AMUL INDIA

1. AMUL
(Anand Milk-Producers Union Limited)
By.Atanu Mukherjee

3. AMUL
• Amul is an Indian Dairy Cooperative, based at Anand in the
state of Gujarat , India. Formed in 1946 , it is a brand managed
by a cooperative body, the Gujarat Co-operative Milk
Marketing Federation Ltd. (GCMMF).
• Amul spurred India’s White Revolution, which made the
country the world’s largest producer of milk and milk
products. In the process Amul became the largest Food brand
in India.
• Dr. verghese Kurien ,founder-chairman of the GCMMF for
more than 30 years (1973-2006)is credited with the success
of Amul.

4. •In 1999,it was awarded the “Best of all” Rajiv Gandhi National
Quality Award.
•Amul ranks 15 in global dairy rankin(BS Reporter/Ahmedabad
sep24,2014)according to a survey by International Farm
Comparison Network(IFCN) a leading ,global dairy knowledge
organization.

5. THREE-TIER “AMUL MODEL”
• 1.VILLAGE DAIRY COOPERATIVE SOCIETY (VDCS).
• 2.DISTRICT COOPERATIVE MILK PRODUCERS’ UNION (MILK
UNION).
• 3.STATE COOPERATIVE MILK FEDERATION (FEDERATION).

6. AMUL KOLKATA UNIT
• Kaira District Co-operative milk producer Ltd(KDCMP),
Kalachara, Chanditala, Hoogly, WB- 712702. The plant has
separate processing section for milk, dahi, candy and ice
cream. The plant gives an average production of 2.5 Lakhs litre
of milk,25 MT of dahi, 25,000 Litre ice cream per day.

7. CIP & COP
• Cip: Cleaning In Place
• Cop: Cleaning Out of Place
 THE CIP PROCESS CAN CONSIST OF THE FOLLOWING
ELEMENTS:
• Supply pump
• Return pump
• Heat exchanger with Black/Plant steam supply
• Chemical tanks i.e. Acid
• Supply Pressure gauge or transmitter
• Supply temperature sensors

8. TYPE OF CIP:
Two types(describe below ) of CIP are applied for hot surface like
pasteurizer, homogenizer, pipes ,packing mechanics ,silos,
inoculation & agitation tank, aging tank etc.
1)Caustic CIP
2) Caustic Acid Caustic CIP (CAC)

9. FLOWCHARTOF CIP:
NORMALCIP
Cip Silo , Tank and pipes
Rinsing of normal water through out silo , tank and pipes, 5min
DF50 solution 80°c for 20 min. (strength 0.9)
Normal water flashing 5min
Hot water circulation ta 90°c to 99°c for 20min
tank cooling
Batch

10. CAUSTIC ACID CAUSTIC(CAC):
Rinicing of Normal water through out silo,pipe,tank for 5 min
0.9 % strength DF 50 solution circulation 80°c for 20 min
Flushing normal water for 5 min
1% strength Nitric acid solution circulation 76 °c for 20 min
Flushing normal water for 5 min.
0.9% strength DF 50 solution 80°c for 20 min
Flushing normal water for 5 min
90°c hot water circulation for 20 min
cooling
batch

11. PASTEURIZER CIP
pasteurizer
Flushing normal water for 5 min
1.4% strength DF 50 solution 80 °c for 20 min and circulation
chilling temp. 75°c
Flushing normal water for 5 min.
0.8% strength DF 50 solution 80°c circulation and chilling
temp. 75 °c for 15 min
Normal water flash 5 min
Hot water 90°c for 15 min
cooling
batch

12. CIP STRENGTH TEST
STRENGTH OF DF 50 TESTING
take 10 ml of sample
Add 2-3 drop phenolphthalein indicator
titrate Hcl
Colourless
STRENGTH OF NITRIC ACID
Take 10 ml of sample
Add 2-3 drops phenolphthalein indicator
Titrate against 1.6N Noah unit pink colour

15. • MILK SILO:
Dairy plants require storage system for the receiving, processing
and keeping the milk or finish product before packing or further
processing. Milk storage tanks and silos are one of the key
equipment in the dairy industry. Manufactured from SS
• Accessories: Agitator, manhole, sight & light glass, air vent,
sampling cock, thermometer, Low/High level probes
• PASTEURIZATION:
• The HTST(High temperature short time) pasteurize in amul
plants give a continuous heating to 79°c to 82°c for 15 seconds
and promptly cooled to 8°c or below.

16. Temperatu
re prove
Chilling
section
1st
regeneratio
n section
2nd
regeneration
section
Final heating
Holding section

17. • CLARIFICATION OF MILK
HOMOGENISATION:
Homogenization refers to the process of forcing
the milk through a homogenizer with the objective
of sub-divided the fat globules
Homogenized at 2500psi two stage 500psi and
2000psi.this cases sub-division of the original fat
globules to less then 2 micron size

19. AMUL MILK
Amu taaza(toned
milk)
3.10 8.60 3.0 8.50
Amul Slim &trim
(double toned
milk)
1.70 9.20 1.50 9.00
Amul Gold(Fcm) 6.20 9.20 6.00 9.00
AmulShakti
(Standard milk)
4.60 8.60 4.5 8.5

20. Amul
taaza(toned
milk)
200 ml 208 to
210
50
500 ml 518 to
520
20
1000 ml 1039 to
1042
10
Amul Silm
&trim
(double toned
milk)
270ml 275 to
280
40
500 ml 518 to
520
20
1000 ml 1039 to
1042
10
Amul Gold
(Fcm)
500 ml 518 to
520
20

21. • CRATES WASHING
Cleaning efficiency is 900 crates per hour.
• PACKING OF MILK
At the time of coding the following points are being
mentioned on the pouches.
Plant name
Packing head
Batch code
Date=use by date(milk for 2days after packing)

22. STANDARDS OF POLY FILM
1000 ml 3.77 225 324 1037-
1040
500 ml 2.22 148 324 517-
520
270 ml 1.50 112 323 275-
280
200 ml 1.27 96 324 208-
210

23. •FORM FILL SEALING MACHINE (FFS):
It is a type of automated product packaging machine (system)
commonly used in the milk packaging.
1,3,4,8,9
2,5,6,
7

25. PLATFORM TEST
• 1.milk tanker temp. test
• 2.smell(order)
• 3.appearance
• 4.sediment
• 5.acidity
• 6.lactometer reading
• Sampling

26. CHEMICAL TEST
• 1. Detection of fat by Gerber method
• 2. . Determination of SNF by lactometer
• Calculation SNF (%)=CLR/4+0.25*FAT%+0.44
• 3. Acidity
• 4. .Clot-On-Boiling
• 5. Alcohol test
• 6. .Creaming Index(CI)

27. MICROBIOLOGICAL TEST
• 1. Methylene Blue Reduction test (MBRT)
• 2. Phosphatase test
• MICROBIAL COUNT TEST:
• 1.YEAST &MOLD COUNT TEST(Potato dextrose agar )
• 2.STANDARD PLATE COUNT METHOD(PLATE COUNT AGER)
• 3.COLIFORM COUNT TEST(VIOLET RED BILE AGER)

28. LABORATORY TESTING OF
PACKING FILM
• 1. THICKNESS OF POLYFILM
• 2. WIDTH OF PACKAGING FILM
• 3. PRINTING INK TEST
• 4.PINHOLE TESTING OF POLYFILM

29. Adulteration test
 Cane sugar
 Starch
 Urea
 Sodium chloride
 Glucose
 Cellulose
 Ammonium compound
 Sulphate
 Nitrates

30.  Foreign fat
 Neutralizer
 Formalin
 Hydrogen peroxide
 Boric acid & borates
 Salicylic acid

32. Transfer to Cold Storage (4-5⁰C)
Blast freezing (-4⁰C)
Incubation at 37-42⁰C until desired acidity(0.66%) is
reached(5hr.)
Packaging through FFS m/c
Culture CHN-11 & RHT744 added and agitated for 15mins
Inoculation tank (capacity 5KL)
cooling section (40°c )
Regeneration
FDV
holding (10min.)
heating(90°c )
Regeneration(65-70°c )
filteration(65-70°c )
Blance tank
A sample for testing acidity, SNF% (11.5) and fat% (3.5) in lab
Processed milk in tank-12

33. PACKING OF AMUL MASTI
DAHI
• Speed of packing machine
STANDARDS OF POLY FILM AND PRODUCT WEIGHT
200ml 51 packets /min
400ml 49 packets /min
1000ml 31 packets /min
QUANTITY LENGTH(mm)
virgin plastic
WIDTH(mm) WEIGHT((min.gm/m
ax.gm)
200ml 91 325 202/204
400ml 127 325 402/404
1000ml 217 325 1003/1005

34. NO. OF POUCH IN A CRATE
200ml 50
400ml 24
1000ml 10

36. •MIX PREPARATION:
Mix INGREDIENTS
butter coca
smp butter
sugar smp
Stabilizer& emulsifier
(lucid)
sugar
water Stabilizer& emulsifier
(lucid)
Flavour water

37. Percentage OF FAT and Total solid in MIX
Lucid: Stabilizer/emulsifier bland
13% 13% 39.5%
6% 6% 35.2%
17% 17% 39.5%
17%( kulfi) 17% 39.85%
13%(chocolate ) 13% 42.03%

38. • FLOWCHART OF MIX
Batch calculation in mixing tank
Milk and water add in the mix tank
 SMP addition At 30⁰C
Sugar addition i at 37⁰C
 Butter addition at 40⁰C
 Emulsifier & Stabilizer addition At 47 ⁰C(mix with sugar)
mix tank (50-52⁰C )
balance tank
Regeneration (60-65⁰C ) 2500psi
 Heating (90⁰C)
Holding for 88-90⁰C for 20 seconds
FDV
Chilling section 1
Chilling section 2( IBT water is used. )
Mix is transferred to Ageing Tank (for 8 hrs,temp ~5⁰C)

39. VANILLA CUP
Speed per min. packaging 190
Wight cup with lead 3g
AMUL VANILLA CUP:
 Flavour is added to it in the FMT & mixed for 10mins
Mix is passed through the Freezer (inlet temp=6-6.5⁰C &
outlet temp= -5⁰C)
Cups are dispatched into the holes made on the rotating plate
of the machine
 Ice cream is filled into the cups by a filler machine
 Lids are put on by in the lidding section
 The cups are lifted in the next round and pushed
 Hardening in hardening room (-26⁰C to -27⁰C)
 cold room(min=-20⁰C )

40. AMUL TRI CONE
 Manual insertion of cones in the 24 holes marked in the cone
machine.
pressure was applied to make the mouth of the cone a perfect
circle
8 g of chocolate was sprayed at the bottom, called a chocolate
'plug'
57 g of the respective I/C flavored mix was dropped in the
next section
4 g of chocolate was topped
 3 g of nuts was added
 As the cone advances to the next section, the lid is fitted and
closed by means of pneumatic pressure
 The cone is pushed up to eject 2 cones on the conveyor

41. Ingredients:
cream 55%
Wafer biscuit 23%
Toping and spray 22%

43. Candy machine
CaCl2 brine is being used in the candy machine of candy
section as the refrigerant. The specific gravity and pH of that
solution is being maintained at 8.5.
Ice-cream station
Stick station
CaCl2 brine dipping station
Chocolate dipping station
packaging

45.  INGREDIENTS (CHOCOBER):
CANDY MACHINE CIP:
Normal water flushing in mold for 10min.
Using vacuum pump for removing water
60⁰C 1% strength SU157 solution through washing mold and
removing water by vacuum pump
Normal water flushing
0.2% solution
70⁰C water used for washing
Chocolate covering(30%)
Coco solid
Coconut oil
Milk solid
suger
Permitted emulsifier&stabilizer
Proboitic straiuns bacteria

47. EFLUENTS TREATMENT PLANT (ETP)

49. • “Eight hours for dairy, Eight hours for
family and Eight hours for sleep”
- Dr. Verghese Kurien