Koyana report

Koyana Sahakari Dudh Utpadak sangh Ltd. Khodashi.
Industrial Training Report.

History of the company –
To meet the demand of milk in urban area and to provide the
complementary and joint business to farmer. The Koyana Co-Operative Dudh
sangh was established by late Raghunathrao Daulatrao Patil and his colleagues
on 1 oct. 1957. That was first Co-Operative dairy Maharashtra established was
during second five years plan finance was made available of about 1 lakh from 5
years plan by State Govt. at first dairy was starting working in hired trend in
shaniwar peth Karad.
The plant was built on the land of 16 acres i.e. donated by Khodshi
Grampanchyat and 6 acres purchased from private owners.
The machinery and mechanical devices was made available by Alfalaval and the
building constructed to M/S New Triyo Builders.
The plant was completed in the end of years 1964 milk co-operative
societies and 84 persons together with share capital Rs. 5370 was only the
Koyana Dairy.

Mokashi College Of Food Technology Rajmachi,
Karad. 1


1. Infrastructure for procurement of milk. In rural areas of Maharashtra
& to ensure on assured market for milk producers throughout the year, as well as
the best remunerative prices.

2. Fulfill the growing needs for milk & milk products of the consumers in
the Maharashtra & elsewhere.

3. Organize the co-operative structure of milk at the villages level.

4. Supplement of programme extension input, with particular reference to
feed & fodder production & implements an intensive breeding programme for
milchy animal to increase milk production.

5. Imparting training for developing human recourses at rural level for
effective leadership, management skills & improvement of services to rural milk
producers.

6. The Koyana sahakari dudh utpadak prakriya sangh Ltd. Karad. Are
aim to get the ISO 9001:2008 Certified company in this year.

7. Running co-operative development cell to increase awareness & active
women participation for better management & their positive role.

Karad. 2


PRODUCT OF THE COMPANY:-

1. MILK:-

Pasteurized Full Cream Milk

Pasteurized Homogenized cow milk

Pasteurized Toned Milk

Pasteurized Double Toned Milk

Flavoured Milk ( Sugandhi Dudh)

2. PEDHA

3. DAHI

4. LASSIE

5. BASUNDI

6. SHRIKHAND

7. AMRAKHAND

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INTRODUCTION:-

The RMRD is the section where unloading, weighing, testing of raw milk
takes place. RMRD at Koyana dairy is well equipped with the advanced equipment
like computers and electronic weighing system, milk testing machinates. There is
spacious area in front of the dock to park the vehicles. The dock having two ran
reception lines, so has two units of each equipment like can opener, weighing tank
Dump Tank, can washer, and crate washer.

In Koyana dairy raw milk is received by cans & tankers from various
societies and chilling centers. Tankers from chilling centers generally receive the
milk which is away from 150 K.M. It has already weighed sampled and cooled.
This raw milk is again tested for SNF, Protein, C.O.B., Acidity & adulteration test.

The process on RMRD starts from unloading the tempos. The cans are
conveyed on chain conveyer. The cow milk and buffalo milk is collected separately
on RMRD. On the way to tilting point lid opener to opens the can lids and
organoleptic tests are conducted. If anything wrong with can then it is detected
and such can is taken out form conveyer. Then these cans are unloaded / emptied
in dump tank manually at tilting point. The suspected / sour milk is not allowed to
mix with good / fresh milk. It is diverted from that line and conveyed to sour milk
is collected separately on RMRD. A lab person or chemist analyses the sample for
platform tests such as Fat, SNF, CLR, Acidity, Heat stability of Milk, etc.

After preliminary testing Milk is poured into the weight scale and note down
on the computer as the using society number codes for simple for create data.
Here the two parameters like quantitative and qualitative parameters of incoming
milk from the societies. These parameters are Fat, CLR and quantity of milk.

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These parameters are used to calculate the price of milk per liter. The same time
agitate milk for 1 to 2 stroke of plunger for well mix milk and correct sample for
testing is taken from the weigh tank. Milk is then transferred to the two dump tank
of 1000 Liter capacity. Nylon filters do filtration at weigh tank and dump tank.
The two 5 HP centrifugal pumps are transferred the milk dump tank to processing
section.The cans, which are not properly cleaned, are taken to can scrubber and
again loaded to can washing for reclining.

TANKER RECEPTION:-

The milk from the various chilling centers as 1} Dabane Milk dairy,
(Kasegaon), Tal.- Walawa, Dist.- Sangali. 2} Jagtap Milk dairy Vai, Dist.- Satara.
3} Gyaneshwari dairy Parkhandi. 4} M/S Dhaphalapure dairy & Agro products
At.- Mugalkhod, Tal.- Raibag, Dist.- Belgaon. 6} Prithviraj Milk & Food
Processing, Banpuri Tal.- Khatav, Dist.- Satara. Etc. is transported by road
tankers. These tankers are on hire basis as add when required subjected to
procurement of milk.

As soon as the tanker arrives at the dock containing processed or chilled milk
it is being tested for organoleptic tests and labtests. After analyzing its quality, it is
accepted for further processiong and production.

The reception starts from 9.00 a.m. during morning and 6.00 p.m. at evening
and continues till all the expected milk is received. The milk handling capacity of
KOYANA dairy is around 1.5 lakh Lit. / day.

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MILK RECEPTION FLOW LINE:-

Reception of cans on platform

Can conveyor

Manual can Opening

Organoleptic Testing
(If doubt then COB testing)

Tilting of Cans
Sour Milk
Weighing
Sample (Testing CLR and Fat )

Processing Dump tank
Reception of milk
Empty can from tankers

Milk Draining

Can Washer Can Scrubbing

Dispatch
Karad. 6


RMRD EQUIPMENT DETAILS: -
1. Can : -

Material of construction = Aluminium & Fibers

Capacity = 40 Liters.

2. Can Conveyor :-

Type = Chain conveyor

3. Organoloeptic Testing :-

At first, milk is well mixed with the help of plunger and following
testes are carried out by experienced persons.

a) Colour b) Smell c) Taste

d ) Temperature by touch to cans.

4. Tilting of cans :-

Mode of operation - Manual

5. Weighing :- Weighing Balance

Operation - Electricity operated

6. Milk Samplers :-

Amount of sample drawn from each lot - 100 ml

7. RMRD Lab :-

Tests are conducted by advanced machines (EKO MILK). These tests are
for Fat, SNF, Protein, which are conducted on the platform.

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8. Screens & Filters :-

Small Pore Size Screens are used to efficiently remove the sediments from
the milk. These are present at weighing tank and dump tank.

9. Can Washer :-

Can Washing by manually by using hot water.

10. Can Scrubber:-

Shape = Semi cylindrical open
Brushes = Nylon hairs
No. of Brushes = 2

CLEANING OF CANS:-
The empty cans are washed in a straight through can washer daily. Once
in a week the cans should be washed manually with schedule programme.

Can Washing Programme: =
1. First washing using can scrubber with solution of hot water and detergent
and pass to this cans to manually washing.
2. Then can washing by using iron strip brush and detergent and then wash to
clean by using hot water.
3. Drain down the water and used to next operation.

Karad. 8


CRATE RECEPTION DOCK: -
The crates returned from distributors are received here and washed out in
crate washer. This section is located at side to the RMRD.

Crates washing by using hot steam and hot water.

Crate Washing Programme:-
1. Pre-rinse with normal water at 40˚C.
2. Drain.
3. Jetting with caustic solution at 75°C, of strength 0.6=0.8% NaOH, pressure =
0.75 kg/cm square and drain.
4. Hot water heated by steam at 80°C & drain water.

TANKER CLEANING:-
After every Emptying & before every filling.
1. Pre-rinse with water.
2. Manual cleaning with hot water, detergent & pads.
3. Final rinse with hot water.
4. Sterilization with chlorine 150-220 ppm i. e. 150ml in 40 liters of water
solution.
5. Man whole cover, gaskets, air vents: Brushing with liquid detergent,
flushing.
6. with hot water & sterilization with chlorine.
7. Valve box steam union Open valve body, union & clean them with detergent &
hot water.

Karad. 9


Organoloeptic Test:-
The milk is tested organoloeptically for smell, colour appearance,
taste & temperature by touching after mixing with plunger, If the
milk is suspected then C. O. B. (clot in boiling) is carried out.

Dock Lab Test:-

1} Clot in Boiling:-
This test is carried out for checking the heat stability of milk.

Procedure:-
1. Pipette out 2ml milk sample in test tube.
2. Kept the test tube on burner for boiling of milk.
3. After boiling of test tube is washed with water & checked for clots on bottom
of test tube.
4. If clots are is observed this milk is not suitable for further processing a so
makes as it may spoil the entire batch of milk.

2} Acidity Test for milk :-
Procedure :-
1. Pipette out 10ml of milk sample in beaker.
2. Add 30 ml of distilled water in it.
3. Add 3-4 drops of phenolphthalein indicator.
4. Titrate against 0.1 N. NaOH solution.
5. End point is colorless to faint pink.

Calculation : - B.R. X 0.09
The acidity of milk should not more than 0.14 in terms of lactic acid.
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3} Fat Test of Milk (Gerber Method) :-
Procedure :-
1. Take 10 ml Gerber sulphuric acid in milk butyrometer by tilt measure.
2. Add 10.75 ml milk in it using 10.75 ml pipette by sanding manner.
3. Add 1 ml of amyl alcohol in butyrometer.
4. Lock the butyrometer by lock stopper.
5. Shake the butyrometer at 45° angle for dissolve the curd.
6. Centrifuge for 5 min. at 1100=1200 R.P.M.
7. Read the reading on fat column & not down fat % in milk.

Detection of Adulteration in Milk :-
1} Detection of Suger :-
Procedure :-
1. Pipette out 10 ml milk sample in test tube.
2. Add 1 ml conc. Hydrochloric acid.
3. Add 1 gm resorcinol powder in it.
4. Properly mix the content in test tube.
5. Keep the test tube in water bath for 5 min.

Observation: - Red color indicate the test is positive. And sugar is present in
milk sample.

2} Detection of Starch :-
Procedure :-
1. Take 5ml milk in test tube.

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2. Boil the sample on hot plate.
3. Immediately cool the sample.
4. Add 2 drops of Iodine solution & Shake the test tube properly.

Obeservation :- Sky blue color indicates starch is test positive.
3} Detection of Urea :=
Procedure :=
1. Take 5ml milk in test tube.
2. Add 5ml of 1.6% of DMAB solution and observe color.

Observation := Yellow color indicate presence of urea, while yellowish white
color gives negative test.

4} Detection of Common Salt :=
Procedure :=
1. Take 5ml of 0.1341% AgNO3.
2. Add 2 drops of 10% potassium chromate.
3. Which gives brick red color.

4. Add 1.0ml of milk and mix, and observe the color.

Observation := Yellow color obtained indicates presence of salt. Brick red
color remains indicates negative test.

5} Detection of Soda ( Neutralizer test ) :=
Procedure :=
1. Take 5ml milk sample in test tube.
2. Add 5ml pure ethyl alcohol in it.
3. Add 4 drop rosalic acid, and observe the color.

Observation :=Rose red color gives +ve & Light brownish color –ve test.

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6} Detection of Phosphatase :=
Procedure:-
1. Take 5ml Phosphatase sodium salt buffer sub substrate solution in test tube.
2. Add 1ml milk sample in it.
3. Shake well & incubate at 37±0.5°C for ½ hour.
4. Compare yellow color on standard disc & determine efficiency of
pasteurization.

Observation: - Yellow color gives +ve test.
7} Detection of Maltose :=
Procedure :=
1. Take 25ml of milk in beaker.
2. Add 1ml HCL in beaker.
3. Filter the sample.
4. Take 5ml sample in test tube.
5. Add 2 drops of Iodine solution.

Observation := Brown color gives +ve & Yellow color gives =ve test.
8} Detection of Cellulose ( CMC ) :=
Procedure :=
1. Take 10 ml of milk in 100ml beaker.
2. Add 50ml hot water & stir for 2 minutes.
3. Filter through a fine mesh nylon cloth.
4. Wash residue on cloth with 50ml hot water twice.
5. Scrap the residue with a spatula & place it in a spotting plate.

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6. Stain a part of residue with iodine – zinc chlorides reagent and another part
with iodine solution and observe the colour.

Observation: = Development of blue color with iodine=zinc chloride reagent
and absence of blue color with iodine solution confirms presence of cellulose.

9} Detection of Skim Milk Powder :=
Procedure:-
1. Centrifuge about 50ml of milk at 3000rpm for 30 min.
2. Decant the supernatant liquid carefully.
3. Dissolve the residue in 2.5ml conc. HNO3.
4. Dilute the solution with 5ml distilled water.
5. Add 2.5ml liquid ammonia and observe the color.

Observation: = Development of orange or yellow color indicates addition of
SMP in sample.

10} Detection of Added Natural Water & Pond Water: =
Procedure: =
1. Take 5ml of milk in test tube.
2. Add 6 to 7 drops of 10% lactic acid and shake for 2min.
3. Take 2ml of diphenylamine reagent in another test tube.
4. Filter the content of the sample tube.
5. Collect about 1ml of filtrate over diphenylamine reagent & observe the color.

Observation: = Development of blue color indicates presence of nitrate in milk
and thus of added natural water.

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INTRODUCTION: =
Milk Processing Section is the heart of dairy industry. The milk received
from the RMRD cannot the instantly processed. So it is first chilled and stored
in silo tanks. Consequently processing is carried out in this section are,
pasteurization, cream separation, filtration, clarification, homogenization,
standardization, reconstitution, chilling storage.

Milk Process: =
The equipment in this section is HTST Pasteurizers, Duplex filters, Clarifier
cum separators, Homogenizer, Balance tank, Cream separator, Chillers &
Storage tank.

Processes carried out in this section are as below: =
Pasteurization:-
Pasteurization is critical control point in processing of milk. Such heat
treatment destroys nearly all pathogenic micro-organism including most heat
resistance. Mycobacterium tuberculosis, E=monocytogens without seriously
affecting composition & properties of milk.
First the milk is pumped out from dump tank & tankers by using 5HP pumps
to the pasteurizer. The four section of the milk pasteurizer are first the Heating
section, second is holding section, third is Regeneration section & fourth is
Cooling section. The first raw milk in to the heating section and the holding
section for the holding purpose at temperature of 78 +/- 2°C for 15 sec. And pass
the hot milk in regeneration section in this section temp. Increased in steps as
35°C, 47°C, 65°C, 80°C hence milk can be sent to separation, homogenization
between the regeneration sections. Pasteurizers are connected to Duplex filter,
Cream separator and Homogenizer. Flow diversion valve is attached after the
holding section. After pasteurization of milk is instantly cooled to 3°= 5°C and
stored in storage tanks.

Karad. 15


Cream separation:-
Centrifugal cream separator used for cream separation. Which function
based on the centrifugal force.
Basic Principle of cream separator: -
Separation of cream from milk is possible because of a difference in specific
gravity between the fat & liquid portion. Whether separation is accomplished
by gravity or centrifugal method. The result is depending upon this difference.
The skimmed milk possesses on average a specific gravity is 1.032 while that of
milk is about 0.93.
Cream is separated for several purpose. The most important is to obtained a
product from which butter may be changed more economically than from whole
milk. Cream also provides a richer product than milk for certain
manufacturing purposes, more especially for ice-cream making and milk
standardization.

Homogenization: =
A three stage homogenizer is installed in processing section, which is used
homogenizing whole milk and it is connected in between regeneration 1 & 2
heating section. The main principle of homogenization is the milk fat in milk is
dispersed in the milk for small size for 0.1-2 µ for the purpose of good flavor for
milk and increase the quality of milk.

Chilling of Milk: =
After milk has been subjected to the temperature of pasteurization the
product is chilled by the using chilled water to temp. of 3°-5°C. And the chilled
milk is passing to storage tank.

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FLOW CHART OF MILK PASTEURIZATION: =
Milk from dump tank`s & Tanker`s

Filter Regeneration 1 (Milk inlet temp 10-15°C)
(Milk outlet temp. 45°C)
Cream Separator

Cream Skim milk Regeneration 2 (Milk inlet temp.45°C)
(Milk outlet temp. 55=60°C)
Homogenizer
Regeneration 3 (Milk inlet temp. 60°C)

Hot Water (85°C) Heating Section (Milk inlet temp. 65°c)
(Milk outlet temp. 78±2°C)
Holding tubes or Holding plates (for 15 seconds)

Regeneration 3 (Milk inlet temp.) 78±2°C)

Regeneration 2 (Milk inlet temp.) 65°C)

Regeneration 1 (Milk inlet temp.) 45°C)
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Chilled Water (1=2°C) Chilling section (Milk inlet temp.) 25°C)
(Milk outlet temp. 3=5°C)

Pasteurized Chilled Milk

Storage Tank

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Standardization is an important procedure for the adjustment of fat and SNF
as per the specified standard. The standardization is done by Skim milk or
Reconstituted milk for buffalo milk while buffalo milk for cow milk. The
tanks are provided agitators inside for through mixing continuously. There are
different ratios for standardized milk whole milk.

Operating parameters for Standardization: -
Product Fat (%) SNF (%)
Standardized Milk 4.5 8.5
Whole Milk 6 9
Cow Milk 4 8.5

Flow Diagram of Reconstituted Milk: -
Skim milk powder

Hopper

Addition of water

Mixing in tank

Agitator (for well mixing)

Pasteurization & Homogenization

Reconstituted Milk

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BULK MILK DISPATCH THROUGH TANKER

Daily near about 60,000 lit. Processed milk is sent to Washi & Amul dairy

for packaging. Before the milk is dispatched through tankers, the tankers are

cleaned properly as per schedule given previously in the RMRD section. The

Pasteurized Whole Milk and Standardized milk is chilled at 1.5=2°C and filled

in tankers and after filling, the sample is given for analysis. After satisfactory

analysis report, the tankers are permitted for transportation to Washi & Amul

for packaging. This is carried out with Glycol chiller. The cooling medium

used in this chilling is Glycol.

Karad. 20


INTRODUCTION: =
This section is very important as it gives the protection to the product and
improves its attractiveness i.e. contributing for enhancing the acceptance.

This section is located just behind the RMRD. It is in between RMRD &
process section. The washed creates are received in pre=pack, section for placing
the pouch of milk and then shifted to cold storage. In this section, there are five
fill=pack machines. This section is laterally connected with cold storage.

The milk, which is pasteurized, homogenized or standardized, is received
from storage tanks in overhead balance tank of fill=pack machine at 4°C. This
flows from overhead balance tank into the pouch by gravity. Machine operates
one electronic and pneumatic principle. Laboratory takes sample for each size
sample for each of pack and after clearance regarding chemical analysis, weight
and length of pouch, from quality control laboratory; machine is run for regular
production.

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Flow Diagram of Pouch Filling: =
Milk from storage tank (4°C)

Over head balance tank

Filling cylinder

Vertical sealing and pouch formation

Filling of milk and Horizontal sealing

Milk pouch

Weighing & leakage testing of pouch

Filling in crates

Crate convey to cold storage

Cold storage (0.5=1°C)

Dispatch

Karad. 22


DETAILS OF PACKING MACHINE: -

In this section, three packaging machines are working. Packaging
material is polythene film. Roll is fixed on the backside of the machine and it
is carried out to the top of front side mechanically by the nib rollers. Vertical
edges of material are sealed to each other by vertical Teflon coated electrode rod
at a temperature of 60°C. Then the material comes down and sealed by horizontal
electrode rod at 90°C. The horizontal rod seals first lower end of pouch
horizontally and after filling adjusted amount of milk with the help of
pneumatically operated pistons having adjustable stroke volume, the pouch slips
down a specified distance and the its upper edge is sealed. Horizontal sealing of
upper side of one pouch and lower side of next pouch & horizontally cutting of
filled pouch is carried out in single stroke of horizontal sealer. Packaging
machine and quantity of milk to be packed without leakage.

Parameters of Packaging Machines: =

No. of Units

1. Power saver (Nichrome)

2. Nichrome

The milk, which is collected from leaked pouches, is sent for reprocessing.
Average milk loss during adjustment & due to leakage is around 6 liters per
hour. Air is used as lubricant in pulling cylinder.

Storage of film: =

1. At dry cool & dust free area.

2. Keep wrapped until taken for use.

3. Stacking on wooden pallets/racks.

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PRODUCT LINE: -

1. PEDHA

2. DAHI

3. LASSIE

4. BASUNDI

5. SHRIKHAND & AMRAKHAND

6. FLAVOURED MILK

1. PEDHA: -

Raw milk

Filtration

Pasteurization (78°C for 15 sec.)

Homogenization

Standardization (6% Fat & 9% SNF)

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Chilling

Fill milk in Khoa machine bowl (80 lit.)

Heating of milk

Semisolid Mass (Khoa stage occurred)

Addition of (Sugar 6.4 kg &)

(Spices 60gm/20kg of Khoa)

Spread on table for cooling

Make desired shape ball

Prepared Pedha
Spices = Nutmeg 100gm +
Cardamom 100gm & it grind well
Packaging & mix well.

Storage

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2. DAHI: - Take raw milk

Pasteurization 78±2°C for 15sec.

Homogenization

Batch Pasteurization 80-85°C for 20 min.

Drop temp. 38-40°C

Addition of 1% lactic culture

Storage of milk in inoculation tank

Packaging in PET

Storage in Incubation chamber

(8 hrs. 40±2°C & Acidity 0.7-0.8%)

Take to Deep Freezer for Blast cooling

Storage in cold room

Karad. 26


LASSI: -

Take raw milk


Homogenization


Drop temp. 38-40°C




(8 hrs. 40±2°C & Acidity 0.7-0.8%)

Addition of same quantity of water

Addition of Sugar (16.5 kg for 100lit.)

Grinding for well mixing
Karad. 27


Batch Pasteurization

Addition Iodized Salt (150gm/100lit. during heating)

Addition of Cardamom (110gm /100lit.)

Chilling

Packaging in PET

Storage (2-4°)

4. BASUNDI: -

Raw milk

Filtration


Homogenization

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Chilling

Fill milk in Khoa machine bowl (80 lit.)

Heating of milk

Semi Liquid Mass (Basundi stage occurred)

Addition of (Sugar 4.6 kg &)

(Spices 60mg/40kg of Basundi)

Open Outlet Valve

Transfer Basundi for Chilling (4-5 °C )

Packaging in PET

Storage (0-2°C)

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5. SHRIKHAND & AMRAKHAND: -

Take raw milk


Homogenization


Drop temp. 38-40°C




(8 hrs. 40±2°C & Acidity 0.7-0.8%)

Hanging of Dahi in muslin cloth (10-12hrs.)

Chakka (Acidity max. 1.4%)

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Addition of sugar (80%)

Shredding

Kesher (0.001) Jaiphal, Elaichi Mango pulp

Jaiphal (0.02%) (0.o2%) (0.1%) (Mixing (13%)

Elaichi (0.1%) (Amrakhand)

Mixing

Cup Filling

Packaging

Cold Storage (below 0°C)

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6. FLAVOURED MILK: -
Raw milk

Filtration


Homogenization


Addition of Sugar (8%)

Flavor mixing (0.02%)

Packaging in PET

Storage (2-4°C)

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After manufacturing of the pasteurized milk & By product's the chemical

& microbial analysis is very important in dairy industry. Various test is carried

out in quality control department under ISO & PFA (Maharashtra)

certification.

A} Analysis of Milk: -

1} Detection of protein in Milk: -

Procedure: -

1. Pipette out 10ml of milk in beaker.
2. Add 0.4ml of potassium oxalate in it.
4. Titrate the sample 0.1N NaOH solution till faint pink color is reaches.
5. Add 2ml of formaldehyde solution in above sample.
6. Keep stand for 5 min.
7. Titrate the sample against 0.1N NaOH solution till faint pink color is
observed.

Calculation: - Second B.R. x 1.7
Standard: - Protein contain in cow milk is not less than 3% & B/M is not less
than 4.5%.

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2} MBR Test (Mythylene blue reduction test): -

Procedure of MBR Test: -
1. Take 10ml milk in sterile test tube.
2. Add 1ml of Mythylene blue working solution in test tube.
3. Work the test tube & mix the content.
4. Keep the test tube in water bath at 37°C for 30min to 6hrs.
5. Observe the change in color of the test tube.

Interpretation: -

Sample Quality Reduction time.
1 Excellent Above 6 hrs.

2 Good 4-3 hrs.

3 Fair 2-½ hrs.

4 Poor Less than ½ hrs.

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Analysis of by product’s: -

1} Acidity of a Product: -
Procedure: -
1. Weight accurately 1gm of sample in beaker.
2. Add 10ml distilled water in it.
3. Add 3=4 drops of phenolphthalein indicator
4. Titrate the sample against 0.1N NaOH solution till faint pink color
Observed.
5. Take the reading & calculate the acidity of product

Calculation: = 0.9 x A x N Where, A= Burrete reading.
W N = Normality
W= Wt. of sample

2} Determination of fat of the milk product products by Gerber
Method: =
Procedure: -
1. Take 10ml sulphuric acid in butyrometer by tilt measure.
2. Add 5gm product sample & add 5ml distilled water in it.
3. Add 1ml of iso-amyl alcohol in butyrometer.
4. Lock the butyrometer by lock stopper.
5. Shake the butyrometer at 45° angle for dissolve the curd.
6. Centrifuge for 5 min. at 1100=1200 R.P.M.
7. Read the reading on fat column & not down fat % in milk product.

Karad. 35


3} Moisture of milk product:-
Procedure: -
1. Weight accurately empty aluminum dish & record the weight.
2. Weight 2.5gm of milk sample in above aluminum dish.
3. Spread the sample evenly on bottom of dish by using glass rod.
4. Place the dish in to hot air oven for 3hrs. At 100°C.
5. after 3hrs. Weight of dish after heating.

Calculation: -1) W1- weight of empty dish.
2) W2- weight of dish with sample.
3) W3- weight of dish after heating.

Formula: -
W2 – W3
Moisture of milk product = x 100
W2 – W1

4} Determination of protein of the milk product: -
Procedure: -
1. Take 3gm of product sample in beaker.
2. Add 10ml of distilled water in beaker.
3. Add 0.4ml of potassium oxalate in it.
5. Titrate the sample 0.1N NaOH solution until faint pink color is observed.
6. Add 2ml of neutral formaldehyde solution in above sample.
7. Keep stand for 5min.

Karad. 36


8. Titrate the sample against 0.1N NaOH solution till faint pink color is
observed.

Calculation: - Formula = Second B. R. x 1.7.

5} Determination of Total Solid Content of the Milk Product: -
Procedure: -
1. Weight accurately empty aluminum dish & record the weight of dish (W1).
2. Weight 2.5gm of milk product in above aluminum dish & note down the
weight (W2).
3. Spread the sample evenly on bottom of dish by using glass rod.
4. After 3hrs. Weight of dish after heating.
W2 – W3
Moisture of milk products = x 100.
W2 – W1
T.S.S. = 100 – moisture.

6} Phosphatase Test for Milk: -
Phosphatase test is carried out for to check the milk properly pasteurized
or un pasteurized.

Procedure: -
1. Take 5ml of Phosphatase solution in test tube.
2. Add 1ml of milk sample in test tube (solution A).
3. Pipette out 1ml of milk in test tube & add 5ml Phosphatase solution.
4. Mark it as solution.
5. Cork the tube and mix the content well.

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6. Keep both test tubes in hot water bath at 37°C for 2hrs.
7. Compare the change in color in test tube (A) with test tube (B) after 2hrs.

Result – Yellow color indicates test is positive & White color indicates test is
negative.

PFA standard for milk & milk products: -
A) Raw Milk in Can: -
Tests Buffalo Cow Milk
CHEMICAL
Fat 6.0 % (Min.) 3.8 % (Min.)
SNF 9.0 % (Min.) 8.5 % (Min.)
COB Negative Negative

PHYSICAL
Smell Satisfactory (Min.) Satisfactory (Min.)

B) Pasteurized Milk: -
Tests Parameters
BIOCHEMICAL
M.B.R. 4 hrs. (Min.)
BACTERIOLOGICAL
SPC 30,000 (Max.)
Coli form. Absent.
C) Buffalo Milk and Cow Milk: -
Tests Buffalo Milk Cow Milk

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CHEMICAL
Fat 6.5 – 6.8 % 3.8 – 4.2 %
SNF 9.0 – 9.3 % 8.5 – 8.7 %
(For standardized Milk Fat % = 4.5 – 4.7 & SNF % = 8.5 – 8.7 %)
Acidity. 0.1 – 0.15 % L.A. 0.1 – 0.15 % L.A.

BIOCHEMICAL
MBR. 4hrs. (Min) 4hrs. (Min)

D) Milk for LASSI: -
Tests Parameters
CHEMICAL
Fat 4.9 % (Min.)
SNF. 8. 6 % (Min.)

E) Milk for CHAKKA: -
Tests Parameters
CHEMICAL
Fat 3.5 % (Min.)
SNF. 9.3 % (Min.)

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Milk is an excellent growth medium for variety organism. To judge the extent
of contamination can be minimized by exercising proper practices.

1. Standard Plate Count: -
This method is used to estimate the total viable bacterial no. in milk & milk
products & other respective samples.

Procedure: =
1. Collect the sample form different places in aseptic condition.
2. Carry out their serial dilution.
3. 1ml of each dilution is transfer to a sterile Petri plate.
4. 15 – 20ml of sterile molten & cooled plate count agar is poured in each Petri
plate.
5. Mix the content by rotating the plates.
6. Place the plate in incubator at inverted position in incubator at 37±0.5°C for
24hrs.
7. after 24hrs. The visible colonies appearing on agar plate are counted.

Result: -
SPC =No. of colonies x dilution factor

Interpretation: - SPC count not more than (30,000) /ml for pasteurized milk.

2} Presumptive Coli form Test: -
Media: - Red bite Agar

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Procedure: -
1. Take 10ml saline water.
2. Add 1ml of sample of pasteurized milk in saline water and mark it as to 10 ¹
to 10¹ dilutions.
3. Transfer 1ml of sample from 10 ¹ dilution in another 9ml saline water &
mark it as 10` also prepare 10 dilution.
4. Pour molten and cooled red bile agar (12 to 15ml) in each Petri dish.
5. Mix the content well by rotation the plates.
6. Incubate the plate in inverted position 37±0.5°C in incubate for 24hrs.
7. After the incubation period count the pink colony & note down the Coli form
count.

Coli form count: - No. of colonies x Dilution factor.
For bacteriology of milk of milk product weight accurately 10 gm. Of sample
and transfer into 90ml peptone water. 10 dilution used for bacteriological
analysis.
Sr. No. Particular SPC count Coli form count

1. Shrikhand/Chakka NMT 50,000/gm NMT 10/gm

2. Khoa NMT 50,000/gm NMT 90/gm

3. Flavoured Milk Nil Absent in 0.1 gm

4. SMP NMT 50,000/gm Absent in 0.1 gm

5. Dahi NMT 50,000/gm NMT 10/gm

6. Cream NMT 50,000/gm NMT 10/gm

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CIP system is located at right hand of processing section of RMRD. It is
having three CIP tanks for storing different cleaning and sanitizing solutions of
various temperatures. These tanks are connected to processing section through
pipeline for cleaning various milk processing equipment and systems.
Cleaning In Place applied to milk lines. Only cream separator & filters are
cleaned manually after each shift.

CIP of Processing Section: -
To maintain the hygienic condition of plant proper cleaning, ventilation
and CIP of milk processing equipment is necessary. For CIP Nitric acid and
Caustic Soda are use in the required proportion. The pasteurizers are cleaned
with CIP, while cleaning of Cream separator and Duplex Filters is done
manually after the 6Hrs. in each shift.

Flow chart for CIP of Processing Section:-

Pre-rinse with hot water
(45°C for 10min.)

Caustic + Syndet powder circulation
(70°C for 30min.)

Hot water rinse
(80°C for 10min.)

Nitric acid circulation

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(60-70°C for 10min)

Hot water rinse
(80°C for 10min. / till removal of acid)

Caustic + Syndet powder circulation
(70°C for 30 min)

Hot water rinse
(80°C for 10min. /till removal of acid)

Hot water + Byosin (80°C for 10min.)

CIP programme for Milk Pasteurizers: =
1. Rinse with warm water for about 8 min.
2. Circulate alkali detergent solution (NaOH Solution). For about
20min. at 75°C.
3. Rinse alkaline detergent with hot water at 80°C for 10min.
4. Circulation of Nitric acid (HNO3) solution about 15min. at 70°C.
5. Flushing with hot water at 75°C for about 6min.
6. Disinfections by circulation hot water at 90°C for about 8min.
7. Gradual cooling either cold water for about 8min.

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The general process of refrigeration system is takes place as follows –
1. Compressor.
2. Condenser.
3. Receiver.
4. Expansion valve.
5. Evaporator.

4

EV 3
Receivers

5
Evaporator 2
Condensers

1
Compressor

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INTRODUCTION: -
The main function of boiler is to produce steam. Steam is the used in
section of plant in cleaning, production, sterilization of dairy equipment. Soft
water is used in boiler to avoid s align over the tubes Hardness of water is
maintained at 0 to 5 PPM.

Generally two types of boilers are used: -
1. Water tube boiler: -
In this the water is circulated inside the tube & smoke is present outside
the tube.

2. Smoke tube boiler: -
In this smoke is present inside the tube & water is circulated outside the
tube.
In Koyana dairy used is smoke tube boiler is used for the heating of water &
produce the steam

Hot Water Boiler : =
Temperature: -90 to 95°C.
Pressure: - 4 kg/cm2.
Energy: - 2.5 lakh kcal.
Pump: - 10 HP.
Capacity of boiler 60,000 – 80,000 lit. / Day & use timber as a fuel and it use 2
tons/day.
Return Water Temperature is 88 - 90°C.

Karad. 45


Schematic flow diagram of ETP Plant: -

Raw Effluent Volumetric capacities 200m3
Tank

By pump

Fat Removal Unit
80m3 x 2

By Gravity

Equalization tank
300m3 x 2
Floating Agitator

Effluent
Recirculation

UASB
500m3

By Gravity

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615m3
Aeration tank

(Fixed Aerators)

Sludge
Recirculation By gravity

Sludge drying
Bed.

By gravity

Treated 4m3

Effluent
Tank

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