar 4.6 kg &) Addition of (Sugar 4.6 kg &)

(Spices 60mg/40kg of Basundi) (Spices 60mg/40kg of Basundi)

Open Outlet Valve Open Outlet Valve

Transfer Basundi for Chilling (4-5 °C ) Transfer Basundi for Chilling (4-5 °C )


Storage (0-2°C) Storage (0-2°C)



5. SHRIKHAND & AMRAKHAND5. SHRIKHAND & AMRAKHAND:: - -

Take raw milk Take raw milk











0.8%)0.8%)

Hanging of Dahi in muslin cloth (10-12hrs.) Hanging of Dahi in muslin cloth (10-12hrs.)

Chakka (Acidity max. 1.4%) Chakka (Acidity max. 1.4%)

Addition of sugar (80%) Addition of sugar (80%)

Shredding Shredding

Kesher (0.001) Jaiphal, Elaichi Mango pulpKesher (0.001) Jaiphal, Elaichi Mango pulp

Jaiphal (0.02%) (0.o2%) (0.1%) (MixingJaiphal (0.02%) (0.o2%) (0.1%) (Mixing

(13%)(13%)

Elaichi (0.1%)Elaichi (0.1%)

(Amrakhand)(Amrakhand)

Mixing Mixing



Cup Filling Cup Filling

Packaging Packaging

Cold Storage (below 0°C) Cold Storage (below 0°C)

6. FLAVOURED MILK: -

Raw milk Raw milk





Addition of Sugar (8%) Addition of Sugar (8%)



Flavor mixing (0.02%) Flavor mixing (0.02%)


Storage (2-4°C) Storage (2-4°C)

After manufacturing of the pasteurized milk & By

product's the chemical & microbial analysis is very important in

dairy industry. Various test is carried out in quality control

department under ISO & PFA (Maharashtra) certification.

A} Analysis of Milk: -

1} Detection of protein in Milk: -



Procedure: -

1. Pipette out 10ml of milk in beaker.

2. Add 0.4ml of potassium oxalate in it.


4. Titrate the sample 0.1N NaOH solution till faint pink color is reaches.

5. Add 2ml of formaldehyde solution in above sample.

6. Keep stand for 5 min.

7. Titrate the sample against 0.1N NaOH solution till faint pink color is observed.

Calculation: - Second B.R. x 1.7

Standard: - Protein contain in cow milk is not less than 3% & B/M is not less than 4.5%.

2} MBR Test (Mythylene blue reduction test): -

Procedure of MBR Test: -

1. Take 10ml milk in sterile test tube.

2. Add 1ml of Mythylene blue working solution in test tube.

3. Work the test tube & mix the content.

4. Keep the test tube in water bath at 37°C for 30min to 6hrs.



5. Observe the change in color of the test tube.

Interpretation: -

Sample

Quality Reduction time.

1 Excellent Above 6 hrs.

2 Good 4-3 hrs.

3 Fair 2-½ hrs.

4 Poor Less than ½ hrs.



Analysis of by product’s: -

1} Acidity of a Product: -

Procedure: -

1. Weight accurately 1gm of sample in beaker.

2. Add 10ml distilled water in it.

3. Add 3=4 drops of phenolphthalein indicator

4. Titrate the sample against 0.1N NaOH solution till faint pink color

Observed.

5. Take the reading & calculate the acidity of product

Calculation: = 0.9 x A x N Where, A= Burrete reading.

W N = Normality

W= Wt. of

sample

2} Determination of fat of the milk product products by Gerber Method: =

Procedure: -

1. Take 10ml sulphuric acid in butyrometer by tilt measure.

2. Add 5gm product sample & add 5ml distilled water in it.

3. Add 1ml of iso-amyl alcohol in butyrometer.

4. Lock the butyrometer by lock stopper.



5. Shake the butyrometer at 45° angle for dissolve the curd.

6. Centrifuge for 5 min. at 1100=1200 R.P.M.

7. Read the reading on fat column & not down fat % in milk product.

3} Moisture of milk product:-

Procedure: -

1. Weight accurately empty aluminum dish & record the weight.

2. Weight 2.5gm of milk sample in above aluminum dish.

3. Spread the sample evenly on bottom of dish by using glass rod.

4. Place the dish in to hot air oven for 3hrs. At 100°C.

5. after 3hrs. Weight of dish after heating.

Calculation: -1) W1- weight of empty dish.

2) W2- weight of dish with sample.

3) W3- weight of dish after heating.

Formula: -

W2 – W3

Moisture of milk product = x 100

W2 – W1

4} Determination of protein of the milk product: -



Procedure: -

1. Take 3gm of product sample in beaker.

2. Add 10ml of distilled water in beaker.

3. Add 0.4ml of potassium oxalate in it.


5. Titrate the sample 0.1N NaOH solution until faint pink color is observed.

6. Add 2ml of neutral formaldehyde solution in above sample.

7. Keep stand for 5min.

8. Titrate the sample against 0.1N NaOH solution till faint pink color is observed.

Calculation: - Formula = Second B. R. x 1.7.

5} Determination of Total Solid Content of the Milk Product: -

Procedure: -

1. Weight accurately empty aluminum dish & record the weight of dish (W1).

2. Weight 2.5gm of milk product in above aluminum dish & note down the weight (W2).

3. Spread the sample evenly on bottom of dish by using glass rod.

4. After 3hrs. Weight of dish after heating.

W2 – W3



Moisture of milk products = x 100.

W2 – W1

T.S.S. = 100 – moisture.

6} Phosphatase Test for Milk: -

Phosphatase test is carried out for to check the milk properly pasteurized or un pasteurized.

Procedure: -

1. Take 5ml of Phosphatase solution in test tube.

2. Add 1ml of milk sample in test tube (solution A).

3. Pipette out 1ml of milk in test tube & add 5ml Phosphatase solution.

4. Mark it as solution.

5. Cork the tube and mix the content well.

6. Keep both test tubes in hot water bath at 37°C for 2hrs.

7. Compare the change in color in test tube (A) with test tube (B) after 2hrs.

Result – Yellow color indicates test is positive & White color indicates test is negative.

PFA standard for milk & milk products: -

A) Raw Milk in Can: -

Tests Buffalo Cow Milk



CHEMICAL

Fat 6.0 % (Min.) 3.8 % (Min.)

SNF 9.0 % (Min.) 8.5 % (Min.)

COB Negative Negative

PHYSICAL

Smell Satisfactory (Min.) Satisfactory (Min.)

B) Pasteurized Milk: -

Tests Parameters

BIOCHEMICAL

M.B.R. 4 hrs. (Min.)

BACTERIOLOGICAL

SPC 30,000 (Max.)

Coli form. Absent.

C) Buffalo Milk and Cow Milk: -

Tests Buffalo Milk Cow Milk

CHEMICAL

Fat 6.5 – 6.8 % 3.8 – 4.2 %

SNF 9.0 – 9.3 % 8.5 – 8.7 %

(For standardized Milk Fat % = 4.5 – 4.7 & SNF % = 8.5 – 8.7 %)



Acidity. 0.1 – 0.15 % L.A. 0.1 – 0.15 %

L.A.

BIOCHEMICAL

MBR. 4hrs. (Min) 4hrs. (Min)

D) Milk for LASSI: -

Tests Parameters

CHEMICAL

Fat 4.9 % (Min.)

SNF. 8. 6 % (Min.)

E) Milk for CHAKKA: -

Tests Parameters

CHEMICAL

Fat 3.5 % (Min.)

SNF. 9.3 % (Min.)



Milk is an excellent growth medium for variety organism. To judge the extent of contamination can be minimized by exercising proper practices.

1. Standard Plate Count: -

This method is used to estimate the total viable bacterial no. in milk & milk products & other respective samples.

Procedure: =

1. Collect the sample form different places in aseptic condition.

2. Carry out their serial dilution.

3. 1ml of each dilution is transfer to a sterile Petri plate.

4. 15 – 20ml of sterile molten & cooled plate count agar is poured in each Petri plate.

5. Mix the content by rotating the plates.

6. Place the plate in incubator at inverted position in incubator at 37±0.5°C for 24hrs.

7. after 24hrs. The visible colonies appearing on agar plate are counted.

Result: -

SPC =No. of colonies x dilution factor

Interpretation: - SPC count not more than (30,000) /ml for pasteurized milk.

2} Presumptive Coli form Test: -

Media: - Red bite Agar



Procedure: -

1. Take 10ml saline water.

2. Add 1ml of sample of pasteurized milk in saline water and mark it as to 10 ¹ to 10¹ dilutions.

3. Transfer 1ml of sample from 10 ¹ dilution in another 9ml saline water & mark it as 10` also prepare 10 dilution.

4. Pour molten and cooled red bile agar (12 to 15ml) in each Petri dish.

5. Mix the content well by rotation the plates.

6. Incubate the plate in inverted position 37±0.5°C in incubate for 24hrs.

7. After the incubation period count the pink colony & note down the Coli form count.

Coli form count: - No. of colonies x Dilution factor.

For bacteriology of milk of milk product weight accurately 10 gm. Of sample and transfer into 90ml peptone water. 10 dilution used for bacteriological analysis.

Sr. No.

Particular SPC count Coli form count

1. Shrikhand/Chakka NMT 50,000/gm NMT 10/gm

2. Khoa NMT 50,000/gm NMT 90/gm

3. Flavoured Milk Nil Absent in 0.1 gm

4. SMP NMT 50,000/gm Absent in 0.1 gm

5. Dahi NMT 50,000/gm NMT 10/gm



6. Cream NMT 50,000/gm NMT 10/gm



CIP system is located at right hand of processing section of RMRD. It is having three CIP tanks for storing different cleaning and sanitizing solutions of various temperatures. These tanks are connected to processing section through pipeline for cleaning various milk processing equipment and systems.

Cleaning In Place applied to milk lines. Only cream separator & filters are cleaned manually after each shift.

CIP of Processing Section: -

To maintain the hygienic condition of plant proper cleaning, ventilation and CIP of milk processing equipment is necessary. For CIP Nitric acid and Caustic Soda are use in the required proportion. The pasteurizers are cleaned with CIP, while cleaning of Cream separator and Duplex Filters is done manually after the 6Hrs. in each shift.

Flow chart for CIP of Processing Section:-

Pre-rinse with hot water

(45°C for 10min.)

Caustic + Syndet powder circulation

(70°C for 30min.)

Hot water rinse



(80°C for 10min.)

Nitric acid circulation

(60-70°C for 10min)

Hot water rinse

(80°C for 10min. / till removal of acid)

Caustic + Syndet powder circulation

(70°C for 30 min)

Hot water rinse

(80°C for 10min. /till removal of acid)

Hot water + Byosin (80°C for 10min.)

CIP programme for Milk Pasteurizers: =

1. Rinse with warm water for about 8 min.

2. Circulate alkali detergent solution (NaOH Solution). For about

20min. at 75°C.

3. Rinse alkaline detergent with hot water at 80°C for 10min.

4. Circulation of Nitric acid (HNO3) solution about 15min. at 70°C.

5. Flushing with hot water at 75°C for about 6min.



6. Disinfections by circulation hot water at 90°C for about

8min.

7. Gradual cooling either cold water for about 8min.

The general process of refrigeration system is takes place as follows –

1. Compressor.

2. Condenser.

3. Receiver.

4. Expansion valve.

5. Evaporator.

4


EV 3 Receivers

2 Condensers

5

Evaporator


INTRODUCTION: -

The main function of boiler is to produce steam. Steam is the used in section of plant in cleaning, production, sterilization of dairy equipment. Soft water is used in boiler to avoid s align over the tubes Hardness of water is maintained at 0 to 5 PPM.

Generally two types of boilers are used: -

1. Water tube boiler: -

In this the water is circulated inside the tube & smoke is present outside the tube.

2. Smoke tube boiler: -

In this smoke is present inside the tube & water is circulated outside the tube.

In Koyana dairy used is smoke tube boiler is used for the heating of water & produce the steam

Hot Water Boiler : =

Temperature: -90 to 95°C.

Pressure: - 4 kg/cm2.

Energy: - 2.5 lakh kcal.

Pump: - 10 HP.

Capacity of boiler 60,000 – 80,000 lit. / Day & use timber as a fuel and it use 2 tons/day.

Return Water Temperature is 88 - 90°C.



Schematic flow diagram of ETP Plant: -

Volumetric capacities 200m3

By pump

80m3 x 2

By Gravity

300m3 x 2

Effluent

Recirculation


Raw Effluent

Tank

Fat Removal Unit

Equalization tank

Floating Agitator

UASB


500m3

By Gravity



615m3

Sludge

Recirculation By gravity

By gravity

4m3


Aeration tank

(Fixed Aerators)

Treated

Effluent

Tank

Sludge drying

Bed.

Koyana report

Documents

Transcript of Koyana report