1

INDUSTRIAL TRAINING REPORT

2014 – 2015

AT

MAHANAND DAIRY

MAHARASHTRA RAJYA SAHAKARI DUDH MAHASANGH

MARYADIT, MUMBAI

IN THE PARTIAL FULFILMENT OF THE REQUIRE MENTS

FOR THE AWARD OF THE DEGREE

OF

B.TECH (FOOD TECHNOLOGY)

SUBMITTED BY

MR. DAPHALAPURE VAIBHAV DILIP (FTR-10/2011)

MR. MANE PRAVIN VILAS (FTR-37/2011)

MR. MOTE PRASHANT MADHUKAR (FTR-43/2011)

B. Tech (Final Year)

SUBMITTED TO

Mokashi College of Food Technology, Rajmachi, Karad.

(Affiliated to Mahatma Phule Krishi Vidyapeeth, Rahuri)

2

INDUSTRIAL TRAINING REPORT

2014 – 2015

AT

MAHANAND DAIRY

IN THE PARTIAL FULFILMENT OF THE REQUIREMENTS

FOR THE AWARD OF THE DEGREE

OF

B.TECH (FOOD TECHNOLOGY)

SUBMITTED BY

MR. DAPHALAPURE VAIBHAV DILIP (FTR-10/2011)

MR. MANE PRAVIN VILAS (FTR-37/2011)

MR. MOTE PRASHANT MADHUKAR (FTR-43/2011)

B. Tech (Final Year)

Mokashi College of Food Technology, Rajmachi, Karad.

(Affiliated to Mahatma Phule Krishi Vidyapeeth, Rahuri)

SUBMITTED TO

MAHANAND DAIRY

MAHARASHTRA RAJYA SAHAKARI DUDH MAHASANGH

MARYADIT, MUMBAI

3

ACKNOWLEDGEMENT

An industrial training is a golden opportunity for learning and self- development in the

practical life. We consider ourselves very lucky and honored to have so many wonderful peoples

lead us through in completion of this industrial training. The industrial training at Maharashtra

Rajya Sahakari Dudh Mahasangh Maryadit, Mumbai has been collaborative effort of many

peoples who helped us in understanding the working fascinating plant.

We wish to express our indebted gratitude and special thanks to " Mrs.Akleker .R .J

(QC, Manager) and Mrs. Choudhari (Production manager) who in spite of being

extraordinarily busy with her duties, took time out to hear, guide and keep me on the correct path

and allowing me to carry out my industrial project work at their esteemed organization and

extending during the training.

We would also like to thank the staff of the department of Quality Control,Processing,

Production, Packaging, Engineering and Administration. We take this opportunity to express my

gratitude and thanks to each and every person whose help, encouragement and intellectual

influence were instrumental in successful of our training. Lastly, we like to thanks them who

helped us directly or indirectly for completing this training.

We extend our gratitude to Dr. P.A. Unde (Principal) and Mr. A.S. Dhane (Vice-

Principal) for giving us the chance to undergo for the industrial training in such prestigious

organization.

At last but not least, words of acknowledgement respectfully go to all our colleagues,

well-wishers and who provided necessary information directly as well as indirectly for our

training work.

Place: ............ Yours Sincere,

Mr. Daphalapure Vaibhav Dilip

Date : .............. Mr. Mane Pravin Vilas

Mr. Mote Prashant Madhuk

4

OBJECTIVES

The objectives of the Industrial Training Programme for B.Tech (Food Technology) are:

To develop the students as skilled professionals through practical work experience

in real life situations.

To develop technical and managerial competence in students in commercialization

of technologies.

To mould the students as job providers rather than job seekers.

To train the students in high quality entrepreneurship skills in all the aspects of

Enterprise management.

To cultivate capabilities suiting emerging job markets and build entrepreneurship spirit

and business management competence among students in that they are able to create

employment for themselves and others.

To adopt and face the challenges given by the boss.

To play a vital role for an organization to achieve the target/goal.

To give quality to the consumers and satisfy the nutritional needs.

5

Location of Training Centre:

―MAHARASHTRA RAJYA SAHAKARI DUDH MAHASANGH

MARYADIT MAHANAND DAIRY, GOREGAON (EAST) MUMBAI - 400 065.”.

6

INDEX

Sr. No

Content

Page No.

1. Introduction

2. Plant layout

3. Organization chart

4. RMRD section

5. Milk processing

6. Dairy products

7. Quality System

8. CIP of processing section

9. Quality control section

10. BIS standards for milk products

11. Preparation of solution and media

12. Fill pack section

13. Utilities

14. ETP

15. Conclusion

7

INTRODUCTION

Mahanand dairy was constructed in 1982 and was commissioned in 1983. It is

situated at western express highway, Gorega0on (East), Mumbai. Starting capacity of dairy is

500lit/day and increased to 65000 lit/day be the end of that year with the progress over year‘s

capacity of the plant is 8, 00,000 lit/day

The Indian dairy industries scenario has made rapid progress. Since independence a large

number of modern dairy plants have been established. Since the time of white revolution, and

establishment of dairies that use modern technology, there has been a drastic rise not only in

production of milk but also in the quality of milk & milk products. Similarly the quantity of

products manufactured in Mahanand dairy has improved various organized dairies have engaged

in commercial production of market milk & various western & Indian dairy products.

The quality of milk for liquid milk supplied had to be outstanding and this demands urgent

attention towards quality of raw milk collected. Therefore the milk producers are being

incentives for quality milk to keep pace with international standards. The adulteration is serious

impediment in the healthy growth of dairy industries and has tarnished his image both in India

and abroad. Therefore the raw milk is tested cleanly before accepting it. Mahanand dairy is an

important part of GMMS (Govt. of Mumbai milk supply) and Govt. Milk Scheme. The main

purpose of GMM is to provide milk at lower constant price in metro city Mumbai. Mahanand

dairy providing processed and good quality milk to the city. Presently Mahanand is the largest

dairy in Mumbai and one of the largest dairy in Maharashtra.

8

ADDRESS OF DAIRY – Maharashtra Rajya Sahakari Mahasangh Maryadit

(MRSDMM) Western express highway Goregaon (E) Mumbai-400 065

MRSDMM is a apex federation of district/taluka milk unions established to implement.

The Operation flood programme in the state of Maharashtra.The main objective rates and

distributes the same to the consumer at reasonable rates.

MRSDMM- was established on 09th

June 1967

At present MRSDMM have 86 member unions (25 district +49 taluka +11 Multi state unions)

With more than 20000 primary milk societies +and 23 lacs which includes appx. 27000Women

members.

The total sale of milk under Mahanand brand name in the state is 8.5 LLPD including the

Sale of milk in Konkan, Pune and Nagpur region

Mahanand Konkan dairy has been established for giving Special impetus for developmentof

backward region. At present,we are selling about 30,000 ltrs. Of milk per day from Konkan dairy

project

Mahanand Pune dairy Plant is established to supply Mahanand milk to the huge population in

Pune city a`nd surround area. At present, we are selling about 45,000 ltrs/day from Pune dairy

project.

Mahanand Nagpur Dairy Plant is established to provide special impetus to backward region of

vidarbh in general and Nagpur in particular. At present we are selling about 50,000 ltrs. Of milk

from Nagpur Dairy.

Mahanand Dairy Latur: During the financial year 2002-03 the MRSDMM has taken over the

Goverment milk Scheme Latur (GOVERMENT OF MAHARASHTRA) on long tern lease basis

(30 years). The Mahanand Latur Dairy Plant has been started to provide special support to

develope dairy activity in Marathawada region. At present we are selling about 30,000 ltrs per

day of Milk from Latur dairy plant which includes sale at Hyderabad.

9

Plant Layout Ground Floor First floor

ORGANISATION CHART

Managing Director

Gate 2 Securiy

office

Gate 1

Administration office

Garden

canteen

ETP plant

Pump

house

Gate3

processing RMRD

Pre-Packing

Production

Cold storage

Deep fridge

Refrige

-ration

section

Josh

plant

Departure of final

product

QC lab

Raw

mater

-ial

store

Wa

-sh

ro

Changing

room

boiler

p

a

r

ki

n

g

Employee quaters

Weigh bridge

Water

tank

10

Chief executive officer

President Vice president

General Manager

Factory Quality Marketing Finance Purchase

Manager Manager Manager Manager Manager

Production Employs

Manager

Assistance production

Manager

Supervisor

Workers

11

RAW MILK RECEPTION DOCK SECTION (RMRD)

Milk reception at Mahanand Dairy is fully atomized and milk is received by tankers in

three shifts as per the production need. There are three milk reception stations each having

capacity of 10,000 lit/hr. The following process is carried out at reception dock:

Flow sheet of milk reception:

Tankers

Weighing bridge

Sampling at dock lab

Testing

Ok

Milk reception

Pumping

Duplex filter

Chiller

Raw milk silo

12

MILK PROCESSING:

Processing section is the heart of any dairy. Hence to preserve the milk and improve it‘s

nutritional and sensory quality by subjecting it to different process depending upon the final

process. Processing section performs various operations such as clarification, pasteurization,

standardization, homogenization, chilling.

1. Pasteurization:

Pasteurization is most common process used to destroy bacteria in the milk. In

pasteurization milk is heated to a sufficient temperature to kill the pathogenic bacteria in milk.

The pasteurization temperature is 760C to 78

0C for 15 sec.

2. Homogenization:

In dairy industry homogenization is used principally to prevent the formation of cream

layer in milk by reducing the diameter of fat globule about 2 microns. Two stage homogenization

is carried out where pressure in first stage being 1500 psi and in second stage 500 psi and

temperature of homogenization is 50-55 o c.

3. Chilling:

Milk is chilled to extend its shelf life by a few days. Due to chilling the growth of

microorganism slowed down. The temperature of chilling at Mahanand dairy is in between

3- 40

C.

4. Standardization:

Standardization refers to the adjustment of FAT and SNF content of the milk.

Standardization is important to manufacture product with desire composition in order to fulfill

the specified standards. Standardization involves the blending of two or more products which act

as source of FAT or SNF.

5. Milk sterilization:

In pasteurization, milk receives mild heat treatment to reduce the number of bacteria

present. In sterilization milk is subjected to intense heat treatment that ensures almost complete

destruction of microbial population. The product has a higher shelf life than pasteurized milk.

13

Operational Parameters:

1. Milk chiller:

Initial temp. Of milk - 4 – 7 oc

Cooling medium - chilled water at 1-2 oc

2. Milk pasteurizer:

Time temp. Combination - 76-78

oc for 15 sec.

Steam pressure - 5-6 kg/cm2

Chilled water temp. - 1-2 oc

Chilled milk temp. - 4-3oc

3. Homogenizer:

Homogenization temp - 55 o c

Pressure in 1st stage - 1500 psi

Pressure in 2 nd

stage - 500 psi

4. Cream separators:

Separation temp. - 40 to 50 oc

14

Flow Chart For Pasteurized Milk:

Receiving milk to balance tank

Regeneration - 1 (30- 35 oc)

Filtration

Regeneration - 2 (50- 55oc)

Homogenization

(1st stage 1500 psi, 2

nd stage 500 psi)

Regeneration -3 (65- 70 o

c)

Heating (75-80oc)

Holding (15 sec)

Regeneration – 3, 2, 1

Chilling (4-5o c)

15

DAIRY PRODUCTS

Products of Mahanand dairy:

1. Shrikhand

2. Amrakhand

3. Dahi

4. Lassi

5. Chass

6. Flavoured milk

7. Paneer

8. Ghee

These are the products prepared in Mahanand dairy as per the market need. The

general protocol of production is given below.

16

1. Shrikhand :

Shrikhand is a popular dessert made from Dahi. It is available in flavours such as

elaichi, badam-pista etc. It is packed in 100 gm, 250 gm, and 500 gm cups.

Flow chart for shrikhand:

Standardized milk

Preheating of milk (40oc)

Inoculation with culture (0.5%)

Incubation

Curd formation

Hanging in muslin cloth to separate whey (5-6 hrs)

Chakka

Blending & mixing of ingredients

(Sugar& dry fruits)

Packaging

Cold storage below 00c

17

2. Amrakhand :

Flow chart for Amrakhand:

Standardized milk

Preheating of milk (40oc)

Inoculation with culture (0.5%)

Incubation (6-8 hrs)

Hanging in muslin cloth (6-8 hrs)

Chakka

Blending & mixing mango pulp with sugar

Packaging

Cold storage below 00c

18

3. Mast Dahi :

Mahanand produces dahi under the brand name of ‗Mast Dahi‘. It is packaged in

cups of 100 gm, 200 gm, 400 gm. Dahi at Mahanand is made from whole or toned milk.

Flow chart for Dahi:

Standardized milk (fat 4.5%& SNF 9%)

Pasteurization

Cooling up to 32o c

Addition of starter culture @ 0.3%

Plungering

Packaging

Incubation at 37oc (for 3-4hrs)

Storage (4oc)

19

4. Lassi :

Lassi is a drink based on Dahi. It is sweet in taste and contains a much higher percentage of

solids since it is made from whole milk. The brand name of lassi produced by Mahanand is

‗Bahar lassi‘. It is packed in 200 ml pouches.

Flow chart for lassi: Pasteurized whole milk

Preheating (37oc)

Culture addition 0.5%

Incubation (4-5 hrs)

Curd formation

Breaking of curd

Addition of sugar(18%) and water(25%)

Mixing with plunger

Online filtration

Pasteurization (78oc for 15 sec)

Homogenization

Filling in 200 ml pouches

Storage at (4oc)

20

5. Masala chass :

Masala chass is another refreshing drink produced from dahi and the blend of spices

that gives distinct flavour.

Flow chart for masala chass:

Standardized milk

Preheating (37oc)

Culture addition 0.5%

Incubation (for 4-5 hrs)

Curd formation

Breaking of curd

Addition of water (50%)

Mix properly

Pasteurization (78oc)& homogenization

Addition of chass masala&

Soak it for 10-12 hrs

Filter through muslin cloth

Plungering

Packaging in 200 ml cups or pouches.

Storage (4oc)

21

6. Flavoured Milk

Mahanand produces flavoured milk in 7 flavours: Rose, Litchi, Kesar-Elaichi, Pineapple,

Strawberry, Banana and Coffeeunder the brand name of ‗Josh‘.

Flow chart for flavoured milk:

Standardized milk.

Pasteurization (78o

c for 15 sec)

Homogenization

Addition of sugar, colour & flavour with constant stirring

Filling (glass bottle)

In – bottle sterilization (at 120oc for 20 min @ 1.2- 1.5 kg/cm

2)

Labelling

Storage at RT

22

7. Paneer :

Paneer is a coagulated milk product also known as cottage cheese. Mahanand markets

the cubs of paneer in 200 gm packs.

Flow chart for paneer:

Pasteurized milk

Heating up to 80oc

Cooling up to 75oc

Addition of citric acid solution (1%)

With constant stirring

Coagulation of milk

Draining of whey

Putting in mould & pressing of paneer for 10-15 min

Cooling in chilled water (4-5 hrs)

Cutting & packaging

Storage in deep freezers (below -14oc)

23

8. Ghee

―Ghee is defined as clarified butter fat or from cream to which no colouring matter is

added according to PFA rules‖

Flow chart for ghee:

Raw cream

Melting of cream (70-800c)

Loading into ghee kettle

Pre- stratification

Cooking at 1100c for 30 min.

Filtration by 9 layer micro filter

Clarification

Storage at 45-500c

Packaging

24

QUALITY SYATEM

A) ISO Certificate 9001-2008 (International Organization For Standardization):

This Indian Standard (Third Revision) which is identical with ISO 9001 : 2008 'Quality

management systems — Requirements' issued by the International Organization for

Standardization (ISO) was adopted by the Bureau of Indian Standards on the recommendation of

the Quality Management Sectional Committee and approval of the Management and Systems

Division Council.

This standard was first published in 1988 and subsequently revised in 1994 and 2000.

This third revision of the standard was necessitated because of the publication of the revised

version of ISO 9001 in the year 2008.

The adoption of a quality management system should be a strategic decision of an

organization. The design and implementation of an organization's quality management system is

influenced by

a) Its organizational environment, changes in that environment, and the risks associated with that

environment,

b) Its varying needs,

c) Its particular objectives,

d) The products it provides,

e) The processes it employs,

f) Its size and organizational structure.

It is not the intent of this International Standard to imply uniformity in the structure of quality

management systems or uniformity of documentation.

The quality management system requirements specified in this International Standard are

complementary to requirements for products. Information marked "NOTE" is for guidance in

understanding or clarifying the associated requirement. This International Standard can be used

by internal and external parties, including certification bodies, to assess the organization's ability

to meet customer, statutory and regulatory requirements applicable to the product, and the

Organizations own requirements. The quality management principles stated in ISO 9000 and ISO

9004 have been taken into consideration during the development of this International Standard.

Process Approach This International Standard promotes the adoption of a process approach when developing,

implementing and improving the effectiveness of a quality management system, to enhance

customer satisfaction by meeting customer requirements. For an organization to function

effectively, it has to determine and manage numerous linked activities. An activity or set of

activities using resources, and managed in order to enable the transformation of inputs into

outputs, can be considered as a process. Often the output from one process directly forms the

input to the next. The application of a system of processes within an organization, together with

the identification and interactions of these processes, and their management to produce the

desired outcome, can be referred to as the "process approach". An advantage of the process

approach is the ongoing control that it provides over the linkage between the individual

processes within the system of processes, as well as over their combination and interaction.

25

When used within a quality management system, such an approach emphasizes the importance of

a) Understanding and meeting requirements,

b) The need to consider processes in terms of added value,

c) Obtaining results of process performance and effectiveness, and

d) Continual improvement of processes based on objective measurement.

The model of a process-based quality management system shown in Figure 1 illustrates the

process linkages presented in Clauses 4 to 8. This illustration shows that customers play a

significant role in defining requirements as inputs. Monitoring of customer satisfaction requires

the evaluation of information relating to customer perception as to whether the organization has

met the customer requirements. The model shown in Figure 1 covers all the requirements of this

International Standard, but does not show processes at a detailed level.

NOTE In addition, the methodology known as "Plan-Do-Check-Act" (PDCA) can be applied to

all processes. PDCA can be briefly described as follows.

Plan: establish the objectives and processes necessary to deliver results in accordance with

customer requirements and the organization's policies.

Do: implement the processes.

Check: monitor and measure processes and product against policies, objectives and requirements

for the product and report the results.

Act: take actions to continually improve process performances.

26

B) HACCP certification (Hazard analysis and critical control point): HACCP is management system in which food safely is addressed through the analysis

and control of biological, chemical and physical hazards from raw material production,

procurement and handling to man of acting distribution and consumption of finished product.

Food safely is global concerned not only because of the continuing importance of public health

but also because of its impact on international trade effective food safely system shall therefore

manage an ensure safely and suitability of food stuff ―HACCP‖ to be put in place by any food

business or organization weather profit making or not and weather public or private, carrying

out any or all of the following activities Preparation, processing, manufacturing, packaging,

storage, transportation, distribution, handling or offering for sale or supply of food stuff.

According to regulation of export council (EC) no 852/2004 of the European parliament

and of the council of 29th

April 2004 on the hygiene of food stuff all food business operator in

the European Union shall implement HACCP. They shall ensure that adequate safely

procedures are identified document, maintained reviewed on the basis of the principle use to

develop the system of HACCP.

The joint FAO/WHO codex alimentation commission describes a series of steps including the 7

HACCP principles, giving guideline for application of HACCP system.

Principles

1. Conduct a hazard analysis

2. Determine the critical control point

3. Establish critical limits.

4. Establish monitoring procedure

5. Establish corrective action

6. Establish verification procedure

7. Establish record keeping and documentation procedure.

Also codex advices that minimum hygiene major should in placed before HACCP is

implemented ―Prior to application of HACCP. To any sector of food chain, that sector should

be operating according to codex general principle of food hygiene, the appropriate codex codes

of practices and appropriate food legislation‖. This pre-requisite programmed should be well

specified and documented, fully operational and verified in order to facilitate the successful

application and implementation of HACCP. The general principle of food hygiene as

recommended by codex from an intrinsic part of the documents ―Requirements specific food

safety requirements are detailed in legislation hygiene codes, customer and consumer

specification were specific requirement do not exist the requisite programmed will be applied

furthermore the seven principle and guideline for the application of HACCP have been

27

combined in this specification with basic elements of quality management systems (ISO:9000)

to establish ―The requirement for HACCP based system.

The Specification ―Requirement for HACCP based food system has been developed by

and is placed under the authority of national based of experts HACCP in order to make

normative documents / standard available all parties involved in food chain are represented in

the national board of experts – HACCP.

These specification can be used by certifying bodies to assess the continuous compliance of

HACCP based food safely systems as developed by food business operators.

Authority is obtained when certifying body in formally accredited by recognized body

to operate the certification system for HACCP based food system and is audited regularly by

these accreditation body accreditation concerns the reliability competence of certifying body.

a) MMPO certification (Milk and Milk product order -1992)

The central government is of opinion that for maintaining and increasing the supply of liquid

milk of desire quality in the interest of general public. It is necessary to provide regulating the

production supply and the distribution of milk and milk product. Therefore product in exercise

of the power confirm by section -3 of the essential commodities under act 1955. The central

government here by makes the order called milk and milk product order 1992. It extents to the

whole of India it shall come in to force on the dates of its publishing on the official gazette.

b) PFA certification (Prevention of food adulteration act 1954)

Prevention of food adulteration rules in 1955. This act to make provision for the prevention of

adulteration of food it in acted by the parliament in the 5th

year of the republic of India it

extends through while of India. It shall come in to force on such date as central government

may by notification in the official gazette appoint. This is applicable for all food articles.

c) FPO certification (Food product order 1955)

In exercise of the power conform by section-3 the essential commodity acts 1955. The central

government here by makes the order is called FPO 1955. It extends to whole of India. This is

applicable for fruit nectar means beverages prepared from pulp or juice extracted from fully

ripped and sound fruits. In general this is applicable for synthetic beverages, syrup, but,

pickles, dehydrated fruits and vegetables, jams, jelly, tomato-ketchup, sources crystallized

fruits, chutneys, canned fruits juices pulps, frozen fruits.

d) BIS certification- Bureau of Indian Standards

The adoption of quality management system should be a strategic decision of an organization.

The design and implementation of an organization quality management system is influenced by

varying needs particular objectives structure of organization. It is not the intent of these

28

international standards to imply informative in the structure of quality management system

requirement specified in this international standard are complementary to requirements for

products.

These international standards can be used by internal and external parties including certification

bodes to assess the organization ability to meet customer regulatory and organizations own

requirements. The quality management principle stated in ISO 9000 and ISO 9004 have been

taken into consideration during the development of these international standards. The

international promotes the adoption process approach when developing implementing and

improving the effectiveness of quality management system to on hence customer requirements

for an organization to function effectively it has to identify and manage numerous link

activities and activities using resources and mange in order to unable the transformation input

into output. Can be consider as a process often the output from one process directly forms the

input to the next to the application of a system of process within an organization together with

the identification and interaction of these process.

e) EIC certification (Export inspection council of India)

The requirement for the approval of the establishment to process milk product meant for export

have been notified wide GOI order and notification S.O.2719 and S.O.2720 both dated

28.11.2000 on the basis of which the establishment processing milk product meant for export

are being approved by the competent authority i.e. export inspection agency establish under

Sec 7 of the export quality control and inspection act 1963.

The primary responsibility for meeting the health requirement of importing countries and also

those specific in GOI notification lives with the processing establishment them sell for which

these establishment are require to plant and implement detail HACCP based notice control.

(Own check system) and to maintain necessarily records. The role of export inspection council

of India is to exercise official control by approving the units and implementing and effective

surveillance system to ensure compliance to requirements as per class 3 of notification no -

S.O.2720 dated 20th

November, 2000.

Application shall accompany by following documents.

HACCP manual including the sanitary standards operating process

Process flow chart

Manufacturing detail in each step.

Self-residual maintaining plan

In the case of establishment mean and for export to the other countries attested / certified copy

of the test report from EIA lab / EIC lab in respect of water complying with EC directive no.

29

CIP OF PROCESSING SECTION :

CIP of processing section :

CIP stands for cleaning in place. This refers to that system of cleaning and

sanitization which does not require the daily dismantling of dairy equipment. To maintain the

hygienic condition of plant proper cleaning, ventilation and CIP of milk processing equipment is

necessary. For CIP caustic soda and nitric acid is used in required proportion.

The strength of caustic solution of CIP is kept between 1-2%.

The strength of acid solution of CIP is kept between 0.5-1%.

Flow chart for CIP :

Plain water washes for 5 min.

Caustic circulation for 10-15 min at 60-75oc.

Hot water circulation at 900c for 10-15 min.

Cold water washes for 10 min.

30

QUALITY CONTROL SECTION :

A) Raw & Processed Milk Testing.

B) Product Testing.

C) Agmark Testing.

D) Microbial Testing.

A) Raw & Processed Milk Test:

Raw and processed milk undergoes following tests:

1) Organoleptic testing.

2) Adulteration test.

3) Acidity

4) Fat

5) SNF.

6) Protein content.

7) Phosphate test.

8) MBR test.

9) EQA test.

10) COB test.

1.Organoleptic Test for Milk:-

As soon as milk is received in the lab for testing, it is assessed for its organoleptic

properties.

Parameter Observation

Taste Sweetish

Flavour Milky

Colour Creamish white

Appearance Pleasant ( free from extraneous matter)

Consistency Uniform

31

2. Adulteration Tests:

After organoleptic test the fresh milk sample is tested for its adultration test. Each fresh

sample should not contain any adulterants otherwise it will be rejected. Procedure for detection

of adulterants‘ in milk is given below:

a) Neutralizer Test ( soda test):

Take 5 ml milk in test tube.

Add 5ml absolute alcohol.

Add 3 drops of rosalic acid indicator.

Observation:

Pink – red colour - Soda present.

Orange colour- Soda absent.

b) Starch Test:

Take 3 ml of milk in test tube.

Boil it.

Cool it; add 3 drops of starch indicator.

Observation: Blue colour – Starch present.

Yellowish colour – Starch absent.

c) Urea Detection:

Take 2 ml milk in test tube.

Add 2 ml of urea reagent.

Shake well.

Observation:

Dark yellow colour-Urea present.

Light yellow colour- Urea absent.

d) Salt Test: Take 5ml salt reagent 1 in test tube.

Add 2 drops of salt reagent 2 & shake it well.

Then add 1ml milk & shake well.

Observation:

If yellow colour appear within 1 min- Salt present.

Brown colour- Salt absent.

32

e)Sugar Test:

Take 25 ml milk in bikker.

Add 1ml conc. HCL

Cogulate milk and filter it than take 1ml test tube.

Take 5 ml resorcinol reagent added with 1ml filtrate sample.

Boil 1 min.

Observation:

Red colour - Sugar present.

White to colourless-Sugar absent.

f) Maltodextrine Test:

Take 25 ml milk.

Warm it in boiling water bath.

Add 5 drops of 5% lactic acid.

Cool it; and filter through a filter paper.

Then take 5ml of filtrate.

Add 3 drops of starch indicator.

Observation:

Brown colour - Maltodextrin present.

Yellow colour- Maltodextrin absent.

g) Hydrogen Peroxide Detection:

Take 1ml of milk.

Add 1ml of hydrogen peroxide reagent.

Shake well.

Observation:

Intenseblue colour- H2O2 present.

h) Detergent Paste Detection:

Take 10 ml of milk in test tube.

Add 2-3 drops of bromothymol blue (1%)

Shake well.

Observation:

Purple colour - Detergent present.

Navy blue colour- Detergent absent.

33

i) Glucose Test: Take 1 ml of milk in test tube.

Add 1 ml glucose reagent 1.

Place it in boiling water bath for 3min.

Cool it.

Then add 1ml glucose reagent 2.

Observation:

Greenish blue - Glucose present.

Sky blue- Glucose absent.

3. Acidity of Milk:

Take 10 ml distilled water in 100 ml clean & dry beaker.

Add 1ml phenolphthalein indicator.

Add 10 ml milk.

Titrate against N/ 9 NaOH.

Take burette reading & calculate % of acidity as lactic acid.

% acidity = 9AN/W

Where,

A=Burette reading.

N= Normality of NaOH.

W= Amount of milk sample taken.

4) Fat Content of Milk:

Take 10 ml sulphuric acid in butyrometer.

Take 10.75 ml of milk in butryometer.

Add 1ml amyl alcohol in butryometer.

Put lock stopper.

Shake well.

Centrifuge for 5 min at 3000 rpm.

Record the fat column.

5) Estimation of SNF of Milk:

Adjust CLR of densitometer to 1.0000 at 21oc using distill water.

Feed milk sample into densitometer & note down the CLR reading.

Calculate % SNF using formula.

% SNF=CLR/4+ (0.21X FAT %) + 0.36

34

6) Protein Content of Milk By Formal Titration(Pynes method):

Take 10 ml milk in 100 ml beaker.

Add 5 drops of phenolphthalein indicator.

Add 0.4 ml of saturated potassium oxalate & keep it for 5 min.

Then titrate the sample against std. Alkali till pink colour appear & judge

the colour intensity visually.

Add 2 ml neutral formalin.

Then titrate it against std. Alkali to the same end point as before.

Note down the burette reading & calculate protein content using formula.

% of Protein= BR X 1.7

7) Phosphate Test:

Phosphate test is used to check the pasteurization efficiency.

Take 5ml of the buffer substrate solution in test tube & bring it to 37oc by

keeping the test tube in water bath for half an hour.

Add 1 ml milk & mix the content.

Incubate test tube exactly at 37oc for 2 hrs.

Observe the colour change in 2 hrs.

Observation:

If the colour change takes place within 2 hrs indicates milk is not properly pasteurized

8) Methylene Blue Reduction Test(MBRT):

Methylene blue is blue in color when it is in oxidized state. As microorganism start

growing in it, they will utilize this oxygen for growth and metabolism. Due to this methylene

blue get reduced and dye becomes colourless. Faster the decolourization, greater the microbial

load and lower the quality of milk. This is done to ensure that processing condition has been

properly followed and that there is no excessive microbial load in milk resulting in its faster

spoilage.

Take 1 ml of MBRT working solution in dry test tube.

Add 10 ml milk in it.

Mix the content by putting rubber stopper.

Incubate at 37oc in serological water bath.

Observe the colour change for every 30 min.

35

9) Emulsion Quality Analyzer (EQA) Test:

This is performed to check the efficiency of homogenization.

Take 250 ml distil water in 500 ml beaker.

Add 10 ml EQA solution.

Add 1 ml milk sample & mix well.

Adjust the absorbance index of emulsion quality analyzer with distil water at

0.0000.

Replace the water with testing sample.

Take reading of EQA for absorbance index of milk sample.

Determine the fat content of that sample.

Note down the result of efficiency of homogenization by observing the chart

of EQA.

10) COB Test( clot on boiling): Take 2 ml milk in test tube.

Boil it on gas burner.

Observation:

If curdle on the bottom- COB positive.

36

B) Product Testing:

Before distribution in markets, the samples of various products from each batch of

production are sent to the quality control lab for checking various parameters such as

acidity, fat, moisture content and total solids.

1) Acidity.

2) Fat content.( Shrikhand/ Amrakhand/ Paneer)

3) Moisture content.

4) Total solids.

5) Fat content (lassi / chass)

1) Acidity ( Shrikhand/Amrakhand/Paneer/Lassi/Chass/Dahi):

Take approximately 1gm sample in clean & dry 100 ml beaker.

Add 10 ml D/W.

Mix the content with the help of glass rod.

Then add 1 ml phenolphthalein indicator.

Titrate against N/9 NaOH solution till faint pink colour appears.

Calculation:

% Acidity = 9AN/W

Where,

A = Burette reading.

N= Normality of NaOH solution.

W = Weight of sample taken.

2) FAT (Shrikhand/Amrakhand/Paneer): Weight 3 gm of sample in cheese butryometer.

Add 10 ml sulphuric acid (92%) in butryometer & put the lock

stopper.

Mix the content of butryometer by shaking carefully until sample is

digested.

Centrifuge it at 3000 rpm for 5 min.

Record the reading.

3) Moisture content ((Shrikhand/Amrakhand/Paneer): Weight clean and dry aluminium dish.

Take approximately 2.5 gm of sample and spread into uniform layer

with the help of spatula.

Keep aluminium dish in Sartorius moisture balance at 1050c for 15-

20 min.

After 15-20 min Sartorius moisture balance gives direct moisture

content.

37

4) Total solids (lassi/chass):

Take CLR reading of the sample with the help of densitometer at

210c.

Calculate the total solids using formula.

Total solids = CLR/4+1.2*fat %+0.5

5) Fat % (lassi / chass): Take 10.75 ml sample in butryometer.

Add 10 ml of sulphuric acid (92%).

Add 1 ml of amyl alcohol and put lock stopper.

Mix the content by shaking.

Centrifuge it at 3000 rpm for 5 min.

Record the fat column.

38

C) AGMARK( Ghee testing ):

AGMARK involves ghee testing. Mahanada has a separate AGMARK

department which test ghee sample from each batch of production. Before the distribution in

market the ghee is tested for various parameters to check whether the quality standards are being

achieved.

Test for ghee:

1) Determination of Moisture: Weight accurately about 10 gm of homogenized ghee sample in previously

weighed beaker.

Keep this beaker in an oven maintained at 1050c for 2-3 hrs.

Remove and cool in dessicator.

Then weight & calculate moisture %.

Calculation:

% of moisture by mass = 100 x weight loss /wt. of sample taken.

2) Determination of Free Fatty Acids: Take 10 gm of ghee sample in conical flask.

Add 50 ml of neutral alcohol.

Warm it up to 700c to dissolve fat in alcohol.

Add 5 drops of phenolphthalein indicator.

Titrate against 0.1 NaOH till pink colour appears.

Calculation:

% of free fatty acids = 2.82 x B.R/ Wt. Of sample

3) Baoudin Test:

Take 5 gm of the ghee in 20 ml measuring cylinder with stopper.

Add 5 ml conc.HCL & 0.4 ml of furfural solution.

Insert the glass stopper & shake vigorously for about 2 min.

Allow the mixture to separate, if pink colour develops in the acid layer then

the test is positive and indicate presence of sesame oil.

Confirmation test: Add 5ml D/W. If pink colour still persists presence of

sesame oil is confirmed.

4) Butryo-Refractometer Reading:

Clean the prism with cotton, wetted with alcohol.

Dry the prism.

Place a drop of test sample on the prism of refractometer.

Convert this reading to refractive index at 400c using reference table.

39

5) Determination of soluble and insoluble volatile acids (Reichert Meissl and

Polenske Value )

Weigh accurately 5 gm of ghee sample in polenske flask

Add 2 ml of 50 % of NaOH and 22 ml of glycerin

Saponify the above mixture on a burner flame.

Add 93 ml hot distill water while the above saponified mixture is still hot and take care

that mixture inside flask does not spatters.

Add 6-7 glass bits to the above flask to avoid bumping of content in flask.

Assemble the polenske flask with the distilling apparatus.

Add 50 ml of dilute sulphuric acid into the flask.

Fix one end if still head to flask and other end to water condenser.

Heat the flask without boiling the content until the volatile acids are completely melted

and golden ring appears on the surface of content of flask the increase the flame and

distill 110 ml in between 19-22 minute.

Keep the water flowing in condenser at a sufficient speed to maintain temperature of the

issuing distillate between 18 0 – 21

0 C.

When the distillate reaches 110 ml , mark remove the flame and replace 110 ml flask by

test tube of 25 ml capacity to catch the draining.

Stopper the 110 ml flask and place it into water at 150

C for 10 minute so as to immerse

the 110 mark.

Remove the flask from the water, dry from outside mix the distillate slightly tilting the

flask avoiding welting the stopper with insoluble acid.

Filter through filter paper no 4 collect 100 ml in dry conical flask and retain the solution

for titration (RM value) .

Detach the still head wash the condenser with 3 simultenous 15 ml portion of cold distill

water passing each wash separately through the cylinder the 110 ml flask the filter and

funnel discard the washings.

Dissolve the insoluble acid by 3 similar washing of the condenser 110 ml flask and filter

with 15 ml of neutralized ethanol. Collect the solution in conical flask and retain the

solution for filtration (PV).

Reichert- Meissl or soluble volatile acid value.

Titrate 100 ml of filtrate containing insoluble volatile acids against 0.1 N NaOH using

phenolphthalein indicator till the appearance of pink color let the reading be T1

Polenske value or insoluble volatile acid value.

Titrate the alcoholic solution of insoluble volatile acids and the reading be T2

CALCULATION

RM value = 1.1 X (T1 - T) T is blank

PV value = T2 - T

40

D) Microbial Testing: In order to enhance their quality control, Mahanand has a separate Bacteriology

department which tests milk & milk products and water sample. Raw milk and water

sample is tested for coliform & SPC and Milk products are tested for E-Coli, coliform,

yeast and mold and TPC (total plate count) at different dilutions.

1) Microbial Analysis of Raw Milk/Water Sample:

a) Coliform Count:

Take 1ml of sample to be tested in test tube containing 9 ml saline and

prepare dilutions 10-1

and 10 -2

Take 1 ml from 10-1

dilution for coliform count.

Add in sterile petriplate.

Pour media (violet bile-red agar) in petriplate in sufficient quantity.

Incubate the plates at 37 0c for 24 hrs & observe the growth.

b) SPC (standard plate count):

Take 1ml sample from 10-2

dilution for standard plate count.

Add in sterile petriplate.

Pour the sufficient quantity of plate count agar in petriplate.

Incubate the plates at 37 0c for 24 hrs & observe the growth.

2) Microbial Analysis of Milk Product:

a) Shrikhand/Amrakhand/Dahi/Paneer:

Take 1gm of sample and add in test tube containing 9 ml Ringer solution.

Then prepare dilution up to 10 -4

.

Take 0.1 ml from 10 -1

for E-coli & 1 ml for coliform, take 1 ml from10-2

dilution for yeast & mould and 1 ml from 10-4

dilution for TPC (total

plate count).

Then pour the sufficient quantity of media in petriplate.

Incubate the plates at 370c for 24 hrs & observe the growth.

b) Chass/lassi:

Take 1ml of sample and add in test tube containing 9 ml Ringer solution.

Then prepare dilution 10-1

, 10-2

& 10-3

.

Take 0.1 ml from 10 -1

for E-coli & 1ml for coliform, take 1 ml from10-2

dilution for yeast & mould and 1 ml from 10-3

dilution for SPC ( standard

plate count )

Then pour the sufficient quantity of media in petriplate.

Incubate the plates at 370c for 24 hrs & observe the growth.

41

c) Flavoured Milk:

Take directly 0.1 ml for E-coli, 1ml for coliform, yeast and mould & SPC.

Then pour the sufficient quantity of media in petriplate.

Incubate the plates at 370c for 24 hrs & observe the growth.

3) Swab Test:

Swab test is used to determine the microbial quality of the equipment or utensils used

for the production. At Mahanand dairy swab test of silo, tankers, plant, storage tanks

is carried out daily. Swab test helps to detect the microbial load on the equipment

used for production and storage of the milk & milk products. Coliform count &

standard plate count (SPC) of swab is taken in the Mahananda dairy.

Take 0.1 ml of swab sample directly for coliform.

Then prepare 10-1

dilution and take 1 ml from it for SPC.

Pour the media in petriplates in sufficient quantity.

Incubate the plates at 370c for 24 hrs & observe the growth.

42

BIS STANDRDS FOR MILK PRODUCT:

Product name

Parameters to be checked

Shrikhand Fat 8.5 min.(on dry basis)

Acidity 1.4% max.

Moisture 42% max.

Amrakhand Fat 7.0 min.(on dry basis)

Acidity 1.4% max.

Moisture 42% max.

Paneer Fat 50%min.(on dry basis)

Acidity 0.4%max.

Moisture 70%max.

Lassi Fat 4.0% min.

Acidity 0.7% max.

Total solids 22% min.

Chass Fat 1% min.

Acidity 0.45% max.

Total solids 4% min.

Dahi Acidity 0.7% max.

Str.flav. milk Fat 3% min.

SNF 15% min.

43

PREPARATION OF SOLUTION:

The solutions required for daily testing are prepared in laboratory as per the

need.

Phenolphthalein Indicator:

1 gm phenolphthalein indicator powder + 100 ml alcohol+ 100 ml D/W

1 N NaOH:

40 gm NaOH pellets dissolved in 1000 ml distilled water.

N/9 NaOH Solution:

120 ml of 1N NaOH solution + 950 ml D/W + mix well.

MBRT Stock Solution:

19 gm of methylene blue powder + 200 ml D/W

MBRT Working Solution:

1:3 (one part of MBR stock solution& 3 part of D/W

Rosalic Acid:

1 gm rosalic acid powder dissolves in 100 ml absolute alcohol.

N/4 HCL:

10 ML conc. HCL + 480 ml D/W

Sulphuric Acid:

1000 ml stock acid + 100 ml D/W

Urea Reagent:

16 gm of p-dimethyl amino benzaldehyde + 900 ml absolute alcohol dissolve it + 100

ml HCL.

Starch Reagent:

1 gm iodine + 1 gm potassium iodide dissolve in 100 ml absolute alcohol.

Glucose Solution:

1 ml acetic acid + 100 ml D/W + 6.5 gm cupric acetate.

Salt Reagent -I

44

Dissolve 0.1341 gm of silver nitrate in 100 ml D/W

Salt Reagent-II

Dissolve 10 gm of potassium chromate (K2CRO4) 100 ml D/W

10 % tartaric acid :

Take 10 ml of tartaric acid and add 100 ml of distill water and adjust pH 3.5

Saline solution :

9 gm of NaCl powder + 1000 ml of distill water in it.

Ringers solution

Sodium chloride 9 gm + potassium chloride 0.42 gm + calcium chloride 0.24 gm +

sodium bicarbonate 0.20 gm + distill water 1000 ml.

45

Preparation of Media :

1) Potato dextrose agar (yeast/ mold) : Take 39 gm of PDA (potato dextrose agar)

Then add 100 ml of distill water in it.

Dissolve it properly and sterilize it.

2) Eosin Methylene blue agar (E.coli) : Take 37.5 gm of EMB agar.

Add 1000 ml distill water.

Heat it properly and sterilize it.

3) Plate Count Agar (TPC/SPC) : Take 1000 ml of distill water

Suspend 23.5 gm of plate count agar in it

Sterilize it.

4) Voilet red bile agar (coliform) : Suspend 41.53 gm of violet red bile agar.

Take 1000 ml of distill water.

Heat it.

46

FILL PACK SECTION

This is important section to protect the product & improve its attractiveness & easy

transporting.

The milk, it is pasteurized or standardized is received from storage tank in over head balance

tank of fill pack machine at 4oC. This milk flow from overhead balance tank into the pouches by

gravity.

Flow Diagram of Pouch Filling:

Milk from storage tank (4oc)

Over head balance tank

Filling cylinder

Vertical seating & pouch formation

Filling of milk & horizontal sealing

Milk pouch

Weighing & leakage testing of pouch

Filling in crates

Crate conveyer

Cold storage (5-100C)

Dispatch

47

Packaging Machine Detail:

For packaging of pouch packaging material is polythene film. Roll is fixed on the backside of the

machine & it is carried out to the front side mechanically by the rub roller. It is sterilized by UV

light.Vertical edge of material is seated to each other by vertical Teflon couplet electrode rod at a

temp. of 6000 C then the material comes down & sealed by horizontal electrode at 90

0C.

The quality of milk is controlled by the electronic control panel & speed also.

Parameter of Packaging Machines:

1) Capacity of head balance tank - 40 lit

2) Air pressure in machine - 6 kg/cm2

3) Air pressure in line - 8 kg/cm2

4) In value regulating for milk flow - 1 kg/cm2

5) Vertical sealing - 600C & 11 volts supply

6) Horizontal sealing - 900C & 9 volts supply

7) Sealing capacity of machine - 40 pouches/min.

8) Leakage - 0.6%

Specification of Milk Polyethylene Film

Packaging material: LDPE, LLDPE

Thickness: 50 micron for 200 & 500 ml pouches

60 micron for 1 lit pouches

48

UTILITIES

A) Refrigeration Section:

“It is the artificial with drawl of heat from the substance or within a space to the

temperature lower than ambient temperature.‖

Refrigeration system

Compression system

Condenser (PHE)

Receiver

Expansion valve

IBT (Ice band tank)

Evaporator (low temp., low pressure, refrigerant 200 C)

Flow sheet no.1 Refrigeration system

Capacity = 300 TR/day

Refrigerants used are glycol (for bringing) negative temperature, brick and ammonia. Beside

compressor oil separator is fixed which separates the lubricating aids coming with refrigerant for

increasing the efficiency of refrigerant.

49

B) Boiler Section:

Introduction:

Steam is the necessity of dairy plant. It is used in the section of production, cleaning.

Steam is produced in boilers. There are two boilers to meet the steam requirement of plant.

Water- tube type boiler is available at Mahanand dairy.

Details of steam production:

Soft water is used for the production of steam in boiler to avoid scaling over the tubes.

Hardness of water is maintained at 3PPM and Ph 9.5. Hot water is taken from solar system. Solar

panels are installed for the purpose of preheating of the water. Its capacity is 30,000 lit/day at a

temp of 70-80oc from the room temperature.

The feed water flows through the tubes and enters the boiler drum. The circulated water

is heated by the combustion of the fuel and converted into the steam at the vapour space in the

drum as per the required pressure. One boiler of 3 tons/ hr capacity is now running over baggase

as the fuel. The combustion the fuel is carried out at the combustion chamber above which the

water tubes are located. The combustion of the fuel heats the water in the tubes and water gets

converted in the steam.

For the safety of the boiler there are two spring-loaded safety valves are fitted. Valves

open if the pressure exceeds 26 kg/cm2 in order to prevent the bursting of boiler.

Blow down valve: - This valve is fitted at bottom centre of the boiler body to blown off the dirt

sediment impurities at each shift for 5-10 min. by opening the valve.

Non return valve: - The produced steam is passes through NRV to header.

50

EFFLUENT TREATMENT PLANT (ETP)

“ETP is used to treat waste water from industry, here effluent from industry is collected

& treated to lease it, by treating this effluent water pollution is control & this treated effluent is

used for gardening & other purposes.‖

Flow sheet for ETP

Raw effluent from plant

PH- 6-9

Screen & raw effluent transfer pump

Fat trap unit

To remove fatty & oily material

Equalization tank

To make proper homogenize efficient

Dosing tank

For chemical dosing

Flash mixer

For chemical & raw effluent mixing

Flocculation Chamber

Big floccules

Primary clarifier

By hydrostatic presser flocks air

continuously removed

Chemical sludge tank

Secondary treatment/Biological treatment

Aeration tank (1st stage)

10 treated effluents is biological degraded in

presence of O2

CO2 + Biomass + H2O

Aeration tank (2nd

stage)

51

Clarifier (stage 1st)

Settling of biologically flocculated liquid &

separation of clear liquid

Recirculation pump

For recirculation excess sludge to aeration tank

Aeration tank (stage 3rd

)

Clarifier (stage 3rd

)

Here effluent water is almost clear

Final Discharge

52

CONCLUSION

During our training in Mahanand dairy was an amazing and great experience. We got to

have practical as well theoretical knowledge about the various products. We have learn that

quality cannot be compromised at any cost.

The staff of Mahanand is very helpful. They are also knowledgeable and do not hesitate

in imparting their knowledge. Our visit to the ETP has made us realize, that in addition to

running a plant efficiently, it is of utmost importance, that the environment is not harmed in any

way.

The fact that the dairy receive milk from people all over the state and the enormity of

the entire plant has made us realize, that a single organization supports the live hood of

innumerable people.

Apart from a good learning experience we also had a golden opportunity to work for the

plant. Overall we had a great experience and we look forward to work for them in future.