The document presents a comprehensive overview of the Amul dairy operations, detailing its history, organizational structure, and various production sections including milk pouch, flavored milk, ghee, and electrical systems. Established in 1946, Amul has grown to become a significant player in the dairy industry, with extensive facilities and a focus on quality and efficiency. Key information includes the operational capacity, branding, and specifics of various plants and processes involved in milk and product production.

2. PRESENTATION
ON
Rinav Doshi
Jagannath University, Jaipur

3. INDEX
 AMUL AT A GLANCE ……………………… 03
 BOILER SECTION ……………………… 10
 ELECTRICAL SECTION ……………………… 16
 MILK POUCH SECTION ………………………. 22
 FLAVOUR MILK SECTION ………………………. 25
 GHEE SECTION ……………………… 27
 AMUL-2 SECTION ……………………… 30

4. AMUL AT A GLANCE
(I) COMPANY PROFILE:-
 Registered Name : The Kaira District Co-Operative Milk Producers ‘
Union Limited , Anand , Gujarat.
 Date Of Registration : 14th December 1946 under co-operatives act.
 Brand Name : “AMUL”
 Slogan : The Taste Of India
 Type Of Industry : Dairy / FMCG

5.  Total Co-Operation Societies : 8000 (Around)
 Size Of Unit : Having Capacity of process 18 lakhs liters of milk producing 10
different products
 Revenue : 3.1 billion $ US [2013-2014]
 Auditors : Internal Auditors and Government Auditors
 Website : www.amul.com
 E-Mail : amuldairy@kairaunion.coop

6. (II) BRAND NAME “AMUL”:-
 The Kaira District Co-Operative Milk Producer Union Limited selected the Brand
name ‘AMUL’ for its range of producers in 1955.
 ‘Amul(अमूल)’ is derived from Sanskrit word “amulya(अमूल्य)” which means
“PRICELESS” OR ‘INVALUEABLE’.
 Recently the brand value of Amul is around 3000 Crores.
 AMUL Stands For…
A : Anand
M : Milk
U : Union
L : Limited

7. (III) LOGO OF AMUL:-
 The logo of AMUL is ring of 4 hands , encircle
by the words “Kaira District Co-Operative Milk
Producer Union Limited”.
 The essence of this logo is the co-ordinate
effort of 4 groups….
1st of : Milk Suppliers
2nd of : Milk Processors
3rd of : Marketers
4th of : Consumers

8. (IV) 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 & the union was known as “KAIRA DISTRICT
COOPERATIVE MILK PRODUCERS’ UNION”.
 In the year 1955 AMUL was established.
 Amul which inspired 'Operation Flood' and heralded the
'White Revolution' in India.

9. (V) AMUL-PLANTS :-
The main plant of AMUL DAIRY is located in ANAND and can be divided into 3
parts….
{a} AMUL-1 :- This was the 1st building when Amul Dairy was started at
Anand . At that time it was pouch packing system . Presently it is used as a
godown for storing raw materials.
{b} AMUL-2 :- When Amul started procuring more & more milk,amul-1 was felt
small . So Amul-2 unit was started . Today , many of the product are made in
this building like butter , ghee etc.
{c} AMUL-3 :- Amul Spray powder is being produced in Amul-3.This unit also carries
production process and is PLC based Plant.

10.  The main plant of AMUL DAIRY is located in ANAND and further AMUL has
more 3 Plants which is used to produce different items….
[1] KHATREJ PLANT : This Plant was established in 1960 and it was inaugurated by
Shri Morarji Desai , the Finance Minister. In this plant the production of CHEESE
is taking place.
[2] KANJARI PLANT : In this plant CATTLE FEED(Amul Dan) is being produced .It is
Donated by OXFAM and was formally commissioned on 31st October 1964 by
Shri Lal Bahadur Shastri.
[3] MOGAR PLANT : In this plant , production of HIGH PROTEIN FOOD, BREAD
SPREAD , CHOCOLATE , & MALTED FOOD (Amul Chocolate & Amul Ganthiya)
is carried out. This plant was established in 1974.Amul Bakery Plant is also
located here.
 Recently , the Amul is Planed to open 2 new plants in 2016 at different
locations of Gujarat .

11. BOILER SECTION
INTroduction :-
 The Boiler section is located at AMUL-2 , for the purpose of steam generation
, which is used for heating the milk products in different section.
 In Amul Dairy, there are 2 Fire Tube Horizontal boilers (if one boiler is in
working then another is in annual maintenance) & economizers.
 The function of steam boiler is to convert chemical energy of fuel into heat by
combustion & transfer that heat to water for generation of Steam.

12. (I) COMBIMAX STEAM BOILER:-
 It is twin drum 3 fire tube horizontal fully wet packaged boiler with corrugated
furnace.
 The water pressure required at the inlet of water softener is 2.5 – 3.5 kg/cm2.
 There are 212 tubes in each fire tube horizontal boiler.
 At 100 °C , the steam output is 10,000 kg/hr.

13. COMBIMAX STEAM BOILER

14.  DETAILS :-
Make : Thermax
Heating Area : 225 m2.
Burner : Thermax
Fuel : Oil / Gas
Steam Pressure : 12.8 kg/cm2.
Design Pressure : 17.5 kg/cm2.
Operating Pressure : 13.2 kg/cm2.
Design Temp. : 250 °C
Fuel Consumption : Natural Gas – 835 m3/hr
LSHS – 640 kg/hr
Furnace Oil – 602 kg/hr
Thermal Efficiency : 92%

15. (II) MARSHALL BOILER:-

16.  DETAILS :-
Make : J.N.Marshall Private Limited.
Burner : Weishaupt
Fuel : Oil / Gas
Set Point Pressure : 11.5 bar
Set Point Temp. : 187 °C
Evaporation : 12,000 kg/hr
Thermal Efficiency : 72.2%
Steam Flow Rate : 2900 – 3100 kg/hr
Chimney Gas Temp. : 185 °C
Blow Down Interval : 30 minutes

17. ELECTRICAL SECTION
 The electric power required for the entire plant is obtained from Gujarat
Electricity Board through 3 lines..
(i) Anand
(ii) Mogar 1
(iii) Mogar 2 .
 The 11 KV high tension line coming from GEB, First enters to the high
tension stations & through bus bars, HT Breakers it get distributed to the
different transformers (Step Down).
 The Dairy has 4 transformers… Two for each AMUL-2 & AMUL-3.
 At the transformer, the voltage is stepped down to 440V.Thereafter it
comes to low tension stations & circuit breakers . From there the supply
goes to the panel of every section in plant.

18.  The two transformers of AMUL-3 have a Tie Breaker system , so that the
voltages on each transformer can be equalized.
 All the section panels are loaded with energy meters so that the load ,
ampere , consumption , and power factor can be measured.
 Currently , the power requirement of plant is about 2890.62 KW and the
power factor obtained is 0.990 , the target being 0.999.
 The rate imposed by GEB is Rs. 6.20 per unit.
CO-GENERATION POWER PLANT :-
• In the case of power interruption , Amul has an Alternator which has a
capacity of generating 1.4 MW.

19.  It is an automatically controlled system with a TEM[ Total Electric
Management ] touch screen panel.
 The power generated by the generator is 440 V and it passes through
LT Breakers to different sections.
 Each section panel is provided with charge over switches to utilize GEB
line or Generator.
 The alternator is of Gas Engine , which use Natural Gas at 2 kg/cm2 as
a fuel.
 The flue gas from the generator is utilized in VAM , thereby co-
generation of refrigeration along with savings in economy takes place.

20. Gas Engine In Amul Dairy , Anand
Company :- DEUTZ POWER SYSTEM,GERMANY
Model :- TBG 620 V16 K

21.  GENERATOR DETAILS :-
Engine Power :- 1.4 MW
No. Of Cylinders :- 16
RPM :- 1500
Exhaust Temperature :- 523 °C (Approx.)
Compression Ratio :- 12:1
Electrical Efficiency :- 40.2%
Thermal efficiency :- 45.6%
Total Efficiency :- 85.8%
GENERATOR MODAL:-
T = Turbo charging
B = mixture charging
G = gas engine
V = v- type cylinder engine
16 = no. of cylinders
K = two circuit cooling system

22. MILK POUCH SECTION
INTroduction :-
 Pouch packing section deals with packing of milk into pouches.
 There are 4 packing machines , each machine consist of 2 identical heads for
packing, each head draws heat sealable polyethylene sheet from a separate
roll & fed with milk to be packed from the overhead tank by gravity.
 The Material moved continuously downward in a strip , the film is folded
longitudinally.
 First vertical sealing occurs , as continuous cylinder moves downwards
transverse heat seals are made by jaws , which have the effect of closing the
bottom of pouch , so that measured volume of milk is filled into the above a
seal.

23.  SamarpanAutomaticMilkPouchSealingMachine:

24. Raw Milk Reception Clarification Standardization
HomogenizationPasteurizationProcessed Milk
Deep Chilling Dispatch
Introduction :-
 The Process Flow of the Milk Pouch Section:

25. FLAVOURED MILK SECTION
INTroduction :-
 Flavoured Milk is sweetened dairy drink made with milk , sugar , coloring &
artificial or natural flavouring.
 The Flavoured Milk Section is in AMUL-2 & it’s the most profitable product of
Amul.
 Flavoured Milk Section generates milk in several flavors like Kesar , Elaichi ,
Rose , Chocolate , Coffee , etc. in 200 ml glass bottles & 180 ml tin cans.
 Shelf life of milk is increased by the sterilization treatment from 2 days to
120-180 days at cool & dry place.

27. GHEE SECTION
production :-
 Sour milk is used for the production of ghee . This milk is sent to the cream
machine for collecting cream.
 Cream is converted in Butter by Butter Section and melted it at 76 °C in an
open melting vat having heating coils in its bottom.
 It is left for about Half an Hour in the vat to separate layer of fat.
 The melted butter is pumped to ‘Settling’ or ‘Pre-stratification’ tank.
 It is heated to 78 °C- 80 °C for 30 minutes and allowed to settle for 2 hours.

28.  The separated butter milk is drained out from the bottom of the tank and is
collected in serum tank.
 The melted fat is them pumped to ghee kettle , where it is taken to 115-117
°C for about 45 minutes.
 Ghee is allowed t settle for 1-2 hours and then clarified in a clarifier.
 After the clarification of ghee , it is stored in Storage Tank.
 From the Storage tank , ghee is pumped to the overhead tank of packaging
machine.
 The packaging temperature of ghee is 40-45 °C .

30. AMUL-2 SECTION
INTroduction :-
 The RMRD(Raw Milk Reception Dock) at Amul-2 receives cow & Buffalo milk
in separate cans .
 The milk is received in 2 shifts..Morning & Evening . The total milk reception
in one shift is around 12000 liters by can.
 This milk is than went for Standardization & Homogenization , which is sent
to Mumbai , Calcutta etc.
 Some milk is then sent to Amul-3 for producing the different milk products.

31. production :-
 For reception of milk , there are two reception lines.
 When the can come, they are manually put on the conveyor.
 Firstly , when the milk cans are put on conveyor , they are tested by putting a
plunger inside it and also by smelling of milk to segregate the sour milk and
curdled milk.
 Milk is then dumped in weighting tank and the sample of it is drawn for the
inspection of Fat & SNF.
 From the weighting tank, the milk is collected in a storage tank and the empty
cans move to can washer.
 The capacity of can washer is 20 cans per minute.

33. Queries..?