The document provides a summary of Prakash Kumar's visit to Parag Dairy in Varanasi and Parle Ji biscuit manufacturing plant. It describes the 3-tier cooperative structure of Parag Dairy including village-level dairy cooperative societies (DCS), district-level unions, and state-level federations. It details the milk procurement, processing, and packaging operations at Parag Dairy including quality testing, pasteurization, and production of products like paneer, ghee, and flavored milk. It also summarizes the 6-step biscuit manufacturing process at Parle Ji including raw material testing, mixing, molding, baking, cooling, and packing.

1. REPORT on
A Day at PARAG Dairy ,Varanasi
&
Parle JI
NAME- PRAKASH KUMAR
ID N.O.- 19212AGC101
STUDENT READY PROGRAMME
Dairy Science & Food Technology

2. PARAG DAIRY
We done milk procurement in 5 disricts namely Varanasi, Chanduali, Jaunpur, Ghazipur,
Badohi.
Varanasi do not have enough cooperative. This cooperative is based on 3 tier structure
business popularly known as ANAND Pattern or AMUL Pattern.
The history behind this is LAL BHADUAR SHASTRI born in Mugalsarai ,study in Varanasi
,When he was Prime Minister of India ,he visted to Anand At that time only AMUL was the
cooperative started in 1946 that time known as Kaira Jila Sarakari Dhuda Sanga Limited.
He visited for cattle feed inaugration there after seeing AMUL processing ,marketing.He was
so impressed & asked Founder chairman Dr. Verghese Kurien ,Father of White Revolution
,Initiator of operation Flood that to replicate same system of AMUL all Over India so that
farmer get benefitted, On his advise he start AMUL All over INDIA & Also ask to regular visit
all over India but he refuge & say I’m servant of farmer So I stay in ANAND only but I will
work on your dream.

3. So he start National Dairy Development in Anand in 1965 . In 1970 blueprint of operation
FLOOD is designed so it start from 1970 to 1996 26 years 3 Phases it goes as a result
Many cooperative are made & 3 Tier structure established all over India.
THREE TIER STRUCTURE- Basically a milk is produced by farmers which reside in villages
So First structure made in village known as DCS (Dairy Cooperative Society) where all
Farmers Put their milk and get the price on the basis of content of fat and SNF.
Higher will get high price. After that for processing milk sent to plant which was in city
known as UNION (Cluster of many Districts) he brought milk from all DCS on fat & SNF
basis after that he process and make products .

4. For 4 District -1 union , UTTAR PRADESH -75 Districts So 18 UNION had estabished in U.P.
So competition may occur in between cooperative for selling of product
So Cooperative works on principle of ‘Cooperation among Cooperatives’ otherwise
Cooperative do not stand So one more institution made known as FEDERATION whose
work is to sell & market the product of UNION at best price .
1State-1 FEDERATION
PCDF(Pradeshik Cooperative Dairy Federation) is not in marketing at present but they
are in policy making and law enforcement. Every UNION has their own marketing within
their territory. But GCMF (Gujarat Cooperative Milk Marketing Federation) AMUL biggest
umbrella this works as FEDERATION buy all milk & market it.
These all structure has their own identity not come under each other.

5. Name of AMUL in different part of INDIA-
GUJARAT- AMUL TAMIL NADU- AAVIN
UTTAR PRADESH-PARAG ANDHRA PRADESH/VISHAKAPATNAM-VIJAYA
ODISHA- COMPHADE CHATTISGARH-DEVBHOG
JHARKHAND-MEDHA MAHARASTRA- GOKUL,MAHANANDA
RAJASTHAN- SARAS KARNATAKA-NANDANI
BIHAR- SUDHA KERALA-MILMA
MOTHER DAIRY is the subsidary of entity . Packaging done at PARAG because it is our
franchise.
IDMC- INDIAN DAIRY MACHINERY COMPANY is also subsidary A Dairy
engineering company. New Plant made by IDMC.

6. SAFAL-Fruit & Vegetable provide frozen vegetables like pea, carrot, etc.
DHARA- Mustard & Refined Oil
All are subsidaries of NDDB.
NDDB is not in business directly Purpose is not to earn profit it provides support financially
& technically to struglling Cooperatives by government projects or NDDB own fund.
Here biogas is funding of NDDB
Previously there is rumour about false smell in PARAG Mik but now we have very
competent & talented persons who check the quality of milk.
BENEFIT OF 3-TIER STRUCTURE-
Profit generated flowing downwards UNION--------> FARMERS
UNION provide input services (Cattle feed, Animal Health support, etc.) to the farmers so
that their productivity will increase.
P&I (PROCUREMENT & INPUT)- A Unit which Coordinates with farmers to provide input
services (Cattle feed, Animal Health support, etc.)
AMUL In Gujarat appointed Veterian Doctor to every village in range of 20 Km. if any animal
is facing health issue then farmer goes to society he submit only Rs 100 A call goes to doctor
Doctor comes to the door step of farmer & treat the animal irrespective of any charge even
done surgery if required.
AI (Artificial Insemination) at Rs50 if AI worker comes home otherwise Rs10 if animal comes
to society.& it is very good quality semen.
SAG BIDAJ (Sabarmati Ashram Gaushala,Bidaj)- Asia one of the best semen station. it was
also supported by NDDB(National Dairy Development Board) .Started by Mahatma Gandhi.

7. AMUL has their own semen station in many district namely ARDA
(AMUL Research & Development Association) .
Banaskantha ,Palanpur-Asia‘s largest milk production cooperative. Per day
they are procuring 85 lakh L per day A huge quantity. For consumption of it they even
made plant in Jaunpur.

8. Cooperative has their own Bilaw Own that basis they have elected governing body
On which A Management Committee Members, A PRESIDENT & they will appoint/recruit
one secretary who take care of society. A Cooperative is a elected body structure they
appoint some staff including secretary to take care of day to day operation of societies
including sample collectors.
Benefit of this cooperative structure is that more than 70-80% revenue which generated
comes to farmers that why more successful compare to others.
SMUL is the brother of AMUL .
Limit of quantity is not there fed any limit.Price is determined by Fat & SNF Content of milk.
TURNOVER OF A SINGLE MILK PLANT-
4 LAKH capacity one plant 2 LAKH Milk Processing & 2 LAKH Powder Processing
At present we are processing 70,000 Litre per day In which PARAG has 27,000L
Remaining Part is MOTHER DAIRY.
In 70,000 L Chhana ,Pada, Ghee, kheer, Basan ke Ladoo, Dahi , flavoured milk ,lassi,
matha ,Etc.
In GCMF they do not control UNION it is coordinating body but In PCDF because of more
Government intervention Government decide about fate of UNION.

10. Salary of Employee is given by NDBB. Recruitment is not there in PARAG since 2008. Major
recruitment done in 1986 that why man power issue is there .
Man Power is hired through outsource. Head is recruited by NDBB.
From Village it start then comes to district From district it come to UNION From UNION
through tanks raw milk comes to PARAG. In BMC where we do chilling After that through
house pipe & moters we receive in our tankers and in small-small BMC it get trnsferred
Through CAN Reception where small traders sell their milk
Milk received in tanker get transferred to BMC(Bulk Milk Cooling) freezing done at cooling
temperature 4oC .
ENDIFORCE MACHINE-Rs1crore made by Denmark gives milk report in 7 second.
4 Test done at different place for Milk Quality Check- 1st in BMC -2nd in DCS -3rd in UNION –
4th in PARAG . After that there is 8 Process.
PARAG done it Quality test by own not take report of previous checker.Reject at instant
if milk is not up-to mark. Money flow in down-flow direction.
If the milk is found not to marks even if Na+ concentration is there whole tanker get rejected.
We process chemical free milk done Organoleptic Test (5 sense organ)if smell is there &
visible report they see accordingly if deducted here Go for ENDIFORCEMACHINE (Gives
Report in 7sec).
Processed Milk can be use up-to 48 hrs only as it is free from preservative chemicals.
4PMST(Pasteurize Milk Storage Tank) & 3RMST (Raw Milk Storage Tank) 2-3 PCST We had.

12. Without Pasteurization we can’t move ahead single line we have that go from
Pasteurization No product will be made without that steps All things are system operated.
From APMC Milk collect at Milkoscan FT-1 First OT Test perform if there is problem
then go chemical test NDDB KIT are there which gives result in 1 min KIT are basically
Based on Positive/Negative result. Butyrometer in that we put fat at 40oC in oven.
We take LR(Lactometer Reading) first In cylinder we fix temperature 15.5oC Check for
CLR(Corrected Lactometer Reading) & SNF,Fat is also calculated.
ODOUR BATH –MBRT(Methyl Blue Reduction Test) perform here which indicate self life
of milk if self life is less than 6Hrs then milk deteriorate faster if it comes 6Hrs+ then it is
in better condition. The milk which comes is having 2Hrs self life after pasteurization it
efficiency increase.
Everyday equipment get calibrated in morning So we put sample in GT(Gerber Centrifuge
Test) & same sample in FT(Forced Milk Testing) & compare fat & SNF to be same After
that adulteration will be calibrated.
So first work of day-day chemist is compare Fat & SNF from FT & GT. 100% accuracy is
compulsory. FT & GT reading same means calibrated. Testing start
We have 2 FT one here other in central lab if defect come here we go with sample in
central lab. If both have problem go for GT.
MBRT is based on bacterial count oxidation Pasteurize milk have 5.5-6+ MBRT If
Unpasteurize Milk so 2-2.5 hrs.
1000L is balanced here so when 1000L milk comes we transfer it to RSMT via moter
Chiller is in between that.

14. Mother Dairy & Parag both are similar in taste. Same milk put in both of them .
30000l batch of full cream milk is made in which 20000l batch is Mother Dairy pack &
remaining10000 batch of Parag pack.
We have pasteurizer pasteurizing 20000L If we made 2 times so 2 times waste of source
CIP also have to done separately. So cost increase that why made togther.
With Pasteurization we can hold milk upto 2 days.
If any thing other than allowed quantity is added in milk(NaCl,Urea) we reject whole milk.
We hold milk upto 7 sec so that some bacteria get killed in Holding Tank at Caugjala
verniti (85oC) .
Pasteurization is done in combination of time and temperature 36oc-30 min
72oC-15 min
From RMST milk comes here we pasteurize it in Balance Tank through phe & After that it
goes to PMST. We have homogenizer(Distribute fat globules in equal size) We fix 2500psi in
1st stage & 500 psi in 2nd stage. Then there is separators which separate milk from cream
Then store it in PCST tank (Pasteurize Cream Tank).
Central Lab – In RSMT we done sample like 6.0 Fat ,9.0 SNF standardize it & maintain it .
Testing done in RSMT --- After that testing done in PMST so result must be same-----
Go to HSMT (Horizontal Storage Tank) here again Lab Test done .
5 Stage Lab testing is done. In Polypack PPM line Drin test done result must be same.
Quality fulfilled here after that Packet Sample is done. After that we realse that it is OK.

15. Product is OK So we can dispatch now.
RSMT pasteurize it and transfer it PSMT to HSMT pasteurize transfer to line and then
packet control sample done.

16. After that for 2 days sample is properly stored so that if any problem come into market then
We show them sample at particular temperature there is no problem in our product .
Pasteurization is best technique to store milk in natural way for two days.it may cause
variation in fat and SNF
PACKAGING UNIT –POLYPACK – From HSMT milk comes yellow light turns into green colour
It indicates milk receive hereafter that we start polypack. Everything is system operated ,On
System its shows this is cow milk /buffalo milk accordingly operater operate he put polyfilm.
Packing starts before that we sample it if okay then we release it in market otherwise return ,
If problem occur put it back in RSMT .In 99% cases there is no problem occur.
CRATE WASHER – We wash crate here, hot water 1200ml and brushes are already fix it is
system operated it washes and on rotating conveyer it passes to channel and release for
dispatch.
AIR COMPRESSOR ROOM – For the machines to work the air is supplied through pipeline
From here.
PCC PANEL- A section of engineering from where we control all system and operate plant.
CHAI SPECIAL MILK=4.9 FAT &9.23 SNF For market growth so that there is more no. of cups
of tea to the customer lead to profit to customer In normal milk SNF 8.9 is maintained.
So that marketing increase & price differ upto Rs7.
WATER TREATMENT PLANT (WTP)- Provide RO water to all section even for mixing in milk .
BIOGAS PLANT- To provide electricity to all section of plant recently setup biogas plant .

18. Parle Ji
In this plant two types of parle biscuit are made- Parle glucose & Parle cream.
Today 140+ unit parle has. As this is third party licensing unit we provide local manpower to
them & parle take care of machinery & remaining things. 10 unit are their own. 60-70% only
parle glucose are made as it is highest selling. Now many varieties of biscuits are there in
Market.
There is highly rivling in between parle & britania & IGC for 2Rs biscuits.
6 STEPS ARE THERE IN BISCUIT MAKING-
1-Raw material testing are there for atta , gluten test for madda, admine oil melting point
testing
2- Mixing
3-Moulding (Give shapes) 12 cups,36 cups 29 times moves
TOTAL CALCULATION-In 23.5 hrs how many biscuits made come out.
4-Oven dipping(High Temperature to Low Temperature)
5-Cooling conveyor (in natural process as we do with roti in home).
6-Packing Machine(Manual & Automatic)
SUGAR TANKER-For making sugar solution in one tanker
Transfer the solution to another tanker for cleaning and filter it after that for cooling it goes
to next.
From automation sugar comes from another area to working area. Syrup once prepared will
Be cooled in another container.

19. MOULDING SECTION –Where biscuits are mold in
proper shape .
CONVEYER- To pass biscuits & cool down.
Biscuit are baked in oven (16ft,56ft,186ft)Divided in 7
zones. all have different temperature
& roles like Puffing, moisture removal, coloring
condition .
The biscuit after baked cool to 0oC in natural process
for creaming layer so that cream do
not melt. In conveyor biscuit turn over movement &
both the sides are visible. We get the
Quality of both side visual of biscuit. The inside
temperature vary from (140-180)oC.
The cooling of biscuit follow principle i.e. hot air at
high altitude & vice versa.

20. The defected biscuits are removed from the lots manually & remaining packed &
stored for transport to different cities.

21. THANK
YOU
I’m very greatful to the Director,IAS BHU ,Prof Yashwant Singh sir , Head ,DSFT-BHU,
Prof DC Rai, Prof Kalyan Ghadei Sir Coordinator SRP
Special Thanks to -
Dr. Tarun Verma Sir and Sunil Meena, Assistant Professor, Department of Dairy Science
and Food Technology for making this trip possible.