IN PLANT TRAINING REPORT

On

SHIVAMRUT DUDH UTPADAK SAHAKARI SANGH MARYADIT;

VIJAYNAGAR, AKLUJ.

Training Report
Submitted for the partial fulfillment of the award of Degree of

BACHELOR OF TECHNOLOGY
IN
(FOOD TECHNOLOGY)
Submitted By

MR. MADANE LAHU POPAT

REG.NO: FSSRU/014/412
Submitted to

COLLEGE OF FOOD TECHNOLOGY, SARALGAON,

MURBAD, THANE-421401
Affiliated to the
DR.BALASAHEB SAWANT KONKAN KRISHI VIDYAPEETH
DAPOLI,(M.S.) INDIA.
2017-18

1
2
 COLLEGE OF FOOD TECHNOLOGY, SARALGAON,

MURBAD, THANE-421401

AFFILIATED TO THE

DR.BALASAHEB SAWANT KONKAN KRISHI VIDYAPEETH DAPOLI.

BONAFIDE CERTIFICATE

This is to certify that the training report entitled, in plant training ―Shivamrut Dudh
Utpadak Sahakari Sangh Maryadit;Vijaynagar, Akluj‖ Maharashtra. Submitted to
College of Food Technology Saralgaon affiliated to Dr. Balasaheb Sawant Konkan Krishi
Vidyapeeth, Dapoli in partial Fulfilment of the requirement of Degree of Bachelor of
Technology, industrial training carried out by Mr. Madane Lahu Popat (FSSRU/014/412)
during the period Nov. 2017 to March 2018.

Principal Sign

Date :

Place: External Sign

3
 DECLARATION

I here by declare that the in plant training completed in Shivamrut Dudh Utpadak
Sahakari Sangh Maryadit;Vijaynagar, Akluj , Maharashtra Submitted to College of Food
Technology Saralgaon affiliated to Dr. Balasaheb Sawant Konkan Krishi Vidyapeeth, Dapoli
During the period Nov. 2017 to Mar. 2018.

Signature of Student

Place : (Mr. Madane Lahu Popat)

Date : (Reg. No.: FSSRU/014/412)

4
 CERTIFICATE

This is certified that the report entitled in plant training ―Radico NV

Distilleries Maharashtra Ltd. Aurangabad‖ Maharashtra is a bonafide record
work of the following candidate who carried out the report work during year
2017-2018

Name of student : MADANE LAHU POPAT

Registration No. : FSSRU/014/412

Certify that candidate was in the viva – voice examination held on

………….

INTERNAL SIGN EXTERNAL SIGN

5
 ACKNOWLEDGMENT

I acknowledge to Dr. Anil B. Rathod, Principal, College of Food Technology Saralgaon Tal-
Murbad Dist- Thane. For his efforts in making possible for me to carry on my in plant training successfully.

I would like to express my thank to Mr. R. Suryawansh Sir and Miss. Sayli Kanade Mam
Training and placement in charge of College of Food Technology, Saralgaon Tal- Murbad Dist- Thane.for
permitting me to do my project work in Shivamrut dudh Utapadak Sahakari Sangh Ltd. Akluj, Dist.
Sholapur.

I wish to place on record my sincere thanks for Teaching staff, Prof. R.C.Kokani, Prof. P.M. Patil,
Prof. Miss. J.R.Dhalgade, Miss. A.A.Kudale, Miss. S.V.Kharmale, Miss. A.K.Dolas, Prof.
K.M.Mangale College of Food Technology, as well as Non-Teaching staff Miss. Varsha Kambale
College of Food Technology Saralgaon, for their kind co-opearation durig completion of my Graduation.

I would like to thanks Managing Director, Mr. Shitole sir, Managing body, General dairy manager
Mr. Kale sir & Production manager Mr. Waghmode sir for granting me permission to work in milk &
giving me their information & guidance.

With sense of gratitude & indebetance. I place on record my sincere thanks to, the Q.C. Officer &
Chemist Mr. Wagole sir & Mr. Vavre sir for their complete guidance &support during my in-plant
training.

I sincerely thankful to all those who helped us in completing this project which has helped us get an
insight into the field of production.This Project has been prepared for partial requirement for the In-plant
training program & Sincere thanks to; Mr. Khare sir (HR), Mr. Borkar Sir (DS)

And last but not, workers& operator for creating a comfortable environment for me to work in
Shivamrut Dudh Utapadak Sahakari Sangh Vijaynagar, Akluj.

Mr. Madane Lahu Popat

B.tech (Food Tech.)

6
 INDEX

Sr. Tittle Page No.

No.
1. About a Industry 10
2. Layout Plan of the Plant 12
3. Staffing Pattern of Organizational Set Up 13
4. Objectives 14
5. Quality Policy 15
6. Department and Section 16
7. RMRD 17
8. Milk Process Department 18
9. Production Department 21
10. Quality Control Department 34
11. Packaging of Product 42
12. Machinery And General Information 45
13. Store Department 47
14. Boiler 48
15. Refrigeration 49
16. Air Compressor 50
17. Electrical Department 51
18. ETP 52
19. Maintenance Department 56
20. CIP 57
21. Conclusions 60
22. References 61

7
 LIST OF FLOW CHARTS

Sr. Flow Chart Title Page No.

No.
1. Layout of Plant 12
2. Staffing Oraganizational Set Up 13
3. Miilk Reception 17
4. Cleaning of can 17
5. Pasteurization 18
6. Market Milk 24
7. Paneer Production 26
8. Dahi Production 26
9. Shrikhand Production 27
10. Flavoured Milk 29
11. Basundi Production 29
12. Pedha Production 30
13. Butter Production 31
14. Ghee Production From Cream 31
15. Ghee Production From Butter 32
16. Gulab Jamun Production 33
17. Refrigeration 50
18. Air Compressor 51
19. Electricity 52
20. ETP 56
21. CIP of Pasteurizer 58

8
 LIST OF TABLES

Sr. Tables Title Page No.

No.
1. Nutritional Composition Of Milk 24
2. Nutritional Composition Of Paneer 26
3. Nutritional Composition Of Shrikhand 28
4. Specification For Effulent 52

LIST OF FIGURES

Sr. Figures Title Page No.

No.
1. Ghee 22
2. Basundi 22
3. Lassi 22
4. Amrkand 22
5. Shrikhand 22
6. Butter 23
7. Paneer 23
8. Market Milk 23
9. Dahi 23
10. Masala Tak 23
11. Flavoured Milk 23
12. Pedha 23
13. Gulab Jamun 23

9
 1. ABOUT A INDUSTRY

Shivamrut Dudh Utapadak Sahakari Sangh, Maryadit; Vijaynagar-Akluj is an classical example

&excellent work of creativity in real sense of them & which play very important role in the development
rural welfare Shivamrut Dudh Sahakari Sangh established in 1976 by late Mr. Shankarrao Mohite-Patil with
the financial assistance provided by shareholder& state Government.

The purpose of establishing of this dairy was to provided additional source of income to the farmer
from the surrounding village to improve their economical, social & educational leaves & to provide
employment.

Here the milk procured from bulk cooler. & at present nearly societies are work in from villages.

Shivamruth dairy plant has milk processing with capacity of 4 lacks liter/day of which 1.5 lacks liter/day
sold as pasteurized &rest of milk is processed in various products.

These products are marketed under the brand name ―SHIVAMRUT‖ products. The different type of
products are prepared like; Ghee, Paneer, Shrikhand, Amrakhand, Basundi, Pedha, Lassi, Flavored milk,
Khoa etc.

Since the Establishment it is continuously progressing.According to products quality has been

certified by HACCP & ISO so that these products have international market value that‘s called greatest dairy
industry in India.

Address of dairy-

Shivamrut Dudh Utapadak Sahakari Sangh, Maryadit; Vijaynagar-Akluj

At.Vijaynagar, Po-Yeahwantnagar,(413118) Tal-Malshiras, Dist- Solapur, (Maharashtra).

Year of establishment: 27 Jan 1976.

Type of organization: Co-operative Society.

Distance from city:

Shivamrut Dudh Utapadak Sahakari Sangh, Maryadit; Vijaynagar- Akluj is 10km away from
Akluj city.

10
Land of dairy: 25 acere

Raw milk collection:

From the all villages of Malshiras, Pandharpur, Indapur, Barshi, Madha, Sangola, Mhaswad
taluka & other different taluka‘s.

Registered no: S.U.R/M.K.T/Dairy 104/1976

Registered for:
Milk collection, processing, By-products making and their Marketing for this union has
developed related activities as per requirement.
Installed Production Capacity: 3, 00,000 Liters per Day
Daily milk collection:
Today the daily collection of milk Is 1,50,000 Liters/day through 150 primary milk co-
operatives of the taluka.
Market Area: - Maharashtra.
Distribution of milk:
Union has its own 20 Tankers for collection of milk From primary dairy co-operatives & 120
insulated vans for milk Distribution to the dealers.15 mini trucks for Aqua distribution.
The Vision:
Innovate with Quality, Grow at speed of light, Serve with passion and Excel with ethics&
turnover of 5,000 Crores.

11
 2. LAYOUT OF PLAN FOR PLANT

Flow Chart No. 1 : Layout of Plant

1. Weigh Bridge 14. Printing Section

2. Gate and Security Cabin 15. Cold Storage
3. Administration Office 16. Store Room
4. Conference Hall 17. CIP Section
5. Marketing Department 18. ETP
6. Washroom 19. Boiler
7. Warehouse 20. Electric Department
8. Packaging Section 21. Mechanical Department
9. Production Departments 22. Warehouse
10. QC lab 23. Gardan
11. Process Section 24. Parking
12. Computer Section 25. Outlet Shop
13. GM cabin

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 3. COMPANY ORGANISATION

Board of Director

Chairman

Managing Director

General Manager HR&Finance M.R. cum HACCP

(Dairy) team leader

Dairy accounts
Production
General
General
Cleaning
Stores
Quality Store Keeper E.T.P.
Control
Supervisor

E.T.P.

Incharge
Mechanical
Department

Electrical Electrical
Electrician Wireman
Department Engineer

Electronics Instrumentation

Department Engineer/Supervisor

Flow Chart No. 2 Company Organisation Set Up

13
 4. OBJECTIVES

 To support milk producers with a package of inputs, required for promoting milk production on one
hand, and undertake processing and marketing on the other.
 To achieve this aim, the following are the specific objectives set forth by the union.
 To organize and arrange the activity of milk procurement from the milk producers/through primary
milk Co-op Societies to the Sangh.
 To processing milk by homogenization and pasteurization in a highly clean condition.
 To find assured and remunerative market for milk and milk products.
 To provide veterinary and breeding services by undertaking A.I. program me with the use of high
quality germ plasma.
 To perform a role of catalyst in the process of securing financial help and purchasing dairy animals
for the beneficiaries in the area.
 To make available medicinal and biological inputs for the dairy animals in the area.
 To undertake production and supply of nutritious and balanced cattle feed.
 To work as an agency for insuring the dairy cattle and for perusing the insurance settlement claims of
cattle owners with insurance companies
 To perform a function of dissemination of modern technical know-how to the dairy farmers in the
area by organizing extension and training program me regularly.

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 5. QUALITY POLICY

Shivamrut Dudh Utapadak Sahakari Sangh, Maryadit; Vijaynagar-Akluj‘s quality policy is a focused
statement on the above mentioned organizational goals and customer requirements. is a Co-operative Dairy
Organisation specialising in the Processing and manufacture of milk & milk products for the commercial
market.

The prime objective of the company is to take care of its producers and to look into their upliftment,
to meet customer requirement & to provide quality products in a timely and cost effective manner.

The senior management of the Shivamrut Dudh Utpadak Sahakari Sangh Ltd. is fully committed to
the implementation and maintenance of the Quality System that conforms with requirements of ISO
9002:1994, Quality systems.

The Company's Quality System emphasizes on prevention rather than detection. To this end, the company has
instituted quality systems which complies with HACCP requirements for food safety & ISO-9002 Quality
Management Systems.

Continuous improvement is the responsibility of every staff member, and all staff members are
expected to participate in all quality related activities.

15
 6. DEPARTMENTS AND SECTIONS

There are following Departments and Sections,

1. Administration Department (HR, Finance, MIS, Accounts)

2. Raw Milk Reception Department (RMRD)

3. Milk (Processing) Department

4. Production Department

5. Quality Control Department

6. Electrical and Electronics Department

7. Mechanical Department

8. Cold Storage

9. Warehouse

10. Dispatch Section

11. Boiler Section

12. Transportation Section

13. Marketing Department

14. Effluent Treatment Plant {ETP}

7. Raw Milk Reception Department (RMRD)

The RMRD is the section where unloading weighing, testing of raw milk take place in Shivamrut sangh.
Raw milk is received by cans & Tankers from receive the milk which is away from long distance. It has
already been weighed sampled &cooled.

The milk reception should be so planed& the equipment so chosen that in take operation is expedited.

Receiving of milk in can‘s

Manually opening can‘s

Organoleptic testing of raw milk

16
 Manually empting of can‘s

Weighing of milk

Filtration [Nylons filter]

Sampling of milk for fat,SNF

Chilling of raw milk40c

Storage of Raw milk in silo

Flow Chart No. 3 Milk Reception-

7.1.1 CLEANING OF CAN’S

The empty cans are washed in Straight through can washer daily.

Inversion of empty can.

Drainage of milk residue.

Prerinsing with warm water.

Rinse with detergent

Hot water rinse.

Hot air drying.

Closing the cans with lid.

Flow Chart No. 4 Cleaning Of Can’s

17
 8. MILK PROCESSING DEPARTMENT

8.1 PASTURIZATION

―It‘s process of heating of each & every particle of milk at760c for 15 sec. to kill microorganism
&increases shelf life of milk & milk product.‖

In this dairy [HTST] pasteurization is followed for milk processing. milk is heated at810c for 15 sec.
Destroy the pathogenic micro-organism mainly Mycobacterium tuberculosis & Coxiellaburntil.

Raw milk tank

Float control tank

Plate heat exchanger

Regeneration1

Filter

Cream sepation

Regenration 2(temp 680c-720c)

Homogenisation

Heating (temp 800c-820c)

Holding (20 sec)

Regeneration [cooling2]

Regeneration [cooling1]

Chilling section ( temp 80c)

Pasteurized milk obtained

Flow Chart No. 5 Pasteurization Process

18
8.2. Detailed Description

a. Raw milk reception and filtration

After clearance analysis report, raw milk is unloaded directly from silo to Float Control Balance
Tank where desired standardization takes place that is addition of solid not fat or by separation of cream.
The fat Solid Not Fat ratio is maintained. Then milk is filtered by passing through duplex filters so as
remove extraneous matter to avoid fouling in Plate Heat Exchanger.

b. Separation

The milk is separated if required cream is separated from milk due to high centrifugal force which
collects fat on top level and extracted up to required calculation.

8..3 Working of cream separator

The milk flows through the distribution holes of in the spaces between the discs. The part
which is discharged as cream is pressed towards the bowl center along the top sides of discs and flows out
through the wear sleeve in the top disc ―internal way‖. The part discharge as skim milk flows along the
lower sides of discs and out to bowl periphery where solid impurities settle in sludge space. The skim milk
flows along the upper side of top disc and leaves bowl via outlet sleeve-―external way‖.

• Cream fat content

The amount of the cream and thus the fat content of cream can be regulated by changing pressure in cream
outlet. The adjustment is affected by means of cream flow mater and its regulating valve.

•Working instruction for operation of cream separator :

1) Check the level of oil, brake lever and hood locking.

2) Check whether separator is online or not.
3) Start separator and check vibrations and sound if any.
4) When speed is achieved then start extracting the cream.
5) When cream extraction is completed stop the separator and do not by pass.
6) By pass separator.

8.4 Heating and holding section

19
The most important operation during pasteurization is heating of milk 77°C ± 2°C for 15 sec and then
holding tube looks like a rectangular spring type shape. Here heating is carried out by steam mixing battery
which mixes steam to increase hot water inlet temperature about 85°C and that of steam mixing battery
85°C. The steam mixing battery is provided with induction motor.

Flow diversion valve

The basic function of Flow Diversion Valve is to cheek required pasteurization temperature from holding
tube outlet. Flow Diversion Valve also forward the properly pasteurized flow and diverts the unpasteurized
milk flow for reprocessing in balance tank of pasteurized.

8..5 Cooling

This is final operation through High Temperature Short Time Pasteurizer. The cooling of heated milk
is achieved by chilled water inlet temperature about (1-2°C) from Ice Bank Tank. The chilled water in
countercurrent flow absorbs heat from hot milk and makes it cool to about 4-5°C. The chilled water then
return back to Ice Bank Tank via the Ammonia chilled where water temperature is again lowered ensuring
that no chilled water wastage occurs thereby lowering the load on Ice Bank Tank.

8.6 Storage

After adequate cooling the milk is pumped to Horizontal Milk Storage Tank which is provided with
agitator.

20
 9. PRODUCTION DEPARTMENT

Shivamrut manufactures following byproducts:

1. Homogenized Pasteurized Milk

2. Flavored milk
3. Lassi
4. Masala Tak (butter milk)
5. Dahi
6. Shrikhand
7. Amrakhand
8. Ghee
9. Butter
10.Basundi
11.Khoa
12.Pedha
13.Burfi
14.Gulab Jamun
15.Paneer

21
 Photo of Product

Fig no. 1 Ghee Fig no. 2 Basundi Fig no. 3 Lassi

Fig no. 4 Ambrakhand Fig no. 5 Shrikand Fig no. 6 Butter

22
Fig no. 7 Paneer Fig no. 8 Milk Pouch Fig no. 9 Dahi

Fig no. 10 Masala Tak Fig no.11 Flavoured milk Fig no.12 Pedha

Fig no.13 Gulab Jamun

23
9.1 MARKET MILK

Milk from storage tank

Overhead balance tank

Filling pipes

Vertical sealing& pouch formation

Filling of milk& horizontal sealing

Milk pouch

Weighing &leakage testing of pouch

Filling in Creates

Storage [cold store temp.40c]

Dispatch

Flow Chart No.6 Pouch Filling

CCP’S FOR PACKING-

 Temperature of cold room should be less than 40c & Should be checked after each hour.
 Door of cold room should be closed.

 Nutritional facts of Cow/Baffalowmilk pouch-

Sr.No. Parameter Cow milk Baffalow milk

1] Energy- 63Kcal 86 kcal
2] Protein- 3.0% 3.2%
3] Carbohydrates- 4.8gm 4.9gm
4] fat- 3.5% 6.0%
5] Calcium- 111mg 114mg
6] Phosphorus- 130mcg 132mcg
7] SNF- 8.5% 9.0
Table No- 1 Nutritional Composition Of Milk

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 Weight of polyethylene bag with milk-
1]200ml- 208gmilk +1.70g packaging material.
2]250ml-257g milk +1.75g packaging material.
3]500ml-515g milk +2.59g packaging material

9.2 PANEER

Paneer is obtained through acid coagulation of casein component of standardized milk, entrapping
through complex physical- Chemical interaction almost all the fat, a part of denaturation whey protein and
colloidal salts as well as a part of the soluble milk solids.

Paneer is marble white in appearance having a slightly spongy body, close knife texture &sweetish
acidic flavor.

Take buffalo milk [fat-6.0, SNF-9.1]

Heating-850c

Cooling at 700c

Addition of Citric acid2%

Milk is coagulated

Whey is Drain out by[muslin cloth]

Feeding in molds

Pressing[5-20min. 2kg/m]

Add in Chill water for 30h min[temp 40c-5c]

Paneer obtained

Packaging [polythene bags]

Cold storage[40c]

Flow Chart No 7 Paneer

Quality standard

25
 moisture content-51%;

T.S. not more than 50%

 Nutritional information per 100 gm

1] Energy 338 Kcal

2] Carbohydrates 2.53 g
3] Protein 19 g
4] Fat 28 g
Table No 2 Nutritional Composition of Panner

9.3 DAHI SECTION

Dahi is manufacture from pasteurized milk. Milk fat is 3.5 & SNF is 9.0. Milk is standardized by
addition of SMP powder because of increase in SNF level & then adds culture at the rate of 1.5-2% of milk.
Incubate 370c to420c for 4-5hrs.

The acidity of curd sample is checked&stored in cold room below 50c

Receiving milk

Standardization [fat-4.0; SNF-9.0]

Processing

Pasteurization

Adjustment of temp.400c

Addition of culture2%

Mix the culture in milk

Filling in cup‘s

Sealing

Incubation370c-400cfor3-4hrs

Storage [at 00c to 40c

Flow chart No 8. Dahi Production

26
 Quality standard-
Acidity-0.5-0.6%
Body texture-firm Dahi

9.4 SHRIKHAND SECTION

―Shrikhand is semi soft sweetish sour whole milk product prepared from lactic fermented curd by
removed whey &using chakka as basic Ingredients.

Standardized milk

↓
Pasteurization of milk [800c to 750c]

↓
Inoculation with culture
[400c ,Incubation 6 to8 hrs]

↓
Hanging in muslin cloth6-8hrs

↓
Collection of chakka
Acidity [1.75%]

↓
Mixing sugar
[Planetary mixture]

↓
Packing in cups.

↓
Transferred to cold storage

↓
Prepared Shrikhand
Flow chart No. 9 Shrikhand

27
QUALITY STANDARD FOR SHRIKHAND

Total solid 58%

Protein 9%
Acidity 1.5%
Moisture 42%

Table No 3 Nutritional Composition Shrikhand

9.5 AMRAKHAND SECTION

Note-Same procedure for Shrikhand production. Only mango pulp is added.

QUALITY STANDARD FOR AMRAKHAND

Total solid-58%
Protein-9%
Acidity-1.4%
Moisture-42%

9.6 FLAVOURD MILK

Different types of Flavoured milk is prepared in Shivamruth dairy like Mango,Pista, Strawberry,
Pineapple, Cardamom, Butterscotch, Etc. & flavoured milk is prepared from toned milk.

Milk fat is 1.8%, SNF-9.0.

Milk

Preheating

Homogenization

Pasteurization [810cfor15sec.]

Cooling

Addition of sugar

colouraddition

Filling

28
 Sealing

Sterilization[1200cfor15min.]

Storage

Flow chart No. 10 Flavoured milk-

 QUALITY STANDARD FOR FLAVOURED MILK-

Turbidity-Negative
Ph-6.0-6.5

9.7 BASUNDI

Basundi is the concentrated milk product In Shivamruth dairy Basundi is prepared as pre demand.

Raw milk-[fat-3.8&SNF-9.0]

Heating[800c]

Sugar addition

Boiling

Cooling

Add cardamom,badam.

Packaging [polythene bag‘s]

Storage

Flow Chart No.11Basundi production

QUALITY STANDARD-

Fat not less than 14-16%.

T.S. not less than 38-40%.

9.8 PEDHA

Pedha is the concentrated milk product. Continuous production of Pedha in Shivamruth dairy.
29
 Take raw milk [fat-4.0 SNf-9.0]

Heating used by[khoa making machine]

At Pet Formation stage add sugar

Obtain solid part Wt.it

Cooling

Pedha is PreparedBy machine

Packaging [box,polythene bags.]

Storage

Flow chart No.12 Pedha Production

QUALTY STANDARD-

 Colour-Uniform
 Flavor-Rich nutty
 Texture Slightly –Oily &granular
 T.S.-Not less than 38-40%.

9.9 BUTTER

Butter is fat concentrate which is obtained by churning cream, gathering the fat into a compact mass
and then working it.

Cream [temp. 100 to 110 c & fat 40-45%]

Loading in churner

Churning [40 – 45 RPM, for 20 – 25 min]

30
 Churning [20 – 25 RPM, for 10 – 15 min]

Butter milk prepared

Fat sample

Butter

Flow chart No. 13 Butter

QUALITY STANDARD FOR BUTTER:

1. Fat content: 82%

2. Moisture:17%
3. Curd:Total:100 -1%

9.10 GHEE

―Ghee is the clarified from cream to which no Colouring matter is added according to PFA rule.

CCP‘s for ghee production- Cooking temp should be 1070c .

Cream[70-75%fat]

Boiling [1070cfor4-5 hr]

Settling [4hrs]

Clarification

Ghee obtain

Packing

Sealing

Storage

Flow chart No.14 Ghee production from Cream

31
QUALITY STANDARD-

B.R.-Range [40c]-41-43%

F.F.A.-Not more than1%

Moisture-Not more than-0.3%

FLOW CHART OF GHEE FROM BUTTER-

Butter[80-85%fat]

↓
Melting in melting vat [At 700c]

↓
Pre-stratification [At 700c for 45min.]

↓
Boiling [1070c for]

↓
Removal of Ghee residue

↓
Settling for 4 hrs Ghee Remove from Reprocess in Ghee boilerat1070.

↓
Clarification

↓
Removal of residue

↓
Packing

↓
Bottles & Bag‘s. ↓
Sealing↓

32
 Packing

↓
Storage at 400c

Flow chart no.15 ghee production from Butter

9.11 GULAB JAMUN

Khoa

Refined wheat flour

Mix well in water

Making dough

Cut in round pieces

Frying in oil

Deep in sugar syrup

Fill in jar

Sealing

Labeling

Storage

Flow chart no.16 Gulab Jamun production from Butter

33
 10. QUALITY CONTROL DEPARTMENT

Quality control department in this department product quality is checked by analytically &microbial.

In this department under two lab-

1] ANALYTICAL

2] MICROBIOLOGY

1. Lab Equipment-
2. Centrifuge
3. Weighing balance
4. Dissector
5. Hot air oven
6. Incubator
7. Autoclave
8. Geber machine
9. Hot plate
10. PH meter
11. Milko screen
12. Brushing strength tester
13. Laminar air flow
14. Magnetic stirrer
15. Thickness meter
16. B.R machine

10.1 Analytical lab

In this lab all milk product is checked &milk is used for Processing before fat &SNF is checked in
this lab.

Analytical testing of milk & milk Product are as fallows.

A] Sensory quality of milk

1] Smell test –

 Smell &taste is checked with help of plunger milk in the can is stirred &smell & test is checked.
 If any doubts n smell &taste then COB test is conducte
34
2] COB [clot on boiling]

 Take 5ml milk sample in test tube.

 Clots of milk at the bottom of test tube this Test is positive.

B] Adulteration Test for milk

1] Sugar

 Take clean pipet &test tube.

 Then pipet out 15ml milk sample in test tube.
 Add in it0.1 gm resorcinol powder. &
 add 1ml hydrochloric acid. & placed in boiled water at 5 min. then observe color if red color is
observed.
 Result -Sugar is present.

2] salt

 Take clean test tube &add in it 5ml 0.134% silver Nitrate.

 Then add 1ml of milk sample. Add2-3 drops of potassium chromate & shakes well.
 Observe the color milk sample i.e. become yellow. Salt is present.

3] Starch

 Take clean test tube.

 Then add 3ml of milk sample these test tube are placed in hot water bath &boil it.
 These test tube cooled at room temp.
 Add 0.1%Iodine solution 2to3 drops .
 blue colour is obtained test tube placed in hot water bath during boiling period cooler is discarded.
 And solution is cooled then colour is developed.
 Given milk sample starch is present.

4] Urea

 Take clean test tube & add 5 ml milk sample.

 Then add 20gm soybeans powder shake well.
 And 0.5% Bromathymol blue indicator 2 drops & mixed well.
 Place room temp foe 10 min.

35
  After 10 min blue color is observed urea is present.

5] Detergent test

 Take test tube add 5ml milk sample

 Add 0.5% bromocresol purple indicator
 After 10min Voilet color is observed ,Detergent is present.

6] Soda

 Take test tube add 0.5ml milk sample.

 Add 5ml Absolute alcohol &mix well.
 And add 2-3 drops of rosalic acid &observe color.
 End point pink color is observed soda is present.

7] Alcohol Test

 Take 5ml of milk in a test tube addan equal quantity of 68%of alcohol.
 Mix the content of test tube by inverting several times.
 Not any flakes or clot.
 The presences of flakes or clot denotes s positive.

8] Malto dextrin test-[Enzymatic method]

 Take milk sample 20ml.

 Then add 1ml citric acid [10%]
 Then add 1ml enzyme solution. Mixwell add in hot water [600c] for 5min.
 After that placed room temp.For 5 min. add in it [urine reagent strip] check the colour.

9] Phosphates test-

 Take 5ml phosphate solution.

 Add1ml of milk sample &mixed well.
 Place in water bath at 370c for 2hrs.
 If yellow color is present pasteurization not done.

C] Milk’s Products-

Different test is carried out for milk product-

1] Acidity of various milk product-

36
 Chakka, Paneer, Lassi, Dahi, Shrikhand.

 Take 2gm+10mlD/w.
 Add 2-3 drops of phenolpthelne indicator&
 Titrate with 0.1n NaOH. &End point just pink.
 Formula of Paneer Acidity

Paneer Acidity = Titration reading *9* Normality of HCL

Wt. of sample.

Acidity = 9*Normality ofNaOH*B.R.

Wt.of sample

2 ]Fat of various milk Product-

Paneer, Butter, Dahi, Shrikhand, Lassi, Flavoured milk.

 Take a butyrometer & add in it milk sample 10ml

 And add in10ml sulphuric acid.
 Add 1ml Iso amyl alcohol.
 Centrifuge at 2200 rpm for3-5min.

Formula-

Shrikhand fat=B.R*2.5

3] Shrikhand protein test

Procedure

 Take 3gm sample.

 Add 10ml hot water.
 Add potassium oxalate 1ml&Add2-3 drops of P.p Indicator.
 This mixture is neutralized with 0.1 n NaOH solutions. Pink color is observed
 Add 7ml Formalin. Color is discarded –then this solution titrates with 0.1N NaoH solution. End point
is pink Color.

37
4] Total solid content of various milk Product-

Lassi, Shrikhand, Paneer

Procedure

 Take milk Sample read the fat.

 And then check the degree of Sample.

T.S.=SNF+Fat

SNF +[0.21*Fat]+0.36

Moisture=100-T.S.

Ghee

Butryo Refractometer Reading

 B.S.For. the Ghee are measured on the Butryo Refractometer

 Take a one drop Ghee on the Machines witch is on & note down reading.
 The standard Butryo Refractometer reading is 40-43%

F.F.A-[Free fatty Acid]

 Take clean beaker &Then Add Sample 5gm. Add 25 ml Ethyl Alcohol [90] %& then add
p.p.indicator. Shake well &then titrate with 0.1nNaoH solution.
 Then solution is boiled &cooled in desicatore.again titrate with NaOH note down reading.

Formula :

Standard range free fattyacid=1%

5] Phof various milk Product

Dahi, flavored milk,

Procedure—

38
  Phelectrode deep in buffer solution & adjust reading 4.
 Then wash electrode with distilled water.
 Electrodedries with filter paper.&Then electrode deep in product & stirrer.Note down reading.

Turbidity of flavored milk

Procedure

 Take clean beaker & add 4gm ammonium sulphate.

 Add 20ml Flavored milk Sample By using filter paper.
 Then filter solution take in test tube kept in hot water for5 min.
 Cool under tap water. Check turbidity is absent /present. If clear solution observed. Test is negative.

10.2 Microbial testing Lab

There is separate microbiological Lab attached with main chemical lab for microbiological testing of
products, equipment, environment, packaging, and materials.

Test performed for products are-

1] SPC

2] Coliform

3] Yeast& mold

4]Salmonella & Shigella.

5] Most Probable number.

6] Swab test.

7] Rinse test

Microbiology Lab
Mainly in microbioloical lab the test for Coliform, Yeast & mold, SPC and spores is performed. MBR is also
performed for raw milk samples.

For all tests, the saline solution is prepared to make dilutions of the samples. It is prepared as follows:

39
 Weigh 8.5 gm NaCl

Add 1000 distilled water

Fill bottles i.e. 100ml, 10ml

Autoclave at 15Psi & 1200C for 20 min

The tests performed are as follows:

a. Coliform test:
Coliform is gram negative, non-spore forming, rod shaped bacteria. It includeenterobacter,
escheria, yersiniaand serratia.
For coliform test, Violet Red Bile Agar is used.

Preparation of medium:

41.53 gm of violet red bile agar

Add in 1000 ml distilled water

Mix well

Autoclave at 15 Psi & 120 0C for 20 min

Solution

Milk or milk product is inoculated in this media solution by dilutions which differ according to
milk or milk product. The dilutions are as follows:

1. For raw milk or cream the dilution is 10-4.

2. For pasteurized milk, paneer, Lassi, Flavourmlk, JeeraTak, Shrikhand, Amrakhand, Ice-cream,
Dahi, SMP and all other samples, the dilution is 10-1.
3. For ghee, the sample is taken as it is without dilution.
The inoculated plates are incubated at 370C for 24 hrs. then colonies are counted.

b. Yeast & mold test:

Preparation of medium:

40 gm of Chloromphenicol yeast glucose agar

Add in 1000 ml distilled water

40
 Autoclave at 15 Psi & 120 0C for 20 min

Solution

Milk or milk product is inoculated in this solution by dilution which is different according to
milk or milk product. The dilutions are as follows:
1. For SFM, Colours and Flavours the dilution used is 10-1.
2. For paneer, Lassi, JeeraTak, Shrikhand, Amrakhand, Dahi, Khoa, Pedha, Ice-cream the
dilution is 10-2.
3. For ghee the dilution taken as it is.

The inoculated plates are incubated at 250C for 96 hrs. Then colonies are counted
c. SPC test:
Preparation of medium:

23.5 gm of plate count agar

Add in 1000 ml distill water

Autoclave at 15 Psi & 120 0C for 20 min

Solution

Milk or milk product is inoculated with a difference in its dilutions as follows:

1. For raw milk and cream the dilution is 10-5.
2. For pasteurized milk, Paneer, Lassi, Flavour milk, JeeraTak, Shrikhand, Amrakhand, Ice-
cream, Dahi, the dilution is 100C.
3. For water, SFM, Colours and flavours the dilution used is 10-1.
The inoculated plates are inocubated at 370C for 48hrs. Then colonies are counted.

41
 11. PACKAGING OF FOOD PRODUCT
Packaging is very important from consumer point of view. So, it should be in proper condition. In
Shivamrut dairy, there are 8 fill pack machines which operate on electronic and pneumatic principles.

Milk from silo (1, 2 and 3) is standardized or toned or double toned and then taken to tanks, which
are located above the packaging section. The milk at 10 is taken in milk tank above the packaging
machine. Packaging roll is set at the backside of machine by nib roller and date is printed on it.

The packaging material comes out from the front side of machine. Firstly is sealed vertically by
Teflon, collated with electrode rod at temperature 60 . Then it is sealed horizontally at temperature 90 .
Simultaneously, milk enters into the pouch by the pressure of 4-5 kg/cm2.

Milk Pouching Section:

•Introduction :
The basic objectives of this section is to pack milk in right quality and under hygienic conditions in
polyfilm for market dispatch. The milk is dispatch in pouches of different varieties i.e. pasteurized and
homogenizedmilk, cow milk.

• Quality Assurance Report Of Milk :

After Quality Analysis clearance of milk for fat, SNF, acidity Methelene Blue Reduction Test, milk
is taken to balance tank of form fill and seal machine. At the start of packing the fat and SNF initial pouch is
checked and then further packing is started. Soundness of seal of pouch is check by drop test. Which quality
assurance carries out weight checking randomly packing operator checks weight machine wise, head wise
every half an hour.

• Procedure For Packing Liquid Milk Pouchs:-

Before start of pouching ensure of check the date, Teflon tape and film roll properly situated.

1) Switch on the power supply and voltage stabilizer.

2) Supply the chilled water at 20°c.
3) Set the air pressure at 6kg/cm2.
4) Connect the machine with C.I.P. supply line and supply of hot water at 80°c.
5) Connect the machine with milk line and 20 to 30 litre. Milk drain out.
6) Check the length, weight, horizontal and vertical sealing, date, coding, leakage etc.
7) Check the all information regularly.
8) Count the pouch in crates.
9) After pouching C.I.P. of machine and pipeline should be done.

• Crating of pouches :-
Washed and cleaned crates are taken and counted pouches are properly placed in each crate.
Leak pouches are segregatedmilk is taken out and stored in cold stored in cold stored for reprocessing.
42
•Length of milk pouch :-

Length of 1000ml 21.5 cm/ 215mm

Length of 500 ml 14cm/140mm

•Number of milk pouch :-

No. of 1000 ml pouches. 16,000 pouches

No. of 500mlpouches. 20,000 pouches.

• Work instruction for shifting from pasteurized and Homogenized :-

1) Select random sample of filled pouches from filling head of prepack machine.
2) Thepouches are dropped from height of four feet on flat, smooth surface.
3) Each pouch is dropped four times in the following sequence:-
a) On flat side.
b) On opposite side.
c) On flat longer side.
d) On opposite longer edge.

• Work instruction to adjust weight of pouch :-

1) Check weight and then set the weight with lever near balance tank.
2) Rotate clockwise for reduction in weight.
3) Rotate anticlockwise for increasein weight.

• Work instruction to adjust length of the pouch :-

To adjust the length of pouch the cam is provided with ―T‖ handle wrench.

1) Make sure that the main switch is ―off‖ or else you won‘t be able to turn the cam shaft.
2) If the cam shafts is at or near the zero position, insert the ―T‖ handle wrench in socket head of the
adjusting screw and turn cam shaft until one of the lock screw is accessible, loose that screws.
Then turn the cam shaft through 180° and loosen second lock screw. Now turn the cam shaft back
to approximately zero position insert the wrench in the adjacent
3) Screw & turn latter to change pouch length.Counter clockwise for loner pouch, clockwise turn of
adjacent screw for shorter pouch.

43
 4) Faster the lock screws again and checks the effect of adjustment and measuring the resulting
pouch on that side.

• Working instruction to stop FFS machine :

1) Switch off injection.
2) Switch off auto.
3) Switch off vertical & horizontal sealing.
4) Switch off motor switch.
5) Turn off the main switch (position I).
6) Stop the chill water pump.
7) Switch off voltage stabilizer.

• In pouching section :
1) Bends are dipped in iodophor
2) Swab test conducted at morning hrs. of filling heads pouching line, filter& valves.
3) All valves filter, balance tank in pouching line cleaned manually.
4) Prevention maintenance of pouching FFS machine is done in & one day per week.
5) Doors of FFS machinekept closed during pouching so that UV light will be achieving on
polyfilm.
6) Sanitizer are circulated through the whole line involved for pouching and at morning sanitizer
will be drained following hot water flushing after that.
7) CAC(Caustic Acid Caustic) is conducted weekly for pouching section.

• Judging horizontal seal :

The correct method of testing horizontal seals is to grip the pouch in the center with both hands (seals
pointed away from people or machinery) and squeeze slowly unit the film begin to stretch. If the pouch can
be ―ballooned‖ in this way without seal failure, the seals are good. If the seal breaks before the sFilm begins
to stretch, adjust the dial setting & little at &time – unit & good is obtains.

• Leakages :-
Mainly two types of leakages:-

1) Weak sealing.
2) Pin holes.

If heating is more then skit may result in pinholes and if the heat is less then it heads to weak sealing.
If the roll winding is improper then roll shifts from its position and this also leads to weak vertical sealing.
Also there is some extraneous matter sticking on the horizontal or the vertical sealing rod it can lead to the
pinholes leakage.

• Packaging film consumption : -

Avg. milk pouches = Total quantity of milk pouches per kg of polyfilm

Total quantity of film

44
 12. MACHINERY AND GENERAL INFORMATION:
Fill Pack machine:
Capacity: 5000 bags/hr

Weighing of bags:
For 1lit: 1020 gm
For 500 ml: 515 gm
For 250 ml: 260 gm
Length of bags:

1 lit. : 220 mm length

Weight of pouch: 2 gm
500 ml: 150 mm length
Weight of pouch: 1.5 gm
250 ml: 90 mm length
Weight of Pouch: 1 gm

Instrument Equipment Learning

Machinery Information:
1. Cow / Buffalo milk Chiller
Manufacturer: TETRA PACK INDIA PVT. LTD.
Max. Working pressure: 4 kg/cm2
Max. Working temperature: 1100 C
Capacity: 10,000 lit/hrs
No. of plates: 41
Milk inlet temperature: 28-300 C
Milk outlet temperature: 6-80 C
Chilled water inlet temp.: 1.5-20 C
Chilled water outlet temp.: 6-80C

2.Milk pasteurizer:
Maker: JEKTRON Engineers pvt ltd. Pune
Max. Working pressure: 4 kg/cm2
Max. Working temperature: 1100C
Capacity: 10,000 lit/hrs
Steam pressure: 2.7 kg/cm2
No. of plates R1: 94
No. Of plates R2: 67
No. of plates R3: 33
No. of plates in heating medium: 40
No. of plates in chilling medium: 54

3.Cream Separator: -
45
Manufacture: ALFA LAVAL INDIA
Capacity: 7000 Lit/hrs.
RPM: 1450
Max. Working Temp.: 110⁰C
Max. Working pressure: 6 kg/cm2
Capacity: 10,000 lit/hrs

4. Homogenizer: -
Type: SHANGHAI SAMRO HOMONIZER
Capacity: - 10,000 lit/hrs. (in milk process section)
And 300 lit/hrs. (in ice-Cream section)
Max. Working Pressure: At First stage – 2000 psi
At second stage- 500 psi
Homogenizer panel: 75KW

5.Ghee Boiler:
Capacity: 500 lit
Steam Pressure: 2kg/cm²
Heating Temperature: 110⁰

6.Can washer: -
Type: straight through
Capacity: 6-8 Can/min
Hot water temperature: 80-90⁰C
Detergent Pressure: 75⁰C
Caustic Soda Strength: 0.3-0.5%
Steam Temperature: 107⁰CSteam pressure: 3kg/cm²

7. Crate Washer: -
Type: Straight Through
Capacity: 1200 crates/hrs.
8. Storage Tank: -
a. Vertical type (silo)
Manufacture: APV Texmaco Limited Calcutta
Capacity: 30,000 lit each
Material: Steel
Agitation: Topv

Feeding and Flushing: Bottom

b. Horizontal Type:
Manufacture: Jektron
No. of units: 5
Capacity: 3 tanks- 10,000 lit each
2 Tanks- 5,000 lit each

46
 13. STORE DEPARTMENT

A Note on the store keeping system at shivamruth.

Introduction

This section deals with.

A] Receipt & issue of Packaging material, Row material Etc.

The work down involves-

Material Receipt
Random Sampling.
Lab. report.
Issued to Production section

B] Dispatch of finished goods-

Finished goods receive through PDI [Pre dispatch inspection]By Q.C0 Net wt. of the product. Challen&Gate
pass prepared.

 Operating Procedure-

1] Issue of purchase requisition note PRN by the user.

2] Sending PRN to the purchaser section by the store.

3] Contacting respective vendor for procuring the material.

4] Receipt action.

5] Issuing of purchase order.

6] Chekiang the quality.

7] Keeping material in location.

47
 14. BOILER

An insight into the steam generating unit of shivamruth dairy.

INTRODUCTION

A steam generator boiler is a closed pressure vessel used to generate steam its function is to
transfer the heat produced by the combustion of fuel to water & ultimately to generate steam.

It consists of the boiler shell/combustion chamber, grate furnace, heating surface, mounting&
accessories.

The selection of the type of a boiler depends upon the capacity working pressure, steam pressure,
availability of fuel & water, load factor &availability space, initial cost, operating cost &maintains ace cost.

In Shivamrut dairy 2types of boiler are available like

1] Furnace oil used boiler [Horizontal]

2] Baggage used boiler [vertical]

-Furnace oil used boiler capacity is-5 tone & it‘s working pressure is 10kg/cm2.

-Baggage used boiler capacity is-3 tone & it‘s working pressure is 7kg/cm2.

All the boilers are equipped with an economizer to preheat the incoming water by utilizing the reaming heat
of outgoing fuel gas.

48
 15. REFRIGERATION SECTION

In this section different type of equipment is used like,

1. Plate Heat Exchanger.

2. Ammonia compressor.
3. PHE condenser & coil condenser.
4. Ice bank tank.
5. Receiver [Ammonia storage tank.]
6. Glycol chiller.

Refrigeration cycle

Receiver expansion valve sludge dum

Condenser Compressor PH

Flow chart no17. Refrigeration

Glycol chiller-

In this system ammonia is used as the 1st refrigeration &Glycol is2nd refrigeration.

It system mostly gives temp.00cto50c.&It‘s worked same as refrigeration system & Shell& tube Glycol
Chiller is used. The main equipment used in this system like-

Cold water storage tank

Hot water storage tank

49
 16. AIR COMPRESSOR

Compressed air is the one of the most important things for the Shivamrut dairy as all the valve is
pneumatically operated using the automation system.

Air

Suction valve

Compression

Discharge

*Cooler cum dryer

Air Refrigeration tank

Transfer to the plant.

Flow chart No.18 Working procedure of Air Compressor

50
 17. ELECTRICITY SECTION

The Shivamrut dairy receives its electricity supply from the Maharashtra state electricity board.

MSEB [supply]

High supply

Step down transformer

Oil circuit breaker

Hot air circuit breaker

Step down transformer

Bus bar

Distribution output

Panel motor control center

All the section.

Flow chart No. 19 Electricity

51
 18. ETP SECTION

Introduction-

The waste water treatment plant plays an important role in controlling the environmental pollution caused by
the industrial waste.The effluent of dairy plant is rich in organic degradable matter &has a very high
biological oxygen demand value.

Maharashtra pollution control board specification for treated effluent-

Sr. No. Parameter Value

1] COD Max.100mg/Lit.
2] BOD Max.30mg/Lit.
3] PH Max.5-5.9MG/Lit.
Table No. 4 : specification for treated effluent

PROCESS OF ETP

Dairy:

Dairy is an industry where milk is processed and various milk products are manufactured.

Description of the Process:

At dairies raw milk is received from various stations and processed. This process involves
pasteurization, standardization, bottling, etc. In addition to processing cream products, (butter, ghee, etc)
milk powder and casein.

Raw milk is usually received in cans and tankers and they are emptied and cleaned immediately in
the place itself. The milk is then subjected to pasteurization, cream separation and then bottled.

Sources of Effluents:

The waste water generated from dairies consist of

52
 i. Wastewater generated from milk processing through milk spillage, drippings, washing of
cans, tankers, bottles, utensils, equipment and floats. Wash water usually contains alkaline
chemicals used to remove milk and milk products and partially caramelized materials
ii. Waste liquor from butter- manufacturing (i.e. process wash water of butter and floor washings
that consist of mainly buttermilk, cream and a small percent of whole milk.)
iii. Waste liquor obtained by cleaning of powder milk plants and its floor washings.
iv. Waste water from the manufacture of cheese including the wash waters and
v. Waste liquor from the manufacture of yoghurt

.List of Lab Analysis: (ETP)

As per Manual:

A. pH :-

Calibrate the electrode pH meter with deeping the electrode in known PH of buffer solution wash the
electrode with distil water and dry with tissue paper take the Water sample Deep the electrode in the sample
and take the reading. OR

Measure the pH of water with the paper strips.

B. Chemical Oxygen Demand (COD)

Chemical oxygen demand is the measure of oxygen consumed during the oxidization of the
oxidizable organic matter by a strong oxidising agent.
Reagents:

1. Potassium dichromate solution 0.25N

2. Ferrous ammonium sulphate 0.1N
3. Ferroin indicator
4. Sulphate acid (H2SO4 Con (SP gr 1.84)
5. Mercuric sulphate
6. Silver sulphate
Procedure:

 Take 20ml diluted sample in COD flask or tube

 Add 10ml of 0.25N potassium dichromate solution

 Add pinch of Ag2SO4 and HgSO4

 Add 30ml of Sulphuric acid

53
  Reflux at least for 2 hours on COD apparatus 150o C temp.

 Remove the flask, cool and add distilled water. Make volume up to 140 ml.

 Add 2-3 drops of Ferro in indicator, mix thoroughly and titrate with 0.1 N ferrous ammonium
sulphate end point greenish to red.

Calculations:

(B-A) x N of FAS x 1000 x8ml of sample

B= ml of titanat with blank

A= ml of titanat with sample

a. Biochemical Oxygen Demand (BOD – 3 days at 27oC)

Biochemical oxygen demand is the measure of the degradable organic material present in a water
sample and can be defined as the amount of oxygen required by the microorganism in stabilizing the
biologically degradable organic matter under aerobic condition.

Apparatus and Reagent:

BOD bottles

BOD incubator

Phosphate buffer

Magnesium sulphate

Calcium chloride

Ferric chloride

Procedure:

Prepare dilution water in a glass container by bubbling compressed air in distilled water for about 30
minutes.

Add 1ml each of phosphate buffer, magnesium sulphate, calcium chloride and ferric chloride solution
for each litre of dilution water and mix thoroughly

Neutralise the sample to pH around 7.0 by using 1N NaOH or H2SO4

Prepare dilution in a bucket or large glass trough. Mix the contents thoroughly. Fill 2 sets of the
BOD bottles.

Keep one set of the bottles in BOD incubator at 20oC for 5 days and determine the DO content and in
another set immediately.
54
Effluent Treated Plant (ETP)

Dairy Waste Water

Bar Screen Chamber

Fat Removal Tank Fat Collection Tank

Surge Tank

Equalization Tank

Anaerobic Reactor

Aeration Tank

Secondary Clarifier

Treated Water Tank Sludge Drying Bed

Treated water used for Dried sludge used as a fertilizer

irrigation

Flow chart No. 20 ETP

55
 19. PLANT MAINTENANCE DEPARTMENT

Note on the step taken to ensure efficient running of the plant.

Introduction-

There are three departments in maintenance section.

1] Mechanical

2] Electrical

3] Instrumentation &Control.

1] Mechanical department-

This department is related with the maintenance of all the mechanical equipment. Machineries this
department carries out both prevent as well as break down maintenance. Preventive maintenance include
change of gasket, water seal of the pump, timely lubrication care of all moving parts in machineries &change
of belts to avoid the break down.

2] Electrical Department-

This Department is related with maintenance of electrical wiring power carrying lines or installation
of new wiring. Its maintenance included the maintenance of light of the whole Plant to prevent any kind of
break down Specially in complicated circuit of electric equipment which are costly as well as important for
regular production & testing.

3. Instrumentation& Control

This is related with maintenance of the entire electronics instrument this department also include both
preventive &breakdown maintenance as a part of breakdown maintenance

It performs the function of calibration of the entire instrument like weighing scale, Pneumatic valve, and
level indicator resistance temp. Device & all other equipment regarding production & testing.

56
 20. C.I.P

CIP OF PROCESSING SECTION

Introduction :-
The basic objective of CIP is to ensure hygienic cleaning of milk handling equipment and pipelines. It
covers all equipments in the processing of milk, ghee, pouching milk, etc.

To maintain the hygienic Condition of plant proper cleaning ‗ventilation &C. I.P of milk processing
equipment is necessary.

For C.I.P caustic & acid are used in the required proportion

All pasteurizer plant.

Caustic/ Nitric acid C.I.P

Normal water flushing

Caustic circulation[1 to 1.2% caustic solution, ]

[Temp.780c-800c ; time 40-45min]

Normal water flushing

Nitric acid circulation [temp.780c to800c ,Time 30-45 min, 0.5 to 0.6% strength]

Hot water Flushing

Caustic circulation [temp.780c-800c ,30-45 min]

57
 Hot water Flushing

Sanitizer circulation

Plant ready

Flow Chart No. 21 CIP for pasteurizer plant

 Strength of Caustic solution 1-1.2%

 Strenth of Nitric acid 0.5 to 0.6%

I) Cleaning of milk storage tank and ageing tanks :

i) After the storage tank has got empty for cleaning the immediate outlet valve and manhole of tank
is dismantled and tank is first flushed with tap water.

ii) The inside surfaces as cleaned with detergent solution by scrubbing thoroughly. It is then flushed
with tap water.

\iii) Manhole lead gasket and inlet/outlet points of tank

are cleaned manually with the same detergent are solution and washed with warm water.

iv) After the manually cleaning of tank, caustic solution of 1.0 - 1.5% strength is circulated at 70 - 75°c for
20 - 25 minutes. After the caustic solution tank is flushed with tap water and trace of caustic is checked.

v) After the storage tank is sterilized either by circulation hot water at 70 - 75°c for 20 - 25 minutes
or with live steam.

vi) For immediate use tank is sprayed with pasteurized chilled water otherwise allowed to cool down.

vii) Surface swab are taken for checking any microbiological content every 10 days on random basis.

I) Cleaning of pasteurizer :
i) Milk pasteurizer plant including pipelines going to various storage tanks, pipeline
connection. Connection separator, Homogenizer, etc. flushed with water after processing.
ii) The specific amount of caustic flake is dissolved in water and added in the balance tank of the
pasteurizer to maintain alkalinity of 1.0 - 1.5% and circulated for 20 - 25 minute at 70 - 75% .

58
 iii) Then hot caustic solution is drained and again flushed with nitric acid cleaning specified with
water. Nitric acid is added to hot water and circulated for 20 - 25 minutes to neutralizer the effect of
nitric acid.
iv) After draining alkaline / nitric acid solution, it is flushed with water and traces of caustic or acid
arte checked by pH paper.
v) Hot water start of operation plant is again sterilized by circulation hot water for 20 - 25 minutes
at 70 - 75°c.

II) Cleaning of cream separator :-

i) After each day processing of milk cream separator is flushed with warm water from
the pasteurizer and it is dismantled.
ii) The separator plates are segregated manually. Cleaned by scrubbing with detergent and the
valves and connections are cleaned manually.
iii) After cleaning the separator is assembled hot water is flushed through it.

III) Raw milk line :

i) After unloading milk tanker, the raw milk pipeline flushed with tap water through connecting
pipelines and it is dismantled.
ii) After each day‘s operation the line is circulated with caustic solution of 70 - 75°c and flushed
with tap water.
iii) Then line is sterilized by circulating hot water at 70 - 75°c.

IV) Pouch filling pipeline :

i) After each day‘s operation pouch filling pipelines and machines are properly flushed with tap
water and the machine is washed by detergent.
ii) Caustic solution of 1 - 1.5% strength is circulated through the pipelines and machines for 20 –
25 minutes at 70 - 75°c.
iii) Tap water is flushed through the lines and machines and traces of caustic are checked. Then
hot water is circulated for 20 - 25 minutes at 70 - 75°c.
iv) Before starting operation of pouch packing all the lines machine and it‘s balance tank is
sterilizer by circulating hot water 20 - 25 minutes at 70 - 75°c.

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 21. CONCLUSION

Shivamut Dudh Utapadak Sahakari Sangh Ltd. Akluj is an ISO& HACCAP certified dairy plant along with
most modern technologies in collaboration with best of the world‘s technologies is about to emerge as one of
the most integrated & best dairy. More over the young & Hard working work force at Shivamrut dairy
claims to be one of the greatest & unique assess of this dairy .with proper planning& systematic execution of
the Shivamruth Ltd. Programme in certainly going to make the company to reach its top level in the market.
As a result it has achieved a identity in the dairy field.

It gives me immense pleasure & innate satisfaction to express my deep gratitude to Shivamrut dairy
Ltd.for my training at this prestigious industry was extremely fruitful & I gained valuable practical
knowledge &experience in production & marketing through this training program. I was able to interact with
some of the finest dairy technologies of India. My knowledge about the various technologies involved in the
production of world class dairy products has been greatly enlighted. My tryst with this great establishment is
sure to provided us brighter future prospects.

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 22. REFERENCES

1. Shivamrut milk & milk product Processing food Industry.

2. Quality department for various quality parameters related to Aseptic milk & milk product .
3. GMQC mannual
4. Sterilization unit operations and details – Operator and manual from ASDVPSA.
5. www.helath.galaxy.com
6. www.wmpc.com- world milk processing council
7. GIZ- India milk Processing segment

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