report on industrial training at amul dairy, anand kaira...
TRANSCRIPT
Report
On
Industrial Training at
Amul Dairy, Anand
Kaira District Co-operative Milk Producers Union Ltd.
Submitted to: Er.Atul Anand Mishra
Submitted by: Arpita Banerjee (15BTFT075)
Priya Rai (15BTFT101)
Anushree (15BTFT065)
Shivam Singh (15BTFT060)
Abhinav Anand (15BTFT046)
Department of Food Process Engineering
Vaugh Institute of Agricultural Engineering and Technology (VIAET)
Sam Higginbottom University of Agricultural Technology and Sciences
(SHUATS),
Allahabad-211007
(U.P State Act No.35 of 2016, As Passed by U.P Legislature)
ACKNOWLEDGEMENT
We sincerely express our deepest sense of hearty gratitude to the following people for supporting and
guiding us ahead in the journey of making the project report of Industrial In-Plant training.
We express our profound gratitude and indebtedness to The Father of “The white Revolution, Dr.
Varghese Kurien” for envisioning this dairy and helping it becomes the stage of learning.
We would like to express our thanks to Dr. D. C. Joshi (Principal of college of food Processing
Technology& Bio-Energy, Anand) for permitting us to do our In-plant training in Amul Dairy, Anand.
We would also like to thank All the professors of our college for supporting & guiding us throughout
our graduation.
We are thankful Dr. K. Ratnam, Managing Director, Kaira District Co-operative Milk Producers
Union Limited for giving us such prestigious opportunity to undergo In-Plant training in this organization.
We are also thankful to Mr. D. R Sharma (Production Manager), Mr. Mrunal Desai (H.R
Department) without whose guidelines and help we would not have been able to complete our In-Plant
training. Our heartiest thanks to Mr. V. R Joshi (Production manager in Kheda satellite dairy) and Mr.
Subhankar Mitra (Production manager in food complex Mogar.
We are also thankful to all section In-charges and operators who gave us positive response and
guidance during our training period.
Last but not the least, we express our deep feelings of love and affection to our beloved parents for
providing us valuable opportunities which helped us to stand out on our own feet this stage.
Thank You
Arpita Banerjee (15BTFT075)
Priya Rai (15BTFT101)
Anushree (15BTFT065)
Shivam Singh (15BTFT060)
Abhinav Anand (15BTFT046)
Place: Amul dairy, Anand
Date: 30/06/2017
INDEX
Sr.
No.
Content
1 List of Tables
2 Introduction of company
3 Product range
4 Amul-3 processing plant
5 Amul-2 processing plant
6 Milk pouch packaging section
7 Buttermilk section
8 Dahi section
9 L & T Powder plant
10 Butter section
11 Ghee section
12 Flavoured Milk
13 QA Laboratory
14 Conclusion
List of Tables
Table No. Title I Company profile
Ii Product Range
1.1 Amul-3 equipment list
1.2 Amul-3 CIP
1.3 CIP of RMRD
2.1 Amul-2 Can washing
2.2 Amul-2 equipment list
2.3 Amul-2 CIP
3.1 FFS pouch packaging machine
3.2 Milk pouch standards
4.1 Specification of buttermilk
5.1 Specification of Dahi
6.1 Specification of powder
6.2 Equipment list (L & T powder plant)
6.3 Powder packaging
7.1 Specification of butter
7.2 Butter section equipment list
8.1 Chemical composition of ghee
8.2 Ghee section equipment list
8.3 Standards of weight
9.1 Product list of Flavoured milk
9.2 Specification of Flavoured milk
9.3 Equipment list
9.4 Standards of weight
9.5 CIP of storage vats
9.6 CIP of filling machine
10.1 Tests done at RMRD lab
10.3.1 Powder analysis
10.3.2 Ghee analysis
10.3.3 Butter analysis
10.3.4 Flavoured milk analysis
10.3.5 Tests for Buttermilk & Dahi
10.3.6 Water analysis
10.3.7 Strength of acid & soda
10.3.8 Packaging material testing
10.3.9 Equipments of Central laboratory
10.4.1 Different microorganisms
10.4.2 Sampling plan for analysis of product
INTRODUCTION
AMUL is based in Anand town of Gujarat and has been a sterling example of a Co-operative organization‟s
success in the long term. It is one of the best examples of Co-operative achievement in the developing world.
“Anyone who has seen… the Dairy Co-operatives in the state of Gujarat, especially the highly successful one
known as AMUL, will naturally wonder what combination of influences and incentives is needed to multiply
such a model a thousand times over in developing regions everywhere.” The Amul Pattern has established
itself as a uniquely appropriate model for rural development. Amul has spurred the White Revolution of
India, which has made India the largest producer of milk and milk products in the world. It is also the
world‟s biggest vegetarian cheese brand.
AMUL means „priceless‟ in Sanskrit. The brand name “Amul,” from the Sanskrit word “Amulya” was
suggested by a quality control expert . Amul products have been in use in millions of homes since 1946 and
made Amul a leading food brand in India.
Today Amul is a symbol of many things.
High-quality products sold at reasonable prices.
Proven model for dairy development.
Genesis of a vast co-operative network.
Today,there are twelve dairies producing procucts under the brand name of AMUL. AMUL is now Asia‟s
largest dairy brand and it is the world‟s second largest firm producing dairy products.
80% of profit is divided to farmers according to ratio of milk procured.
Company profile:
Name of plant
Kaira district co-operative milk producer‟s
union ltd.
Date of registration 14th
December 1946,under cooperative act
Registration no. p.330/1946
Brand Name Amul
Societies
1176 villages co-operative societies with
6,69,566 members
Premises
49.55 acres
Milk procurements 40 lakh liter per day
Plants Dairy plant – Anand
Kaira Satellite Dairy – Khatraj
Food complex – Mogar
Kanjari Plant – Nadiad
Amul research & development
association.
(table no: i)
History & development of AMUL:
Amul-cooperative registered on 14th December 1946 as a response to the exploitation of marginal milk
producers by traders or agents of the only existing dairy, the Polson dairy, in the small city distances to
deliver milk, which often went sour in summer, to Polson. The prices of milk were arbitrarily determined.
Moreover, the government had given monopoly rights to Polson to collect milk from Kaira and supply it to
Bombay city.
Angered by the unfair trade practices, the farmers of Kaira approached Sardar Vallabhbhai Patel under the
leadership of local farmer leader Tribhuvandas K. Patel. He advised them to form a cooperative and supply
milk directly to the Bombay Milk Scheme instead of Polson (who did the same but gave them low
prices). He sent Morarji Desai to organise the farmers. In 1946, the milk farmers of the area went on a strike
which led to the setting up of the cooperative to collect and process milk. Milk collection was decentralized,
as most producers were marginal farmers who could deliver, at most, 1–2 litres of milk per day. Cooperatives
were formed for each village, too.
The cooperative was further developed and managed by Dr.Verghese Kurien with H.M. Dalaya. Dalaya's
innovation of making skim milk powder from buffalo milk (for the first time in the world) and a little later,
with Kurien's help, making it on a commercial scale, led to the first modern dairy of the cooperative at
Anand, which would compete against established players in the market. Kurien's brother-in-law K.M. Philip
sensitized Kurien to the needs of attending to the finer points of marketing, including the creation and
popularization of a brand. This led to the search for an attractive brand name. In a brainstorming session, a
chemist who worked in the dairy laboratory suggested Amul, which came from the Sanskrit word "amulya",
which means "priceless" and "denoted and symbolised the pride of swadeshi production."
The trio's (T. K. Patel, Kurien and Dalaya's) success at the cooperative's dairy soon spread to Anand's
neighbourhood in Gujarat. Within a short span, five unions in other districts – Mehsana, Banaskantha,
Baroda, Sabarkantha and Surat – were set up. To combine forces and expand the market while saving on
advertising and avoid competing against each other, the GCMMF, an apex marketing body of these district
cooperatives, was set up in 1973. The Kaira Union, which had the brand name Amul with it since 1955,
transferred it to GCMMF.
Three tier Model of AMUL:
The Amul model of dairy development is a three tiered structure.
1. Dairy Co-operative societies(DCS) at village level. – The role of DCS is to procure & collect milk
from milk producers and transport it to the milk union at district level.
2. Milk union at district level. – The role of MU is processing & value addition in milk and to form
various processed products of milk.
3. State federation(GCMMF) – Selling & marketing of processed products is done only by state
federation.
AMUL LOGO
The logo of AMUL is ring of four hands, encircled by the words “KAIRA DISTRICT CO-OPERATIVE
MILK PRODUCER UNION LIMITED”. The essence of this logo is co-ordinate effort of four groups of
people.
First hand is for farmers or producers, without whom the organization would not be existed. Farmers are
the inspiration of the Amul the taste of India.
Second hand is for the representative of processors by whom the raw milk process in to different finished
products.
Third hand is for marketers without whom the products would not been able to reach the consumers.
Fourth hand is for customers without whom the organization could not carry on because they are the
people who consume the products.
Motto of AMUL The main motto behind the AMUL moment was to help the farmers of Kaira District. The AMUL system
works with the objective of paying highest possible price to the milk supplier and lowest possible price to the
consumers. The farmers supply raw milk for which they are paid cash on daily basis for milk they bring to
milk collection centres. AMUL union is one of the pioneers which started using profit for milk supplier‟s
welfare.
ORGANIZATIONAL STRUCTURE OF AMUL
PRODUCT RANGE:
Products
Fresh milk
Amul shakti (pasteurized standardized milk)
Amul T-special (standardized homogenized milk)
Amul (pasteurized homogenized tonned milk)
Amul Gold (full cream milk)
Amul Lite slim-n-trim milk(Double tonned milk)
Amul Fresh cream
Amul Snowcap softy mix
Fermented Products
Amul Masti Dahi (fresh curd)
Amul lite Dahi
Amul Buttermilk
Amul Jeera Butter milk
Amul Lassi
Butter
Amul Utterly Butterly delicious
Amul White butter
Bread Spreads
Amul delicious
Amul lite
Ghee
Amul Pure Ghee
Amul Brown Ghee
Amul Cow Ghee
Milk Powders
Amul full Cream milk Powder(WMP)
Amul skimmed milk powder(SMP)
Amulya(Dairy whitener)
Amul Spray(Infant milk food)
Whey Powder
Flavoured milk
Amul kool café
Amul kool koko
Amul shakers ( mango, strawberry, saffron, cardamom, rose)
Cheese Range Amul Cheddar cheese
Amul processed cheese
Cheese spread
Amul Pizza (Mozarella) cheese
Amul ETG(easy to grate) cheese
Amul Emmental cheese
Amul Gouda cheese
Amul malai Paneer
Chocolate &
Confectionery
Amul Milk chocolate
Amul Dark chocolate
Amul Fruit & Nut chocolate
Amul Bindazz
Amul Chocozoo
Amul ChocoMinis
Energy bar
Almond bar
Mithaee Range (Ethnic
sweets)
Amul shrikhand( Mango, saffron, Almond pistachio, Cardamom)
Amul Amrakhand
Amul mithaee Gulabjamun mix
Amul mithaee Gulabjamuns
Amul mithaee kulfi mix
Avsar Ladoos
Amul basundi
Amul paysum (Khir)
Sweetened Condenced
Milk
Amul Mithaimate Sweetened condensed milk
Amul Ice-creams
Royal Treat Range( Butterscotch, Rajbhog, Malai kulfi)
Nut-o-Mania Range (Kaju Draksh, Kesar Pista Royale, Fruit Bonanza,
Roasted Almond)
Nature‟s Treat ( Alphanso mango, Fresh litchi, shahi Anjir, Fresh
Strawberry, Black current, santra mantra, Fresh Pineapple)
Sundae Range (Mango, Black current, sundae Magic, Double sundae)
Assorted Treat ( Chocobar, Dollies, Frostik, Ice Candies, Tricone,
Chococrunch, Megabite, Cassatta)
Utterly Delicious ( Vanilla, Strawberry, Chocolate, Chocochips, Cake
magic)
Amul sugar free ice cream range
Amul prolife proboitic ice cream
Malt based product
Amul pro(Whey protein malt beverage)
(table no.: ii)
1. Amul-3 Milk Processing Plant
In this Section milk is received only through Road tankers from different village chilling units & chilling
centers. There are 3 Milk Reception Line (RMRD) each having capacity of 30,000 L/hr. It has facility of
computerized reception.
Process Description:
As milk tanker arrives in line first agitation is carried out for 15 min by using plunger. QA
staff/Process Operator after inspection of the integrity of seals; draw a sample to check temperature
and other quality parameters. The results are recorded. The QC officers permit to accept the milk
having acidity up to 0.15% L.A & temperature should be 10oC. In case of higher acidity, the same is
reported to in charge (production) for further action.
In case, milk do not confirm to the specification, process staff consults their immediately supervisor
for further action. In case of higher acidity in milk the tanker is sent to Amul-2 dock for unloading
and immediate processing.
The entire process of milk reception, storage, processing and dispatch is controlled through PLC
(Programmable Logic Controller).
After all tests, the raw milk from tankers after chilling is send to raw milk buffer tank having
capacity of 15,000 L. Then this raw milk is sending to clarifier in which the undesirable solid
particles are removed by centrifugation, this particles called as sludge. After every 15min undesirable
sludge discharge in sludge tank (capacity – 5000 L).Then it sends to sludge treatment tank in which
heat treatment gives to sludge & then it used to produce casein. After clarifier milk is store in raw
milk silos at 4oC.There are 5 raw milk silos, 4 silos having 1.5lakh L capacity & 1 having 60,000 L
capacity.
From raw milk silos milk is pumped to Balance Tank of pasteurizer & undergoes pasteurization
(77oC/15 sec). There are 5 Pasteurizers. One is for Cream Pasteurization, rest are for Milk
Pasteurization. Meanwhile after Preheating, milk is separated to Cream & Skim Milk.
The cream is sent to cream buffer tank & milk is sent to milk silos.
The self-standardization is done in ALFAST UNIT i.e. Alfa Laval Fat Analyzing Standardization
Unit. The separated milk is used for manufacturing powder i.e. WMP, SMP, Amul Spray & Amulya.
Process Flow chart:
Raw chilled milk in tankers
Sampling Deaerator Empty tanker
Tankers Pump CIP of tanker
. Grading & Analysis
Acidity test OK Non-return Valve
. (If not ok)
Chiller (25 oC)
Sour Dump tank Buffer tank
Ghee Section Clarifier Sludge Sludge tank
Raw milk silos
(4-5 oC) Sludge treatment tank
PHE
(Heating to 60oC, Cooling to 10
oC)
Balance Tank of Pasteurizer
Pasteurizer Industrial Casein
Regeneration-1(50 oC)
Pre heating (62 oC) Cream Separator Cream
Regeneration-2(73oC) Auto Std. Chilling
Heating (77 oC) Pasteurization
Holding tube (15 sec) Cream silos
Flow diversion Valve Balance tank
Ok
Chiller (5 oC)
Pasteurized milk silos
Amul-3 Amul-2 Road Tanker Rail Tanker
Equipments:
Equipments Capacity No. of
equipment Raw milk buffer tank 15000 L 3
Cream buffer tank 15000 L 2
Raw milk chiller 10,000 L/hr. 3
Rail tanker chiller 30,000 L/hr. 1
Milk clarifier 30,000 L/hr. 3
Balance tank 350 L 5
Cream pasteurizer 10,000L/hr. 1
Milk pasteurizer 10,000L/hr. 4
Homogenizer 10,000 L/hr. 1
Cream separator 30,000 L/hr. 3
Cream chiller 10,000 L/hr. 3
Bactofuge 30,000 L/hr. 1
Pasteurized milk buffer
tank
15,000 L 1
CIP tanks
Rinse tank
Lye tank
Acid tank
Water tank
10,000 L
10,000 L
8,000 L
1
CIP tanks for tankers
Rinse tank
Water tank
Lye tank
Sludge tank 5000 L 1
Sludge treatment tank 1000 L 2
Rinse milk collecting
tank
(1)15000 L
(2)2000 L
2
Raw milk silos 1,50,000 L(4)
60,000 L(1)
5
Butter milk silos 40,000 L 2
Pasteurized milk silos 1,50,000 L(4)
40,000 L(1)
5
Cream silos 60,000 L(2)
40,000 L(3)
5
(table: 1.1)
Standardization in ALFAST UNIT:
1. Density Transmitter
2. Flow Transmitter
3. Control Valve
4. Control Panel
5. Constant Pressure Valve
6. Change over Valve
7. Check Valve
In online standardization cream fat content system works on the basis of Cascade control. It is a
combination of accurate measurement of fat content and rapid flow metering, known as Cascade
control. In cascade control accurate fat content is measured by density transmitter and flow
transmitters.
In Cascade control, there are mainly 3 flow meters:
1. Density Transmitter:-It senses the density of flowing fluid so it indirectly helps in measuring
flow for standardization.
2. Flow Transmitter:-According to density meter, flow meter adjusts the flow of skim milk and
cream as per the required standardized milk.
3. Control Valve:-It is the heart of ALFAST system. It adjusts its opening according to required
flow for milk.
Auto Standardization in ALFAST UNIT:
Cream Separator
Cream Skim Milk
Density Transducer Liquid Density Transducer
Flow Meter Flow Meter
Mixing
Pasteurizer
Homogenization
Standardized Pasteurized Milk to Different Sections
Cleaning of Amul-3:
CIP steps Pasteurizer Silo/Tanks Transfer Lines TIME(min) TEMP(
oC) TIME(min) TEMP(
oC) TIME(min) TEMP(
oC)
Rinsing with
Water
10 Ambient 5 Ambient 5 Ambient
Lye
Circulation
30 80 20 80 5 80
Fresh Water
Circulation
6 Ambient 7 Ambient 5 Ambient
Acid
Circulation
20 60 15 60 5 60
Fresh Water
Circulation
10 Ambient 7 Ambient 5 Ambient
(table: 1.2)
CIP of RMRD:
CIP Steps Reception Lines Milk Tankers TIME(min) TEMP(
oC) TIME(min) TEMP(
oC)
Rinsing with Water 5 Ambient 1-3 Ambient
Lye Circulation 15-20 80 5 60
Fresh Water
Circulation
7 Ambient 5 Ambient
Acid Circulation 20 60 - -
Fresh Water
Circulation
10 Ambient - -
(table : 1.3)
2. Amul-2 Processing plant
Reception dock is the very first department of any dairy, where milk is unloaded & simultaneously
tested. Amul-2 has a well-designed RMRD, situated in west wing of dairy. The milk is collected from
many societies on different routes by trucks & is brought to dairy. There are 2 reception lines for
unloading of milk cans, but recently only 1 is in working. There is 1 reception line for tankers in Amul-2.
Sour/Curdled milk quality is tested & sends to ghee section.
Process Description:
Milk cans are put on conveyor manually & is tested by the person first. They check the milk by putting
plunger inside it & organoleptic test is carried out.
Milk is then dumped in the weighing tank & is weighed &sample is drawn for Fat & SNF testing.
The milk is collected in collecting tank & cans move to can washer. Can washer has a capacity of 20
cans/min. The total milk reception in one shift is around 12,000 L by cans.
There is 1 reception line for tankers in Amul-2.
Processing plant capacity of Amul-2 is 3, 60,000 L/day for milk. Milk of tanker is also tested by
person also organoleptic test is carried out. Then it is collected in collecting tank.
Then raw milk is taken from the raw milk silos, then the milk is standardized & Pasteurized according
to requirement.
Then the cream is separated by cream separator and stored in to cream silos.
The cream is used for butter making, ghee making & standardization of milk. The skim milk is also
separated & collected in skim milk silos & also used to prepare Skim Milk Powder.
The butter milk is collected in butter milk silos from the butter section.
Curd is made from Tea special milk, Taaza, skim milk (only Homogenized milk is used).
Flow Chart of Amul-2 RMRD:
Unloading of Cans
Chain conveyor
Removal of Cans lid ghee Section
Physical inspection & Organoleptic grading segregation of sour Milk cans
Empty cans & lids Transfer of milk to dump tank Milk Tanker
Can washer Filter
Weighing
Raw milk collection tank
Pasteurization & Standardization
(At 80 oC+/-3
oC for 15 sec)
Processed Milk Tank
Sent for different product manufacturing & for market milk packing
Routine activities of RMRD:
1) Preparation of RMRD for reception - Dock is thoroughly cleaned after each reception (in afternoon and
in night) so that it remains clean and dry for next reception. Before start of reception, conveyor, moving part
of motor and can washer is lubricated by grease and lubricating oil, all conveyor motors and moving parts are
checked for opened before reception to help up the water and steam valves of can washer are opened before
reception to heat up the water and alkali solution to required temperature.
2) Reception -Milk can truck or milk tankers first report at security gate of premise. Then they come to gate
of RMRD premise having a provision of weighbridge, weight of tanker is recorded and weight of milk is
calculated. The milk cans are unloaded and loaded to twin chain conveyor. Supervisor performs the
organization test with help of plunger after opening the lid by a lid remover and judge the quality of milk.
Sour and curdled milk cans are identified and diverted to another chain conveyor.
3) Sampling - 50 ml of milk is taken with the help of a fixed volume sample dipper in a 150 ml plastic bottle
previously filled with 1 ml 10% potassium dichromate. Two sample are taken for each society one for cow
milk and other for buffalo milk. If milk quality from a society is more than 500 lit weighing is done in parts
and a composite sample is taken. The sample from each society is mixed together and tested in milko-scan
for FAT & SNF. The same sample can be tested incase if there is some kind of dispute.
4) Can washing - After reception cans and lids go to can washer. It is a straight through type can washer
with three sections. It has „NO CAN-NO JET‟ system. Total residence time of can washer is 1 minute.
Section Nozzle Medium Temperature Pressure
Pre-rinse section
(2)
52 Water 35- 45⁰C 5 kg/cm2
Detergent section
(4)
126 NaOH (0.4%) Min 75⁰C 5 kg/ cm2
Final rinse section
(3)
68 Water Min 75⁰C
Sterilization (1) - Steam 100⁰C 2 kg/cm2
Drying (1) - Hot air 92⁰C
(table: 2.1)
Acid cleaning is done once in a month using HNO₃ and jet nozzles are cleaned once in a week.
5) Reloading of cans - Washed cans and dried cans are reloaded to the trucks according to the sequence of
societies in the routine.
6) Other activities in RMRD - Can scrubbing – manual cleaning are practiced for cans of four routes. In the
case of incoming of sour milk or curd it is tipped separately and pumped directly to ghee Section.
Equipments:
Equipments Capacity No. of equipment Pasteurizer
Milk Pasteurizer
Cream Pasteurizer
BM Pasteurizer
20,000 L/hr
20,000 L/hr
10,000 L/hr
3
Chiller 1
Cream separator 20,000 L/hr 1
Buttermilk Tanks 5000 L 7
Cream Tank 5000 L 1
Homogenizer 10,000 L/hr
Balance Tank
For milk
For cream
For Buttermilk
3
Hot water PHE 1
Tank 5000 L 8
Butter milk tank 50,000 L 2
Raw Milk tank 1 lakh L(4)
1.5 lakh L(2)
25,000 L(2)
8
Can washer 20 cans/min 2
Can scrubber Manually
Lid Remover Manually
Conveyor
Can loading conveyor
Can unloading conveyor
30 feet/min
24 feet/min
2
(table: 2.2)
CIP of AMUL-2: CIP steps Pasteurizer Silo tanks Transfer lines
Time
(min)
Temp.
⁰C
Time
(min)
Temp. ⁰C Time (min) Temp. ⁰C
Rinsing with
water
5-8 50-55 5-8 50-55 5-8 50-55
Lye circulation
(1.5%)
40-45 80-85 9-11 80-85 15-20 80-85
Fresh water
circulation
5-8 50-55 5-8 50-55 5-8 50-55
Acid circulation
(o.8%)
40- 45 70-75 9-11 70-75 15-20 70-75
Fresh water
circulation
8-11 50-55 5-8 50-55 8-11 50-55
(table: 2.3)
3. Pouch packaging section
Flow Chart for Milk pouch packing:
Milk (Amul-2 & Amul-3)
Horizontal milk storage tank
Overhead tank of FFS packing machine
Pouches Milk damaged Pouches
Crates Cut open & Milk Reprocess
Cold storage room (<5⁰C)
Dispatch
FFS machines:
FFS No. Product Specifications Capacity
1 500 ml milk Twin head
Vertical sealing temp: 140oC
Horizontal sealing temp: 160oC
75pouches/min/head
2 500 ml milk 70pouches/min/head
3 1 L milk 32pouches/min/head
4 500 ml butter milk 60pouches/min/head
(table: 3.1)
Amul pasteurized milk standards:
Sr. No Milk Fat (%) SNF (%)
1 Amul shakti
(Pasteurized standardized milk)
4.55 – 4.60
4.60 (GCMMF)
8.60 – 8.70
8.60 (GCMMF)
2 Tea Special milk
(Pasteurized, std., homogenized milk)
4.55 – 4.60 8.60 -8.70
3 Amul Gold milk
(Pasteurized full cream milk)
6.05 – 6.10 9.10 – 9.15
4 Amul Taaza
(Pasteurized Toned milk
3.5 – 3.55 8.60 – 8.65
(table: 3.2)
4. Buttermilk
Buttermilk is a liquid left behind after churning of butter out of cream. It is prepared in Amul-2. It is
standardized & packed in pouch. It has a fat of minimum 0.5%, total solids 6-7% and acidity 0.39 to 0.41%.
Operation:
Buttermilk from butter section of Amul-3 after pasteurization at 72-75oC for 18sec is sent to
buttermilk tanks in Amul-2 Section.
In buttermilk tank, the standardized & pasteurized mixture is heated 39-4 o
C
DVS Culture is added & is inoculated at 0.1% buttermilk quantity.
Keep on checking Acidity every 3hrs. Once the Acidity reaches 0.350%, chilling takes place till the
temperature is dropped to 9oC & then sample is tested in quality analysis laboratory for total solids.
The buttermilk is sent for pouch packing via pipelines. Packing is done at temperature less than 8 oC.
Leaked pouches are stored to temperature less than 5oC and dispatched after storing for at least 1-2
hours in cold store at minimum 5oC.
Flow chart for Cultured Buttermilk:
Buttermilk from butter section
Pasteurization (75 – 77 oC, 16 sec)
Buttermilk silos (2 silos, Cap-50,000 L)
Standardization (In silo)
Pasteurization (40oC)
Silos
Culture addition in silo (DVS culture @ 1% of buttermilk)
Acidity maintaining (0.35%)
Chiller (10 oC)
(To chill BM, circulate in silo to chiller till 10oC obtain)
Sampling from silo to check TS
Packaging
Cold storage (<5 oC)
Specification of buttermilk: Sr. No Parameters Specification
1 Temp. of dispatch Not more than 8 oC
2 Acidity (%) LA 0.35 - 0.45 %
3 Fat (%) Min. 1.00
4 Total solids Min. 6.5
5 Organoleptic Test (OT) Fresh, free from any off flavour
(table: 4.1)
5. Dahi
Dahi is the fermented milk product produced by bacterial fermented of milk.
Masti Dahi:
Pasteurized homogenized milk having fat 4.5% is taken.
It is then standardized to 3.2% to 3.3% fat & SNF 11.1% to 11.2% by addition of skimmed milk or
SMP.
It is then pasteurized at 90oC for 10 min.
Pasteurized mixture is then chilled to 42-44oC.
It is then transferred to vat, where DVS culture is added with agitation (15-20 min). DVS culture used
for making masti dahi is RST 744.90 units and CHN11:10 units per 1000 lit of milk.
Then it is packed in pouch & cup & put in crate.
It is then incubated for 42oC-43
oC for 3hrs.
Keep on checking acidity every 3hrs. Once the acidity reached to 0.6 – 0.7% LA. It is transferred to
cold store (8oC) where it is kept for 24 hrs.
After 24 hrs. acidity reaches to 0.8% - 0.9 % LA & the Masti Dahi is ready. It is stored in cold
storage at below 5oC.
Amul Lite Dahi:
Amul lite Dahi manufacturing process is same as that of Masti Dahi; the difference is in its
standardization.
In case of Amul lite dahi, pasteurized milk is standardized to 0.5% fat.
Flow chart for Dahi:
Milk in to standardize tank
Standardization
Heater
Inoculation tank -1
Circulate in to heater (90oC)
Inoculation tank -2 (for 10min)
Circulate into chiller (42-44oC)
Transfer in vat
Culture addition
Mixing (15-20 min)
Pouch or Cup filling
Incubation room (42-43oC, 3hrs)
Acidity is checked at every 3hrs
(Acidity reached at 0.6 to 0.7% LA)
Transfer to Cold Store (temp-8 oC, 24hrs)
After 24hrs Acidity should be 0.8 – 0.9% LA
Storage (below 5 oC) & Dispatch
Specifications of Dahi:
Sr. No Parameters Specifications
Amul masti Dahi Amul lite Dahi 1 Fat (%) 3.5 0.5
2 SNF (%) 11.5 12.0
3 Acidity (%) as Lactic acid Max. 0.128 0.125
4 Acidity (%) as LA at transfer to cold store Min. 0.500 0.500
5 Acidity (%) as LA at dispatch Max. 1.00 1.00
6 Dispatch temperature Max. 10 oC 10
oC
(table: 5.1)
6. L & T Powder Plant
Introduction:
L&T stands for Larson & Turbo.
L&T plant is a fully automated Tall Form Drier plant in which two stage drying of standard milk
takes place in Spray Dryer and Vibro Fluidized Bed drier.
The capacity of the plant is 60 MT/day.
Milk is received from processing site is used to make milk powder using different procedures. In the
plant Skimmed milk powder, Whole milk powder, Dairy whitener (Amulya) and Infant milk food
(Amul Spray) are produced.
Amul Spray & Amulya Agglomerated
SMP & WMP Non-agglo OR Agglomerated.
Dryer Principle:
Spray drying operation involves the conversion of concentrated liquid milk to dried powder. This is
carried out by transforming the liquid milk into milk droplets and contacting these droplets with hot air in
a controlled fashion. Due to the enormous area available for heat and mass transfer, the water evaporation
from milk droplets and drying takes place.
Process flowchart:
Standardized milk from silos (4-5⁰C) + Ingredients
Balance tank
Pre heater (6 to 1)
Flash vessel (regeneration)
Swirl heater- HHP (90-95⁰C)
CCP
Holding tubes
Flsh vessel (flash cooling)
Calendria1st
(70-73⁰C)
Calendria & vapour separator (2 to 5)
Hydro cyclone
Concentrated milk (50% TS) in Concentrate tank
Scrapped surface heat exchanger
Feed pump
Homogenizer (as a high pressure pump)
Atomizer (nozzle) Fines
Non-agglo
Heated Air(1830C) Tall form drier (TFD) Cyclone Exhaust air
Agglo
Vibro fluidizer (12mmWC vacuum) Fines
Vibrating sieve Lumps
Bulk packaging (25kg) Hopper
Dense phase vessel
Pneumatic conveyor
Powder silo
Vibrating tubes
Hopper
Vibrating tubes
Rotary valve &Rotary Sifter
FFS packaging machine
The whole plant is divided in the five sections: 1. Feed Preparation
2. Evaporation system
3. Drying section
4. Powder conveying & storing section
5. Packaging section
1) Feed Preparation: Milk from milk silos first comes to the section. The section has two milk silos each having 40000 lit. Milk
capacities. In the Dairy Whitener and Infant milk food sugar is added as syrup prepared in sugar Dissolving
tanks having 3000 lit capacity. The tanks are double jacketed for heating. The prepared solution is pumped
into milk silo through inline double filters. Tri sodium phosphate (for pH adjustment) and Vitamins (A, D, B,
C) & Mineral mixture (both for Amul Spray only) are added in the milk silo.
Preparation of various Additives:
Addition of BHA (for WMP only) – BHA @ 50g per metric ton of milk powder is added by
dissolving BHA in 2 -3 L in lukewarm water and is added to milk in silo.
Addition of TSP – Addition of buffering salt @ 0.2% for SMP, 0.6% for Amul Spray and 0.3 %
for Amulya. TSP is not added to IMF – 1 and 2 WMP.
Sugar – Water is taken into sugar vats and heated to 50 - 60⁰ C. Required quantity of sugar is
added into sugar vat and dissolved. Sugar solution is pumped to milk silos through filter.
Vitamins and minerals – Vitamin A + D mix is dissolved in milk and added into sugar solution.
Water soluble vitamins and mineral premix is mixed in lukewarm oil and added to vegetative oil
cream. Lecithin is mixed in lukewarm oil/ghee and heated to about 60 -70⁰c in order to melt lecithin
in free flowing form and added into vegetable oil cream mixture.
2) Evaporation section:
Milk is pumped from these silos into a feed balance tank of evaporator. Typically milk is concentrated from
14% solids to 48% solids in evaporator.
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 parts about 35 %, is evaporated during this section and we get 48
% total solid ( TS ) in milk. For concentration of the milk, Multiple Effect Evaporator (5 effect) with
Forward Feed Mode of Evaporation is used. Concentrated milk from evaporator is gathered in Concentrate
tanks. There are three tanks.
3) Drying section: The milk concentrate (50% TS/ 50
0C) is pumped through a scraped surface HE where it is further
concentrated and then to the Spray dryer with the help of a high pressure homogenizer. .
Homogenizer has 3 functions, main function to pump liquid up to the head of the dryer (fifth floor),
to raise the temperature of condensed milk to 70⁰c and to partly homogenize the milk. The Spray
dryer is of Tall Form design of 8 nozzle spraying atomizer, which consists of Air dispersing system,
Electromagnetic hammers, Cyclones, Fire extinguishing system and Vibro fluidizer.
The drying chamber is a cylindrical vessel with 450 conical bottom. The drying process proceeds in a
co-current mode. Milk is atomized by nozzles at from the top.
Cyclones are present for collecting fines by centrifugal force. In case of agglomeration these fine
particles are added back in the dryer along with milk.
Vibro fluidizer is a vibrating housing which is divided into two parts by a special perforated plate. Air
is blown into lower part which is called Plenum chamber and the powder is fluidized in the upper
vibro shifter. There are three regions in Vibro
1. Initial heating region - 60oC
2. Heating with dehumidified air - 45oC
3. Dehumidified cooling - 40 oC
Vibrator mounted on the lower side produces the vibration. The vibro fluidizer operates at a vacuum of
12mmWC. At the outlet of vibro there is a sieve for removal of lumps. Lumps are reconstituted into milk.
4) Powder conveying section: The powder coming out of vibro sieve enters the dense phase conveying unit and from there it is
pneumatically conveyed into powder silos. The powder from the silos is conveyed through vibrating tubes to
packing machine.
5) Packing section: The powder is packed in pouches. The pouches are inserted in cartons. The cartons are collected & put into
cases. Cases are sealed & conveyed to stores on a belt conveyour.
Specification:
(table: 6.1)
Equipment details:
EQUIPMENT CAPACITY
Milk Silos 40,000 lit ×2
Sugar dissolving vats 1000 lit ×2
Evaporator feed handling capacity 22,000 lit/hr
Balance tank for milk condensing plant 150 lit
Concentrate tank 3000 lit ×2
Powder silos 30,000 kg ×2
Homogenizer 6300 lit/hr
Evaporation Capacity 30,000 lit/hr
Dryer Capacity 7400 lit/hr
(table: 6.2)
Parameter Amul Spray Amulya SMP WMP Fat 18.5% min 20.5% min 1.5% max 26% min
Moisture 4% max 4.5% max 4% max 4% max
Protein 22% 20% 35% 15%
Lactose 31% 32% 50% 50%
Sucrose 17% 17-18% - -
Ash 8.5% 5.5% 8.2% 7.3%
Packing: Packaging is done in two ways:
Manual bagging
Automatic packaging
Manual bagging: Powder from vibro sifter is sent to bagging line for bulk packaging of 25kg. Bags are packed manually and
sent to cold storage for Industrial use.
Automatic packaging: For automatic packing, powder is taken into powder silos. Each silo has 30000 kg capacity. With the help of
dense phase vessel, powder is conveyed through vibrating tubes, rotary valve and rotary shifter and is taken
into packaging machine hoppers. Form, Fill and Seal machine packs 50 gm. pouches of Amulya and 1 kg and
½ kg pouches for Amul spray.
Type of
product
Weight of
packaging
material
Net Weight Total Approx.
wt.(gm.)
M.R.P. Packing
Capacity/min
1kg Amul
spray,
Amulya
15gm
1000gm 1050gm 1015-1017 340 40 packs
500g Amul
spray,
Amulya
8.5gm 500gm 509gm 509-511 178 60 packs
200g Amul
spray,
Amulya
4.5gm 200gm 205gm 205-207 72 70 packs
27g Amul
spray,
Amulya
2.2gm 27gm 29gm 29-30 10 120 packs
13g Amul
spray,
Amulya
1.7gm 13.5gm 15gm 15-16 5 60 packs
13.5g Amul
spray (double
head, FFS)
1.7gm 13.5gm 15gm 15-16 5 80 packs
(table: 6.3)
7. Butter Section
Introduction: The Butter section is located in Amul-3 which manufactures Table butter, White Butter.
The section is completely computerized and is equipped with most modern imported equipments. Amul
white and table butter is exported to USA and Gulf countries. Amul Table butter maintains AGMark
standards.
Process: The cream for manufacturing Butter is receiving from Amul-3 processes while standardization of milk. The
milk fat will be separated at above 60C; the centrifugal cream separators in line with milk pasteurizer
separate this as cream.
The cream thus separated is pasteurized and then pumped by positive displacement pump to the cream buffer
tank and then to the cream silo.
After ageing at 8 C for 24 hours cream is pumped to cream chilling unit in the butter section . There the
temperature of cream is adjusted to the required churning temperature (9-11 C) of continuous butter making
machine.
Process flowchart:
Pasteurized Cream from Silos (20 hr ageing)
Cream Balance Tank (8-9 oC)
Cream Heater PHE (to adjust temp 8-10 oC )
Continuous Butter Making Machine (CBMM)
Churning (500-1200 RPM)
Butter Grain Butter Milk
1st Washing with BM BM Chiller (below 10
oC)
Working (30-70 RPM) BM silos
2nd
Washing
Working under Vacuum (450-500 mm Hg)
Blender (17-30 RPM, Vacuum 450-500 mm Hg) Addition of Salt & Colour
Butter Silo
Packing section
10 g Blister Pack 100 g Refill pack 500 g Refill pack 400 g Tin
Butter wrapping (by vegetable parchment paper)
Secondary Packaging
CBX
Storage at below 4oC
Process flowchart for colour & salt solution:
110 L Pasteurized Water
100 Kg Salt
2000 to 4000 ml Annatto
15min Agitation
Filtration
Add in to Salt dozer
Working Principle of CBMM: The CBM machine works on the “Frits” process of continues butter manufacture, in the accelerated churning
process, there is a quick fat separation in cream (38 to 42% fat) is affected by high speed beaters followed by
draining of butter milk. In the churning section cream is subjected to high speed beater (variable speed 1200
to 1500 rpm), which guides cream to cylinder walls simultaneously causing foam formation accompanied of
fat globules tale place in cylinder during churning process, formation of pinhead sized butter granules take
place, the mixture of butter granules and butter milk falls into the screw conveyer and then into the rotating
drum where butter granules and butter milk gets separated. The butter granules fall below between a set of
rotating augers (contained chilled water jacket) where the granules are worked upon and then finally
extruded in form of a ribbon directly into butter trolleys.
Major section of the CBMM
1. Churning section:
This section has a horizontal cylindrical with the cooling jacket and beater for churning of cream. The
churning process lasts for 2 to 3 sec during which the oil in water emulsion of the cream is broken into
water in oil emulsion existent in butter. The water content of the granules and the fat loss in the
buttermilk depend largely on beater speed and the temperature of cream at the time of churning. The
beater is driven by power transmitted from a motor through a V-belt. The speed of the beater is adjusted
so that butter granules have a suitable size when they press through the separating section.
2. Separating section:
This section has horizontally positioned cylinder resting on rollers and the other supported by a bearing.
The cylinder is fitted with paddles, which stresses the granules suspended in the butter milk to librated
most of their buttermilk content. A draining section is provided where the granules are separated from the
buttermilk and are then passed into the working section. The speed of paddles is 34 rpm.
3. Kneading section:
The kneader consists of two contra rotating augers 40 to 60 rpm that are in mesh with one another. The
front screw ends in perforated discs there are 3 agitating blend per screw operating sequentially between
the perforated discs. Spacer rings ensure the distance between the perforated discs. In the kneader the
gear unit driving the screw is driven by a v-belt through a motor. All parts of beater, draining unit,
washing unit and kneader are made up of high alloy chromium nickel steel
4. Salt dosing unit: Salting for adjusting the water content or for water content or for salting the butter, water or salt solution
can be added through an opening immediately in front of the perforated plates.
Salting is carried out by injection of 50/50 salt/water slurry into butter early in working stage to avoid
color mottle in the butter a micro fined salt less than 50 micron is used. The salt slurry is loosely filtered
through wire gauze before injection. The slurry is metered to the butter maker by positive displacement
pumps. The dosing system may also be used for adding water to unsalted or slightly salted butter to
maximize yield.
SPECIFICATION:
Characteristics FSSAI specification AGMARK specification
Moisture % Max. 16.0 % Max. 16.0 %
Milk fat % Min. 80.0 % Min. 80.0 %
Salt % Max. 3.0 % Max. 0.3 %
Curd SNF % Max. 1.5 % Max. 1.5 %
Acidity % L.A. - Max. 0.15 %
Total plate count Max. 5000 / g -
Coliform count Max. 5 / g Absent in 0.1 g
E. coli Absent in 1 g -
Yeast & mold count Max. 20/g Max. 20/ g
Salmonella & Shigella Absent in 25 g -
Staphylococcus aureus Absent in 1 g -
Anaerobic spore count Absent in 1 g -
Listeria monocytogenes Absent in 1 g -
(table: 7.1)
Shelf life: Best before 12 months from packaging when stored refrigerated at 4 oC or below
Storage condition: At 4oC or below
Equipments:
EQUIPMNTS
NAME
CAPACITY NO. SPECIAL INFORMATION
Cream balance tank 350l 2
Cream chiller - 2 Temp- 8-10ºc
Plate length- 207-273
Continuous butter
making machine
2000kg/hr
5000 kg/hr
800kg/hr
3 Made- Contimab
Churning speed-500-1200rmp
Butter blender 1 Vacuum pressure 400-500mm hg
Butter silo 3.5 tones 1
Pasteurized water
tank
5000 lit 1
butter milk buffer
tank
450 lit 1 Temp- 1-2ºc
Wash water tank 500 lit 1 -
Fat recovery tank 450 lit 2 -
Salt dosing unit - 1 Agitator rmp-1380/min
(table: 7.2)
Packaging machine: 1) SIG machine
500 g packing – Capacity – 60-62 pack /min
2) BENHIL case packer machine
100 g packing – Capacity – 150 pack /min
3) HASSIA butter Tub filling machine (Blister pack)
10 g packing - Capacity – 525 packs /min
4) Tin packing machine
400 g Tin - Capacity – 36 packs /min
Packaging machine used: o Parchment paper – used directly for wrapping
o Carton – used for secondary packing,
a. Single laminated foil is used for INDIAN local market.
b. Double laminated is used for EXPORT.
o Tin – used for 400g, Army pack
o Card Board Box – used for tertiary packing.
o Plastic Box – used for school pack
CIP of Butter section:
CIP is done after every 24 hrs. (usually in third shift).
Melting of residual butter is done with hot water for 25 min and molten butter is drained into recovery tank.
Degreasing is done for 10 min.
8. Ghee Section
Introduction:
Ghee, also known as clarified butter or anhydrous milk fat, is prepared by heating butter or cream to just
over 100°C to remove water content by boiling and evaporation, then filtering out the precipitated milk
solids. Ghee is known as ghrta (commonly spelled ghrita) in Sanskrit. Ayurveda has traditionally considered
ghee to be the healthiest source of edible fat, with many beneficial properties. According to Ayurveda, ghee
promotes longevity and protects the body from various diseases.
Amul has a well laid out Ghee section just behind processing section of Amul – 2. It has got all
facilities of white butter melting, sour cream or curd churning, Ghee processing & storage. Ghee is
manufactures mainly by Pre-stratification method from white butter manufactured in butter section. When
Curd is received in dairy or fat is separated from sour milk or sour cream, it is churned to make butter. This
butter is heat clarified to make Ghee for local market. The Ghee manufactures is also export to gulf countries
USA. In this section AGMARK Special Grade Ghee is prepared. The production Capacity of Ghee section is
22-24 TPD.
Definition:
According to FSSR-2011, ghee means the pure heat clarified fat derived solely from milk or curd or from
desi (cooking) butter or from cream to which no colouring matter or preservative has been added.
Product Description and Chemical Composition of Ghee: Ghee could be in liquid, semisolid and some time in solid state based on the storage temperature. Ghee made
from buffalo milk is whitish with greenish tinge and that of cow milk is golden yellow colour. It is usually
prepared form cow milk, buffalo milk or mixed milk.
Composition: Ghee is a complex lipid of glycerides (majorly triglycerides), free fatty acids, phospholipids,
sterols, sterol esters, fat soluble vitamins, carbonyls, hydrocarbons, carotenoids, (only in ghee derived from
cow milk). Its detailed chemical composition is given below.
Constituents Cow milk ghee Buffalo milk ghee
Fat (%) 99 – 99.5 99 – 99.5
Moisture (%) <0.5 <0.5
Carotene(mg/g) 3.2-7.4 -
Vitamin A(IU/g) 19-34 17-38
Cholesterol (mg/100g) 302 – 362 209 – 312
Tocopherol(mg/g) 26 – 48 18 – 31
Free fatty acid (%) 2.8 2.8
(table: 8.1)
Milk fat contains at least 500 fatty acids and fatty acid derivatives with 4 – 20 or more carbon atoms in their
chain. The fatty acid may saturated or unsaturated and usually contains an even number of carbon atoms.
Composition of fatty acid also varies between buffalo milk fat and cow milk fat.
Methods for manufacturing Ghee:
Different methods are used for the preparation of ghee. The adoption of a particular method is mainly
dependent on the scale of production. The classification and description of these methods is given as below:
1. Indigenous (Desi) method
2. Direct cream method
3. Creamery butter method
4. Pre-stratification method
5. Continuous method
From these methods Pre-stratification is used in Amul - 2 Ghee section.
PRE-STRATIFICATION METHOD: To produce ghee in Amul-2 sour cream, sour milk, serum, curd, whey fat, & white butter is used. When
sour cream, sour milk, serum, curd, whey fat is used, first it is churned in butter and then it is melted at 95oC.
While white butter received from butter section is melted at 95oC in an open melting vat having steam coil in
its bottom. It is left for 1 hour in the vat to separate layer of fat. During this period, butter stratifies into three
parts. The top layer consists of clotting, denatured protein & impurities; the middle layer fat; and the bottom
layer consist of butter milk serum.
The melted butter is pumped to pre-stratification tank. The division helps in removal of butter & buttermilk
serum. It contains about 80% of moisture & 70% SNF content. Fat layer is settled down in settling tank for 2
hours. The melted fat is then pumped to ghee melting pot where it is heated to 110 - 115oC for about 45
mins. For brown ghee, temp. is 143 – 145oC for same time. Ghee is allowed to settle for 1 - 2 hours in ghee
tub and then it is transferred to filter & then to clarifier. After clarification, ghee is stored in storage tank.
Then, it is pumped in overhead tank of packaging machine. Ghee is packed at 45oC in pouch, Tin, & in jar.
Flow chart for Ghee: White butter Sour cream/sour milk/serum/curd/whey fat
Butter churner (45 min, cap – 2000 to 3000 L) buttermilk
Addition of chilled water for washing
Churning (15 min)
Draining of water
Hard grain of fat
Melting vat (95oC, 1hr) clotting, buttermilk serum
Fat Serum portion
Settling tank (2 hrs.) Serum tank
Melting pot Fat recovery
(110 to 115oC, for brown ghee 143 to 145
oC, for 45 min)
Ghee tub
Filter
Clarifier (in brown ghee clarifier is not used) Ghee residue
Buffer tank Cattle feed
Packaging (packed at 45oC)
Storage (21oC)
Equipment:
Equipment Capacity No. of equipment Melting vat 1)150 blocks of 15kg butter
2)100 blocks of 15kg butter
2
Butter churner Top churn – 2500 L
Drum churn – 3000 L
2
CBMM - 1
Pre-stratification tank 1)2000 L
2)2000 L
3)5000 L
3
Melting pot 1)900 L
2)600 L
3)450 L
4)1500 L
4
Serum tank 2000 kg 1
Fat Recovery Tank 1500 L 1
Ghee tub 1)1 Ton
2)1.5 ton
2
Buffer tank 3000kg(3)
4)20,000 kg
5)15,000 kg
6)15,000 kg
6
Filter - 2
Clarifier 2000 L 1
(table: 8.2)
Packaging of Ghee:
Ghee is packed in 200ml, 500ml, and 1000ml pouches by ghee pouch packing machine having two
heads.
Density :- 0.90 gm/cm2
Thickness of packing material- 100µm.
Type:
Prepack (pneumatic machine)
Make: Samarpan Fabrications, Thane
Capacity: 13-14 pouch/min
Air consumption: 6kg/cm3
Cooling Water: 100litre/hr at 20oC
Ghee is also packed in tins in 500ml, 1ltr, 2ltr, 5ltrs, and 15 kg.
Gasti Packing Machine
Make: Gasti India Ltd.
Capacity: 15 tins/min.
Filling & seaming machine
Make: Unitech India ltd.
Standard of weight:
Wt. of product Wt. of packing
material (gm.)
Net Weight
(gm.)
Total Weight
200 ml 2.5 181 – 183 183 - 185
500 ml 4.9 452 – 456 456 – 459
1 lit 8.0 904 – 908 912 – 916
500 ml tin Empty tin: 58.43
Bottom: 16.5
452 – 456 526 – 530
1 L tin Empty tin: 97.325
Bottom:16.5
904 – 908 1018 – 1022
2 L tin Empty tin: 168
Bottom:30.58
1810 – 1814 2009 – 2013
5L tin Empty tin:344.5
Bottom:59.11
4528 – 4532 4932 – 4936
15 kg Empty tin:932.5
Bottom:30.5
14.998 – 15.662
(kg)
15.962 – 15.966
(kg)
(table: 8.3)
CIP of ghee plant:
After use of every melting system hot water of 70 - 75 oC is filled up & flushed.
Then it is cleaned with 0.2 – 1% of lye solution at temperature 70 oC & circulation & drained.
After this the cleaning procedure is carried out with hot water of 70 - 75 oC without lye. The system is
washed third time with water for 25 – 30 min.
Finally rinsing is done.
CIP of Clarifier:
Detergent solution, hand brush cleaning with hot water having temperature of 40 - 45 oC is used for
cleaning after every use.
9. Sterilized Flavoured Milk
Amul kool is refreshing milk with test. It is an easy to use delicious drink that refreshes you immediately
with goodness of milk. It is available in use-and-throw glass bottles & metal cans. Coffee & Coco flavours
are available in glass bottles. Metal can is used for all flavour.
Products: Coffee Flavoured Milk
Coco Flavoured Milk
Rose Flavoured Milk
Milk Shakers (Strawberry, Mango, Almond )
Sr.
No
Product Type Prize(200ml) Shelf life
Can Glass
bottle
Can Glass
bottle 1 Coffee Flavoured Milk 40 22 270 days 180 days
2 Coco Flavoured Milk 30 22 270 days 180 days
3 Rose Flavoured Milk 30 22 270 days 180 days
4 Milk Shakers (Strawberry, Mango,
Almond )
30 22 270 days 180 days
(table: 9.1)
Specification:
Characteristics Specification Fat Min 3%
SNF Min 9%
Added Sugar 7-8 %
TS Min 20 %
Acidity Max 0.13 % L.A
Alcohol test Should be –ve
Flavour As required
Colour Artificial max 100ppm
Organoleptic Evaluation No Abnormality
(table: 9.2)
Flow chart for Amul kool koko:
Milk from A2 & A3 to storage tank
(Min 2.1 % fat, Min 8.7% SNF)
Slurry tank
+Cocoa powder
+Cocoa extender
+ Dark Choco mass
+Milk Choco mass
Heated to 80-85oC
Provat
+Sugar 8-10 %
+Stabilizer
(Fat, SNF, Protein, Lactose test)
PHE (60-65oC)
Homogenizer
1st
stage: - 180 to 200 kg/cm2
2nd
stage: -80 to 100 kg/cm2
Chiller (Below 10oC)
Bulk Milk Cooler
(Cream Index, T.S, pH, Acidity Test)
Filling Machine (Can Filling / Glass Bottle Filling)
Sterilizer (121oC for 21 min at 1.5 Kg/cm
2) CCP
Cooling (through cooling fans)
Flow chart for Amul Kool cafe:
Milk from A2 & A3 to storage tank
(Min 4.9 %fat, Min 8.7% SNF)
Provat
+Sugar 8-10 %
+Stabilizer
(Fat, SNF, Protein, Lactose test)
PHE (60-65oC)
Homogenizer
1st
stage: - 180 to 200 kg/cm2
2nd
stage: -80 to 100 kg/cm2
Coffee (0.8%) Chiller (Below 10oC)
Coffee Blender Bulk Milk Cooler
(Cream Index, T.S, pH, Acidity Test)
Filling Machine (Can Filling / Glass Bottle Filling)
Sterilizer (121oC for 21 min at 1.5 Kg/cm
2) CCP
Cooling (through cooling fans)
Flow chart for Amul shakers:
Milk from A2 & A3 to storage tank
(Min 5.2 %fat, Min 8.7% SNF)
Provat
+Sugar 8-10 %
+Stabilizer
+SMP
(Fat, SNF, Protein, Lactose test)
PHE (60-65oC)
Homogenizer
1st
stage: - 180 to 200 kg/cm2
2nd
stage: -80 to 100 kg/cm2
Coffee (0.8%) Chiller (Below 10oC)
Coffee Blender Bulk Milk Cooler (Flavour Slurry)
(Cream Index, T.S, pH, Acidity Test)
Filling Machine (Can Filling / Glass Bottle Filling)
Sterilizer (121oC for 21 min at 1.5 Kg/cm
2) CCP
Cooling (through cooling fans)
Equipment:
Equipment Capacity No. of Equipment Milk tank 10,000 L 3
Process vat(Provat) (1)2500 L
(2)5000 L
2
Slurry tank 15000 L 1
Pasteurizer 10,000 L 1
Homogenizer 5000 L 1
Chiller 10,000 L 1
Bulk Milk Cooler (1)5000 L
(2)2500 L
(3)2500 L
3
Metal Can filling
Machine
100 cans/min 1
Glass bottles Filling
Machine
80 cans/min 1
(table:9.3)
Standards of weight:
Product name Specific Gravity Wt. of packaging
material (g)
Net wt.
(g)
Gross
wt. (g)
Approx.
wt. (g)
Empty
can
/Bottle
Bottom
/ Crown
Koko Can 1.069 32 5.4 214 251 251 - 253
Coffee Can 1.058 32 5.4 212 250 250 - 252
Milk shakes/badam
Can
1.066 32 5.4 213 250 250 - 252
Koko bottle 1.069 150 2.2 214 366 366 - 368
Coffee bottle 1.058 150 2.2 212 364 364 - 366
(table: 9.4)
CIP (Cleaning In Process)
CIP for process vats, storage vats, PHE, bulk chiller, Homogenizer and pipelines:
CIP steps Time (min) Temperature (oC)
Rinsing with water 20 60
Lye circulation (0.8 %) 40 80
Fresh water circulation 20 60
Acid circulation 30 70
Fresh water circulation 20 60
(table: 9.5)
CIP for can filling machine, overhead tank/bottle filling machine:
CIP steps Time (min) Temperature (oC)
Rinsing with water 5-10 50-55
Lye circulation (0.5-0.8%) 20-30 75-80
Hot water circulation 15 50-55
Acid circulation (0.4-0.6%) 15-20 72-75
Hot water circulation 15 50-55
Lye circulation 5-10 75-80
Hot water flushing 20 50-55
(table: 9.6)
Cleaning of Sterilizer:
All sterilizers are cleaned manually from inside daily.
10. Q A LABORATORY
Introduction:
Quality Assurance (QA) is a way of preventing mistakes or defects in manufactured products and avoiding
problems when delivering solutions or services to customers, which ISO 9000 defines as “part of quality
management focused on providing confidence that quality requirements will be fulfilled”.
This Department in the dairy plant has to perform multifarious activities and keep track of different aspects
while maintaining a strict vigil on the quality of every packet of every product originating from the dairy. In
laboratories all the raw material, ingredients, products in progress, finished products as well as packaging
materials are tested for their physical, chemical and microbiological quality to maintain hygienic condition in
the production area.
There are FOUR main quality control /assurances laboratory at Amul dairy as follows:
1. Milk reception Laboratory at Amul-3
2. Milk reception Laboratory at Amul-2
3. Central laboratory
4. Microbiology laboratory
The tests done in the Reception lab of Amul – 3 include the analysis of raw milk as well as Pasteurized milk.
In the Reception lab of Amul – 2, mainly the quality of raw milk, flavored milk and dried milks are tested.
In Microbiology lab the microbial analysis of product is done.
The Central Laboratory is the main lab where all the in process checks, finished product analysis, packaging
tests, water analysis are done.
1. Milk reception laboratory at Amul-3 Amul-3 testing lab is a reception laboratory; therefore platform tests are performed here to for acceptance or
rejection of the raw milk. In addition with that the adequacy of pasteurization of pasteurized milk is also
checked here.
After arrival of milk tanker first of sampling is done & following parameters are checked for acceptance or
rejection:
Temperature: using digital thermometer it should be below 10oC.
Smell: should be free from taints or abnormal smell.
Visual inspection: should be absence of abnormality
Taste: pleasant.
Then sample is taken to reception lab for following tests:
Sr.
No.
Test Procedure Interpretation
1 Acidity 10 ml milk + 5 drops of phenolphthalein
indicator. & Titrate against N/9 NaOH till
faint pink colour appears.
Acidity = Titre value×0.1 % as lactic acid
It should not exceed 0.14% for
cow milk & 0.17% for Buffalo
milk.
2 MBRT test Take 10 ml milk + 1 ml methylene blue
dye in a test tube. Close it with rubber cock
This test is used to check the
bacterial load in the milk. If milk
& put it into water bath at 37oC. Check at
15 min intervals & note down the time
taken to reduce the dye.
is having high bacterial count the
dye will be reduced in lesser time
& vice versa.
3 Phosphatase test Take 1 ml milk + 5 ml test solution in a
test tube; put it in water bath at 370C for
30min.
If yellow colour appears this test is +ve &
white colour remains means test is –ve.
This test is used to check the
adequacy of pasteurization in
milk.
4 COB Approx. 5 ml milk sample taken in test
tube & boiled for 2 min in a water bath.
Then it is observer for any precipitated
particles.
It is a quick test to determine
developed acidity and suitability
of milk for processing. Milk
should not curdle upon heating.
5 Alcohol test Take 2 ml milk + 2ml alcohol (68% conc.).
Mix vigorously & check the curdling on
the test tube.
If there is no flakes of curd the
test is –ve. The milk that is used
to make flavour milk should be
alcohol –ve.
6 Fat(Gerber
method)
Take a butyrometer add 10 ml H2SO4 (92%
conc.) + Few drops of water + 10.75 ml
milk + 1ml amyl alcohol.
Stoppered & centrifuge at 1100 rpm for
5min.
It should be around 4% for cow
mil & 6% for buffalo milk.
This method is also used to
standardize the Milkoscan.
7 SNF It is measured by gravimetric method.
SNF% = TS% – Fat%
It is around 9%.
(table: 10.1.1)
The constituents of milk can directly know by using Milcoscan like fat, SNF, Lactose, sucrose, FPD, etc.
There is a Bactoscan also. Bactoscane is used to determine the total bacterial load in the raw milk sample. It
employs the use of ethylene bromide red dye (fluorescent dye) to stain or highlight the bacteria the filler used
top allows the bacterial cell (0.2-10 micron size) to pass through and all other cells are filtered. The
highlighted bacterial cells are thus obtained in the filtrate and the amount of light (blue) scattered from their
cell gives the bacterial load. The count is obtained as individual bacterial count (IBC) can be considered as
colony forming unit.
2. Milk reception Laboratory at Amul-2 This lab is mainly used for the pricing of milk. Every village society sent a sample of their milk with the milk
tanker. These samples are tested here for fat & SNF using milkoscan & on that basis pricing is done. A SMS
showing % fat & SNF & amount of their milk is sent to that village society immediately after testing. If they
have any doubt regarding to their sample they can report within 24 hrs. After 24 hrs. samples will be
discarded.
Other activities: In this lab they also keep the records of average weight of milk pouches & flavor milk cans.
PH of flavour milk is checked using the pH meter.
Acidity & alcohol test is done of milk sample from the batch taken for preparation of flavor milk.
Moisture of powder checked using Moisture analyzer.
Clarity of ghee is observed after melting on hot plate. If there is any ghee residue that batch will be
reprocessed.
3. Central laboratory: In the central lab all the finished products are tested for their parameters using different methods. In addition
to that water analysis, strength of soda & acid, packaging material tests are also done.
Tests done for Powder:
Sr.
No
Tests Procedure Observation &
Interpretation
1 Grading For reconstituting any powder 200 ml water
is used. Into it SMP- 20gm, Amul spray -
28g,Amulya – 28g,WMP – 26g are added
and dissolved with the help of a flat blade
disc blender for 90 sec with 4000rpm.After
the reconstitution grading is done by looking
at the top and bottom of the beaker. The
grade is given according to number of
scorched black particles.
The black particles denote
burnt particles. After
filtration if wt. of burnt
particles are
0-7mg - A grade.
7-15mg – B grade
Above 15mg – C grade
C grade should be
reprocessed.
2 Insolubility index
It is volume in milliliter
of sediment obtained
when a dried milk or
dried milk product is
reconstituted.
50 ml of reconstituted milk is taken in an
Insolubility index tube up to 50 ml mark and
centrifuged at 1100 rpm for 5min.
After centrifuging, the
insoluble powder settles
down. The volume of this
powder should be less
than 1.5 ml, else the CIP
of system is required as
drying may be
incomplete.
3 Moisture 2-2.5 gm of powder is taken in the
Automatic Moisture Analyzer. The meter
gives reading in 5 min.
The moisture content
should be between 2.6 –
3.3%. If it is more, the
batch is rejected and test
is done for condensed
milk and the flow rate of
milk to the dryer is
reduced.
4 Fat content Take 10ml conc.H2SO4 (92%) + 2.5g
powder + 1ml Isoamyl Alcohol + 1ml
distilled water into 36%butyrometer. Rubber
stopper it & centrifuge it at 1100rpm for
5min.
SMP – 0.5 to 1%
WMP – 26 %
Amul spray – min 18%
Amulya – min 20%
5 Coffee Test
To check heat stability
150ml distilled water is heated to 90oC &
1.5g of coffee powder is dissolved. When
it‟s temp. reaches 80oC, 5g of powder is
added and stirred with a spoon for 15 sec in
clockwise & anticlockwise direction.
Observe bottom & Upper
layer, if there is any clots
coffee test is negative.
Take 50ml solution, put it
in centrifuge & observe
sediment layer.
6 Acidity The No. of ml of 0.1N NaOH solution
required to neutralize a quantity of
reconstituted milk. Until pink colour
obtained in the presence of phenolphthalein
indicator.
Acidity should be up to
1.5%.
7 Wettability test
Wettability is the ability,
Take 13g powder sample, and then add this
powder in 100ml water at 45oC. Temp of
For Agglo powder 19 to
20 sec
expressed as the time in
seconds, necessary for a
given amount of powder
to penetrate the quiet
surface of the water
powder is 35oC. Then note down time.
For non-Agglo powder
max 40sec
8 Bulk density
Bulk density depends on
water content & particle
size in measuring
cylinder.
Take 10 gm. of powder & tape 100 times in
Stampf-volumeter & note down volume.
BD = Mass/ Volume
Up to 0.6
9 % Agglomerate
Powder
This test is done for Amulya & Amul spray.
50g powder is sieved manually on sieve
(250µ) mesh for 5min.
The mass of powder
retained on sieve
multiplied by 2, gives %
agglomerate. It should be
around 36-38%.
10 Total solids of Milk
concentrate
Take 2g of milk concentrate in a disc. Put it
on a boiling water to evaporate moisture.
Then Place it in Oven maintained at 98-
100oC, 3hrs. Weigh the dish at hourly
interval until constant weight attain.
TS% = (wt. of residue/sample wt.)*100
45 to 50%
11 Ash Take 3g of powder in crucible & put it in a
muffle furnace at 550oC for 5-6 hrs.
Ash = (wt. of sample after drying/before
drying)*100
Max 8.5%
12 Presence of vitamin 50 ml reconstituted milk+2-3 drops of
indophenols blue
Blue colour appears
vitamins are present
13 Presence of Iron 10 ml reconstituted milk + Ammonium
thiocyanate + conc.HCl
Formation of red
precipitate shows
presence of iron
(table: 10.3.1)
Ghee Analysis:
Sr.
No
Tests Procedure Interpretation
1 Baudine test Take 5ml ghee in test tube. Add equal
quantity of concentrated HCl. Add furfural
solution, Mix it well. Observe.
This test should be –ve.
2 FFA Take 9.4 ml ghee in conical flask.
Add 50 ml neutralized spirit & plug it by
cotton. Put on hot place / boiling.
Cool at room temperature.
Titration against 0.1 N NaOH & Observe
light pink colour and note the reading.
FFA % = Titrate value × 0.3
Special grade: 1.4%
FFA(max)
General Grade: 2.5%
FFA(max)
Standard Grade : 3.0%
FFA(max)
3 RM value Take 5gm sample in Polenske flask. Add
20ml glycerin + 2ml 50% NaOH solution.
Heat the flask over a flame until mixture
become perfectly clear. Cover the flask with
watch glass & cool. Add 93ml boiling
Should be 28 min.
distilled water slowly drop by drop + 50 ml
dil.H2SO4 (2.5 N). Connect the flask with
distilled unit. Heat the flask until insoluble
acids are completely melted (without
boiling). Collect the distillate at 19-21 min
(100-110ml). At 110ml remove the flame,
cool it. Immerse in water at 15oC. Take 100
ml filtrate, add 1ml phenolphthalein
indicator. Titrate it with 0.1N NaOH
solution, Light pink colour appear.
RM Value = (Burette reading – Blank
reading) * 1.1
4 Polenske value Wash the condenser with the 45ml portions
of cold distilled water passing each washing
separately through the 25ml, cylinder the
110ml flask. Dissolve the insoluble acids by
three similar washings of the condenser with
45ml of neutralized Alcohol & titrate it.
Filter it. In filtrate add 1ml phenolphthalein
indicator & titrate with 0.1 N NaOH solution.
Polenske Value = (Burette reading – Blank
reading)
1.0 to 2.0
5 Peroxide value Take 10gm of sample in 250ml conical flask;
add 30ml Acetic acid-chloroform solution.
Swirl the flask until sample is dissolved
+0.5ml of saturated KI solution, allow the
solution
to stand for 1min. 30ml distilled
water, shake well. Add starch as indicator.
Titrate with 0.01N sodium thiosulphate
solution till yellow colour disappears.
PV = (vol.of sodium thiosulphate * No. of
sodium thiosulphate*1000) / wt. of sample
0.55
(table: 10.3.2)
Butter Analysis:
Sr.
No.
Tests Procedure Interpretation
1 Moisture Take 10g of butter in aluminum dish. Heat
the dish on electric hot plate with constant
stirring. Curd at the bottom has attained the
characteristics slightly brown colour. Allow
the cup to cool in desiccator. When cooled
place the cup on the balance
Moisture content = (wt. before heating – wt.
after heating) / (wt. before heating)
16%(max)
2 Salt Take 10 g of sample in a beaker.100 ml
distilled water, heat it. Add into sample &
mix it well. Take 10ml sample & titrate with
3%(max)
0.1N AgNO3 with K2CrO4 indicator.
Salt = (titre value*mol. wt. of AgNO3)*100/
(wt. of butter)
3 Curd Take 10gm sample. Melt it. Give 3 wash of
petroleum ether. Dry it in oven 1 hr. &
weigh.
1.5%(max)
4 Fat Fat =100 – Moisture – Salt – Curd 80%(min)
(table: 10.3.3)
Flavoured milk analysis:
Sr.
No
Tests Procedure Interpretation
1 Alcohol test
For Raw milk
Take 2 ml milk + 2ml alcohol (68% conc.).
Mix vigorously & check the curdling on the
test tube.
The raw milk used for
flavoured milk should be
alcohol –ve.
2 pH Using pH meter. 6.3 to 6.5
3 Fat
Gerber method
Take 10ml conc.H2SO4 (92%) + 2.5g
powder + 1ml Iso Amyl Alcohol + 1ml
distilled water into 10%butyrometer. Rubber
stopper it & centrifuge it at 1100rpm for
5min.
Koko- 2.4 to 2.5
Kafe- 4.85 to 4.90
Shakers- 3.4 to 3.5
4 SNF SNF% = TS% – Fat% 8.6 to 8.8
5 Cream Index(CI)
Used to check the
efficiency of
homogenization
Cool the milk sample at 20oC & take 50 ml
in each of the 2 centrifuge tubes. Centrifuge
the tubes at 1000 rpm for 15 min. Using fine
pointed pipette take 5ml upper part of the
layer & collect in a beaker. Then collect the
remaining milk in another beaker.
Determine fat content of A & B.
CI = (A-B)/B*100%
It should be <10%
(table: 10.3.4)
Tests for Buttermilk & Dahi:
Sr.
No
Tests Procedure Interpretation
1 TS Take 10 gm. of Buttermilk in a plate & place
it in a Hot air oven at 100oC until constant
wait attains.
Buttermilk – 6 to7%
2 Acidity 10 ml Buttermilk/Dahi + 5 drops of
phenolphthalein indicator. & Titrate against
N/9 NaOH till faint pink colour appears.
Acidity = Titre value×0.1 % as lactic acid
Buttermilk- 0.39 to 0.43%
Dahi - 0.55%
3 Fat Gerber Method Butter milk- 0.5%
Dahi- 3.1-3.3%
4 SNF SNF% = TS%-Fat% Butter milk – 4.5 to 5%
Dahi – 11.27%
(table: 10.3.5)
Water analysis:
Sr.
No.
Tests Procedure Calculation
1 Hardness
Pipette 100ml water into a conical flask.
Add 2 drops ammonia buffer solution (pH
10) followed b) 3 drops of Eriochrome
Black T indicator solution.
Titrate with 0.02 M EDTA until the
solution turns from wine red to sky blue
with no hint of red.
Total Hardness (as mg/lit of
CaCO3) = Reading X 10 ppm
2 Chloride Pipette 10ml water into a conical flask.
Add 2 drops of 5% K2CrO4 solution as
indicator.
Titrate with 0.1 N AgNO3 until the
solution turns from yellow to brie red
colour.
Chloride = (Reading X N X
35.45 X 1000)/V = Cl ppm
3 Alkalinity Take 20.0ml water sample and add 2-3
drops phenolphthalein indicator and titrate
with 0.1 N H2SO4. Note down the reading
as a reading (A). (Pink to colourless is end
point). Then add 2-3 drops mix indicator
and titrate with 0.IN H2SO4.
Light green to pink Colour is end point.
Note down reading as (B).
1) Phenolphthalein
Alkalinity (AS mg/lit
of CaCO3) = A*N *
50000 / V
2) Total Alkalinity (AS
mg/lit of CaCO3) =
((A+B)* N * 50000) /
V
Where, N= Normality of
H2SO4
A = Reading of
Phenolphthalein indicator
titration (1st Titration)
B = Reading of Mix indicator
titration (2nd
Titration)
V = Volume of water = 0.108
3) Alkalinity (As mg/lit
of NA2CO3) = (1.06 X
Total Alkalinity) -
Total hardness
(table: 10.3.6)
Strength of Acid & soda:
Sr.
No.
Tests Procedure Calculation
1 Caustic Soda Take 10ml dist. Water in 250ml conical flask Strength of Caustic soda
% = (Reading*N x 40) /
and weight 0.5g caustic soda in 250ml
conical flask. Add 2-3 drops phenolphthalein
indicator and titrate with 0.5N HCl. Pink to
colourless is end point.
(Weight of caustic soda*
10)
2 Nitric Acid
Take 10ml dist. Water in 250ml conical flask
and weight 0.5g Nitric Acid in 250ml conical
flask. Add 2-3 drops phenolphthalein
indicator and titrate with 0.5N NaOH.
Colourless to pink is end point.
Strength of Nitric Acid %
= (Reading X N x 63) /
(Weight of Nitric Acid X
10)
Where, N = Normality of
HCI or NaOH
(table: 10.3.7)
Packaging material tests:
Sr.
No
Packaging material
& its characteristics
Tests Procedure Interpretation/
Calculation
1 Card board Box
(CBX)
5 ply
(12×1kg Box)
Weight test weigh the entire package in box form
without cutting any part of it on a
sensitive balance.
-
Dimensions Measure the inner dimensions of the
folded box with an accurate cm scale
L*b*h
Bursting
Strength
Using digital bursting strength
apparatus.
The bursting
strength should be
12 kg/ Cm2 .
Grammage
(GSM)
A 10×10 cm specimen is cut from the
CBX and then put it on boiling water
for 10min so that starch based adhesive
melts and the ply layers get separated.
The individual layers allowed to dry at
room temp for 30 min & the oven dried
for 10 min. then each layer weigh
separately.
The resultant
weight is multiplied
by 10 to give GSM.
Outer printing
of CBX
The card board random sample is
chosen & viewed for its outer printings.
Correct details
regarding title of
manufacturer,
weight of product,
stackability, etc.
2 Milk pouch & Ghee
Pouch
(LDPE+LLDPE)
Grammage A 10×10 cm square is cut and weighed. It represents Grams
per square meter.
Thickness Using micrometer Milk pouch-55
micron
Ghee pouch- 100
micron
Outer printing A random sample is picked up and all
printed features such as Principle
display panel, Manufacturer detail,
Product detail, Nutritional facts,
Address of Company, etc.
All the details
should be correct.
3 Tin containers Lacquering
(table: 10.3.8)
Equipments present at central lab:
Sr.
No.
Equipments / Instruments Purpose
1. Milkoscan Fat, SNF, Protein, Lactose
Determination
2. Food scan Fat, moisture, Protein, Lactose
of butter, cheese
3. Auto Titrators Acidity Determination
4. Conductivity Meters Conductivity of CIP Chemicals
5. Microwave Moisture Analyzer Moisture Detection
6. IR Moisture Analyzer Moisture Detection
7. Stamp Volumeter Density of Powder
8. Bursting Strength Analyzer For Packaging Material
9. pH Meter pH Measurement
10. Solubility Index Mixer Solubility Index of Powder
11. Electronic Weighing Balance For Weighing Purpose
12. Gerber Centrifuge For Determination of Fat
13. Muffle Furnaces For Ash
14. Spectronic 20 For colour determination
15. Oxygen Analyzer For determination of Oxygen
content in packages
16. Bulk Density Apparatus For determining Bulk density
17. Electric Hot Plate For heating purpose
18. Remi centrifuge For determination of
insolubility index
19. Refractometer For determination of
Refractive Index
20 Food Scan For chemical analysis of butter
& powder
(table: 10.3.9)
4. Microbiology laboratory:
Since milk and milk products are extremely susceptible to microbial contamination during their
production and processing, it becomes a necessity to assess the microbiological quality of these products in a
quality control lab. As bacterial load is the function of the species of bacteria as well as their number, a
program for controlling the total bacterial load of milk and dairy products must include metabolic activity
test (indirect test) as well as test involving the enumeration of bacteria or test for the presence and absence of
specific pathogenic organism(direct test). The routinely used method in quality control laboratories are:
One random sample of every product is analyzed daily for SPC, Coliforms and Yeast & mold using
readymade dehydrated petrifilms. Pathogen tests are done weekly or once in two weeks.
Different microorganisms:
Type of
Microorganism
Media pH of the Medium Appearance of the Colony
Total viable count Plate count agar 7.0 +/-0.2 -------
Coliforms Violet red bile agar 7.4+/-0.2 Red/ Purple colony
Yeast & mold count Potato dextrose agar 5.6+/-0.2 White/grey/yellow/ black
colony formed
E.Coli Eosin methylene blue
agar
6.8+/-0.2 Green metallic sheen, black
centered colony
Salmonella Bismuth sulphite agar 7.6+/-0.2 Black metallic sheen
Shigella Brilliant green agar 6.9+/-0.2 Pink coloration
S. aureus Baird parker agar 6.8+/-0.2 Black colony surrounded by
clear zone
B. cereus Bacillus cereus agar 7.2+/-0.2 Pink/ white colony
Listeria
Monocytogenes
Listeria agar 7.2+/-0.2 Black colony
Fecal Streptococci Mac Conkey‟s agar 7.4+/-0.2 Pink colony
Vibrio Cholera Thiosulphate citrate bile
salt sucrose agar
8.2+/-0.2 Yellow colony
Anaerobic Spores Liver meat infusion agar 6.9+/-0.2 ----------
(table: 10.4.1)
Sampling plans for analysis of products:
PRODUCT PARAMETERS FREQUENCY REJECTION CRITERIA
Raw milk Plate Count 2 Tankers/ day >5000000 cfu/ml
Pasteurized Milk
from running
Pasteurizer
Plate Count, Coliform
Count
1 sample /day >30,000 cfu/ml
Present in 0.01ml
Pathogen Test 5 samples /month Present
Railway tanker
milk
Plate Count, Coliform
Count
Every tanker >30,000 cfu/ml
Present in 0.01ml
Sterilized
Flavoured milk
Plate Count, Coliform
Count
1 sample / shift
> 5 / ml
Spore Count
Various milk
powders
Plate Count Composite sample of
two / shift
> 40000 / g
Coliform Count Present in 0.1 g
Pathogen Present
Butter Plate Count 2 samples / line / shift
>5000 / g
Coliform Count > 5 / g
Yeast & Mold Count > 5 / g
Pathogen Weekly- 7 days
composite
Present
Export Butter
Plate Count 100 g – every 50th
case of each
consignment.
500 g – every 100th
case. Composite
sample for each
consignment.
>5000 / g
Coliform Count > 5 / g
Yeast & Mold Count > 5 / g
Pathogen Present
Raw materials-
Maltodextrin ,
Salt, Annatto,
Coliform Count Each consignment or
Twice in a month
Present in 1 g
Yeast & Mold Count Present in 1 g
Vitamins , Corn
oils, Colour
Pathogen Present
Raw materials –
Sugar , TSP
Coliform Count Twice in a month Present in 1 g
Yeast & Mold Count
(Table: 10.4.2)
CONCLUSION
Amul spurred India‟s White Revolution, which made the country the world‟s largest producer of milk
& milk products. In the process Amul become the largest food brand in India and has ventured in to
markets overseas.
Amul committed produce safe and wholesome food to continually remain as the market leader by the
providing the food product delight customer expectation & best of safety.
Here in Amul learned about the practical working at the Industrial level. The various problems that
can occur & the different ways to shoot them.
The important of working environment and how to generate highly professional work environment.
We also learnt about how to manage the available resources to extract maximum production and the
handling of manpower to get the professional work experience.
Working in any industry is difficult without mutual understanding, co-operate nature and team work.
Here in Amul learned about all these things. To learn all the above things the historic unit of Amul is
one of the best place in the World.
Thank you………..