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Mother dairy- A report

  2. 2. Executive summary The project was started on 2013-09-23, gradually developing and compiling information about various operational and strategic aspects of the mother dairy plant under the guidance of our mentor professor Anchal Gupta. The first part of the report involves the study of brief history, operational strategy and supply chain management. The second part includes product design and effective product design strategies used my mother dairy. The third part includes process design and analysis as well as facility layout, capacity utilization other expansion strategies, assembly line layout at mother dairy. The Fourth part captures the variants of product development process and product designing including mother dairy‟s facility location (patparganj,New Delhi) and factors affecting the location decision. For all the above mentioned parts help from internet sources as well s newspaper articles were taken.
  3. 3. MOTHER DAIRY: INTRODUCTION: Mother Dairy was set up in 1974 under the Operation Flood Programme. A wholly owned company of the National Dairy Development Board (NDDB). It is Mother Dairy‟s constant endeavour to ensure that milk producers and farmers regularly and continually receive market prices by offering quality milk, milk products and other food products to consumers at competitive prices and uphold institutional structures that empower milk producers and farmers through processes that are equitable. It was set up initially to cater to the demand of the Kolkata urban agglomeration spread over the Kolkata Metropolitan area, later it reached out to the consumers of other districts also. The commissioning of the Dairy started in July 1978. Initially, the management of Mother Dairy was looked after by the National Dairy Development Board . On 24th March 1982 , the then Honourable Chief Minister ShriJyotiBasu dedicated Mother Dairy Calcutta to the rural milk producers and urban milk consumers of West Bengal. Mother Dairy has over the past 3 decades, harnessed the power of farmer cooperatives to deliver a range of delicious products and bring a smile on your face. ORGANISATION FUNCTIONS: Mother Dairymanufactures, markets & sells milk and milk products under the Mother Dairy brand (Milk, Cultured Products, Ice Creams, Paneer and Ghee), Dhara range of edible oils, Safal range of fresh Fruit & vegetables, Frozen Vegetables, Processed Fruit & Vegetable Products, Fruit Pulps & Concentrates in bulk aseptic packaging and fruit juices at a national level through its sales and distribution networks for marketing food items. 1
  4. 4. Varieties in Milk : Sl.No Product Fat content Solid not Fat (SNF) Water 1 Double Toned Milk 1.5% 9.0% 89.5% 2 Toned Milk 3.0% 8.5% 88.5% 3 Full Cream Milk 6% 9% 75% 4 Cow Milk 3.5% 8.5% 88% 5 Skimmed Milk 0.5% 9.5% 90% VALUE ADDITION CONCEPT: Mother Dairy transforms milk into various dairy products like 1. Dahi 2. Lassi 3. MishtiDahi 4. Ghee 5. White Butter 6. Table Butter 7. Cheese 8. UHT Milk 2
  5. 5. PRODUCTION SYSTEM: Processing of milk is controlled by process automation whereby state-of-the-art microprocessor technology is adopted to integrate and completely automate all functions of the processing areas to ensure high product quality, reliability and safety. At mother dairy, the processing of milk is done by process automation whereby state of the art microprocessor technology is adopted to integrate and completely automate all functions of the milk processing areas to ensure high product quality/reliability and safety. There are four ways of milk processing – Firstly,Clarification, in which milk is spun at very high speed, removing all dust particles that are invisible to the naked eye. Secondly,Standardisation which help to maintain uniformity by raising or lowering its fat and SNF (solid not fat) percentage to a desired levels, so as to deliver milk to consumers as per prescribed PFA norms. Thirdly, it is Homogenization which improves palatability of milk and Finally, Pasteurization, which kills all pathogenic bacteria present in the milk and thus making it safe for consumption. 3
  6. 6. Packing: The Filling and packing is considered to be most sensitive operation having appropriate access control. Zoning principles are applied in these areas to avoid any cross contaminations in our Finished Product. Online quality control checks (e.g. net weight, leakages, seal integrity, batch coding, packing material quality, filling temperature etc.) are carried out and recorded by our Packing In-charges. Only QC approved and released Packaging materials are used for packing operations. Packaging material used for our products is with the objective of retaining taste, freshness and unique natural appeal. RESPONSIBILITY OF PRODUCTION MANAGER: Innovation Mother Dairy established its Innovation Centre, the first of its kind in India‟s organized Dairy & Food sector, in April 2010 at its central location in Delhi,. It has been setup for the purpose of developing healthy, nutritious and convenient Dairy and Horticulture products. Mother Dairy‟s R&D Team is continually engaged into development of novel products and innovative packaging systems as well as renovating its existing products at its state of the art Innovation Centre. The major thrust has been on developing functional foods targeting consumers‟ health & wellness, supplying products with the taste of western classic delicacies and replicating the home made taste in Indian traditional products 4
  7. 7. The Centre is fully equipped with state of the art modern laboratory equipped with sophisticated lab scale processing equipment. In order to support the analytical and shelf life studies associated with product development activities, the Centre is equipped with highly sophisticated instruments. Packaging innovations are also taken up at Innovation Centre with various packaging materials and those are tested for various parameters which include Tensile and Seal Strength, Bursting Strength, Automated Leak Detection, Compression Strength etc. OPERATION STRATEGY: Implementing robust Mother Dairy Management System, which is an Internal System, developed to meet the all Process Requirements based on National & International Standards. • Implementing International Management System Standards (ISO) • Bench Marking, Best-In-Class requirements • Process Optimization: Constantly working on latest innovative Technologies • Capability Development across the Organization • Auditing &Assessments: Mother Dairy has established a frame work for Auditing & Assessments of Complete Food Chain • Consumer Satisfaction It is our endeavour to create a culture of “Total Quality” where continuous improvement of our people, processes and products becomes a way of life. 5
  8. 8. STRATEGIES FOR COMPETITIVE ADVANTAGE: The company‟s derives significant competitive advantage from its unique distribution network of bulk vending booths, retail outlets and mobile units. Mother Dairy ice creams launched in the year 1995 have shown continuous growth over the years and today boasts of approximately 62% market share in Delhi and NCR. Mother Dairy also manufactures and markets a wide range of dairy products that include Butter, Dahi, Ghee, Cheese, UHT Milk, Lassi&Flavored Milk and most of these products are available across the country. STRATEGY FORMULATION PROCESS: Mother Dairy has commitment with excellence. The evolving needs of customers drive to continual improvement in processes and systems. 1. Apply state of the art technology and processes to enhance productivity that ensures quality at competitive price. 2. Apply processes for clean production, pollution prevention and optimize resource utilization in all operations. 3. Follow food safety management system and apply HACCP (Hazard Analysis Critical Control points) principles to provide safe products to customers. 4. Develop and empower our people for maintaining a vibrant work environment, which encourages excellence. 5. Comply with applicable regulations and legislations. ORDER QUALIFIER AND ORDER WINNER: Order Qualifier: Milk and milk products which are the essential requirements for daily household. 6
  9. 9. Order Winner: Mother Dairy maintains stringent measures to ensure the quality and purity of the milk provided to its consumers. Each batch of incoming and outgoing milk is subjected to 21 quality tests including presence of foreign matter and bacteriological tests. The quality of milk accepted and dispatched meets certain predetermined standards. The milk goes through various processes such as Clarification, Homogenization, Standardization and Pasteurization, to ensure that it is safe for human consumption. Our motive for following such strict quality measures is to ensure that there is no contamination while processing or packaging. Mother Dairy promises its consumers that it will continue to produce products of the highest quality standard. Its Dairy products are processed & packed in ISO certified plants & strict controls are exercised by quality assurance department on all the plants. Most of our plants are certified for FOOD SAFETY MANAGEMENT SYSTEM. Quality Assurance Laboratory at Mother Dairy Delhi is certified by National Accreditation Board for Testing and Calibration Laboratory (NABL)-Department of Science and Technology, Government of India. All the operations in our organization are manned by qualified & highly experienced personnel. We at Mother Dairy focus on motivated & hard working, well qualified & trained personnel in front end as well as back end operations. The dedicated Field QA team ensures that the products manufactured at the plant are handled properly once the products dispatched from manufacturing units. 7
  10. 10. QUALITY CONTROL Stringent quality control methodologies are employed in Mother Dairy: a) The milk is tested for adulterations and quality at the time of collection from the farmers. b) The Milk that comes from the collection points to the Mother Dairy plant is ensured to have a temperature of not more than 4°C and is subjected to 15 product and quality checks. c) The Milk quality is checked repeatedly after each processing phase and the temperature is judiciously maintained less than 4°C always. d) Before the milk leaves the plant for the delivery/distribution outlets the milk is tested again. e) The temperature of milk in the delivery trucks is always maintained less than 4°C. f) All the trucks that deliver milk have specified guidelines to bring back 100 litres of milk after distribution. This is done in order to test the delivered milk and to ensure that the tankers are not adulterated during distribution. g) Since all the employed processing procedures are automated, no contamination by human hands takes place. h) To ensure milk freshness the collection and distribution points are always chosen such that the travel time between them is always less than 36 hours. Out of the total production about 9% goes directly to the institutions ,23% is the loose token milk and the rest is distributed through LAD‟ s. 8
  11. 11. Quality Process in depth Procurement: Fresh milk is sourced directly from state level co-operatives and Mother Dairy own New Generation Co-operatives (NGC). Milk received from individual producer is checked for all basic quality parameters meeting company specifications & requirements at respective collection & chilling centers. Milk is then supplied to the Dairy units through insulated Milk Tankers under refrigerated conditions to maintain the freshness. Strict Quality checks are performed for all incoming Milk received at Dairy units. These includes organoleptic (Taster, Odor& Appearance), Physico-chemical (e.g. Temperature, Foreign matter, % Fat, % SNF, %Acidity, % Protein etc.), microbiological (e.g. MBRT), also presence of any adulterations in Milk (e.g. Formalin, urea, starch, sugar, Glucose, maltodextrin, nitrate, Salt, Hydrogen Per-oxide, neutralizer, ammonium compounds and Fat adulterations). Commodities, ingredients & packaging material used for our products are checked, approved and released by Quality functions as per company specifications and requirements. GMP & Hygiene: Good manufacturing Practices (GMP) for our manufacturing units are „a given‟, they are part of our heritage of producing best quality and safe products. They maintain highest level of GMP and hygiene requirements for production and handling of safe products for our valued customers and consumers Processing: The products are manufactured in state of the art manufacturing facilities using innovative Process & Technologies. The Milk received at the plant undergoes various processing steps before it reaches to the customer. Process steps include filtration, clarification, pasteurization, chilling, filling, packing and storage for our liquid milk category. For other dairy product category, few of the process steps are homogenization, vacreation, ultra heat treatment, evaporation, dehydration etc. Cleaning & Sanitation of the processing equipment is ensured using automatic Cleaning in Place (CIP) systems by applying „5T‟ principles viz. Technology, Time, Temperature, Turbulence and Testing. Critical control points (CCP), Operational Prerequisite Programs (OPRP) are identified for each process using scientific methodology and appropriate control measures are applied to ensure compliance of Quality and Food Safety requirements. Process control parameters are monitored, recorded and reviewed as per the Quality Plan to ensure right product right at first time. Manufacturing processes are benchmarked against best-in-class standards towards continual improvement for infrastructure and system requirements. 9
  12. 12. Packing: The Filling and packing is considered to be most sensitive operation having appropriate access control. Zoning principles are applied in these areas to avoid any cross contaminations in our Finished Product. Online quality control checks (e.g. net weight, leakages, seal integrity, batch coding, packing material quality, filling temperature etc.) are carried out and recorded by our Packing In-charges. Only QC approved and released Packaging materials are used for packing operations. Packaging material used for our products is with the objective of retaining taste, freshness and unique natural appeal. Product Testing & Release: Finished product is tested for the specified quality parameters of each product category as per our internal standardized sampling plan and test procedure. Test results are recorded, reviewed by Quality functions. It is ensured that only good quality product is released for dispatch and reaches our valued customer & consumer. MERCHANDIZING Products are marketed through a chain of our own Milk Shops, retail outlets and mobile vending units maintaining best-in-class hygiene standards. They ensure that products are available, displayed appropriately and cold chain conditions are maintained to retain product quality & freshness. 10
  13. 13. PRODUCT CAPACITY The company markets an array of fresh and frozen fruit and vegetable products under the brand name SAFAL through a chain of 400+ fruit and vegetable shops and more than 20,000 retail outlets. Fresh produce is handled at the company‟s modern distribution facility in Delhi with an annual capacity of 200,000 MT. An IQF facility with capacity of around 75 MT per day is also operational in Delhi. A state-of-the-art fruit processing plant with a handling capacity of 120 MT per day, a 100% EOU, set up in 1996 at Mumbai supplies quality products in the international market. With increasing demand another state-of-the-art processing plant has been set up at Bangalore with fruit handling capacity of around 250 MT per day. 11
  14. 14. SUPPLY CHAIN MANAGEMENT: 1. Milk Procurement: - Mother Dairy sources its requirement of liquid milk from dairy co-operatives and producer institutions. Milk is received from farmer cooperatives through insulated tankers at 2°C temperature in order to retain its freshness. 2. Milk distribution: -Tankers in the morning and in the evening bring in milk from the regional collection centres. After collection the same tankers are utilized for the delivery of the processed milk to the distributors. Mother Dairy has about 51 Distributors in the city of Kolkata. Each of these LAD‟ s(Local area distributor ) place their demand by raising an invoice one day in advance. The demand is also calculated using the „Calendar‟ Scheme, in this depending on the pre-calculated seasonal demands the outlets place their orders accordingly. In order to satisfy immediate demand, 20 to 25 tankers are provided with a buffer stock of 500 litres each day so that they can be mobilized to cater the demand in an area. To coordinate its operations all the tankers are equipped with HAM radios. 12
  15. 15. 3. Distribution Channels: a) Token Distribution: Also, termed as “Lohekibhains” (metal buffalo), is an automated milk vending machine. b) Distributors: The packaged milk is distributed via the distributor network throughout the city. 13
  16. 16. PRODUCTS AT MOTHER DAIRY  Milk  Dairy Products  Ice cream  Edible oils  Fresh fruits and Vegetables  Frozen  Juices and Fruit beverages  Processed food  Grossary 14
  17. 17. Based upon the parameters of pure/impure, slow/fast Perishable, Mother dairy lies in the fourth quadrant which means that it‟s products are perceived by the customers as pure and slow perishing. 15
  18. 18. Based upon the four parameters of taste-good or bad, healthy or unhealthy, the Mother Dairy lies in the first quadrent, which means that customers perceive mother dairy as a healthy and tasty product. 16
  19. 19. OUTSOURCING Galaxy Management services has signed an agreement with Mother dairy in July2009 to provide a suite of recruitment services including job outsourcing work and Customer care operations for the specific business needs and under cost saving exercise. ASSEMBLY LINE LAYOUT
  20. 20. LIST OF MAIN EQUIPMENT: Turbo Mixers / Blenders. Plate Heat Exchangers Butter melting vat HTST Pasteurizer with FDV Two stage Homogenizer Aging vats Continuous Freezers with PLC control, make Tetra Pak, Denmark Candy making & flow wrapping machine, make Tetra Pak. HOYER. Cup & Cone filling machines Hardening Tunnel for Novelties Semi Automatic CIP system Metal separator Cold rooms Allied Service Equipment like Refrigeration, Boilers, Generators, etc. PRODUCT DEVELOPMENT PROCESS The product is developed after thorough market analysis and consumer preferences with the aim of providing healthy choices at reasonable price. This has also enabled improvising the existing product packaging and taste to constantly delight our consumers. New Product Development process includes Concept Development, Lab trials, Shelf life Studies, Consumer Research. Packaging Material Development is also carried out at Innovation Centre. We select quality ingredients from reputed manufacturers across the globe meeting all Quality and Food Safety requirements. 18
  21. 21. Food Safety is of utmost importance while designing the manufacturing process for each new product. R&D Scientists monitor and control first few batches of commercial production to ensure conceptualized quality and organoleptic characteristics of new products. INNOVATION STRATEGIES For the first time in India, we introduced Probiotic Dahi “b-Active” and Probiotic Drink “Nutrifit”. As a result of extensive research, they enriched the „Probiotic‟ products with dietary fiber to have Synbiotic effect and made it as a healthier option. „Dietz Sugar Free‟ icecream was launched which is suitable for diabetic patients, calorie conscious and containing high dietary fiber. Products developed in the in fresh dairy product range includes: Kheer, Bottled Lassi (variants: Plain, mango and strawberry), MishtiDoi, TadkaChach etc. 19
  22. 22. In the frozen category, Kulfi in traditional flavors viz., Rose, Pan and Rabri, Dollies in Raspberry & Guava chilly, Indian Classics, Western Classics and Dietz Sugar Free are the most recent product ranges. Innovation in Dairy Products Probiotic Dahi • The first Synbiotic (combination of pro- and prebiotic) fermented product in India • The most ideally suited vehicle to carry millions of beneficial bacteria as well as fiber to consumers on a regular basis • Proven Probiotic Strains Bifidobacteriumanimalis Bb12 and Lactobacillus acidophilus A-5 with strong clinical evidence • Improves Gastro Intestinal ( GIT) health • Inhibits enteric pathogens • Improves phagocytosis &Ig levels • Texture & taste liked by Indians • Low fat fermented products • Provides 8 % dietary fiber need as per ADA • Sensory quality comparable to indigenous Dahi • Post acidification negligible throughout shelf life • Marketed as B-Active Plus Dahi Probiotic Drink • Probiotic Strains Bifidobacteriumanimalis Bb12 and Lactobacillus acidophilus A-5 Probiotic strains BB-12 and LA-5 which helps improve immunity • Contains real fruit with natural goodness • Assurance of bottle sterility for packaging • Provides 8% daily dietary need as per ADA • Favorably modulate GI microflora • Sold under the brand Name Nutrifit Paneer • Traditional Culinary Dairy product • Soft, good slicing /cutting properties & excellent taste • Extended Shelf life after vacuum packaging MistiDoi • Traditional Bengal Delicacy • Newly improved formulation with better sensorial properties • Product attributes similar to home made product. Rice Kheer • Popular Indian dessert • Creamy rich taste with goodness of dry fruits and nuts 20
  23. 23. Lassi • In three varieties – plain, mango fruit and strawberry fruit • Convenient trendy bottle packaging • Most suited for on-the go consumption Innovation in Ice creams Natural Vanilla Chocofudge Cake • Product with natural vanilla Flavour & chocolate sauce throughout ice cream • Better taste & appearance • Chocolate cake as base to relish the product Kulfi Range • Indian flavors – Kesar, Pista, Rose and PaanKulfi to meet the local tastes • New shape of Kulfi on stick – high selling value • Richness & creaminess due to high solid content Fruit Classics • Goodness of real fruit in product • No added artificial Flavour • No added synthetic food color Fortified Ice Candies • Fortification with Vitamin-C meant for kids & youths • Provides 25% RDA (Recommended Dietary Allowance) • Benefits of Vitamin-C Indian Classics • Icecream with traditional indigenous flavors – KajuKishmish, Basundi and Kheer ,kesarpista • Filled with nuts and fruits Western Classics • An all new range with a true western experience packed with chocolate, cookies and cake to delight and enrich the experience of ice cream • Launched exclusively for the indulgent ice cream consumers Dietz Sugar Free • No added sugar with low fat • Sensory attributes at par with regular ice cream • Clinical study carried out satisfactorily by Diabetic Foundation of India 21
  24. 24. Innovation in Fruit & Vegetable products: RTS Fruit Drinks • Peach Drink • Plum Drink • Pineapple Drink • Mango Drink • Guava Drink • Litchi Drink • Orange Drink Apple Juice, Natural – 100% Peach Jam with pieces – Natural (No added Colour, Flavour & preservatives) AlooTikki – Frozen Masala Sweet Corn – Frozen o Plain Salted o Indian Magic Masala Innovation in Product Packaging Sterility of Bottles • The bottles are formed at high temperature and sealed immediately to maintain sterility • The sterile bottles are cut open, filled and sealed under aseptic condition maintained by Laminar Air Flow of 0.3 Micron filtered air • The filled product is immediately transferred to refrigerated storage. New Bottle Holders / Collators • Convenient to customer • Better POP effect • Better shelf display • Economy of operation Multilayer Pouch • UV treatment to pouches to avoid microbiological contamination • Specialized multilayer pouch for vacuum packing of paneer to extend shelf life • Comparable barrier properties of latest polymer structure • Improved economy IcecreamMonocarton/ Paper Tubs • Introduced food grade virgin paperboard for packaging Ice Creams • Poly extrusion and water resistant food grade varnish coating 22
  25. 25. Innovative Thermoformed Tray • First to introduce in India • Hygienic Secondary Packaging for 90, 200 and 400 g Dahi SKUs • Most convenient and economical secondary packaging • Reusable and recyclable Microwavable Cups • Forkheer and corn chatkara • The contents can be microwaved in the same cup without emptying 23
  26. 26. FACILITY LOCATION ANALYSIS MOTHER DAIRY Patparganj, Delhi Unit Profile “Mother Dairy” is the single largest brand of milk in Delhi, India as well as in Asia, marketing about 1.9 million litres of milk per day. Mother Dairy commands 40% market share in the organized sector in and around Delhi, primarily because of consistent quality and service whatever be the crisis-floods, transport strike, curfew etc. Mother Dairy, Patparganj, Delhi, is presently manufacturing & selling around 8.5 lakh litres of tonned milk through bulk vending shops. Mother Dairy, Delhi is an IS/ISO-9001:2000 and Hazard Analysis Critical Control Points (HACCP) and IS- 14001:1996 Environment Management System (EMS) Certified organization .Mother Dairy was the first industry in country to implement ISO- 14031(environment Performance Evaluation) project. The company‟s Quality Assurance Laboratory is ISO/IEC-17025:1999 certified by NABL (National Accreditation Board for Testing and Calibration Laboratory), Department of Science & Technology, India. This provides assurance to the consumer in respect of Quality and Safety of products manufactured and marketed by Mother Dairy. The National Dairy Development Board (NDDB) commissioned Mother Dairy in the first phase of Operation Flood in 1974. Considering the success of Dairy industry NDDB established Fruit & Vegetable Project in Delhi in 1988 with “SAFAL” as its umbrella brand. With a view to separating the commercial activities from developmental activities, the NDDB merged Mother Dairy and the Fruit & Vegetable project into a wholly owned company named Mother Dairy Fruit & Vegetable Ltd (MDFVL) in April 2000. This becomes the holding company of Mother Dairy India Ltd (MDIL) - a marketing company and Mother Dairy Foods Processing Ltd (MDFPL)- a processing company. MDFPL is a multi-unit company, with units at various locations in India. Mother Dairy, Delhi is one of the units of MDFPL. The company is a highly trusted household name for its wide range of milk products like Milk, Flavored Milk, Ice-Cream, Dahi, Lassi, Table Butter, Dairy Whitner, Ghee etc. Mother dairy has taken up the concept of Total Productive Maintenance (TPM) whole heartedly. The number of employees involved in KAIZENS and the no of KAIZENS per employee are very encouraging. Mother Dairy is a member of CII-TPM Club and the KAIZENS done by Mother Dairy employees have been selected and presented in 2nd and 3rd National Kaizen Conferences held on 7-8 October, 2003 & 1-2 September, 2004 respectively. The TPM efforts have resulted in increase in MTBF and decrease in MTTR. 24
  27. 27. Mother Diary has received "Best Productivity Performance" award for three consecutive years starting from 1987-88 to 1989-90 and again from 1995-96 to 1997-1998 from National Productivity Council and a commendation Certificate for Rajiv Gandhi National Quality Award. Energy Consumption There has been steady decrease in Electrical & Thermal consumption per equivalent lakh liters of milk due to implementation of various energy conservation improvements 25
  28. 28. DESCRIPTION UNIT 2001-02 2002-03 2003-04 Annual milk production Lakh litres 2657.2 2525.8 3073.3 Total electrical energy consumption /annum Lakh Kwh 102.85 98.25 117.28 Specific energy consumption-Electrical Kwh/Lakh 3870.62 3889.86 3816.09 Total Thermal(Fuel) consumption /annum Mkcal 6160.46 5653.63 6650.13 Specific energy consumption- Thermal(Fuel) Mkcal/Lakh 2.32 2.24 2.16 YEAR ELECTRICITY THERMAL(FUEL) Consumption (Kwh/Lakh Litres) % reduction Consumption % reduction over 2001- 2002 (Mkcal/Lakh) over 2001- 2002 2001- 02 3870.62 -- 2.32 -- 2002-03 3889.86 -0.50 2.24 3.45 2003-04 3816.09 1.41 2.16 6.67 26
  29. 29. Energy Conservation Commitment, Policy and Organizational Set up Mother Dairy has a single comprehensive policy named "MANAGEMENT SYSTEMS POLICY" incorporating the elements of Energy Conservation, Environment Management, Food Safety(HACCP), Quality Management System, Safety & Hygiene. MANAGEMENT SYSTEMS POLICY Mother dairy is committed to: Apply state of the art technology and processes to enhance productivity that ensures quality atCompetitive price. Apply processes for clean production, pollution prevention and optimize resource utilization in all operations Follow food safety management system and apply HACCP (Hazard Analysis Critical Control Points) principles to provide safe products to customers Comply with applicable regulations and legislations. Pledge to provide quality and safe products under clean and hygienic environment. Environment and Safety Mother Dairy, Delhi is committed to the protection of environment by Prevention of Pollution and Continual improvement in our processes and systems to improve Environmental Performance. The company is ISO14001:1996 (EMS) certified by BVQI. Mother Dairy was the first industry in country to implement ISO-14031(Environment Performance Evaluation) project. The following steps are taken and ongoing efforts are continuously made as per our "Management Systems Policy" • Minimize Waste generation • Conservation of resources • Use of renewable energy • Recycling & re-use 27
  30. 30. The Effluent Treatment Plant (ETP) was installed at the inception of the Dairy Plant. The company complies with applicable regulations and legislations of Delhi Pollution Control Committee (Department Of Environment, Govt. of NCT of Delhi). The Dairy has reduced total effluent generation by 24% and water consumption by 29% during the period 2001- 02 to 2003 -04 The water consumption has been reduced over the year as a result of the implementation of following initiatives: Installation of water recuperation system in the year 2001-02 where in the final water rinse quantity after Cleaning in Place (CIP) is taken in the water recuperation tank for reuse as the initial rinse in the subsequent CIP operation. In-house water audit is carried out every year and by a continual process of educating the employees about the importance of water conservation and motivating them to do KAIZENS directed to reduce water consumption. Water consumption in all the activities in the Dairy is regularly monitored with the help of data furnished by magnetic flow meters installed at various locations. The Dairy has installed a Solar Plant for hot water generation and solar heat recovery to the tune of 200 to 250 M kcal per annum is achieved through it. The Dairy has constructed Rain Water Harvesting by dividing the entire premises into six zones to harvest maximum possible potential of rain water run-off available in the campus. Accordingly unit has constructed rain water harvesting structures at the locations that experience water logging in each of the zones during rainy season. By this unit has achieved increase in water table ranging from 30 cms to 150 cms in our existing tube wells in the Dairy. Industrial safety is of paramount importance at Mother Dairy. A Safety Committee headed bySr. Manager (Mfg.) as Chairman and members drawn from workmen and officers cadre from different sections meet regularly to review and initiate safety measures in all the activities of the Dairy. Numbers of mock drills are carried out from time to time. Internal safety audits are carried out to locate unsafe conditions, acts and thorough investigation of accidents if any, strict enforcement of safety rules and procedures including work permit system and use of Personal Protective Equipment (PPE).The Dairy is member of National Safety Council and also celebrates safety week every year. The Dairy has ZERO fatal accident since the date of its inception 28
  31. 31. BIBLIOGRAPHY   division.html   e.aspx?HLID=7  expand-operations.html  ******