ACKNOWLEDGEMENT

It is a great pleasure for us to acknowledge the assistance and

contribution of all the people who helped me to make my in
plant training success. My training would not have been so
successful without the dedicated assistance given by those
individuals.

First of all, I would like to express my heartiest gratitude to Mr.

Mansinhbhai Patel (Chairman) and Mr. Arun H. Purohit (M.D)
for their approval of training. I am thankful to Mr. Bhupesh
Parikh (HR), Mr. Hiral Parikh (Production Manager) and all Shift
incharges for their guidance. I am indeed deeply indebted to
all section incharges and all the employees who extended their
whole hearted help and support during my training period.

I am grateful to Dr. Manju G. (Training coordinator GNPCDS, S.

K. Nagar) for his kind help to avail my training at Sumul Dairy,
Surat. I am also thankful to all college professors for their
guidance in each and every step of acquiring this opportunity
of practical experience.During training period of 26th
September,2023 to 5th December,2024.

Regards
Students of GNPCDS, S. K. Nagar

1
 INDEX

Sr. No. Title Page No.

1. RMRD 4
2. Process 8
3. Pouch Packaging 14
4. Sanjivani/Elecster 24
5. ETP 30
6. Workshop & 33
Instrumentation
7. Refrigeration 36
8. Sweet 40
9. Ghee 54
10. Butter 61
11. Buttermilk 65
12. Lab section 69
13. Paneer 88
14. Dahi 95
15. Lassi 102
16. CIP 105

2
 INTRODUCTION
Sumul or Surat Milk Union Limited, which is now renamed as
The Surat District Co-operative Milk Producers' Union Ltd, is
one among the 17 district unions which acts as manufacturing
units of dairy products for Gujarat Co-operative Milk
Marketing Federation Limited, the marketers of Amul brand of
products.

Surat District has been a Pioneer in India in channeling trade

in Cotton and Milk through cooperatives. Before SUMUL
stepped in, traditional Private Milk Traders were dominant in
the area. The private trade was monopolizing the Milk market
and exploiting both the Milk Producers and Consumers alike.
The milk procurement price which used to be fixed by the
traders (traditional Bhatias) was very low and was fluctuating
from time to time at their sole discretion.

These has capitalized on the absence of any infrastructure and

processing facilities and has managed to keep producers from
deriving equitable benefits from the marketable surplus
generated. As such their income from milk was very low and
they had no incentive for modern dairy farming. The farmers
resented the system, but were helpless in the face of these
traditional constraints and to their own lack of resource
lessness.

3
 RMRD
In this section, how raw milk is received, how their platform
tests are carried out, how tankers are weigh, how CIP process
is to be carried out are discussed.
Raw milk reception docks are the starting section of the dairy
plant, where milk comes from different villages & societies at
≤ 5°C nearer to district or dairy plant. After that milk is tested
by platform tests & after clearance from lab milk stored at ≤
5°C in raw milk silo and processed as per the requirement.

Milk collection:
Milk producers are sell their milk to the village co-op. societies
on the basis of fat & SNF content of milk then they transfer
4
this milk to BCU, from BCU district co-op. societies will collect
then sent to the dairy plant for further processing.
Activities carried out at RMRD section:
1. Tanker receiving of milk from BCU
2. Tanker weighing
3. Milk Sampling and analysis
4. Storage milk in raw milk silo
5. Cleaning of tanker
Step 1: Tanker receiving
• Raw chilled milk in milk tanker from BCU’s arrive as soon
as at dairy, seal are checked and verified with challan.
• In Sumul dairy, daily average 100 tanker are received.
Capacity of tanker varying with size of tanker.
Step 2: Tanker weighing:
• When tanker arrives at dairy, it is weighed on weighbridge
before and after unloading.
• Weighbridge works on principle of strain gauge. Strain
gauge is a heart of load cell.
• Load cell is one type of force transducer in which force or
weight converted into an electrical signal. Strain gauge
changes resistance when it is stressed so whatever weight
loaded on this gauge which make change in resistance of
strain gauge. This change in resistance is measured and
converted into weight.
5
 • Company = Avery Weigh Tronix
• Software used = ORACLE
• Max Capacity = 80,000 kg
• Min Capacity = 10 kg
• 𝑇𝑜𝑡𝑎𝑙 𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑚𝑖𝑙𝑘 𝑟𝑒𝑐𝑒𝑖𝑣𝑒𝑑 =
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑡𝑎𝑛𝑘𝑒𝑟 𝑤𝑖𝑡ℎ 𝑚𝑖𝑙𝑘 – 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑒𝑚𝑝𝑡𝑦
𝑡𝑎𝑛𝑘𝑒𝑟
Step 3: Milk sampling and analysis:
1. When tanker arrive at sampling dock first of all check the
temp. of milk (temp.< 10⁰C), and then milk is mixed by help of
plunger (In 1 tanker approx. 20-30 plunger).
2. Marking on sample bottle:- 1)Tanker No, 2)Date of Received,
3)Temp. of milk
3. Then after sample goes to RMRD laboratory and sample
tested with following parameters:- 1)Alcohol 2)% Acidity 3) %
Fat & % SNF 4) COB
Step 4: Storage milk in raw milk silo
• After RMRD lab clearance, tanker arrived at BAY- 1,2,3,4
Connecting with hose pipe and Open the lid of tanker and
put the water spray ball in taker lid.
• After the butterfly valve of tanker is opened, milk goes to
Balance tank of BAY then it is transfer to RMST using CF
pump (Capacity: 10 HP, 35 m3/hr).

6
 • After the tanker emptied 200 liter
water is sprayed by spray ball for 25
seconds. this flush water is also transfer
to the RMST.
Step 5: Cleaning of tanker:
• After flushing the tanker, tanker is
cleaned Inside and Outside manually
using High pressure jet water &
Scrubber.

7
 PROCESS
In this section processing of milk by doing different
operations, their standards, time and temperature are
discussed.

Equipment details:
Sr. Name No. Capacity Company
No of Name
1. Milk 5 30000LPH GEA,Kelvin
Pasteurizer
2. Cream 1 10000LPH Kelvin
Pasteurizer
3. Homogenizer 2 30000LPH GEA
4. Separator 3 30000LPH GEA

8
 Silos details:
Sr. Name No. Capacity Company
No of Name
1. RMST 8 1.5 LAC IDMC/ABC

2. PMST 3 1 LAC IDMC

3. PMST 6 1.5 LAC Chengalva/IDMC

Standardization:
It may be defined as the adjustment of one or more of the
milk constituents to a nominated level.
In dairy industry, to standardize the milk cream may be added
or removed from milk for fat adjustment and for SNF
adjustment SMP is used, Also water is used.
Milk standardization algebraic method is use in the form of
table.
Milk Standardization:
Sr. Variety of Sumul FSSAI Standard
No. Milk Standard
%Fat %SNF %Fat %SNF
1. Amul Gold 6.10 ± 9.1 ± 6.0 9.0
0.05 0.05
2. Amul 4.6 ± 8.6 ± 4.5 8.5
Shakti/ T- 0.05 0.05
Special

9
3. Amul 3.1 ± 8.6 ± 3.0 8.5
Taaza/T-Top 0.05 0.05
4. Sumul Cow 3.7 ± 8.6 ± 3.6 8.5
Milk 0.05 0.05
5. Amul Slim-N- 1.6 ± 9.1 ± 1.5 9.0
Trim /Sumul 0.05 0.05
D-lite
6. Sumul - 8.7 ± 0.5(Max) 8.7
Skimmed 0.1
milk

Separation:
The process of separating milk into cream and skim milk is
known as separation.
Separation may be done in two ways: Separation by gravity
and separation by centrifugal force(cream separator).
1. Gravitational Method:
Principle: Separation is to be carried out by gravitational
force. Traditional method also known as small scale
method hence not used in commercially due to the
following reason:
▪ Time consuming
▪ Less efficient
▪ Not economical
2. Centrifugal Method:

10
Principle: When milk comes in contact with Centrifugal
force serum portion start moving towards peripheral and
cream part used to collected nearer to the center this is
due to the difference in specific gravity.
• In this method centrifugal force is created with the
help of motor Centrifugal force is much higher than
gravitational force. It is operated at 4800-rpm having a
minimum temperature of 45°C - 50°C and the
separated Cream is pasteurized at 85 - 900C with no
hold.
• This method is used commercially because:
• Able to separate
Cream more efficiently
• Economical
• Less time Consuming

11
Homogenization:
Homogenization is process in which fat globules in milk are
broken down to a size small enough to prevent the formation
of a cream layer.

Principle of homogenization:
In raw milk, the diameter of the fat particles varies from 2 to
12 μ, while a diameter of about 2 μ or less is required to keep
that fat rising in stored condition. The milk is forced at high
pressure through a narrow slit, which is only slightly larger
than the diameter of the globules. The
velocity of milk in the narrow slit can be 100- 200 m/s. This
can cause high shearing, stresses, cavitations and
micro-turbulances. The globules becomes deformed, wavy
and then breakup.
• Milk enter in homogenizer at 65 – 70 ⁰ C. to avoid lipase
activity in milk.
• Inlet pressure of milk is more than 3.5 bar and outlet
pressure is less than 3 bar.

12
 Pasteurization:
It is refer to as the process of heating of milk every particle of
milk of different classes to at least 63 ⁰ C and holding at such
temperature continuously for at least 30 minutes or heating
it to at least 71.5 ⁰ C and holding at such temperature
continuously for at least 15 seconds or an approved time
temperature combination that will serve to give a negative
phosphate test.
• In Sumul milk is pasteurized at 78 ± 2⁰ C and chilled less
than 5⁰ C.
Pasteurization Holding Chilling
Temperature(⁰C) time(seconds) temperature(⁰C)
Milk 78±2 21.79 ≤5
Pasteurizer
Cream 88 ± 2 No hold ≤10
Pasteurizer

13
 MILK POUCH PACKAGING
Introduction:
➢ The science, art, and technology of enclosing or preserving
goods for shipping, transportation, storage, sale, and use is
known as packaging.
➢ In SUMUL dairy vertical Form Fill Seal (FFS) machines are used
for pouch packing of milk and buttermilk.
➢ In SUMUL dairy, fluid milk product is packed as Pasteurized
Standardized Milk, Full Cream Pasteurized Milk, Homogenized
Toned milk. The milk pouches are filled in plastic creates for
easy handling and transportation as well as easy accountability.
Each crate is used to fill the pouches to a capacity of 12 ltr. of milk
i.e., 24 pouches of 500 ml or 48 pouches of 250 ml or 60
pouches of 200 ml and 2 pouches of 6 ltr. constant watch is
kept to prevent leaky, underweight andoverweight pouches to
be filled. Crates after filling are stored in cold store at temp. up
to 5°C.
Packaging is done due to following reasons:
➢ To Protect The Product From Contamination
➢ To Prevent Losses.
➢ To Prevent The Product Direct From Oxygen And Light
➢ To Facilitate Handling.

Functions of FFS Machine:

➢ Film pulling
➢ Film sterilization
14
 ➢ Film unwinding
➢ Pouch forming
➢ Vertical sealing
➢ Horizontal sealing
➢ Product filling
➢ Pouch parting
Check list before starting machine:
➢ Check the pressure of air is 6Kg/Cm2
➢ Check adequate supply of water with proper
temperature.
➢ Ensure proper electrical supply.
➢ Ensure the efficient running of crate washer which is
fulfilling both the requirements i.e. quality and
quantity.
➢ Ensure the work force is evenly distributed onall the
machine.
➢ Ensure the rolls of the proper type of milk are loaded.
➢ Check the milk for its clearance from QC.
➢ Check the proper sanitary condition of the machine
before taking up the milk.
➢ Set the machine as required weight which would be
packed

15
❖ Checking of Pouch:
• Check the weight of pouches periodically.
• Check the leakages of pouches periodically(By
Drop Test).
❖ Storage of Pouch in Cold Storage:
• Milk after packaging is conveyed on th conveyors
towards cold store maintained at <8⁰C.
❖ Dispatch
• Dispatch can be done twice in a day i.e. morning
dispatch and evening dispatch. For the dispatch
FIFO (First In First Out) method is followed. 1)
10:00am to 1:30pm. 2) 4:30pm to 10:00pm.

16
 • Sequence arranged trucks are made available on
dispatch dock and milk is loaded. Accordingly the
order from each agent.
• Leakage pouch are separated at the dock and
recording of the same is done.
• Milk from the leakage pouches at the dock, is
decamped at the dumping tank and milk is
reprocessed after checking of COB.

Equipment details:
Sr. No Name of No. of Capacity
Equipment equipment
1. Chiller 6 35KLPH
2. Milk Tank 7 20KL
3. BM Tank 7 20/15 KL

Deatils of FFS Machine:

M/C Manufacturer: SetPac, Deccan, Samarpan
Total M/C:- 49
Based on speed: Low-16 (35-45)
Medium-18 (50-70)
High-10 (70-80)
6 ltr.- 5 (9-10)
Construction motor in M/C:
1) Main servo motor
2)clutch servo motor
3)unwinding motor
4)injection motor

17
Weight Specification:

Volume of Weight of Weight of

pouch Milk(gm) Buttermilk(gm)
200 ml 208-210 202-205
250 ml 260-262 -
500 ml 517-519 505-510
6000 ml 6225-6245 6080-6120

Packaging material details:

Milk and Buttermilk is packed in 3 layer film.

1)LDPE layer

18
2) HDPE layer(Tio2)

3)LDPE layer

Thickness of Packaging material is as below:

Varient Thickness(µ)
200 ml 50 ± 5
250 ml 50 ± 5
500 ml 50 ± 5
6000 ml 110 ± 5

Yield of film:
Yield of packaging material can be measured by two ways:

1. Theoritical Yield
MASS = Ꝭ x V
2. Practical Yield measured using direct calculation using
pouch filled.

Sr. No Varient Number of

pouch/kg
1 200 ml 650-655
2 250 ml 540-560
3 500 ml 400-410
4 6000 ml 36-37

OPRP &QCP of section:

OPRP 1: The product in cold store is maintained at <5⁰C
OPRP 2: (Intact sealing)The filled pouches coming out
19
from m/c are checked initially for intact sealing by drop
test method.
QCP 2: (Filter bag)Clean intact filter bag of mesh size
1440 / inch2 is placed with filling tube.
QCP 3: (Coding)The coding unit with 4 ml ink initially
and 2 ml after 4 hrs /as per the requirements and 2 hrs of
m/c run is mounted affixing necessary use by date, m/c
number and m/c head are coded and checked.
QCP 4: (Weighing) as per table given above.
QCP 5: Dispatch temperature of pouch: Temperature
<5⁰C.

Coding on milk pouch:

1) ink printing:-

2) Domino printing :-
Two types of domino printing done in sumul dairy.
1) L 39 A, 12/12/22 08
2) 12/12/22, 32 L 08 A

20
Table of various variety packaging of milk andbuttermilk:
Sr Variety Quantity Crate color Price
.
No
1 Amul Gold 500 ml Red 32
1000 ml 65
6000 ml 360
2 Amul Shakti 500 ml Green 29
3 Amul T-Special 500 ml Green 28
4 Amul Taaza 250 ml Blue 13
500 ml 25
5 Amul T-Top 200 ml Blue 11
500 ml 25
6 Amul Slim & Trim 200 ml Yellow 10
500 ml 22
7 Sumul Cow Milk 500 ml Blue 26
8 Sumul D-lite 200 ml yellow 10
500 ml 21
9 Sumul Pasteurized 6000ml grey 204
skimmed milk
10 Sumul Buttermilk 500 ml grey 16
6000 ml 180
11 Sumul Taak 500 ml grey 16
12 Sumul Masala 200 ml Red(small) 10
Buttermilk
13 Sumul Pro-fit 200 ml Red(small) 10
Buttermilk

21
 Crate Washer:
Equipment details:
Sr. No Name Number Capacity
1 Elevator 5
2 Crate 6 22-25
washer sec/crat
e
3 lifter 8 34-47/min

Elevator:
Elevator use for taking return or dirty crate to the
crate washing section.
Crate Washer:
In Crate washing section crate cleaning and washing is
carried out for filling of milk pouch andexternal use.

Crate washing is done with 3 stages:

1. Pre-rinse: this step is done with normal watertemperature
is approximately 35⁰C
2. Rinse with detergent wash: this step is done with e-codec
chemical.
1. Final rinse with hot water: this step is done with
hotwater. Temperature of hot water is between
40-55⁰C.
22
 2. In Crate washing e-codec chemical use for
detergentwash.
3. After every 1200 sec check e-codec solution
strength.
4. Composition of e-codec:
a. Sodium hydroxide : < 5%
b. Sodium laurl sulfate : < 5%
c. Anionic sulfate : < 5%
Lifter:
Lifter is used for provide washed crate to
filling machine.

23
 ELECSTER / SANJIVANI
Introduction:
• Elecster is a Finnish company. The machinery provided in
this section is from this company.
• Elecster section is specially installed for extent the shelf
life of milk at normal room temperature andnational
scheme for protein supplement sanjivani for mid-day
meal scheme (by government).

Elecster Processes Following Varieties and Their Standards:

Variety Pack size Fat% SNF%

Sanjivani 200 ml 1.5%(min.) 9.0%(min.)
Jome 200 ml 1.5%(min.) 9.0%(min.)
Diet + 500 ml 0.5%(max.) 8.7%(min.)
Health + 500 ml 3.0%(min.) 8.5%(min.)

24
Composition of sanjivani:

PARAMETER VALUE
Fat %(min.) 1.5
Added sugar % 8
(max.)
Total solid % (min.) 17.5
Acidity of base milk 0.150
% LA (max.)
Color & appearance Apple green color Flavor & taste
Pleasant, sweet, cardamom,
butterscorch, green apple, rose
flavor &free from any off flavor.

25
Additives & processing parameters in differentvarieties:

Parameter Variety
Sanjivani Jome Diet + Health
+

Color-apple 200 --- --- ---

green gm/1000lit
Color-orange --- 200 --- ---
red gm/1000lit
Sugar 8% of milk 8% of --- ---
milk
Vitamin A & D 1.0 --- --- ---
lit/10,00
0lit milk
Cardamom 250 --- --- ---
ml/1000
lit.
American ice- --- 500ml / --- ---
cream soda 500 lit. of
flavor milk
26
Homogenization 760C 760C 760C 760C
temp.
Homogenization 195 bar 195bar 195bar 195bar
pressure
Sterilization 1400C for 1400C for 1400C 1400C
temperatur 3.5 sec 3.5 sec for 3.5 for 3.5
e sec sec

27
Varieties :

Variety Type of Flavor Packi Packing Shelf-

milk ng /Min. life
size (Days)

Sanjivani Double Elaichi 200 65 -68 30

toned g
milk
Jome Double Elaichi 200 65 – 68 45
toned g
milk
Health+ Toned NO 500 32 45
milk g

Diet+ Skim NO 500 32 45

milk g

28
CCP of section:
CCP 1: UHT temp. 140±2ºC for 3.5 sec.
CCP 2: Aseptic Filling.
CCP 3: seal check

Packaging film specification:

Variety Packing Length Width Micron
size (cm) (cm) (µ)
SumulJomeelaichi 200 g 11 31.9 90.90
SumulJome 200 g 11.3 31.9 94.89
American
SumulSanjivani 200 g 11.2 31.9 93.86
Sumulya Health+ 500 g 16.9 31.9 93.19
Sumul Diet+ 500 g 16 31.9 93.86

29
 Effluent Treatment Plant
Introduction:
Effluent Treatment Plant plays an important role in
controlling the pollution of water and soil by Dairy effluent.
ETP is a process designed for treating the industrial waste
water for its reuse or safe disposal to the water environment.
An ideal factory should contribute minimum to the pollution.
ETP is necessary to meet the standards laid down by the
Gujarat Pollution Control Board for treated effluent and for
disposal into municipal sewage system.
The Surat District co-operative milk Producers’ union ltdhas
entrusted the work of modification and up gradation of
Effluent Treatment Plant of capacity 15, 00,000 liters/day at
their Sumul Dairy, Surat conforming to standards specified by
Gujarat Pollution Control Board.

Waste Water Source:

At Sumul Dairy waste water is being generated and
discharged from the milk processing plant. The sources of
waste water are: Spilled milk, sour milk.
Wash water from milk tankers, equipment’s, bottles,cans,
Plant washing, flow washing etc.
Overflow spoilages and leakages from pump and other
equipment’s.
30
31
Effluent Characteristics:
Sr.
Parameter Units Value(Treated) Value(Raw) GPCB
No
1 TDS mg/ltr 1310 13/9 2100
6.5-
2 Ph 8 7-8
8.5
3 BOD mg/ltr 17.8 1000 30
4 COD mg/ltr 45.6 6156 100
Suspended
5 mg/ltr 55 1187 100
solids
Oil &
6 mg/ltr 5.2 322 10
grease

Test to be performed in ETP Lab:

COD (chemical oxygen demand)

BOD (biological oxygen demand)

DO (dissolved oxygen)

Total solid

MLSS

Alkalinity Dissolved solids

Suspended solid

32
 WORKSHOP & INSTRUMENTATIONS

Pumps:
• HPP(High Pressure Pump)
• CIP Pump
• Centrifugal Pump
• Hydraulic Pump
• Reciprocating Pump
Fumigator:
• In Dahi, Paneer, Sweets, Powder section
Valves:
• Seat Valve
• Mix Proof Valve
• Butterfly Valve
• Control Valve
Valve Actuators:
• Rotary Actuators
• Linear Actuators
Maintenance:
• Routine Maintenance e.g. Oiling in chains of conveyer

33
 etc.
• Preventive Maintenance e.g. Change oil of Bearings
after limit of working hours reached

Instrumentation:
Instrumentation is an art and science of measurement and
control of process variables within production and
manufacturing area.
Total Equipment in field:
SCADA( Supervisory Control And Data Acquisition) = 38
PLC(Programmable Logical Controler)
At Machine = 117, At Control Room = 15
HMI(Human Machine Interface)
5 inch = 50, 7 inch = 6, 10 inch = 12
Switch/Sensor
Level(LS) = 252, Capacitance type flow switch = 36
Transmitter
LT(Level Transmitter) = 79
PT(Pressure Trans mitter) = 62
CT(Conductivity Transmitter) = 17
TT(Temperature Transmitter) = 417
34
Turbidity = 17
Pneumatic Operated Process Control Sanitary Valves on
ASI(actuator sensor)network brain on top with ligh
Diverter = 330, Mix Proof = 450, Shut Off = 466,
Butterfly = 108
PID(Proportional Integral Derivative)Controller
Steam = 61, Water = 30
Flow Meter/Transmitter
Mass = 8(Low Density Fluid Cream)
Magnetic = 80(Mik:Water)
Vortex = 15(Steam)

Objectives of Automatic Process Control:

Supressing the influence of external disturbances
Optimizing performance
Increasing productivity
Cost effective

35
 Refrigeration
• This section is one type of utility section.
• This section is important to give cooling effect in cold
storage, chilling of milk by using cooling media.
• Milk & milk products being perishable commodity get
spoiled at room temperature due to rapid growth of
microorganisms, which can be avoided by keeping them
at low temperature.
• Capacity of refrigeration plant in Sumul is 1650 TR.

Definition:
Refrigeration is a process of removing heat from a
lowtemperature reservoir and transferring it to a high
temperature reservoir.
Refrigerant:
In a refrigeration system, the refrigerant acts as a heat
conveying medium by absorbing heat from a lowtemperature
system and releasing it into a highertemperature system.
Ammonia is the type of refrigerant used in Sumul dairy.
Compressor:
Screw compressor is featured in sumul dairy. Two helical
rotors that are mounted in a single housing make up the main
part. Gas is sucked into the spaces between the teeth as the
rotors spin and becomes trapped in the clearance as it enters
as pipe between the teeth. As the rotors rotate, the space
between their teeth gets smaller and smaller as the cap living
gas travels along their length. Pressure builds up as the gas is
gradually compressed. The condenser receives the
compressed refrigerant in addition.
36
In order to decrease leakage between the gaps in the rotor,
oil is typically placed over the meshing faces of screw
compressors. It might be able to achieve high efficiency in this
even at slow speeds. Before the condenser, an oil trap
separates the oil from the vapour.

Condenser:
A crucial component of the high-pressure side of the
refrigeration system is the condenser. The high pressure and
temperature vapour refrigerant is cooled and condensed in
coils of tubing that make up this system. While moving
through the condenser, the refrigerant converts from a
vapour to a liquid state by releasing latent heat to the
surrounding condensing medium.
Receiver:
A receiver is a container used to retain condensed liquid
refrigerant and supply it to expand during evaporation.

37
Expansion Valve:
An essential part of a refrigeration system is a metering
device, sometimes known as a throttle or throttling device.
The purpose of an expansion device is to allow a liquid
refrigerant that is under high pressure and temperature to
pass when its pressure and temperature are reduced at a
controlled rate. While some liquid refrigerant evaporates as it
moves through the expansion device, the majority is
vaporised at low pressure and temperature in the evaporator.
Evaporator :
It is employed in the refrigeration system's low-pressure side
and is made up of coils of pipe. The expansion valve allows
low pressure and low temperature liquid refrigerant to enter
the evaporator, where it absorbs heat from the area around
the evaporator coils and transforms into vapour.
The liquid refrigerant absorbs the medium's to-be-cooled
latent heat of vaporisation as it evaporates.
Accumulator:
If the compressor receives both liquid and vapour refrigerant,
it must do the additional task of evaporating the liquid and
increasing its temperature. Additionally, it will set the
compressor's default marking such that it can only be used to
compress pure vapour refrigerant. An insulated vessel known
as an accumulator or pre-cooler is utilised in the system to
get around this problem. The discharge from the expansion
valve (a mixture of liquid and vapour refrigerant) is received
by the accumulator, which exclusively supplies the
evaporator with liquid refrigerant.

38
Cooling Tower:
When the water needed for the condenser is insufficient or
expensive, the same water is repeatedly cooled and utilised.
For bigger installations, absorption, refrigeration units, and
central refrigeration units, cooling towers are employed.

Refrigeration is required in following place in Sumul dairy:

Plate chiller
Pasteurizer
Cream tank jacket
Chilled water in Butter churn
Air cooler in butter packaging room
In pouch cold storeroom
In dahi cold storeroom
In chilling of paneer
In paneer cold storeroom

39
 Sweet section
Introduction:
• in SUMUL dairy demand of sweet is very high especially
on festival time.
• Khoya, peda, shrikhand, mathho etc. are main products
of section.
• Special surti sweet “ghari” is also prepared during
festival time in SUMUL dairy. This section is running on
contract basis.
Variety of Sweet
• Amul Sweet
• Sumul Sweet
Amul Sweet:
Sr. No Variety Varient Price Shelf life
200 gm 110.00
1 Malai Peda
500 gm 250.00
Sugar free
2 200 gm 130.00
malai peda
200 gm 115.00 45 days
3 Kesar peda
500 gm 265.00
200 gm 115.00
4 Milk cake
500 gm 260.00
Kaju akhrot 200 gm 135.00 60 days
5
plaza 500 gm 310.00
Rajwadi 200 gm 120.00
6
Halwa 500 gm 275.00
Keasr kopara 200 gm 120.00 45 days
7
pak 500 gm 275.00

40
 Moong daal 200 gm 120.00
8
halwa 500 gm 290.00
Motichoor 200 gm 100.00 60 days
9
laddoo 500 gm 220.00
200 gm 110.00 90 days
10 Besan laddoo
500 gm 250.00
200 gm 115.00 60 days
11 Mohanthal 500 gm 260.00
200 gm 85.00 12month
12 Frozen khoa
500 gm 210.00
Sumul Sweet:
Sr. Pack Shelf
Variety Varient Price
No size life
200 gm 102.0
Elaichi peda 0
500 gm 225.0
0
1 kg 450.0
0
200 gm 122.0
Akhrot plaza 0
500 gm 265.0
Sumul
0 30
1 khoabased 1 kg 530.0 days
sweets 0
200 gm 112.0
Kesar peda 0
500 gm 260.0
0
1 kg 520.0
41
 0
Mix mithai 200 gm 112.0
0
500 gm 250.0
0
1 kg 500.0
0
Special 200 gm 112.0
burfi/chocolat 0
eburfi 500 gm 250.0
0
200 gm 102.0
Desi peda 0
500 gm 225.0
0
Milk cake 200 gm 112.0
0
500 gm 250.00
1 kg
390.00
packet 15
2 Plain khoya khoya 500 gm 195.00 days
200 gm 102.00
200 gm 172.00
Dry fruit 30
3 Kaju-katari 500 gm 410.00
based 1 kg 820.00 days
500 gm 125.00 30
4 gulabjamun gulabjamun
Loose 240.00 days
mohanthal 200 gm 112.00
500 gm 255.00
1 kg 510.00
42
5 Besan 200 gm 97.00 30
Motichoor 500 gm 215.00 days
base
laddoo 1 kg 430.00
d
Kesar badam 250 gm 170.00
pista ghari 500 gm 340.00 30
6 ghari Sugar free
250 gm 215.00 days
ghari
Angur rabadi/
300.00
Anjir rabdi
Cream salad 310.00
Other Basundi 270.00 3
7
sweets Dudhi days
halwa/gajar 360.00
halwa

43
Shrikhand and Maska:
Sr. No Variety Pack size Price
100 gm 24.00
200 gm 44.00
Elaichi 500 gm 110.00
1
shrikhand 1 kg 215.00
Loose 215.00
100 gm 26.00
200 gm 52.00
KDF 500 gm 120.00
2
shrikhand 1 kg 235.00
Loose 235.00
Mango 500 gm 110.00
3
shrikhand Loose 225.00
500 gm 110.00
4 Mango delite
Loose 225.00
Rajbhog 500 gm 120.00
5
delite Loose 240.00
American 500 gm 130.00
6
delite Loose 255.00
Pineapple 500 gm 110.00
7
delite Loose 225.00
8 Masko Loose 250.00

44
Preparation of condensed milk for sweet:

Preparation of peda:

45
Chemical standard for peda:
Parameter Sugar Sugar free
% Fat(minimum) 16.0 18
% 20.0 15
Moisture(maximium)
%Acidity(maximum) 0.3 -
Added 32 -
sugar(maximum)

46
flow diagram of Kaju-katari:

47
Recipe of Mohanthal:
Sr. No Ingredient Quantity(kg)
1 Gram flour 33.33
2 Sugar 33.33
3 Ghee 25
4 Pasteurized whole 10.5
milk
5 Cardamom 0.1
6 Nutmeg 0.1
7 Kesar 0.05
8 Silver leaves 500
9 Total 102.41

Flow diagram of mohanthal:

48
Milk Cake:
Recipe for making 100kg sweet khoya
Sr. No Ingredient Quantity(kg)
1 Milk 371.80
2 Sugar 33.33
3 Cardamom 0.07
4 Total 405.20

Recipe for making 100 kg Milk Cake:

Sr. No Ingredient Quantity(kg)
1 Sweet khoya 85.5
2 Ghee 10
3 Liquid Glucose 4.5
4 Total 100

49
Flow diagram of milk cake:

50
Akhrot plaza:
Recipe for making 100 kg Sweet khoya:
Sr. No Ingredient Quantity(kg)
1 Milk 371.8
2 Sugar 33.46
3 Potassium 0.1
Sorbate
4 Benzoic acid 0.03
5 Total 405.39

For making 100 kg Akhrot plaza:

Sr. No Ingredient Quantity(kg)
1 Sweet khoya 80.96
2 Walnut 3.5
3 Custard apple 0.04
flavor
4 Cashew nut 1
5 Ghee 10
6 Liquid Glucose 4.5
7 Silver leaves 500
8 Total 100

51
Shrikhand:
Flow diagram of shrikhand:

Variety vise ingredient:

Sr. Variety Masko Suga Other
No (kg) r(kg)
1 KDF Shrikhand 15 16 1.5kg dry fruit
2 Ealichi shrikhand 15 16 100 gm elaichi
powder
3 Mango Shrikhand 15 16 1.5kg mango pulp
52
Chemical standard of Sweet:
Parameter Peda/Sp. Sug Milk Moha Rajw Besa
Burfi/ch ar Cake nthal adi nlad
ocolate free halwa doo
burfi peda

%Fat(mini 16 18 23 30 27 29.9
mum) 7
%Moisture 20 15 13. 4.01
(Maximum 23
)
Acidity(% 0.3 0.3 0.35 0.35
LA) 5
Add 32 36 36 26
sugar(maxi
mum)

53
 GHEE

Introduction:
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.

Principle of ghee manufacturing:

When butter is left undistributed at a temperature of 80- 85⁰
C for 15 to 30 mins. It stratifies, i.e., separates into 3 distinct
layers. Viz., a top layer of floating denatured particles of curd,
a middle layer of fat, and a bottom layer of buttermilk. This
separation into layers has been called pre-stratification. The
bottom layer of buttermilk contains 60-70 percent of solids-
not-fat and also over 80 percent of the moisture originally
present in the butter. The buttermilk is mechanically removed
without disturbing the top and middle layers. Afterwards, the
temperature of the remaining two upper layers (of denatured
curd and fat) is raised to the usual clarifying temperature of
110- 120⁰ C.

54
Equipment in ghee section:
Sr. Equipment No. of Capacity
No Equipment
1 CBMM 1 1.5 TPH
2 Butter Melting Vat 4 1 Tone
3 Butter coil 1 -
4 Pre-stratification 3 2.5KL
Tank
5 Ghee coil 1 -
6 Ghee Boiler 3 2 KL
7 Ghee Clarifier 2 2KLPH
8 Cooling coil 1 -
9 Ghee storage Tank 3 5KL
10 Butter Churn 2 5KLPB

55
Manufacturing Flow Diagram of Ghee:

56
QCP & OPRP in Ghee Section:
QCP 1: Clarification
QCP 2: Cooling of Ghee at 39 -41⁰ C through well water
cooling coil
QCP 3: Weighing
OPRP 1: Boiling in ghee kettle at 107-112⁰ C
OPRP 2: Filtration through 180 & 300 mesh size Nylon food
grade filter

Diacetyl Culture Preparation for Sumul Ghee:

• For preparation of cultured cream, pasteurized cream of
required quantity is taken in previously cleaned and
sanitized cans and maintained at 18-20⁰C. DVS freeze
dried culture CHN-22 is added @ 1% min. and kept at 18-
20⁰ C for 6 to 8 hr until PH 5.6 to 5.2 achieved. Cool it to
14 to 16⁰ C and kept for 4 to 6 hr until PH 4.6 to 4.8 is
achieved. Now the temperature brought down to 8 to 9⁰
C and kept for 2 hr before use.
• The bulk culture shall be stored at room temperature
and shall be used within 48 hrs. The mother culturecan
be stored at below 9⁰ C for max. 10 days.
• At least 2 can (5% max.) of cultured cream, after getting
tested for diacetyl from QC, is added to the ghee boiler
in each lot for enhancing aroma.

57
FSSAI Standard of ghee:
Parameter Requirement
Moisture, 0.5
maximun%(m/m)
Milk fat, 99.5
minimum%(m/m)
BR, Reading at 40⁰ C 40 -43.5
RM value, minimum 24
Polenske value -
FFA as oleic acid, 3.0
maximum%
Peroxide value(milli- -
equivalent of oxygen/ kg
fat), maximum
Baudouin Test Negative

AGMARK Standard:
Grade Color of letter and
circular border
Special Red
General Green
Standar Chocolate
d

Sumul Standard:
Parameter Requirement
Fat Min.99.7%
Moisture Max.0.3%
RM value Min.28
58
 PV value 1-2
% FFA value Max.0.5
Peroxide value Max.0.6%
Baudouin test Negative
Added color No
Grade type Special

Price of ghee:
Sr. Varient Price
No
1 200 ml ghee poly bag pouch 112
2 500 ml ghee poly bag pouch 278
3 1 ltr ghee poly bag pouch 555
4 200ml ghee poly bag pouch 115
cow
5 500ml ghee poly bag pouch 282
Cow
6 1ltr ghee poly bag pouch cow 565
7 15 kg ghee pack teen cow 10000
8 1ltr ghee pack teen 550
9 5ltr SUMUL ghee pack tin 2825
10 15kg ghee tin 10000
11 200 ml ghee jar 117
12 500 ml ghee jar 265
13 500 ml gir cow ghee jar 625
14 1 ltr gir cow ghee tin 1250
15 1 ltr Amul ghee pouch GUJ-530
ROI-545
59
 16 500 ml Amul ghee pouch GUJ-269
ROI-275
17 1 ltr Amul cow ghee pouch 560
18 500 ml Amul cow ghee pouch 280

Coding system in Ghee Packaging:

1) Ghee pouch
Melt No.- 3261-B
Mfg Date- 22/11/22
Exp Date- 21/05/23
MRP- 278
USP: ₹ 0.56/ml
2) Ghee tin
MRP.: 2825.00 USP: ₹ 565.00/L
MELT NO.: 3283
MFG. DT: 24-NOV-2022
EXP. DT.: 21-AUG-2023

60
 BUTTER
Introduction:
Butter means the fatty product derived exclusively from milk
of cow and/or buffalo or its products principally in the form
of water-in-oil type of an emulsion. The product may be with
or without added common salt and starter cultures of
harmless lactic acid and/or flavour producing bacteria.

Butter is considered as high calorie food as 100 g of butter

provides almost 700 Kcal. Butter is extremely rich in minerals
like Calcium, Phosphorus and Potassium. It has good amount
of sodium and small amounts of fluoride, selenium, zinc and
magnesium. It is also rich in Vitamin A, Vitamin E, Riboflavin,
Niacin and Pantothenic acid. It also has Vitamin K, Folate and
Vitamin B12 in small amounts.

Principle involved in butter making:

The churning Process :- This involves the use of high speed

beaters to destabilize the fat emulsion in the chilled cream,
and thus cause the formation of grains of butter in a matter
of seconds. The buttermilk is drained away and the resulting
grains worked in a kneading section prior to extrusion.

61
Equipment Details:
Sr. No Name of No. of Capacity
Equipment Equipment
1 Cream 4 10 KL
Storage
Tank
2 Cream 2 350 L
Balance
Tank
3 Cream 1 10 KLPH
PHE
4 CBMM 2 1.5 &2
TPH
5 Butter Silo 1 3 Tone

2 Stage CBMM:

62
Manufacturing flow diagram of butter:

63
OPRP of the section:
OPRP 1: Pasteurized cream receipt & ageing (9 - 12⁰C)
OPRP 2: Storage at and below minus 4⁰C
OPRP 3: For recombined butter sore at -15⁰C

Standard of Butter:
Constituents FSSAI Standard Sumul standard
%Fat 80 84
%Moisture 16 14
%Salt 3.0 -
%Curd (SNF) 2 2

Yield of butter:
• 10860 kg butter produced from 24179 kg cream.
• 44.91% from cream.

Coding System on Butter:

Variety of Butter Manufactured:

1) Pasteurized White Butter 2) Pasteurized Cow Butter.

Shelf life of Butter: 15 Months at -18⁰C.

64
 BUTTERMILK
Introduction:
• Buttermilk is a by product obtained during churning of curd
which is known as “chhas”.
• Daily 2-2.5 lakh liter of buttermilk is prepared in SUMUL
dairy.
• Milk which used for preparing of butter milk is standardized
with whey received from different section and powder.
• Standardized Milk should have 3.5%fat and 11.5%SNF.

Equipment details:
Sr. No Name Number of Capacity
equipment
1 CDT (curd 10 20 KL,
tank) 15KL
2 Buttermilk 1 30 KLPH
Pasteurize
r
3 Homogenizer 2 30 KLPH
4 BMT 7 20KL, 15KL
(Buttermilk
tank)

65
Process chart of buttermilk:

66
CCPs & OPRPs of the section:
CCP 1: Heating at 73-78⁰C & cooled at <11⁰C
CCP 2: Dissolve in hot water at temperature ≥85⁰C and add
jeera essence for MBM mixing. It with plunger
OPRP 1: pouch filling through filter bag
OPRP 2: sealing
OPRP 3: Storage ion cold store at ≤10⁰C
Bulk culture preparation for BM:
• After cleaning and sterilizing the SS can with soap water,
heat the can to 41± 2⁰C with UHT Tonedmilk/ UHT skim
milk.
• To make culture DVS culture FVV -311, 2 unit in 400 ltr
milk. And then incubate this can at 41± 2⁰C.
• When Ph level 4.0 to 4.5 is reached transfer the can into
cold store.
• This can use as mother culture for inoculation at the rate
of 1%.
Culture details:
FVV311
• Streptococcus thermophilus
• Lactobacillus delbrueckii ssp. Bulgaricus
Standard of BM:
Details Sumul Standard
% FAT 1.0-1.5
% SNF 5.0-6.0
Acidity (% LA) 0.55-.065
AP test Negative

67
Ingredient use for MBM preparation: for 1000 lire of
Buttermilk:
Ingredient Quantity
Salt 4 kg
Cumin 2.125 kg
coriander 0.375 kg
Cumin essence 0.100 kg

68
 QUALITY CONTROL LAB
Introduction:
It is a section where testing of milk and its products is done
chemically and microbiologically to decide its suitability for
further processing and also to determinethe shelf life.

What is milk quality control?

Milk quality control is the use of approved tests to ensure the
application of approved practices, standards and regulations
concerning the milk and milkproducts. The tests are designed
to ensure that milk products meet accepted standards for
chemical composition and purity as well as levels of different
micro-organisms.

Lab sections:
RMRD laboratory
Process laboratory
Main laboratory

69
 Lab Test performed
name
Manually Fat, SNF, OT, acidity,
RMRD alcohol,
COB, pH
By Fat, SNF, protein, lactose,
machin lactic acid, casein, FFA,
e (MILK adulterations (ammonium
O sulphate, detergent, maltose,
SCAN) salt, glucose, melamine,
@40°C sodium carbonate, sodium
citrate, starch, sucrose, urea,
sorbitol, veg oil,
formaldehyde)

Process Fat, SNF, OT, acidity,

alcohol,COB, MBRT, APtest,
homogenization index GC –
(gas chromatography)

Main all required test of final

product

70
Adulteration limits for milko scan:

Limit of
Sr.N Effect on which
Adulterants detection
O reading
(min%)
Ammonium
1 0.0900 SNF
sulphate
2 Maltose 0.2400 SNF
3 Melamine 0.100 SNF (protein)
4 Salt 0.2700 SNF
5 Glucose 0.1500 SNF (carbohydrate)
Sodium
6 0.0700 SNF
carbonate
Sodium
7 0.0900 -
citrate
8 Starch 0.300 SNF (carbohydrate)
9 Sucrose 0.1200 SNF (carbohydrate)
10 Urea 0.0500 SNF (protein)
11 Sorbitol 0.1500 -
12 Veg oil 0.3600 Fat
Formaldehy
13 - -
de
14 Detergent 0.1500 -

71
Chemical and microbial test of the milk and milk products:
Sr.
Products Chemical test
No
Organoleptic test, Fat, SNF, Acidity,COB
1 Raw milk , Alcohol test, MBRT,
Adulteration
test.

Moisture, FFA,RM Value (Reichert

2 Ghee Meissel Value), PV Value (Polenske
Value), BT Test (Baudouin Test),
Refractive Index (BR Reading)

Flavor and Aroma, Body and Texture,

Color, Moisture Content ,Acidity, Curd
3 Butter Content, FFA,RM Value, PV Value, BR
Reading ,BT Test (Baudouin Test)Moisture
analysis by moisture analyzer, Fat test
(Gerber method)

4 Powder Bulk density of powder ,Insolubility Index

Testing test ,Turbidity test, Acidity, Moisture

5 Buttermilk Acidity,Fat, pH, SNF

6 Lassi/dahi Fat, acidity, TS

72
7 Sweets Moisture,Fat,TS, sugar, acidity

8 Paneer / khoa TS, Moisture, Fat

9 Shrikhand/ TS, Fat, Acidity, Sugar, moisture

masko

Estimation of fat %:
Gerber Method:
The milk is mixed with sulphuric acid and isoamylalcohol in a
special Gerber tube, permitting dissolutionof the protein and
release of fat. The tubes are centrifuged and the fat rising
into the calibrated part of the tube is measured as
percentage of the fat contentof the milk sample. The method
is suitable as a routineor screening test. It is an empirical
method and reproducible results can be obtained if
procedure is followed correctly.
Procedure:
1. Measure 10 ml of sulphuric acid into a butyrometer tube.
2. Mix the milk sample gently and fill the milk pipette above
the graduation line. Run the milk into the butyrometer tube
along the side wall without wetting the neck. Add 1 ml of
Amyl alcohol, close with a lock stopper, shake until
homogeneous,inverting it for complete admixture of the acid.
3. Keep in a water bath for 5 min. at 65±2°C taking care to
have casein particles if any to dissolve fully, and centrifuge for
4 min. at 1100 rpm. Allow the centrifugeto come to rest.

73
Remove the butyrometer tubes and place in water bath for 5
min. at 65±2°C.
4. Read the percentage of fat after adjusting the height inthe
tube as necessary by movements of the lock stopper with the
key.
5. Note the scale reading corresponding to the lowest point
of the fat meniscus and the surface of separation of the fat
and acid.
Sampling:
Milk/ flavored milk/ lassi = 10.75ml,
Khoa / all sweets = 1.69gm+ 5ml distilled water
Paneer/ shrikhand/ masko/ cream = 5 gm+ 6ml Distilledwater

Estimation of acidity:
Acidity test:
1.Take 10 ml distilled water in a small beaker
2.Add 10 ml milk sample
3.Add few drops of phenolphthalein indicator
4.Titrate it by adding 0.1N NaOH solution till appearance of
light pink color
5.Note the volume of NaOH used & calculate thetitratable
acidity Formula for Calculation of Titratable acidity:

Acidity= 0.09× reading

Sampling:
milk/ lassi/ buttermilk/ flavored milk= 10ml+10ml distilled
water.
Dahi= 1g+ 10ml distilled water.
sweet= 10g+ 100ml distilled water.

74
powder= 1g+ 10ml warm distilled water + 10ml cooldistilled
water.

Estimation of TS:
Determination of Total Solids (Gravimetric method):
• In this procedure, a known quantity of milk is dried on a
boiling water bath. Subsequently sample is dried in hot
air oven at 102 ±2°C and from the weight of the
residue, the total solids content in milk is determined.
Procedure:
1. Heat a dish with its lid alongside in the drying oven at least
1 hour. Place the lid on the dish and immediatelytransfer to a
desiccator. Allow to cool to room temperature. Add 5 ml of
prepared sample, place the lid on the dish and weigh again.
2. Place the dish without the lid on the vigorously
boilingwater bath in such a way that the bottom of the dish is
directly heated by the steam. Continue heating tillmost of the
water is removed.
3. Remove the dish from the water bath, wipe the underside
and place it in the oven alongside the lid anddry in the oven
at 102±2°C for 2 hours.
4. Place the lid and transfer to the desiccators Allow to cool
and weigh again. Repeat the operation again until the
difference in the two consecutive weighing doesnot exceed 1
mg. Record the lowest mass.
Calculation:
Total Solid Content = (M2 − M0)/ (M1 − M0) x 100

75
Where M0 = mass in g of dish + lid, M1 = mass in g of dish +
lid and test portion, M2 = mass in g of dish + lid and dried test
portion
Generally, 2-5g sample taken for estimation

Estimation of SNF:
Principle:
Solid non-fat is an important criterion of milk selection for
further processing. Milk solids nonfat would include the
nitrogenous substances, milk sugar andmineral matter. The
determination of solid non-fat is done by taking Lactometer
reading at 27°C (base on lactometer type).
Procedure:
1. Warm the milk sample to 27°C.
2. Mix the contents by rotating and inverting the bottle,
taking care to avoid air bubbles. Alternatively, mix the
contents in a beaker.
3. Pour about 50 ml of milk in the measuring cylinder.
4. Insert the lactometer gently to wet the stem not More
than a short length, about 3 mm beyond the position of
equilibrium. Note the reading regarding top of the meniscus
on the stem.

Calculate:
specific gravity = 1+ CLR\1000
SNF % (Solids Not Fat) = CLR\4 + 0.21xF + 0.36

76
Alcohol Test:
Alcohol test is based on the principle of curdling of milk in
presence of alcohol. This forms the principle for testing of
synthetic milk, which is composed of neutralizers, stabilizers
and detergents.
Take 1 ml of milk sample in a petri dish. Add 1 ml
(equalamount as milk) 68% alcohol mix, warm and observe
for clotting.

Clot on boiling test(COB) test:

The C.O.B test is for acid milk that is too acid, pH <5.8or
abnormal milk. If a milk sample fails in the test, it contains
either many acid and. This milk cannot stand the heat
treatment in milk processing and must be rejected for
consumption.
Procedure:
• Take a 5 ml milk sample in a test-tube and put it in
aboiling water bath for 5 minutes.
• Remove the test-tube from the water bath without
shaking it.
• Samples showing precipitated particles are recorded as
positive C.O.B. test and the milk must be rejectedon the
receiving platform.

MBRT (Methylene blue reduction time) test:

Test is the most widely used test for hygiene and the keeping
quality of raw milk. Methylene blue is a dye indicator. The
methylene blue solution can later be used to test the
microbial activity in a given milk sample.

77
Procedure:
In this test 1 ml of Methylene Blue is mixed in 10 ml of milk
sample in a serial test tube. After stopping thetest tube, it is
incubated at 37⁰C and the length of time taken by milk to
decolorize Methylene blue is recorded.

MBR Time (hr) Quality

5 & above Very good
3&4 Good
1&2 Fair
0.5 & below Poor

Homogenization index:
Range:<20
For checking of milk is completely homogenize or not
Procedure:
1. 50 ml sample of milk take in centrifuge tube
2. Rotate at 1100 RPM/ 15 min
3. Separate the upper creamy layer = 5ml – tag it A sample
4. And rest portion of milk is called B sample
5. Estimation of sample A &B fat:

AP test:
for detection of milk is properly pasteurized or notprocedure:
1. take 5 ml AP solution in test-tube
2. add 1 ml milk sample
3. put in water bath at 37°C/ 30min.
78
4. check color change if yellow color not pasteurized

Gas chromatography:
Principle:
• The sample solution injected into the instrument enters
a gas stream which transports the sample into the
separation tube known as the “columm”.
GenerallyHelium or nitrogen is used as carrier gas. The
various components are separated inside the columm.
The detector measure the quantity of the component
that exit the columm.
• The mobile phase is usually an unreactive gas like
helium, nitrogen, hydrogen and argon. The stationary
phase is a microscopic layer of viscous liquid on asurface
of solid particle on an inert solid support insidea piece of
glass or metal tube called a columm.

Part of GC:
COC – cool and column (80°C sample enter)
Col- column (heating 370°C)
3.FID- flame ionization detector
Silica layer in column work as a binder agent. This layer binds
the oils free fatty acid and release at specific temperature and
this FFA are burnet by flame and produce electrons and
produce current detect the amount by the FID unit and show
in the PCas a graph. And measure the value of FFA in
sample.PC read the area produce by FID unit.

Gases are use in the GC are:

79
1.Helium gas – carrier of sample (15ml/ min)
2.Hydrogen (30ml/min) and oxygen (400ml/min) for flame
production
3. Nitrogen (25ml/min) for enter the help of particles in FID
unit with force

S. value Limits
Soya 98.05 - 101.95
Coconut & palm kernel 99.42 - 100.58
Palm oil & beef tallow 95.9 - 104.10
Lard 97.56 - 102.04

Sampling flow chart:

80
Moisture Analysis:
Moisture analysis is done by automatic moisture analyzer. It
is automatic machine that result percentage of moisture in
the product that is indicated on the digital display. Moisture
analysis is done for different dairy products like Paneer, Peda,
Shrikhand, Powder, Butter, etc. Here moisture is measured in
machine at different temperature.

Procedure:
1. Take 1 aluminum dish, and put in to the moisture analyzer,
here very sensitive weighing balance to weight it, then tare it.
2. Take 2.5 to 3 g sample and put the shutter down slowly.
When it closes, it automatically starts. It takes about 15
minutes to get results and indicate in % moisture. It
automatically ends and display result on digital screen.

Standard results for the products:

For Paneer, result should be in range of 50% to 60% moisture.
For Powder, result should be less than 3%.
For Peda, result should be about 17%.
For Shrikhand, result should be about 30% moisture.

Moisture Analysis in Ghee:

The moisture content of ghee is the loss in mass, expressed
as a percentage by mass when the productis heated in a hot
air oven at 105 ± 1°C to constant mass.

Procedure:
Procedure Weigh accurately about 10 g of the sample into a
moisture dish which has been dried previously and weighed.
81
Place in air oven for 1 hour at 105 ± 1°C.Remove the dish
from the oven, cool ina desiccator and weigh.
Repeat the process by keeping the dish in the oven for half
hour each time,cool and weigh till two successive weighing do
not exceed 1 mg.

Calculation:
Moisture and volatile matter %/w = (M1− M2)/ (M1−M) x 100
Where, M1 = Mass in g of dish with ghee before drying M2 =
Mass in g of dish with ghee after drying M = Mass in g of
empty dish

Determination of Free Fatty Acids in Ghee:

The acidity (free fatty acid content) of a fat is normallya
measure of the extent to which hydrolysis has liberated the
fatty acids from there ester linkage with the parent
glyceride molecule. Partly for this reason, acidity of ghee is
extensively quoted as a free fatty acidcontent percent
(%FFA). The FFA content of fresh gheevaries from 0.09 to
0.28% with an average of 0.16%. The sensory quality of ghee
deteriorates with increasein FFA content. Level of acidity
shows the proneness of fat to oxidation. Highly acidic ghee
shows faster oxidation, and thus haspoor keeping quality.
With the increase in acidity, there is decrease in consumer
acceptability

Procedure:
Weigh 10 g of the ghee sample in a 250 ml conical flask. In
another flask bring 50 ml of ethanol boil above 70°C,
82
neutralize it to phenolphthalein (using 0.5 ml). Bring the
mixture to boil and while it is still hot, titrate with 0.1 N
NaOH, shaking vigorously during the titration. The end point
of the titration is reached light pink color= +ve
Free fatty acids:
The acidity of ghee is frequently expressed as the percentage
of free fatty acids in the sample, calculatedas oleic acid, using
following formula:
Free fatty acids (as Oleic acid) = (T/ M) x 2.82
Where T = volume of 0.1 N alkali required for titration in
ml; M = mass in g, of ghee sample taken.

Boudin Test:
To detect presence of sesame oil.
Procedure:
1. Take 5 ml of the melted ghee in 25 ml measuring cylinder
provided with a glass stopper, and
2. add 5 ml of hydrochloric acid and 0.4 ml of furfural
solution.
3. Insert the glass stopper and shake vigorously for 2 min.
Allow the mixture to separate.
4. The development of a pink/red color in the acid layer
indicates presence of sesame oil.
5. Confirm by adding 5 ml of water and shaking again. If the
color in acid layer persists, sesame oil is present.If the color
disappears, it is absent.

83
Determination of Reichert-Meissel and Polenske Value in
Ghee:
The Reichert-Meissel (R.M.) value is the number of ml of 0.1
N aqueous alkali solution required to neutralize the water-
soluble, steam volatile fatty acids distilled from 5 g of ghee
under the precise conditions specified in the method.
Procedure:
1. 5 gm of sample is taken in a 300 ml conical flask
2. Add some glassbid into the flask which is antiburningagent
3. Add 2 ml of 50 % NaOH solution and 20 ml glycerin isadded
4. Heat on burner by applying direct flame with vigorous
shaking till complete saponification occurs(solution becomes
clear and transparent)
5. Allow to cool at room temperature
6. Heat 95 ml of distilled water and then add into it
7. Add 50 ml of 1 N dilute H2SO4 and distillate by placing
the flask on stand fix the head and connect with condenser
8. Heat with burner and shake the set up till golden
ringappears in the surface of the solution
9. Only boil till the appearance of golden ring but do not
distillate till the appearance of ring by removing flame
if distillation starts
10. By the appearance of ring (golden color) start
distillationby applying continue flame
11. In 22 minutes110 ml of distillate has to be collected
12. Then suddenly cool the distillate by placing the flask
in ice for 30 minutes
13. Then filter it after 30 min and filtrate use for PV value.

84
14. wash the distillation tube with 45 ml chilled water and
allow to filter in another flask then wash with 50 ml
ethylalcohol (rectifier spirit) and also filter it and titrate
it.
15. And then titrate it against 0.1N NaOH using
phenolphthalein as an indicator
16. Color will be changed to pink
Note down the reading.
RM = [(R-0.1)×1.10x5] ÷ wt. Of sample PV = R-0.1, R=
reading of titration value.

Butter Testing:
Moisture, Curd & Fat:
Procedure:
1. Take an empty aluminum disk & weight it (W1)
2. Take 10 g butter sample in it & weight it (aluminum disc
3. + sample) = W2.
4. Heat the sample on hot plate till it converts into the ghee.
5. Cool down it to room temp & weight it(W3)
6. Take out the moisture by: [Moisture% = (W2 - W3/W2 -
W1) ×100]
7. Now take an empty glass beaker and weight it (W4).
8. Add Petroleum sprit in the aluminum disc w3 to dissolve
the ghee into it
9. Take out the spirit into the glass beaker slowly till the curd
remains in the disc
10. Heat the disc in hot air oven so the curd dry & cool it to
room temp weigh it = W5 and calculate the calculate the curd
in present butter = W5-W1

85
11. Now heat the glass beaker containing the sprit till all the
sprit evaporates and the ghee will remain inside it
12. Cool down it to room temp
13. Weight it(W6)
14. Calculate the Fat in butter = W6 - W4

acidity of butter (%LA):

1. Take 10g sample of butter
2.Add 100ml hot distilled water
Cool it and add phenolphthalein indicator 4-5 drops
Titrate with 0.1 N NaOH and note the reading
Calculation = 0.09× (ml NaOH use)
Max 0.040% LA (by FSSAI)

Powder Testing:
Bulk Density of Powder:

Procedure:
Measured by B.D. Apparatus. (Taped density)
1. Take two empty 25 ml measuring cylinder.
2. Add 7 gm of powder sample in each.
3. Put the tubes on the B.D. Tester.
4. Set the Bulk Density apparatus for 5 minutes.
5. Take the volume reading of both of the tubes.
6. Calculate the bulk density on the given formula:
7. [B.D. = weight / volume] Bulk density:-0.18 to 1.25 gm/ml

86
Insolubility Index of Powder:
Procedure:
1. Take 14 g of powder sample; dissolve it into 100 ml distilled
water. Then pour sample in to solubility index tube
(centrifuge tube) up to 50 ml making.
2. Then put the tubes in to centrifuge machine at 1100 rpm
for 15 min.
3. After than whatever insoluble particles settle on bottom, so
remove upper portion of sample and add some water, then
after it again put in Centrifuge machine for centrifuge for 5
min.
4. After that take reading that indicate on scale of index tube
that particles are remaining in this plate
Insolubility index = not more than 2 ml

87
 PANEER
Introduction:
Paneer is a heat-acid coagulated milk product obtained by
coagulating standardized milk with the permitted acids at
specified temperature. The resultant coagulum is filtered and
pressed to get the sliceable curd mass. Paneer has a firm,
close, cohesive and spongy body and smooth texture. It is
mainly prepared from buffalo milk and used for large number
of culinary dishes.
Principle of Paneer Production:
The phenomenon of coagulation involves formation of large
structural aggregates and network of protein in which milk fat
globules gets embedded. Acid and heat treatment causes the
physical and chemical changes in casein.
• Heating causes interaction of ß-lactoglobulin with
ĸcasein and the complex formed between ß -
lactoglobulin and α-lactalbumin.
• Acidification initiates the progressive removal of
tricalcium phosphate from the surface of the casein and
it gets converted into mono-calcium phosphate. Further
calcium is progressively removed from calcium hydrogen
caseinate to form soluble calcium salt and casein.
• Colloidal dispersion of discrete casein micelles changes
into large structural aggregates of casein. Under such a
circumstance dispersion is no longer stable, casein gets
precipitated and forms coagulum. Fat is embedded in
the casein network.

88
Equipment details:
Sr. Equipment Number of Capacity of
No Equipment Equipment
1 HMST 2 20KL
2 Milk Preheater 1 10KLPH
3 Water Pasteurizer 1 5KLPH
4 Water Chiller 3 10KLPH
5 Citric acid tank 1 200L
6 Coagulation Vat 4 2KL
7 Paneer Press 6 -
8 Dipping Vat 6 -
9 Vacuum Packaging 5 -
Machine
10 Whey Storage tank 2 15KLPH
11 PWST 2 10KLPH

89
Manufacturing flowchart of Paneer:

90
CCP & OPRP of the section
CCP 1: Heating of potable water in PHE at 76-80⁰ C and
cooling.
CCP 2: Vacuum sealing 22-45 mbar.
OPRP 1: For Amul paneer heat treatment in hot water tank
(92-95⁰ c/30 min)
OPRP 2: Storage 3-5⁰ C
OPRP 3: rejected 100g/200g/500g packed pack dipped in hot
water at 75-85⁰ C for 45 min.
OPRP 4: rejected 5 kg or/ leaky pouches are shredded and
reprocess @ 10%max
Preparation of 1.0 % Citric acid solution and 0.02% CaCl2.
In Case Ⅰ,
Prepare 1000-liter 1.0% citric acid solution.
To make 1000-liter, 1.0% citric acid solution 10 kg
citric acid powder required.
In Case Ⅱ,
Prepare 0.02% CaCl2 for 1600-liter milk
Weight of CaCl2 = 1600*0.02/100 = 320 gm
5% solution of 320 gm CaCl2,
5 gm Cacl2 in 100 ml water
320 gm CaCl2 in
= 320*100/5
=6400 ml water
6.4-liter water required to make 5 % solution of 320 gm
CaCl2 powder.

91
Chemical Standard of Paneer:
Parameter Value
%Fat 22
%Carbohydrate 4.5
%Protein 20
%Acidity (LA) 0.5

Microbiological Standard of Paneer:

Count Agar used Range
1,50,000-
SPC SPC agar
3,50,000/g
Coliform VRBA 10-100/g
Yeast & Mold CYGA 50-150/g
E. coli <10/g

Composition Of Paneer Whey:

Parameter Value
% Fat 0.71
Protein 03-0.4
Acidity 0.14-0.16
TS 6.8-7.0

92
Yield of Paneer:
Batch capacity = 1600-liter milk
= 1600*1.027(sp. Gr. Of milk)
= 1643.2 kg
Weight of Paneer = 264.45 kg
Now, yield of Paneer = (264.45/1643.2) *100
= 16.09%
Holding tube length calculation:
Flow-rate of milk in holding tube = 10000 LPH
Inner diameter of the tube = 63 mm
Holding time of milk = 10 min.
Flow rate = volume of milk / holding time of milk =
Area*Length / Time
From the above expression,
Length = Flow rate*Time / Area =534.66 m
So, the length of holding tube is ≈ 535 m
Coding system :
MRP: 80 ₹
USP₹0.40/gm PKD:
25/SEP/2022
EXP: 09/NOV/2022
B. No: UAL2685
93
 Paneer Hoop details:
1. Total weight of hoops= 21 kg
2. Empty weight of hoop= 7 kg
3. Paneer from hoop= 9-10 kg
Variety of Paneer & Price:
Sr.
Variant Amul Amul(goa) Sumul
No
1 100 gm 41 43 40
2 200 gm 80 85 80
3 500 gm - - 175
4 1 kg 370 385 375
5 5 kg - - 1720

Shelf life of Paneer:

Amul Paneer is 45 days.
Sumul Paneer shelf is approximately 22 days.

94
 DAHI
Introduction:
➢ Curd is a fermented dairy product, created by fermentation
process by intentionally adding live,harmless, lactic acid
forming bacteria in the form of bacterial culture to milk.
➢ By using lactose present in the milk, lactic acidbacteria added
in the form of starter culture multiplyand expand, producing
lactic acid, acetic acid, and carbon dioxide.
➢ Some bacteria use milk's citric acid to manufacture volatile
organic compounds, mostly diacetyl, which is responsible for
curd's taste. A well-balanced mix of acid-producing and flavor-
producing microorganisms in the starter aids in the
development of firm, flavorful curd.
➢ Fermentation imparts an acidic flavour to milk, which is
especially soothing in hot weather and also contains
medicinal properties not found in milk. As a result, fermented
dairy products are an integral partof the human diet in many
parts of the world. Fermentation causes a partial
breakdown of milk constituents, particularly lactose and
proteins, and improves the digestibility of cultured milk
products.

95
Principle behind curd production:
Curd has live cultures and the lactose in the milk is converted
to lactic acid by the action of starter cultures and the lactic acid
act as preservative for the milk and the low PH (4.5 – 5.0) also
inhibit the growth of harmful microorganisms, thus increasing
the shelf life of the product. Dahi is manufactured using single
or mixed cultures, Lactococcus cremoris, Lactococcus
diacetylactis, along with leuconostoc species, Lactococcus
lactose, a combination of acid and flavor producing bacteria.
These bacteria are responsible for imparting firm body,
sweetness, and a mild acidic flavor to the dahi increasing its
acceptability to the consumers.
Equipment details:
Sr. Item No. of Capacity
No equipme
nt
1 HMST 3 15KL
2 Recoverytank 1 15KL

3 Recon tank 1 3KL

4 Turbo blender 1 -

5 PHE 1 10 KLPH
6 Homogenizer 1 5KLPH
7 Cultured tank 3 5KL
8 Pasteurizer 1 5KLPH
9 FFS Machine 2 60/min

96
10 Hamba 1 119/min
Machine
11 Samrpan 1 125/min
Machine
12 Rotary cup 1 22-23/min
filling
machine(IFS)
13 Tub/bucket 2 Manual
filling machine

97
Flow Chart for Dahi Production:

98
CCP & OPRP of the section:
CCP 1: Heating of milk in PHE at 90 ± 2⁰ C for 10 mins.
CCP 2: Filling cups & sealing of cups
CCP 3: Filling & sealing 2kg tub & 10 kg bucket
OPRP 1: Coding/Filling/Sealing (Pouch)
OPRP 2: Transfer of cartoons, cups, pouches, 2 kg tubs& 10 kg
buckets to cold room maintained ≤ 5⁰ C. before putting first
trolley ad stored ≤ 10⁰ C.
Coding on Dahi Packing:
BN : UAL 343, 2A, 08:23
Mfg: 09-DEC-2022
Exp: 24-DEC-2022
MRP: ₹ 42.00, USP ₹0.11/g
Culture details:
Sr. Milk use for
Variety Culture
No preparation
➢ Combination of
Amul RST-744,CHN-
1 masti/Sumul 11,YFL-333. PTM
Dahi ➢ KD2
➢ Curddana
Sumul Combination of
2 PTM
Probiotic dahi KD2 & Curddana

99
 Light dahi/
3 skimmed milk YFL-94, DH-1040 PSM
curd

Chemical standard of dahi:

Type
Amul Masti Dahi /
Sr.
Parameter Sumul Dahi/Sumul Skimmed
No
Milk Dahi
Probiotic Dahi

1 Fat Min3.1% Max0.5%

2 SNF min 10.5% max10.5%

3 pH 4.65 4.65

4 Whey Max 3 ml for200 ml Max3 ml

Separation cup for200ml
Firm with
5 Texture Firm with whey
whey
separation separation
6 Acidity 0.68 to 0.72% 0.68 to 0.72%

Shelf of dahi:
Shelf life of dahi is generally 15 days.

100
Variety vise price:
Sr.
Variety Varient Price
No
200 gm 21.00
1 Amul Masti 400 gm 42.00
2 kg tub 176.00
2 400 gm 45.00
Sumul Punjabi Dahi 1 kg 70.00
pouch
10 kg 880.00
bucket
3 Sumul pro-biotic dahi 200 gm 25.00
400gm 45.00
Sumul skimmed milk 80 gm 15.00
4 curd
200 gm 30.00
10 kg 720.00
bucket
100 gm 12.00
5 Sumul light dahi
200 gm 18.00
200 gm 14.00
pouch
1 kg 58.00
pouch

Details of packaging material:

1) Cups = PS / PP 2)Pouch = LDPE 3)Bucket = HDPE
4) Tub = PP
101
 LASSI
Introduction:
• Lassi is a traditional Indian drink, made by blending dahi
with water, sugar or salt and spices like cardamom,
cumin etc.
• In SUMUL dairy lassi is prepared from full cream
pasteurized milk.
• SUMUL lassi is main product of section.
Equipment list:
Number of
Sr. No Name Capacity
Equipment
1 PHE 1 10KLPH
Lassi
2 2 20KL
Storage tank
Sugar syrup
3 1 100L
making vat
FFS
4 4 -
machine
Warming
5 1 10KLPH
PHE

102
Flow chart of lassi

103
CCP & OPRP of the Lassi section:
CCP 1: Thermization in Lassi PHE (67±2⁰C)
OPRP 1: Coding filling & sealing Lassi in 200 ml Pouch
OPRP 2: Storage of Lassi in cold store <5⁰ C
Culture addition:-
RST-744
• Lactococcus lactis
• Streptococcus thermophilus
Chemical standard:
Parameter value
% fat 2.8-3.2
% TS 18-22
% Acidity (LA) 0.4-0.6
sugar 12

104
 CIP
Introduction:
Cleaning refers to the removal of soil from the surface ofthe
equipment, while sanitization implies destruction of all
pathogenic and almost all non-pathogenic organisms.
Continued deposition of the soil leads to accumulation of
larger and harder particles that are known as milk stones.
Cleaning reverses the soiling process and requires a supply
of energy usually in the form of mechanical and/or heat
energy.
The soil removed from the surface is then dispersed or
removed in the solution by scattering, deflocculation or
emulsification Market Milk 154 and finally, the surfaceis
rinsed to prevent re-deposition of the dispersed soil on the
cleaned surface. Cleaning may be done by manual means,
mechanically or by cleaning-in-place.
Factors affecting C.I.P.:
• Contact Time
• Temperature of solution
• Strength of reagent
• Mechanical action
• Surface area
• Quality of solution

105
Purpose of CIP:
• Increase shelf life of product
• Maintain hygiene
• Prevent defect in product
• Prevent bio film on surface of
equipment Increaseefficiency of plan
Dosing and temperature of solutions:
Acid ▪ HNO3 ▪ 1 to 1.1% v/v ▪ 63±2°C
Lye ▪ NaOH ▪ 1 to 1.1%v/v ▪ 72±2°C

Hot water ▪ 50-55 ppm 63±2°C

Flush water ▪ 50-55 ppm ▪ 30±2°C

106
 Step Rec Rec Rec Rec Rec Rec Rec Set
ipe ipe ipe ipe ipe ipe ipe Time
1 2 3 4 5 6 7 (sec)
Pre- ✓ ✓ ✓ ✓ ✓ 200
rinse
Lye ✓ ✓ ✓ ✓ ✓ ✓ 600
circulat
ion
Interm ✓ ✓ ✓ ✓ 300
ediate
rinse
Acid ✓ ✓ ✓ ✓ 600
Circula
tion
Final ✓ ✓ ✓ ✓ 250
rinse
after
acid
circulat
ion
Final ✓ ✓ ✓ ✓ 250
rinse
after
lye
circulat
ion
Steriliz ✓ ✓ ✓ ✓ ✓ 600
ation
Draina ✓ ✓ ✓ ✓ ✓ ✓ ✓ 20
ge

107
Notes:
Recipe 1: PMST 2 times in month

Recipe 2: RMST 2 times in month

Recipe 3: PMST daily and plant every 5-6 hrs
Recipe 4: Daily in RMST
Recipe 5: Before starting plant
Recipe 6 & 7: Everyday for plant one time

108