Verka milk plant ppt
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Transcript of Verka milk plant ppt
Submitted by:Nishant SachdevaL-2010-A-03-B.tech FT
Industrial TrainingThe Ludhiana District Co-operative Milk
Producer's Union Ltd.
Introduction First Milk Plant, of the State was setup at Verka near
Amritsar. The brand name of Milk and Milk Products was adopted
as Verka. The Foundation stone of Milk Plant, Ludhiana was laid by
Hon. S. Parkash Singh Badal, the then Chief Minister of Punjab in 1970.
Commissioning of the Plant was done by Punjab Dairy Development Corporation in 1974.
Inauguration was done by Late Smt. Indira Gandhi the Prime Minister of India.
The capacity of the plant was 1.00 lac. Litre per day, and now the milk handling capacity is 4.00 Lac Liter per day.
• Amritsar • Bathinda• Chandigarh• Faridkot• Ferozpur• Gurdaspur
• Horshiarpur• Jalandhar • Ludhiana• Patiala• Ropar
(Mohali) • Sangrur
MILKFED has its milk unions in almost all the districts of Punjab. These
district units are:-
MILKFED PLANTS LOCATION
These plants in all these unions are being run under the brand name VERKA.
Present Status No. of societies increased from 94 to 802 and its
membership from 5400 to 78500. Milk Procurement has increased from 10200 LPD to
2,50,000 LPD. Highest milk price is being paid to the milk producers as
compare to other plants in the states Products being manufactured by Ludhiana Plant are sold
at premium rates through out of the country and in the International Market.
City supply has increase from 66000 LPD to 1,98,000 LPD. Turnover the plant touched to 283 crores Profit of the
union has increased manifold. Capacity utilization of the plant is more than 85%.
VERKA MILK PLANT - PROFILE Full name : The Ludhiana District Cooperative Milk Producers Union Ltd.
Foundation : Laid by Hon. Sh. Prakash Singh Badal in 1970
Capacity : Then 1 lakh L/day, Now 6 lakh L/day
Head office : Punjab State Co-operative Milk Producers Federation Ltd. S.C.O.153-155, Sec. 34-A, Chd.
Inauguration date : 31stOctober, 1974
Chairman : Sh. Ajmer Singh
No. of societies : 816
No. of Chilling centers : 4
Brand name : VERKA
Products marketed by : The Punjab State Co-operative Milk Producers Federation. Ltd.
Quality certificates : International Quality Certificate ISO-9002 & IS-15000 (HACCP)
VERKA MILK PLANT• Verka milk plant (VMP), Ludhiana is known as The Ludhiana Dist.-Co-
operative Milk Producer’s Union Limited, Ludhiana . It is situated on
Ferozpur Road, about 5 km. away from both railway station and main bus
stand.
• The plant has bagged first position in Northern Zone
• It is fully equipped with modern fluid milk plant facilities. The latest state
of art technology in milk drying is available in this plant.
• The products manufactured by this Plant at present are STM, DTM, FCM,
SMP, WMP, Ghee, Butter, Paneer, Milk-Cake, Dahi, Kheer, Lassi .
Contd…
Some objectives of the Milk Plant are:-• To uplift social and economic status of milk producers.• To develop dairy as industry allied to agriculture.• To provide better and remunerative prices for milk.• To provide veterinary aids to animals of milk producers at their doorstep.• To provide better quality cattle feed at reasonable rates.• To educate the milk producers about lowering down the cost of milk
without compromising quality.• To create employment opportunities for rural youth by milk production
activities.• To provide awareness among milk producers for socio-economic change
through co-operative set-up.
VERKA MILK PLANT
PRESENT STATUS OF VMPProduct brand name : VERKA
Milk handling capacity : 6 lakh litres per day
Production of market milk : 2.5 lakh litres per day
Production of butter : 13000 Kg per day
Production of ghee : 14 MT per day
Production of powder : 30 MT per day
Production of paneer : 400-450 Kg per day
Production of kheer : 200 Kg per day
Production of milk cake : 30-40 Kg per day
Production of dahi : 1400 Kg per day
Production of lassi : 3000 Kg per day
POWDER SECTION• There are definite indication of greater future
productions of dried milk & milk products due to their better keeping quality, they require less storage space & lower transportation costs. All these are economically attractive.
• Dried milk provides a means of handling the excess milk supply in a dairy factory during flush season, while in lean season that meant for the production of dry milk can be diverted to market milk. Thus, dried milk is called the balance wheel of dairy industry.
• VERKA MILK PLANT, LUDHIANA has two separate drying plants.
POWDER SECTIONThe Dairy has two separate drying plants, viz: • Powder section with MVR unit & TVR unit (30TPD)• Powder section with TVR unit only (6.5TPD)Compositional & other Standards maintained :-
Parameters SMP Standard grade SMP Extra grade WMP
Moisture (%) 3.2-3.6 3.0-3.4 Max. 3
FAT (%) Max. 1.3 Max. 1.2 26.5-27.5
Acidity (%LA) 1.0-1.25 1.0-1.2.5 Max. 1
B.D. Agglomerated (gm/ml) 0.45-0.55 0.5-0.6 0.5-0.6
Insolubility Index (50ml) Max. 0.15 Max. 0.15 Max. 0.5 Ash content (%) Max. 8.2 Max. 8.2 Max. 0.5Coliform Nil Nil Nil
PROCESS CONTROLLumpiness in Powder
1. Ensure proper cooling of powder
2. Dehumidifier should be properly operating
Low moisture in Final Product 1. Increase flow rate
2. Adjust outlet temp
Burnt Powder Particles 1. Adjust inlet temp
2. Check the function of feed flow controller & feed pump
3. Nozzle of jets are whether chocked partially
Sooty Powder 1. Clean or change the filter.
2. Check up air heater
Very Fine Powder A Particles 1. Increase in degree of concentration
2. Control the feed temp.
Solubility Index Increased 1. Check the outlet temp.
2. Control feed rate
OPERATING PARAMETERS FOR EVAPORATING PLANT
PARAMETER STANDARD & EXTRA GRADE W.M.P CONCENTRATED MILK
Milk feed rate (lts/hr) 16000-17000 3500-14500 16000-17000
Steam pressure (kg/sq.cm) 5-6.5 5-6 5-6.5
Thermal vapor recompression (kg/sq.cm.)
2-2.5 2-2.5 1-1.5
High heater (temp oC) 90+/-2 95-100 90+/-2
Holding heater temp (oC) -Do- -Do-` -Do-
Flush vessel temp (oC) 73-85 73-85 73-85
Jacket temp (oC) 69+/-1 69+/-1 69+/-1
Vapor Separator I (oC) 66+/-2 66+/-1 66+/-1
Vapor Separator II (oC) 58+/-2 58+/-1 58+/-1
Vapor Separator III (oC) 50+/-2 50+/-1 50+/-1
Vacuum in condenser 0.9m bar 0.9m bar 0.9m bar
T.S. % of condenser 20+/-3 20+/-3 20+/-3
OPERATING PARAMETERS FOR DRYING PLANT
PARAMETERS SMP WMP
Chamber inlet air temperature (oC)
170+/-10
180+/-10
165+/-5
170+/-5
Vibro fluidier air inlet temperature (oC) 90+/-5 65+/-10
Chamber outlet temperature (oC) 80-90 80-90
Vibro fluidier outlet temperature (oC) 64+/-2 65+/-2
Chamber vacuum (mm.w.c) 5+/-2 15+/-2
Atomizer load (amp) 55+/-5 55+/-5
Load on exhaust fan (amp) 95+/-5 95+/-5
Powder output (kg/hr) Min. 1375 Min. 1500
Powder Plant
Drying Chamber
Cyclone
Control Panel
Processing Operations
• Chilling: Milk is chilled below 4 ºC. The raw chilled milk is utilized for the various products processing operations. The chilled milk is stored in tank called as Silo. The chiller is plate heat exchanger type.
• Pasteurizing: Milk is heated at 63 ºC for 30 minutes or 75-80 ºC for 15 sec and then cooled immediately below 14 ºC.
Type of milk received :- Cow Milk :- Fat Min. 3%, SNF Min. 7.9% Buffalo Milk :- Fat Min. 6%, SNF Min. 8.6% Mixed Milk :- Fat Min. 5.4-5.5%, SNF Min. 8-8.5%
RAW MILK RECEPTION DOCK (RMRD)
Make : Cast iron grid tiles, edges are of cast iron planting
Width : To overcome heavy stressesTypes : 1.5mmSlope : OpenCans : 40 Liters capacity, weighing 6-6.5 kg Material : Aluminum
• Starting the RMRD• Unloading and Conveying• Opening the lids• Grading• Weighing and Sampling• Cleaning & Washing of cans• Recording of cans• Loading• Closing down RMRD
OPERATIONS AT RMRD
PRODUCTION SECTION
Composition of Milk
Characteristic Cow milk Buffalo milk
Fat 4.0-4.5 % 6.5-7.0%
Carbohydrates
4.5 % 4.7 %
SNF 8-8.5 % 8.5- 9.0%
Proteins 3.3 % 3.6 %
Minerals 0.6 % 0.7 % Water 87-88 % 84-85 %
PRODUCT FLOWMilk
Fluid MilkPacking Given
Prefernce
Lassi
Milk-cake
Kheer
Dahi
Surplus FatTable Butter
White ButterGhee
Skim Milk
Skim Milk Powder
City Supply Section
PANEER SECTION
Compositional & other Standards maintained :-
Equipments used are- Steam Jacketed Vat, Trolleys, Sealing Machine, Hoops, Automatic Machine For Processing.
• Cleaning of vats, hoops & muslin cloths is done manually, then they are sanitized with 0.5% teepol & hot water at 55-60oC
Fat Not < 50% of dry mater basis
Moisture Not > 70%Texture Soft & spongy
Taste & flavor Pleasant
Whole milk
Heating (90oC) for 15 min
Filtration (with clean muslin
cloth)
Coagulation (1-2% citric acid)
Separation of whey
Hoping
Pressing
Cutting into blocks
Dipped in pasteurized &
chlorinated chilled water (4-10oC/45-60 min)
Cut into pieces & weighing
(200gm manually)
Packing in polythene
sachets
Storage at butter cold store Dispatching
Flow diagram for Paneer manufacture
DAHI SECTION This dairy plant follows the ISI standard of dahi. Mostly it is
manufactured every two alternate days in flush seasons.
Compositional & other Standards maintained :-
Equipments used are- Steam Jacketed Vat, Weighing Balance, Cans, Incubation Chamber, Dahi Packaging Machine.
Fat 4-5%
Protein 3.2 -3.4%
Acidity 0.8-1.0%
Taste Cream-sour
Flavor Acid
Milk is taken in Vat For Dahi Preparation
Standardization &
Homogenization
Pasteurization (80-90oc/15-30
Min)
Cooling (37°C)
Inoculation with Lactic Culture (from previous
day Dahi)
Filling by pipe filler in
polystyrene cups
Sealing the Cups
Putting 12 Cups in each Card Board Box
Incubation (37oc/1.5-2hr)
Dahi Prepared
Cooling & Storage (5oc)
Dispatch
Flow diagram for Dahi manufacture
BUTTER SECTIONLudhiana milk Plant is engaged in making two types of butter viz Table Butter White Butter (White Butter is made and stored as stock and is
used in lean season for recombination and is also used as base material for ghee & often supplied for bulk demand).
The dairy produces butter by batch churn method. There is also a provision for continuous butter making machine.
The packed butter is stored at -17 to -29oC till dispatch.
Operating Parameters for Table Butter
Loading of churn 1/3rd volume of drum capacity
Loading temp (oC) < 10-12 oC
Churning temp (oC) < 10-12 oC
Color addition 1ml/kg fat
Spray water temp (oC) Max 5
Speed of churning
28-30 rpm (1st gear)
14-18 rpm (2nd gear)
7-8 rpm (3rd gear)
Salt addition (dissolved in pasteurized warm
water)22mg/kg of butter yield
Vacuum during operation 300-350mm
FAT % in cream 40-42
Cream from separator
Cram pasteurization
Storage in cream tank for
ageing
Feeding to butter churn
(In case of table butter
color is added @ 1ml/kg/fat)
Churning at 1st gear up to
breaking point (30-35min)
Churning at 2nd gear (30-45
min)
Churning at 4th gear of white
butter
Removal of buttermilk
Washing at 2nd gear (6-8oC/15
min after adding water)
Equal in volume of buttermilk removed)
Draining of water
2nd washing
Salt @ 2.2% is added (for table
butter)
Working & controlling of moisture at 2nd
gear
(25-30 min. 300-350mm)
Unloading (before it rotate at 2nd gear for 5
min)
Packaging (500, 100, 10
gm)
Storage (-17 to -29oC)
Package in card board boxes
Flow diagram for Table Butter manufacture
GHEE SECTIONCompositional & other Standards maintained :-
• Equipments used are- Butter Melting Vat, Pre-stratification Tank, Ghee Boiler, Settling Tank, Filling/Storage Tank, Ghee Clarifier, Electronic Weighing Balance, Closure Punching Machine, Pouch Filling Machine.
Flavor & color Pleasant & white or yellowMoisture Max. 0.25%
F.F.A (% Oleic Acid) Max. 0.03%B.R. reading at 40oC 40-43
Peroxide value Max. 1Sediment Absent
Operating parametersPre-melting temp (oC) 75-80
Cooking temp (oC) 105-112
Batch time (hr) Max. 4
Steam pressure in kettle (kg/sq.cm.) 2
Filtration Falalin cloth
Clarification temp (oC) 95+/-5
Setting time (hr) Min. 6
Ghee filling tank temp (oC) 43+/-5
Ghee filling temp (oC) 42+/-5 °C
After packaging the packed corrugated boxes are kept in granulation room for 24 hrs. Then the boxes are transferred into storage room till dispatch.
LASSI : Lassi is a drink made of standardized milk with 50:50 dilutions with water.
Receiving milk
↓Standardization(4.5%fat and 8.5%snf)
Heating of milk 85°c /5min
Cooling down to 40°c
Inoculation with culture at 1% at 40 °cInoculation at 40 °c(till acidity reach 0.67%)
Addition of pasteurized chilled water 2%
Breaking of coagulum( acidity o.54%)
Packaging
Cold storage less than 5°c
Kheer is concentrated heat desiccated indigenous dairy product.
Taking milk in double jacketed
vat
Heating milk to desirable reached with consistency with continuous
stirring
Addition of basmati rice in boiling milk and
stirring
Heating it till desired
consistency reached with
stirring
Addition of sugarAddition of
mixture of sodium benzoate and Elaichi powder
Stirring for some time and filling in
cups(200 g)Storing in cold
room(below 8˚C)
Thank you
Any question ?