PR Re
PR Re
TOPIC :DAIRY
PRODUCTS &
MANAGEMENT
SUBMITTED BY
ANIKET KUSHWAHA
PRIYANSHU
PRASHANT
SHIVAM RAHORE
DAIRY ENGINEERING 2ND YEAR
(STUDENTS OF GOVERNMENT POLYTECHNIC ETAWAH)
Basic information
About company
Headquarters : Lucknow
Humble Beginnings
Initially started with two products – Gyan Skimmed Milk Powder &GyanDesi Ghee.
About Plant
o Address : Village Gudamba , Kursi Road , Luckow 226026, Uttar Pradesh
o Milk Routes : 40
Collection
Collection directly or indirectly depends on the
Within four hours of milking milk should be cooled or should be Sent to chilling centers
Milk is collected:
Through agents
Corporative structure
MAINLY IF THE MILK IS BROUGHT AT THE COLLECTION CENTER, IS CHILLED AT 4°C AND AFTER COOLING MILK
IS TRANSFERRED IN THE CANS OR IN TANKS AS PER THE REQUIREMENT FOR TRANSPORTATION.
In this plant milk is mainly brought from the collection center where the milk is chilled at 4°c and after cooling
milk is transferred in the cans or in tanks as per the requirement for transportation.For a large quantity of milk
cans are laborious and slow so tanks are used to transport milk from farms or from collection centers to dairy.
Strainer (3x)
Centrifugal pumps (1x 5HP , 1x 7.5 HP) for chiller
Milk chiller (1 x 20KLPH ,1 x 10KLPH)
Centrifugal pumps (1x 5HP , 1x 7.5 HP) for transferring milk to RMST
RMST (3x 60 KL , 2x 55 KL)
3 intake lines are installed to unload the milk from tankers in which 2 lines have chiller installed
between RMST and strainers and 1 line is installed without chiller.
Sampling
Testing/ grading
Weighing
Measuring or recording
Most raw milk is nowadays delivered to the dairy plant through milk transport tankers, either trucks or trailers
varying from approximately 7,500 to 25,000 in capacity. The receiving operation is divided into three
Phases: (a) preparing to unload (b) unloading and (c) weighing.
(a)Preparing to unload normally involves agitating the milk. Inspecting for off -flavors (generally odours) and
connecting the unloading hose
Testing/grading
The significance of reception dock test is as follows:
Antibiotics test indicates if milk from sick animals were commingled with milk from healthy cows .if such
commingled occurs the entire tank load is rejected. Presence of antibiotic in the milk poses a 2 fold danger.
First, antibiotic sensitive individual can suffer from consuming tainted milk. Secondly, in the manufacturing of
cultured milk products, the presence of antibiotics may pose barrier for acidity development.
Protein and fat contents are used to determine the payments and to gain full accounting of raw material
received (also helps balancing calculation and losses occurring during packaging and processing) ⚫ Freezing
point of milk is another important test to determine adulteration with water whether accidental or
intentional. Adulteration of milk is a prosecutable offence
The classification of milk on the basis of quality is usually referred to “grading of milk”. So grading of milk is
done on the basis of platform tests which include organoleptic as well as preliminary tests.
Appearance:The milk should be normal in color, free from churned fat globules and reasonably free from any
floating extraneous material.
Temperature: The temperature at which milk is delivered is often an indication of its quality. A temperature of
5°C or below is satisfactory.
Acidity: ‘Natural’ or ‘apparent’ acidity of milk is desirable which does not adversely affects its heat stability.
However, ‘developed acidity (Natural + Developed Titratable acidity) adversely affects the quality of milk
which cannot be processed in pasteurizer.
Lactometer reading : The addition of water to milk results in lowering its density. Hence, this test is applied for
detection of adulteration of milk with water. The reading for cow and buffalo milk should be about 28 to 30
and 30 to 32 respectively, when measured at 15.5°C.
Sampling
The importance of securing an accurate and representative sample of milk for chemical and bacteriological
analysis cannot be over emphasized. While strict precautions regarding sterility of the stirrer, sampler,
container etc. are required for obtaining a bacteriological sample, dryness and cleanliness of the above
equipment should be sufficient for a chemical sample. The first pre-requisite of sampling is thorough mixing of
milk. This can be done with a plunger or stirrer (agitator), operated manually or mechanically for milk
contained in cans or tankers, as the case maybe. With the former, a representative sample may be taken after
dumping the milk in the weigh tank, whereby it gets mixed in so thoroughly that a representative sample may
be taken without further mixing.
The composite milk sample must not spoil by the time it is analyzed. This is accomplished by use of a
preservative. It is wise to place the preservative in an empty bottle before milk is added. A wide mouthed glass
bottle with a rubber stopper is suitable for keeping composite samples of milk or cream.
Weighing
Volume by passing it through a flow meter, and its measurement converted into weight by multiplying volume
with density (m = d x v). In case of road milk tankers weighbridge can be used to determine its weight .
(weight of tanker when full – weight when empty).
Mostly the records are kept in digital forms to save time & physical space.
Balance tank
Centrifugal pump
Milk Pasteurizer (10 KLPH) having 3 regenerations
Cream Seperator (10 KLPH)
Centrifugal pump and Booster Pump
Homogenizer 2 stage (10 KLPH)
Holding Tube (15 Sec)
Flow Diversion Valves x 2
Balance tank
Centrifugal pump
Milk Pasteurizer (10 KLPH) having 3 regenerations
Cream Seperator (10 KLPH)
Centrifugal pump and Booster Pump
Homogenizer 2 stage (10 KLPH)
Vacreator (10 KLPH)
Holding Tube (15 Sec)
Flow Diversion Valves
Balance tank
Centrifugal pump
Milk Pasteurizer (20 KLPH) having 3 regenerations
Cream Seperator (20 KLPH)
Centrifugal pump and Booster Pump
Dearator (20 KLPH)
Holding Tube (15 Sec)
Flow Diversion Valves
2 x 30000 Ltrs
3 x 15000Ltrs.
2 x 1000 Ltrs.
(E) Power
3 phase supply is required for milk processing plants. As most of the electrical equipments works
on a three phase supply.
Working procedure :
(1) Skimming: The raw milk during pasteurization undergoes milk skimming through common centrifugal
separator application; the milk is passed through a clarifier or a separator which spins the milk through
a series of conically shaped disks. The purpose of this process is to separate the debris, skim milk, and
cream. Clarifier removes debris and any sediment present in the raw milk. The separator separates the
heavier milk fat from the lighter milk at a temperature between 45° to 55° C to produce cream and
skim milk.
(2) Fortifying: The skimmed milk may be added with Vitamins A and D at this stage. A peristaltic pump
helps in dispensing the required amount of vitamin concentrate into the milk.
(3) Pasteurization: In this plant the CCP of pasteurizing temp. is 78 to 82 degree centigrade. Pasteurization
process helps in destroying bacteria and other microorganisms that may affect the milk shelf-life and
also may affect consumer’s health.
(4) Homogenizing: In this process, the size of the remaining milk fat particles is reduced evenly.
Homogenizing helps to prevent the milk fat from separating and floating to the surface. This process is
done in two stages. In 1ststage the hot milk is pressurized to 2,500 to 3,000 psi by a multiple-cylinder
piston pump it breaks the fat particles from 22 microns to less than 2 microns. In 2 nd stage the milk is
pressurized to 500 psi to remove clustration of fat particles.it is done by passing milk through tiny
sections in an adjustable valve. When the fat particles break down evenly into the proper size, to avoid
harming its taste, the milk is quickly cooled to 4°C.
Cream Seperator
Homogenizer ( 2500 To 3000 Psi 1st Stage , 500 Psi 2nd Stage)
Regeneration 3
Regeneration 2
Regeneration 1
Storage In PMST
Balance tank
#Milk Processing Plant 2 (10 klph) flow diagram
Balance Tank
Cream Seperator
Homogenizer ( 2500 To 3000 Psi 1st Stage , 500 Psi 2nd Stage)
Regeneration 3
Regeneration 2
Regeneration 1
Storage In PMST
#Milk Processing Plant 3 fully automatic (20KLPH) flow diagram
Balance Tank
Cream Seperator
Dearator
Balance tank
Flow Diversion Valve
Regeneration 2
Balance tank
Regeneration 1
Storage In PMST
Balance tank
#Packing section of milk
Packaging: The final stage in the dairy Processing Plant is packing. The milk is packed in 16 different
varients( different varieties and sizes) .The packets are stamped with the date of packing. The milk packets are
placed in transport containers and refrigerated. Transporting of milk packets to various retail outlets and
distribution centers is carried out in refrigerated vehicles and are kept in refrigerated display cases.
Note: for packing of milk the LDPE recyclable polyethylene is used having density of (.910 to .915 )
The LDPE used in Gyan Dairy is manufactured by Montage Enterprises private limited, Haridwar.
*this is not a official list. It is based on observation during summer training. Does not claims any price guarantee.
Cream SECTION
Details of Machines &Equipments:
Balance Tank
Pasteurizer (5 KLPH)
Centrifugal pumps
Balance Tank
Pasteurizer (5 KLPH)
Centrifugal pumps
Materials Used:
#Work Procedure:
Raw Milk
Cream Seperator
Cream
Balance Tank
Pasteurization(90±2˚ C)
Cooling (5 - 10 ˚ C)
Storage Tanks
Butter SECTION
Details of Machines &Equipments:
Materials Used:
Cream (35-40% Fat) from cream storage tank.
Other basic requirements for plant i.e. power supply, steam, chilled water etc.
#Specification of Products
ButterIngredients:
Ripening ( Optional)
Packing
Storage (-20±2˚C)
Ghee SECTION
Details of Machines &Equipments:
Continuous Butter Making Machine
Butter Melting Vat
Pre Stratification Tank (3 X 1500 , 1 X 2000)
Ghee Kettles (4 X 2000)
Ghee Settling Tank ( 4 X 1500)
Ghee Clarifier (1000 Lph)
Ghee Filling Tank (3 X 10KL)
Materials Used:
#Specification of Products
Ghee Ingredients:
Milk Fat
Clarifier
Packing ( At 45 ˚ C)
Storage ( 20 ±2˚ C)
#Packing:
Ghee ( 99.7% Fat)
Balance tank
Centrifugal pump
Milk Pasteurizer (5 KLPH) having 1 regeneration(whey)
Holding Tube (10 Min)
Flow Diversion Valve (90 ˚C)
Plate Heat Exchanger
Materials Used:
Raw milk.
Other basic requirements for plant i.e. power supply, steam, chilled water etc.
#Specification of Products
Paneer Ingredients:
Coagulation
#Packing:
Paneer
Balance Tank
Pasteurizer (5 KLPH)
Homogenizer (5 KLPH)
Balance Tank
Pasteurizer (3 KLPH)
Homogenizer (3 KLPH)
Balance Tank
Pasteurizer (2 KLPH)
Homogenizer (2 KLPH)
Materials Used:
#Work Procedure:
Skim Milk Powder Mixing
HMST Tanks
Packing
Incubation (45˚ C)
(T.A. 0.6 To 0.7)(ph 4.4 To 4.7)
*For Sweet Dahi sugar and flavor is added either at the time of pasteurization or packing
#Specification of Products
Milk Solids & lactic Culture Milk Solids sugar& lactic Culture
Nutrition per 100 ML(approx. values) Nutrition per 100 ML(approx. values)
#Packing:
Standard Dahi ( 3.0% Fat , 10.50 % SNF)
*this is not a official list. It is based on observation during summer training. Does not claims any price guarantee.
Chaach section
Details of Machines &Equipment:
Materials Used:
#Work Procedure:
#Specification of Products
Nutrition per 100 ML(approx. values) Nutrition per 100 ML(approx. values)
#Packing:
Plain Chaach ( 1.0% Fat , 6.0 % SNF)
1. Pouch 170 ml 7
2. Pouch 325 ml 10
3. Cup 180 ml 15
*this is not a official list. It is based on observation during summer training. Does not claims any price guarantee.
lassi section
Details of Machines & Equipment:
Materials Used:
#Work Procedure:
Standard Lassi Mango flavored Lassi
#Specification of Products:
Lassi Ingredients:
Mango Flavor Lassi Ingredients:
Milk, milk solids, water , sugar& lactic culture.
Milk, milk solids, water, sugar , lactic
culture contains added flavor(Natural
identical Flavor Substance)
Nutrition per 100 ML (approx. values)
Nutrition per 100 ML (approx. values)
Energy - 84 kcal
Fat - 2.0 % Energy - 84 kcal
Carbohydrate - 14.5 g Fat - 2.0 %
Sugar - 12.0 g Carbohydrate - 14.5 g
Protein - 2.1 g Sugar - 12.0 g
Calcium - 100 mg Protein - 2.1 g
Calcium - 100 mg
#Packing:
Lassi ( 2.0% Fat )
1. Pouch 180 ml 15
3. Cup 200 ml 20
*this is not a official list. It is based on observation during summer training. Does not claims any price guarantee.
Conclusion
Based on the observation during my training at GYAN MILK PLANT 1 Lucknow ,
From 25 july 2022 to 22 August 2022.
it can be concluded that the fluid milk products manufactured here are of high quality and are highly acceptable
to the consumer.
The management is dedicated to manage the affairs correctly and accurately.
There is proper coordination among the workers and management, which helps the plant to run smoothly.
The behaviour of all workers and technical staff and official staff is appreciatable.
from the present status of this plant, it can be said that with positive and creative thinking of management and a
strong will power of each staff of the plant, can easily raise this to the legendary one in the world of dairying.
As a trainee, it should be confessed that it is appropriate place conducting complete, practical based training.