11days@amul

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The Taste of India

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11days@amul

  1. 1. ANAND MILK UNION LIMITED A Project Report on : “Short term training” @ Kaira District Co-operative Milk producers’ Union Ltd. , Anand . ► Training Period : Starting From 22/12/08 to 2/01/09 ► Shift Time : 12:30pm to 4:30pmPrepaid By : ► Ronak Thakkar ► Jaymin Zala3rd Year students of B.E.(FPT) , ADIT , New V.V.Nagar.
  2. 2. Anand Pattern STATE FEDERATION Marketing Money PRODUCTS DISTRICT UNION Milk Procurement & Manufauring of Dairy Products & Technical Inputs and Co-operative Development Programmes to FarmersMoney AI AH FEED EDU MILK PRIMARY VILLAGE CO-OPERATIVE SOCIETIES Milk Production and Pooling through farmer producers
  3. 3. Introduction For a milk farmer, whose life and livelihood is in our rural hinterland, Amul is, Amul does! This is the crux of the Amul brand and stems from the support and ownership by over two million milk producers of Gujarat For the Consumer, Amul simply means Value For Money and Quality as it should be. Amul makes each bite that much more special because in our humble way, we care for feelings that are truly "Indian".
  4. 4. HISTORY In the year 1946 (14th December 1946) the first milk union was established. This union was started with 250 liters of milk per day. In the year 1955 AMUL was established. In the year 1946 the union was known as “KAIRA DISTRICT CO- OPERATIVE MILK PRODUCERS’ UNION”. The brand name Amul means “AMULYA”. Amul which inspired Operation Flood and heralded the White Revolution in India. http://www.amul.com/. Is Indias first national cyberstore, functioning in some 120 cities, and an Amul Cyberstore Gifting Service capable of serving consumers in more than 220 of our cities, on specific occasions. This has been made possible by creating an IT network.
  5. 5. Amul-2 RMRD This is very first department of any dairy where truck (cans) loaded with milk are unloaded and simultaneously the milk is tested and processed further in other departments. The RMRD at AMUL – 2 received cow milk and buffalo milk in separate cans. Even today around 60% of mandadis (600) send milk to the amul dairy by cans each can have capacity of 65lit. Regular 33truks arrive here in morning. Milk is taken in B.T. & by pump it is forwarded to the pasteurizer.
  6. 6. ▓▒Equipments :1. Pasteurized milk storage tanke - 10 no. - 35729lits. each - 16ft. deep2. pasteurizer - 3 no. Capacity – P1 = 17000 liters , P2 = 7500 liters ,P3 = 12000 liters3. separator - 2no.s & speed 4600rpm4.Butter milk tanks – 5no.s5.Can Washer – 2no.s6.Weighing balance tank Capacity – 500 kgs & Collection tank Capacity – 2000 liters7.Butter milk heating equipment (New arrived , IDMC)
  7. 7. Milk Pouch Packaging Here Packaging of milk ,buter milk ,dahi is done. In different sizes 200ml,500ml & 1lit.(T-special).* Made by : pre pac , pamar pan , set pac Pouches are the most popular, convenient and accepted packaging for marketing of liquid milk. The Packaging Film Project (PFP) was established to give a competitive edge to the Co-operative Dairy, by ensuring access to the best quality food grade packaging pouch film, for high speed pouch filling machines, that operate at speeds 75 per cent higher than at present.* Packaging Film Project, Gandhinagar. U.V. light is used to protect pouches from bacteria. speed selector is used for 200,500,1000ml pouches. Horizontal & vertical sealing injection. – on/off Impression coder is (of printech India) is used for marking Mfg. date & Batch no. Valve control penal : from which we can select inlet tank(silo) & line. , for different products.
  8. 8. Flavor Section☺Now a days amul is manufacturing of “14” types. 6 – in bottles & 8 –in tins. Namely : KOOL café , coco , kesar , nutramul , rose , elaichi , Milk sek badam , banana , strabery , mango.☺The plant have capacity to manufacture 1lac. Tins & 1lac. Bottles per day.☺coming soon is whey milk in coco flavor. (in next 6 months). We are try to make this in R&D laboratory(central lab) .
  9. 9. Process Flow chart Sugar hopper Sugar conveyor Slury tank Provat Homogenizer Coffee blender Bulk cooler Packaging Sterilizer Cooling PrintingCartoon packaging
  10. 10. Amul – 3 Reception & process “quality is prevention of wrong things”► Purpose : To ensure that the process of milk reception , processing & issue or dispatch as per documented procedure.
  11. 11. Process Flow diagramSource: Internet
  12. 12. Name of EQUIPMENT Capacity NumberRaw Milk Silo 1,50,000 Liters 4Milk Clarifier 30,000 Liters 3 (Rpm – 1400 to 1500)Raw Milk Buffer tank 15000 Liters 3Milk Pasteurizer 30,000 Liters / hour 2 (PHE-type)Cream Separator 30,000 Liters 2Cream Ripening Silos 40,000 Liters 5Cream Buffer Tank 40,000 Liters 3Cream Pasteurizer 10,000 Liters per hour 1 (PHE-type)Balance Tank 350 Liters 3Pasteurized milk silo 1,50,000 Liters 2Butter milk storage tanks 40,000 Liters 2CIP tanks for tankers Water tank – 8000 Liter Capacity 1 each Lye tank – 8000 Liters CapacityCIP tanks Lye tanks Capacity – 10,000 Liters 1 each Acid tank – 10,000 Liters Water tank – 8,000 LitersSludge Process or Collection Tank 1 Cubic Meter 1Sludge Stratification Tank 5000 Liters 1Rinse tank 1Rail tanker chiller Chilled upto 2ºC 1Battery S.R.C valve & S.M.P valve
  13. 13. Butter►With the financial help from UNICEF, assistance from the govt. of New Zealand under the Colombo plan, of Rs. 50 millions for factory to manufacture milk powder and butter was planned. Dr.Rajendra Prasad, the president of India laid the foundation on November 15, 1954. Shri Pandit Jawaharlal Nehru, the prime minister of India declared it open at Amul dairy on November 20, 1955.►Largest plant in Asia. ( atli-butli delicious amul)► They are paying Rs. 87/ton for AGMARK.►Today , market share 85% Amul , 5% britaniya & 10% others.► Here 100ton butter is prepared from 2lac lit. cream , everyday. A M U L
  14. 14. Process Flow diagramSource: Internet
  15. 15. Ghee Section
  16. 16. Flow Diagram PAST CURDED MILK CREAMWHITE BUTTER ↓ ↓ CHURNING BUTTER ↓ WASHING ↓ MELTING VAT ↓ PRE-STARDIFICATION ↓ Ghee Residue HEATING ↓ FILTERATION ↓ CLARIFICATION ↓ STORAGE TANK ↓ PACKING
  17. 17. Process for rework ghee(A) process for pouch• Separate the leakage pouch• Cut by clipper & take ghee in separate can.• filter ghee in can,• Transfer into melting vat• reprocess by heat• empty pouch wash two time by hot water & take it into scrap(B) process for tin• separate leakage tin & re-work tin• keep in tray for half an hour• cut tin & take ghee in separate tank• Transfer into melting vat & reprocess• empty tin wash two time by hot water & take it into scrap
  18. 18. ☺ Amul ghee is export in 14 countries• Self life• 15 months- AUSTRALIA, U.S.A., KR OMAN, CP BAHRAIN, QUATAR, HONG KONG, BRUNEI, CHINA, SINGAPORE, T. KUWAIT.• 12 months- ABU DHABI, CP DUBAI, EGT DHABI, CP DUBAI, EGT DUBAI, JAPAN
  19. 19. LaboratoryA. Amul-3 reception lab :►Following are the test of raw milk ---1. Determination of titrable acidity in raw milk2. Clot on boiling test3. Alcohol Test4. Methylene blue reduction test (MBR test)5. Fat Test6. Determination of phosphate activity
  20. 20. B. Central lab• The dairy factory produces a variety of dairy products like powder, butter, ghee etc. The various tests are carried out to check its quality.• BUTTER• Following are the tests carried out to check the quality of butter1. Determination of moisture content in butter2. Determination of salt content3. Determination of SNF (curd) content in butter• GHEE• Following are the tests carried out to check the quality of the ghee.1. Organoleptic grading test2. Moisture content3. Free fatty acid Test4. Iron test
  21. 21. Refrigeration• In refrigeration there are three diff. sections1. -2 deg. C. system - Used for chilling the water2. – 10 deg. C. system - Used for maintaining the temperature for ice silo.3. – 30 deg. C. system - Used for cold storage and deep freezers In amul lll 40% electricity consumed by refrigeration plant Main parts of refrigeration sectios1) Compressor2) condenser3) ammonia receiver4) economizer
  22. 22. Boiler In AMUL Plant, there are total four boilers and all are fire – tube type boiler. The three boilers are having the capacity of 4 to 5 tonnes steam production per hour and the fourth boiler having the capacity of 10000 steam productions per hour. The fuel gas that is used are off two types – 1.Natural gas 2.Furnace oil. The water used for boiler should fulfill the following conditions – The pH is 8.5 to 9.5 Hardness is 10 to 40 ppm Chloride content is 400 to 800 ppm.
  23. 23. Substation• Contract demand: 2800 KVA Incoming Main power from two sub station :1. Anand sub station2. Mogar sub station Main two part of dairy plant1. Amul l & ll2. Amul lll For both plants separate sub station ,Anand & Mogar electricty available for both dairy plants
  24. 24. Amul l & ll Amul lll Main 11 KV power supply comes in pole structure, ↓ Metering point. ↓ 4 Nos. High tension (HT) breaker 4 Nos. ↓ 11KV 2 Nos. Transformer 2 Nos. (1000 KVA) ↓ 440v (1500 KVA) Low tension LT breaker ↓ Power control centre (PCC) (MCCB OR Switch Fuse Unit (SFU)) ↓ Motor control centre (MCC) (MCB, Relay, Contactor) ↓ Motor (Machine)
  25. 25. ETP (Effluent Treatment Plant)• 15 lac. Liters wastewater is treated per day.Sr No. Parameter GPCB range Amul maintained1 PH 6.5 to 8.5 7.52 COD 100 mg/l 80-903 BOD 30 mg/l 20-244 S.S. 100 mg/l 40-605 TDS 2100 mg/l 11006 OIL 10 mg/l 3-67 CL 650 mg/l 140-165

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