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Mother Dairy Kolkata Dissertation Report

Mother Dairy in Kolkata produces and sells various dairy products like milk, yogurt, paneer and ghee. It ensures quality through various processes like pasteurization, homogenization and standardization during milk production. Several tests are conducted in the quality assurance lab to check for adulteration, nutrients, microbes and other specifications. These include organoleptic tests, acidity test, fat and SNF measurement, microbial count, moisture in paneer and various chemical analyses. Strict processes and quality checks help Mother Dairy provide safe and nutritious dairy products to consumers.

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A Project Reporton Dissertation in MOTHER DAIRY Kolkata Presented by: Sukanya Halder B.Tech/M.tech Dual Degree Year- 5th Roll Number - 1060070 KIIT SCHOOL OF BIOTECHNOLOGY
◊ Introduction ◊ Vision and Mission ◊ Milk & Traditional Products ◊ Products Manufactured ◊ Product Specifications & Details ◊ Milk Process ◊ Milk Production System ◊ Manufacturing & Processing ◊ Quality Control ◊ Product Testing in QA Lab ◊ Tests Carried out in QA lab ◊ Test Result & Discussion ◊ Picture Gallery ◊ Bibliography Presentation Flow
Introduction  MOTHER DAIRY CALCUTTA, a Government of West Bengal project, was started under Operation Flood II of National Dairy Development Board . It was set up initially to cater to the demand of the Kolkata urban agglomeration spread over the Kolkata Metropolitan area.  Mother Dairy is also reaching out to the consumers of other Districts. The commissioning of the Dairy started in July 1978 and the first Distribution vehicle loaded with milk sachets rolled out of the Dairy in the morning of 8th December 1978. Initially, the management of Mother Dairy was looked after by the National Dairy Development Board .  Mother Dairy safeguards the interest of the rural milk producers by encouraging co- operative movement & marketing the surplus milk available from the villages, thus helping the milk producers to realize their own potential for organized endeavour & the creation of more rural wealth in the shape of 'Anand Pattern' as profounder by Dr. V.Kurian , The Milk Man of INDIA.  In November 1996 , the management of Mother Dairy was taken over by West Bengal Cooperative Milk Producers’ Federation.
Vision And Mission Vision – “Provide quality food and beverages to consumers at affordable prices while ensuring fair returns to the producers.” Mission – “Mother Dairy’s heritage is intrinsically linked to the cooperative movement in India. With determination & pride we will continue to serve our farmers, rural India & our consumers. Our values reflect who we are & what we firmly believe in.”
Milk Conversion of Milk into Traditional Indian Dairy Products Cultured PrecipitationCondensed Shrikhand Ghee Lassi Misti Doi Rabri Kheer Khoa Paneer Sandesh Chhana Rasgolla Pantoda Rasmalai Barfi Pedha Kalakand Gulabjamun
Products Of Mother Dairy Double Toned Milk Toned Milk Cow Milk Mishti Doi Probiotic Yogurt Flavoured Yogurt Paneer Cow Ghee Ice Creams
Product Details Product Milk fat SNF Sugar Protein Carb. Caramel Flavour Energy (100gm) Sweet Yoghurt 3.0 13 18 4.8 7.0 0.2 146 kcal Probiotic Yoghurt 3.0 11 4.8 71 kcal Flavoured Yoghurt 3.0 13 13 4.8 7.0 Green- mango Chocolate Pineapple Vanilla 126kcal Yoghurt For preparing yoghurt about 11% cultures of each Streptococcus thermopiles and Lactobacillus bulgaricus is used.
Product Details Specific Details of Types of Milk produced in Mother Dairy Kolkata Type of milk Minimum fat Min. SNF Cow Milk 3.5 8.5 Toned Milk 3.0 8.5 Double toned Milk 1.5 9.0 Full Cream Milk 6.0 9.0 Cholesterol free Milk 0.5 8.9 Standardized Milk 4.5 8.5
Product Specefications Cow Milk: Fat-3.5% & SNF-8.5% Double Toned Milk: Fat-1.5% & SNF-09% Toned Milk: Fat-3% & SNF 8.5%
Product Specefications Sweet Yogurt: Fat-3 % & SNF-13% Probiotic Yogurt: Fat-3 % & SNF- 11% Flavoured Yogurt: Fat-3 % & SNF-13%
Some Other Products :- Different Flavoured Yogurts Probiotic Dahi
RAW MILK RECEPTION HOMOGENISATIONPASTEURIZATION STANDRADIZATIONCLARIFICATION PROCESSED MILK DEEP CHILLING DISPATCH Milk Process
Pasteurization Kills all pathogenic bacteria present in the milk. Thus making it safe for consumption Homogenization Improves palatability of milk Standardisation Maintain uniformity by raising or lowering fat and SNF (solid not fat) percentage to desired levels Clarification Milk is spun at very high speed, removing all dust particles Milk production system
Manufacturing of Sweet Yoghurt :- Milk, powder, water and sugar are added in the vat It is agitated It is heated up to 90◦C It is cooled to 45◦C Culture and caramel is added It is packaged It is stored in incubator room at 43◦C for 4-5 hours It is then transferred to cold room It is dispatched Manufacturing Process
Continued.. Manufacturing of probiotic yoghurt :- Milk, powder and water are added in the vat It is agitated It is heated up to 90◦C It is cooled to 45◦C Culture is added It is packaged It is stored in incubator room at 43◦C for 4-5 hours It is then transferred to cold room It is dispatched In case of probiotic yoghurt commercial cultures like DH-111 and YOLP are used
Continued..Manufacturing of flavored yoghurt :- Milk, powder, water and sugar are added in the vat It is agitated It is heated up to 90◦C It is cooled to 45◦C Culture and flavor l is added It is packaged It is stored in incubator room at 43◦C for 4-5 hours It is then transferred to cold room It is dispatched Amount of flavour added:- Green mango: 0.5% Vanilla : 1% Chocolate : 0.3% Pineapple : 0.25%
Continued.. Manufacturing of mango flavored ghol :- Curd water, salt and sugar are added in the vat It is agitated It is heated up to 90◦C It is cooled to 10-15◦C Yoghurt and flavor is added It is agitated and mixed properly It is packaged and put in cold room It is dispatched
Milk is heated at 90◦C It is brought to 86◦C Citric acid is added Curdling of milk occurs and it is allowed to settle for 10 minutes Agitation is given Paneer water is drained Paneer is put in hoof bar It is compressed for 10 minutes at 4-6 kg pressure It is then put in cold water at 7-8◦C for 2 hours for the paneer to solidify Processing Processing of Paneer :-
It is put in brine water solution for 1 hour to increase self life It is kept in cold room overnight It is cut into pieces(100gm, 250gm, 1kg and 5kg) It is put into packets Vacuum packaging is done It is kept in cold store and is ready to be dispatched Continued..
Milk is tested for adulterations and quality at the time of collection The temperature is judiciously maintained less than 4°C always No contamination by human hands takes place, since processes are automated. The trucks that deliver milk have specified guidelines Travel time between collection and distribution points is always less than 36 hours to ensure milk freshness. Quality Control
Why is Testing Necessary ? Milk testing and quality control is an essential component of any milk processing industry whether small, medium or large scale. Milk being made up of 87% water is prone to adulteration by unscrupulous middlemen and unfaithful farm workers. Moreover, its high nutritive value makes it an ideal medium for the rapid multiplication of bacteria, particularly under unhygienic production and storage at ambient temperatures. Product Testing in QA Lab
Some Tests Carried out in QA Labs Organoleptic Evaluation Check taste and flavor of milk. COB Test Conduct COB test by taking about 2 ml milk in a test tube, boil on the flame of a spirit lamp formation of clots in the test tube indicates COB positive milk and is unacceptable. Acidity Test Taking 10 ml milk in 10 ml conical flask. Titrate against N/10 NaOH using phenolphthalein indicator to check acidity. Acidity above .153% is not acceptable. Rosalic Acid Test To 5 ml 60% alcoholic Rosalic acid in a test tube add 2 ml of milk . Rose red color development indicates neutralizer presence in milk and formation of flakes indicates disturbed salt balance.
Some Tests Carried out in QA Labs Alcohol Test Alcohol test is done to know the quality of milk. To 2 ml milk in a test tube add 2 ml 68% alcohol. The presence of flakes indicates alcohol positive and such milk is rejected. The alcohol test determines the susceptibility of milk to coagulation due to developed acidity, salt unbalance or high albumen content. FAT & SNF Fat & SNF can be determined using Gerber’s method or using a Milcoscan. SNF can also be determined using lactometer reading and Fat value and putting the formula CLR/4 +Fat x .2 + .29 Milkoscan is the latest technology machine for scanning of milk and uses infra red rays to analyze the milk for • Fat • Protein • Lactose • SNF
Continued… Tests Carried out in QA Labs Microbe Test For testing the presence of microbe, plating method is done. In this process 1ml of various sample (milk, yoghurt, ghol ,butter and paneer) is collected and its dilution is prepared. Then it is plated according to the drop plate method. For paneer 1gm paneer is grinded with sterile phosphate buffer and then its dilution is prepared. Also for preparing dilutions of other samples sterile phosphate buffer is used. For plating two types of media is used : •Violet Red Bile media- it is used to observe the coliform growth in the sample •Milk agar media- it is used to determine the total plate count of the sample.
Continued… Tests Carried out in QA Labs Paneer Test Appearance -- Shall be clear and free from dirt, surface discoloration and insect's contamination. It shall not have any free moisture. Flavour -- It shall have pleasant odour and characteristic mild acid flavour Texture – It shall have a closely-knit smooth texture and spongy body. Moisture 2 gm. shredded paneer is weighed in a dish. Mix with 4 ml hot distilled water with glass rod. Wash off the particles on glass rod using 1 ml water. Mix the contents thoroughly. Heat the dish at 100 + 2◦ C for 4 hrs. Cool in desiccators. Observe the final weight. Calculation : Moisture % = 100 (W1 - W2) (W1 – W) W1 = dish + sample before drying W2 = dish + sample after drying W = Mass of empty dish
Continued… Tests Carried out in QA Labs . Lactometer Test It is an instrument use to measure the SNF present in milk. In this process the lactometer is dipped in milk n it shows the reading. Calculation: SNF= (CLR/4) + .25f+ .44 CLR = Lactometer reading f = % of fat Lactometer Test
Details about some Tests carried out in QA Labs Tests for Free Fatty Acids It is done to measure the % of Oleic Acid 10 gram ghee is taken Neutralizer is prepared Neutralizer are added to the ghee It is kept at 50°C for 15 minutes with repeated shaking It is then titrated with 0.1N NaOH
Continued.. Protein Test 10 ml Milk + .4ml Saturated potassium oxalate Keep Undisturbed for 3 minutes Titrate with NaOH Then add Formalin solution (2ml) Titrate with N/10 NaOH
Continued.. Acid Value Test for Butter 20 gram Butter + 90ml boiling water Add Phenolphthalein about 1ml Titrate it with NaOH Calculation:2.28*V÷W W: weight of the sample(20gm) V: volume of NaOH used Standard : 0.06 Maximum
Continued.. Gerber Test :- 5gm butter /10.75 ml milk is taken and to that 10 ml of Gerber sulfuric acid :( specific gravity 1.823) at 15-21c is added into Gerber Butyrometer Add 1ml of iso amyl alcohol and insert the lock stopper grasp the test bottle at the graduated column and shake it until the curd is completely digested. Adjust temperature of the milk sample to 22-21C°. Place them in a Gerber centrifuge close the cover and lock. After the required speed of1500 rpm centrifuge for 5 mint, stop the centrifuge. Standard : 80 to 84% Milk should be heated at 40°C and then brought to room temperature.
Continued.. MBR Test 10 ml Milk + 1ml Methylene Blue. Put in water bath till the color becomes white. Standard : If Milk quality is good then it will take 6-7 hours to discolour. BR Test Heat Butter till it forms Ghee/Heat ghee at 40◦C Filter it and remove the residue Put in Butyro Refractometer and take BR readings Standard : 40 - 44 %
Continued..RM Value It is done for both butter and ghee. In case of butter it is first heated to high temperature to convert it into ghee and then the test is performed. It is used to measure the volatile fatty acid present in the sample. Standard: 21-28 5 gm. ghee/butter is taken 20gm of 98% glycerol is added 2 ml of 50% NaOH is added Heated till it is clean It is kept covered and cooled
Continued.. 50ml diluted sulfuric acid is mixed 93 ml boiled water is added which was boiled for 15 minutes 3-4 glass balls were added to prevent the flask from blasting and it is heated Then it is distilled by the process of distillation Distilled fluid is collected for 1st 20 minutes
Continued.. The fluid is kept at 15◦C for 10 minutes It is mixed and titrated with N/10 NaOH with 1 ml phenolphthalein as indicator Calculation: Reading – (0.2)*1.1 Blank reading-- 0.2 Ammonia Test 5ml Milk + 1ml Nessler’s Reagent. Standard : If yellow spot appears at the bottom, then it contains Ammonium Salt. Test for presence of Urea Take 2 ml milk in a test tube & add 2 ml DMAB solution and mix the contents. Standard: Appearance of yellow color indicates the presence of urea making the milk unacceptable.
Continued.. Phosphatase Test The Phosphatase test is applied to dairy products to determine whether pasteurization was properly and also to detect the possible addition of raw milk to pasteurized milk. Pasteurization results in deactivation of Phosphatase enzyme. 1ml of Milk is taken Substrate is added (5ml) Put in water bath at 37 ± 1 °C for 2 hours Standard: If yellow color, then Pasteurization not done properly. If it is colorless, then Pasteurization done properly.
Continued.. Milk Powder Test Milk powder is dissolved in water It is centrifuge at 1100 rpm for 5 minutes The sediment is observed Standard: The layer of the sediment should not exceed 0.5 cm
Continued.. Homogenizing Efficiency Test Take some milk and dilute it with water Smear the milk on the slide Cover it with cover slip Smear it with cedar wood oil Observe it under microscope Standard: The size of the fat globule should not exceed 2 micron
Continued.. Salt Test The salt used in the plant should be free from iodine. So to test this some amount of freshly prepared starch solution is added to the salt. If blue-black appears then it is rejected Chlorine Test 1ml chlorine + 10ml glacial acetic acid + 2gm potassium iodide Keep in dark for 5 minutes Titrate it with N/10 Sodium Thiosulphate till it becomes straw yellow Add 1ml starch Titrate it with N/10 Sodium Thiosulphate till it becomes colorless Calculation: Strength of chlorine at ppm= 3546*(1st reading - 2nd reading) Standard: 40000 minimum
Continued..Caustic Strength Test 10 ml Caustic is taken Add 2-4 drops of Phenolpthelin Pink Color appears Titrate with 2.5 Normal Sulphuric Acid until it becomes colourless Standard: 0.7 to1.5 Specific Gravity Test for Caustic Cool the caustic till 20◦ C Immerse the hydrometer Note the reading on hydrometer Standard : 1.45
Hardness test Take 10 ml water Add 4 drops of ammonium buffer solution Add 3-4 drops of Erichrone Black solution Titrate it with N/50 EDTA till the color changes from purple to dark green and note the reading. pH Test : It is done with the help of pH meter. Standard is 7-8. Total Dissolved Solid Test (TDS) it is done with TDS instrument which gives the reading directly. The reading varies according to the sample. Continued..Water Tests
Continued.. Milk Polypack Test Thickness Test: It is done by dial thickness gauge. Standard is 49-50 microns. Printing Test: Print should not come out on a cello tape when it is stuck and peeled out. Width Test: The standard value is 323 (± 2) mm Drop Test: It should be dropped 2m for 500ml and 1m for 1000 ml. Milk Polypacks
Test Result And Discussion Test Name Result And Discussion COB TEST (Clot On Boli) Formation of clots in the sample indicates COB positive milk and is unacceptable. Generally milk from Midnapur district were sometimes COB positive. ACIDITY TEST Acidity above .153% is not acceptable All milk samples have acidity below the given standard. ROSALIC ACID TEST Rose red color development indicates neutralizer presence in milk and formation of flakes indicates disturbed salt balance. Peach color tends to deepen if caustic (neutralizer) is present depending on the amount of caustic. Generally all sample produce light peach color indicating the presence of little amount of caustic in it, added to increase the self- life ALCOHOL TEST The presence of flakes indicates alcohol positive and such milk is rejected. The alcohol test determines the susceptibility of milk to coagulation due to developed acidity, salt unbalance or high albumen content. Majority of the samples tested were alcohol negative.
Test Result And Discussion Test Name Result And Discussion FAT & SNF TEST It is done either by Garber method or with the help of Milkoscan Majority of the time the results were according to the standard, if it was more or less than the standard then the batch were rejected. MBRT TEST Milk with MBR time of less than 7 hours is unacceptable. All the milk samples had MBR time of around 7 hours. TEST FOR PRESENCE OF UREA Appearance of yellow color indicates the presence of urea making the milk unacceptable. Majority of the samples were Ammonia free. PHOSPHATASE TEST Yellow color determines that pasteurization was not done properly. Pasteurization results in inactivation of phosphatase enzyme. All samples appeared colorless i.e. properly pasteurized. MICROBE TEST Microbes were observed only on plates that were plated by Dahi samples. Count of around 400 colonies (approx.) was accepted. More than that were recorded and reported. Generally all samples gave a colony count below the standard. MOISTURE TEST FOR PANEER Differences of about 2gm were acceptable before and after drying. e.g.: BNIL paneer weight around 16.7191 before drying and 14.7160 after drying. Therefore the diff is around 2gm
Test Result And Discussion Test Name Result And Discussion LACTOMETER TEST Standard for raw milk is around 30. Generally though it never reached exact 30 but around or more than 28.5 is accepted. e.g.: once milk from Midnapur was rejected as it was 26.75 TESTS FOR FREE FATTY ACIDS Standard is around or less than 3.0. It is the % of Oleic acid in ghee. e.g. BLIN ghee has a value of 1.1844 PROTEIN TEST Standard is around 8.5% Below that the sample is rejected. Ones milk from Haringhata was rejected due to lower protein content around 6.2%. ACID VALUE TEST FOR BUTTER Standard is 0.06% All samples were around the given standard. GERBER TEST Standard : 80-84% Once milk pouch from BNIL was rejected as it had Gerber test value of around 60% BR TEST (Butyro Refractometer) Standard: 40-45%. Below or above that range that sample was rejected. No sample was rejected on the basis of this test.
Test Result And Discussion Test Name Result And Discussion RM VALUE Standard: 21-28% No sample were rejected on the basis of this test. AMMONIA TEST If yellow spot appears at the bottom, then it contains Ammonia. Generally, rarely ammonia was found in the milk samples. MILK POWDER TEST The layer of the sediment should not exceed 0.5 cm. Generally on samples were rejected on the basis of this test. HOMOGENISING EFFICIENCY TEST The size of the fat globule should not exceed 2 micron. It is used to check the efficiency of homogenizer. Once the fat globule size exceeded 2 micron due to fault in homogenizer SPECIFIC GRAVITY TEST FOR CAUSTIC Standard : 1.45 No samples were rejected. WATER HARDNESS TEST Standard: .5ml If the volume of EDTA is more than that then the sample is rejected. Samples were rarely rejected.
Test Result And Discussion Test Name Result And Discussion WATER pH TEST Standard: 7-8 No samples were rejected WATER TDS TEST (Total Dissolved Solid) Standard: 300(approx.) No samples were rejected SALT TEST Appearance of blue black color in the salt indicates the presence of iodine and the sample is rejected. No sample is rejected. CHLORINE TEST Standard : 40000 More the strength better it is as it is used for CIP (Cleaning In Place). Sample with less than 30000 is rejected and rejection is rare. MILK POLYPACK TEST Thickness Test: Standard is 49-50 microns. Printing Test: Print should not come out on a cello tape when it is stuck and peeled out. Width Test: The standard value is 323 (± 2) mm Drop Test: It should be dropped 2m for 500ml and 1m for 1000 ml. No samples were rejected.
Some Photos of Production Department Dahi Plant Set Up
Some Photos of Instruments used in QA Testing Department Centrifuge MBRT Lactometer
Some Photos of Instruments used in QA Testing Department Milkoscan Attached to Computer
Some Photos of Packaging Department Polypack Packaging And Final Packaging
Mother Dairy, Kolkata is committed to the protection of environment by Prevention of Pollution and Continual Improvement in our processes and systems to Improve Environmental Performance. Minimize Waste generation Conservation of resources Use of renewable energy Recycling & re-use Environment and Safety: Storage Area
o http://en.wikipedia.org/wiki/Mother_Dairy /Calcutta o http://www.mannventures.com/mother-dairy-kolkata- division.html o http://www.motherdairy.com/MotherDairyPages/home.aspx o http://www.motherdairy.com/MotherDairyPages/branddetailpag e.aspx.html o http://www.deccanherald.com/content/224908/mother-dairy- expand-operations.html o http://www.hrgms.com/news.html Bibliography
Mother Dairy Kolkata Dissertation Report

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Mother Dairy Kolkata Dissertation Report

  • 1.
    A Project Reporton Dissertation in MOTHERDAIRY Kolkata Presented by: Sukanya Halder B.Tech/M.tech Dual Degree Year- 5th Roll Number - 1060070 KIIT SCHOOL OF BIOTECHNOLOGY
  • 2.
    ◊ Introduction ◊ Visionand Mission ◊ Milk & Traditional Products ◊ Products Manufactured ◊ Product Specifications & Details ◊ Milk Process ◊ Milk Production System ◊ Manufacturing & Processing ◊ Quality Control ◊ Product Testing in QA Lab ◊ Tests Carried out in QA lab ◊ Test Result & Discussion ◊ Picture Gallery ◊ Bibliography Presentation Flow
  • 3.
    Introduction  MOTHER DAIRYCALCUTTA, a Government of West Bengal project, was started under Operation Flood II of National Dairy Development Board . It was set up initially to cater to the demand of the Kolkata urban agglomeration spread over the Kolkata Metropolitan area.  Mother Dairy is also reaching out to the consumers of other Districts. The commissioning of the Dairy started in July 1978 and the first Distribution vehicle loaded with milk sachets rolled out of the Dairy in the morning of 8th December 1978. Initially, the management of Mother Dairy was looked after by the National Dairy Development Board .  Mother Dairy safeguards the interest of the rural milk producers by encouraging co- operative movement & marketing the surplus milk available from the villages, thus helping the milk producers to realize their own potential for organized endeavour & the creation of more rural wealth in the shape of 'Anand Pattern' as profounder by Dr. V.Kurian , The Milk Man of INDIA.  In November 1996 , the management of Mother Dairy was taken over by West Bengal Cooperative Milk Producers’ Federation.
  • 4.
    Vision And Mission Vision– “Provide quality food and beverages to consumers at affordable prices while ensuring fair returns to the producers.” Mission – “Mother Dairy’s heritage is intrinsically linked to the cooperative movement in India. With determination & pride we will continue to serve our farmers, rural India & our consumers. Our values reflect who we are & what we firmly believe in.”
  • 5.
    Milk Conversion of Milkinto Traditional Indian Dairy Products Cultured PrecipitationCondensed Shrikhand Ghee Lassi Misti Doi Rabri Kheer Khoa Paneer Sandesh Chhana Rasgolla Pantoda Rasmalai Barfi Pedha Kalakand Gulabjamun
  • 6.
    Products Of MotherDairy Double Toned Milk Toned Milk Cow Milk Mishti Doi Probiotic Yogurt Flavoured Yogurt Paneer Cow Ghee Ice Creams
  • 7.
    Product Details Product Milkfat SNF Sugar Protein Carb. Caramel Flavour Energy (100gm) Sweet Yoghurt 3.0 13 18 4.8 7.0 0.2 146 kcal Probiotic Yoghurt 3.0 11 4.8 71 kcal Flavoured Yoghurt 3.0 13 13 4.8 7.0 Green- mango Chocolate Pineapple Vanilla 126kcal Yoghurt For preparing yoghurt about 11% cultures of each Streptococcus thermopiles and Lactobacillus bulgaricus is used.
  • 8.
    Product Details Specific Detailsof Types of Milk produced in Mother Dairy Kolkata Type of milk Minimum fat Min. SNF Cow Milk 3.5 8.5 Toned Milk 3.0 8.5 Double toned Milk 1.5 9.0 Full Cream Milk 6.0 9.0 Cholesterol free Milk 0.5 8.9 Standardized Milk 4.5 8.5
  • 9.
    Product Specefications Cow Milk:Fat-3.5% & SNF-8.5% Double Toned Milk: Fat-1.5% & SNF-09% Toned Milk: Fat-3% & SNF 8.5%
  • 10.
    Product Specefications Sweet Yogurt:Fat-3 % & SNF-13% Probiotic Yogurt: Fat-3 % & SNF- 11% Flavoured Yogurt: Fat-3 % & SNF-13%
  • 11.
    Some Other Products:- Different Flavoured Yogurts Probiotic Dahi
  • 12.
  • 13.
    Pasteurization Kills all pathogenicbacteria present in the milk. Thus making it safe for consumption Homogenization Improves palatability of milk Standardisation Maintain uniformity by raising or lowering fat and SNF (solid not fat) percentage to desired levels Clarification Milk is spun at very high speed, removing all dust particles Milk production system
  • 14.
    Manufacturing of SweetYoghurt :- Milk, powder, water and sugar are added in the vat It is agitated It is heated up to 90◦C It is cooled to 45◦C Culture and caramel is added It is packaged It is stored in incubator room at 43◦C for 4-5 hours It is then transferred to cold room It is dispatched Manufacturing Process
  • 15.
    Continued.. Manufacturing of probioticyoghurt :- Milk, powder and water are added in the vat It is agitated It is heated up to 90◦C It is cooled to 45◦C Culture is added It is packaged It is stored in incubator room at 43◦C for 4-5 hours It is then transferred to cold room It is dispatched In case of probiotic yoghurt commercial cultures like DH-111 and YOLP are used
  • 16.
    Continued..Manufacturing of flavoredyoghurt :- Milk, powder, water and sugar are added in the vat It is agitated It is heated up to 90◦C It is cooled to 45◦C Culture and flavor l is added It is packaged It is stored in incubator room at 43◦C for 4-5 hours It is then transferred to cold room It is dispatched Amount of flavour added:- Green mango: 0.5% Vanilla : 1% Chocolate : 0.3% Pineapple : 0.25%
  • 17.
    Continued.. Manufacturing of mangoflavored ghol :- Curd water, salt and sugar are added in the vat It is agitated It is heated up to 90◦C It is cooled to 10-15◦C Yoghurt and flavor is added It is agitated and mixed properly It is packaged and put in cold room It is dispatched
  • 18.
    Milk is heatedat 90◦C It is brought to 86◦C Citric acid is added Curdling of milk occurs and it is allowed to settle for 10 minutes Agitation is given Paneer water is drained Paneer is put in hoof bar It is compressed for 10 minutes at 4-6 kg pressure It is then put in cold water at 7-8◦C for 2 hours for the paneer to solidify Processing Processing of Paneer :-
  • 19.
    It is putin brine water solution for 1 hour to increase self life It is kept in cold room overnight It is cut into pieces(100gm, 250gm, 1kg and 5kg) It is put into packets Vacuum packaging is done It is kept in cold store and is ready to be dispatched Continued..
  • 20.
    Milk is testedfor adulterations and quality at the time of collection The temperature is judiciously maintained less than 4°C always No contamination by human hands takes place, since processes are automated. The trucks that deliver milk have specified guidelines Travel time between collection and distribution points is always less than 36 hours to ensure milk freshness. Quality Control
  • 21.
    Why is TestingNecessary ? Milk testing and quality control is an essential component of any milk processing industry whether small, medium or large scale. Milk being made up of 87% water is prone to adulteration by unscrupulous middlemen and unfaithful farm workers. Moreover, its high nutritive value makes it an ideal medium for the rapid multiplication of bacteria, particularly under unhygienic production and storage at ambient temperatures. Product Testing in QA Lab
  • 22.
    Some Tests Carriedout in QA Labs Organoleptic Evaluation Check taste and flavor of milk. COB Test Conduct COB test by taking about 2 ml milk in a test tube, boil on the flame of a spirit lamp formation of clots in the test tube indicates COB positive milk and is unacceptable. Acidity Test Taking 10 ml milk in 10 ml conical flask. Titrate against N/10 NaOH using phenolphthalein indicator to check acidity. Acidity above .153% is not acceptable. Rosalic Acid Test To 5 ml 60% alcoholic Rosalic acid in a test tube add 2 ml of milk . Rose red color development indicates neutralizer presence in milk and formation of flakes indicates disturbed salt balance.
  • 23.
    Some Tests Carriedout in QA Labs Alcohol Test Alcohol test is done to know the quality of milk. To 2 ml milk in a test tube add 2 ml 68% alcohol. The presence of flakes indicates alcohol positive and such milk is rejected. The alcohol test determines the susceptibility of milk to coagulation due to developed acidity, salt unbalance or high albumen content. FAT & SNF Fat & SNF can be determined using Gerber’s method or using a Milcoscan. SNF can also be determined using lactometer reading and Fat value and putting the formula CLR/4 +Fat x .2 + .29 Milkoscan is the latest technology machine for scanning of milk and uses infra red rays to analyze the milk for • Fat • Protein • Lactose • SNF
  • 24.
    Continued… Tests Carried outin QA Labs Microbe Test For testing the presence of microbe, plating method is done. In this process 1ml of various sample (milk, yoghurt, ghol ,butter and paneer) is collected and its dilution is prepared. Then it is plated according to the drop plate method. For paneer 1gm paneer is grinded with sterile phosphate buffer and then its dilution is prepared. Also for preparing dilutions of other samples sterile phosphate buffer is used. For plating two types of media is used : •Violet Red Bile media- it is used to observe the coliform growth in the sample •Milk agar media- it is used to determine the total plate count of the sample.
  • 25.
    Continued… Tests Carried outin QA Labs Paneer Test Appearance -- Shall be clear and free from dirt, surface discoloration and insect's contamination. It shall not have any free moisture. Flavour -- It shall have pleasant odour and characteristic mild acid flavour Texture – It shall have a closely-knit smooth texture and spongy body. Moisture 2 gm. shredded paneer is weighed in a dish. Mix with 4 ml hot distilled water with glass rod. Wash off the particles on glass rod using 1 ml water. Mix the contents thoroughly. Heat the dish at 100 + 2◦ C for 4 hrs. Cool in desiccators. Observe the final weight. Calculation : Moisture % = 100 (W1 - W2) (W1 – W) W1 = dish + sample before drying W2 = dish + sample after drying W = Mass of empty dish
  • 26.
    Continued… Tests Carried outin QA Labs . Lactometer Test It is an instrument use to measure the SNF present in milk. In this process the lactometer is dipped in milk n it shows the reading. Calculation: SNF= (CLR/4) + .25f+ .44 CLR = Lactometer reading f = % of fat Lactometer Test
  • 27.
    Details about some Testscarried out in QA Labs Tests for Free Fatty Acids It is done to measure the % of Oleic Acid 10 gram ghee is taken Neutralizer is prepared Neutralizer are added to the ghee It is kept at 50°C for 15 minutes with repeated shaking It is then titrated with 0.1N NaOH
  • 28.
    Continued.. Protein Test 10 mlMilk + .4ml Saturated potassium oxalate Keep Undisturbed for 3 minutes Titrate with NaOH Then add Formalin solution (2ml) Titrate with N/10 NaOH
  • 29.
    Continued.. Acid Value Testfor Butter 20 gram Butter + 90ml boiling water Add Phenolphthalein about 1ml Titrate it with NaOH Calculation:2.28*V÷W W: weight of the sample(20gm) V: volume of NaOH used Standard : 0.06 Maximum
  • 30.
    Continued.. Gerber Test :- 5gmbutter /10.75 ml milk is taken and to that 10 ml of Gerber sulfuric acid :( specific gravity 1.823) at 15-21c is added into Gerber Butyrometer Add 1ml of iso amyl alcohol and insert the lock stopper grasp the test bottle at the graduated column and shake it until the curd is completely digested. Adjust temperature of the milk sample to 22-21C°. Place them in a Gerber centrifuge close the cover and lock. After the required speed of1500 rpm centrifuge for 5 mint, stop the centrifuge. Standard : 80 to 84% Milk should be heated at 40°C and then brought to room temperature.
  • 31.
    Continued.. MBR Test 10 mlMilk + 1ml Methylene Blue. Put in water bath till the color becomes white. Standard : If Milk quality is good then it will take 6-7 hours to discolour. BR Test Heat Butter till it forms Ghee/Heat ghee at 40◦C Filter it and remove the residue Put in Butyro Refractometer and take BR readings Standard : 40 - 44 %
  • 32.
    Continued..RM Value It isdone for both butter and ghee. In case of butter it is first heated to high temperature to convert it into ghee and then the test is performed. It is used to measure the volatile fatty acid present in the sample. Standard: 21-28 5 gm. ghee/butter is taken 20gm of 98% glycerol is added 2 ml of 50% NaOH is added Heated till it is clean It is kept covered and cooled
  • 33.
    Continued.. 50ml diluted sulfuricacid is mixed 93 ml boiled water is added which was boiled for 15 minutes 3-4 glass balls were added to prevent the flask from blasting and it is heated Then it is distilled by the process of distillation Distilled fluid is collected for 1st 20 minutes
  • 34.
    Continued.. The fluid iskept at 15◦C for 10 minutes It is mixed and titrated with N/10 NaOH with 1 ml phenolphthalein as indicator Calculation: Reading – (0.2)*1.1 Blank reading-- 0.2 Ammonia Test 5ml Milk + 1ml Nessler’s Reagent. Standard : If yellow spot appears at the bottom, then it contains Ammonium Salt. Test for presence of Urea Take 2 ml milk in a test tube & add 2 ml DMAB solution and mix the contents. Standard: Appearance of yellow color indicates the presence of urea making the milk unacceptable.
  • 35.
    Continued.. Phosphatase Test The Phosphatasetest is applied to dairy products to determine whether pasteurization was properly and also to detect the possible addition of raw milk to pasteurized milk. Pasteurization results in deactivation of Phosphatase enzyme. 1ml of Milk is taken Substrate is added (5ml) Put in water bath at 37 ± 1 °C for 2 hours Standard: If yellow color, then Pasteurization not done properly. If it is colorless, then Pasteurization done properly.
  • 36.
    Continued.. Milk Powder Test Milkpowder is dissolved in water It is centrifuge at 1100 rpm for 5 minutes The sediment is observed Standard: The layer of the sediment should not exceed 0.5 cm
  • 37.
    Continued.. Homogenizing Efficiency Test Takesome milk and dilute it with water Smear the milk on the slide Cover it with cover slip Smear it with cedar wood oil Observe it under microscope Standard: The size of the fat globule should not exceed 2 micron
  • 38.
    Continued.. Salt Test The saltused in the plant should be free from iodine. So to test this some amount of freshly prepared starch solution is added to the salt. If blue-black appears then it is rejected Chlorine Test 1ml chlorine + 10ml glacial acetic acid + 2gm potassium iodide Keep in dark for 5 minutes Titrate it with N/10 Sodium Thiosulphate till it becomes straw yellow Add 1ml starch Titrate it with N/10 Sodium Thiosulphate till it becomes colorless Calculation: Strength of chlorine at ppm= 3546*(1st reading - 2nd reading) Standard: 40000 minimum
  • 39.
    Continued..Caustic Strength Test 10ml Caustic is taken Add 2-4 drops of Phenolpthelin Pink Color appears Titrate with 2.5 Normal Sulphuric Acid until it becomes colourless Standard: 0.7 to1.5 Specific Gravity Test for Caustic Cool the caustic till 20◦ C Immerse the hydrometer Note the reading on hydrometer Standard : 1.45
  • 40.
    Hardness test Take 10ml water Add 4 drops of ammonium buffer solution Add 3-4 drops of Erichrone Black solution Titrate it with N/50 EDTA till the color changes from purple to dark green and note the reading. pH Test : It is done with the help of pH meter. Standard is 7-8. Total Dissolved Solid Test (TDS) it is done with TDS instrument which gives the reading directly. The reading varies according to the sample. Continued..Water Tests
  • 41.
    Continued.. Milk Polypack Test ThicknessTest: It is done by dial thickness gauge. Standard is 49-50 microns. Printing Test: Print should not come out on a cello tape when it is stuck and peeled out. Width Test: The standard value is 323 (± 2) mm Drop Test: It should be dropped 2m for 500ml and 1m for 1000 ml. Milk Polypacks
  • 42.
    Test Result AndDiscussion Test Name Result And Discussion COB TEST (Clot On Boli) Formation of clots in the sample indicates COB positive milk and is unacceptable. Generally milk from Midnapur district were sometimes COB positive. ACIDITY TEST Acidity above .153% is not acceptable All milk samples have acidity below the given standard. ROSALIC ACID TEST Rose red color development indicates neutralizer presence in milk and formation of flakes indicates disturbed salt balance. Peach color tends to deepen if caustic (neutralizer) is present depending on the amount of caustic. Generally all sample produce light peach color indicating the presence of little amount of caustic in it, added to increase the self- life ALCOHOL TEST The presence of flakes indicates alcohol positive and such milk is rejected. The alcohol test determines the susceptibility of milk to coagulation due to developed acidity, salt unbalance or high albumen content. Majority of the samples tested were alcohol negative.
  • 43.
    Test Result AndDiscussion Test Name Result And Discussion FAT & SNF TEST It is done either by Garber method or with the help of Milkoscan Majority of the time the results were according to the standard, if it was more or less than the standard then the batch were rejected. MBRT TEST Milk with MBR time of less than 7 hours is unacceptable. All the milk samples had MBR time of around 7 hours. TEST FOR PRESENCE OF UREA Appearance of yellow color indicates the presence of urea making the milk unacceptable. Majority of the samples were Ammonia free. PHOSPHATASE TEST Yellow color determines that pasteurization was not done properly. Pasteurization results in inactivation of phosphatase enzyme. All samples appeared colorless i.e. properly pasteurized. MICROBE TEST Microbes were observed only on plates that were plated by Dahi samples. Count of around 400 colonies (approx.) was accepted. More than that were recorded and reported. Generally all samples gave a colony count below the standard. MOISTURE TEST FOR PANEER Differences of about 2gm were acceptable before and after drying. e.g.: BNIL paneer weight around 16.7191 before drying and 14.7160 after drying. Therefore the diff is around 2gm
  • 44.
    Test Result AndDiscussion Test Name Result And Discussion LACTOMETER TEST Standard for raw milk is around 30. Generally though it never reached exact 30 but around or more than 28.5 is accepted. e.g.: once milk from Midnapur was rejected as it was 26.75 TESTS FOR FREE FATTY ACIDS Standard is around or less than 3.0. It is the % of Oleic acid in ghee. e.g. BLIN ghee has a value of 1.1844 PROTEIN TEST Standard is around 8.5% Below that the sample is rejected. Ones milk from Haringhata was rejected due to lower protein content around 6.2%. ACID VALUE TEST FOR BUTTER Standard is 0.06% All samples were around the given standard. GERBER TEST Standard : 80-84% Once milk pouch from BNIL was rejected as it had Gerber test value of around 60% BR TEST (Butyro Refractometer) Standard: 40-45%. Below or above that range that sample was rejected. No sample was rejected on the basis of this test.
  • 45.
    Test Result AndDiscussion Test Name Result And Discussion RM VALUE Standard: 21-28% No sample were rejected on the basis of this test. AMMONIA TEST If yellow spot appears at the bottom, then it contains Ammonia. Generally, rarely ammonia was found in the milk samples. MILK POWDER TEST The layer of the sediment should not exceed 0.5 cm. Generally on samples were rejected on the basis of this test. HOMOGENISING EFFICIENCY TEST The size of the fat globule should not exceed 2 micron. It is used to check the efficiency of homogenizer. Once the fat globule size exceeded 2 micron due to fault in homogenizer SPECIFIC GRAVITY TEST FOR CAUSTIC Standard : 1.45 No samples were rejected. WATER HARDNESS TEST Standard: .5ml If the volume of EDTA is more than that then the sample is rejected. Samples were rarely rejected.
  • 46.
    Test Result AndDiscussion Test Name Result And Discussion WATER pH TEST Standard: 7-8 No samples were rejected WATER TDS TEST (Total Dissolved Solid) Standard: 300(approx.) No samples were rejected SALT TEST Appearance of blue black color in the salt indicates the presence of iodine and the sample is rejected. No sample is rejected. CHLORINE TEST Standard : 40000 More the strength better it is as it is used for CIP (Cleaning In Place). Sample with less than 30000 is rejected and rejection is rare. MILK POLYPACK TEST Thickness Test: Standard is 49-50 microns. Printing Test: Print should not come out on a cello tape when it is stuck and peeled out. Width Test: The standard value is 323 (± 2) mm Drop Test: It should be dropped 2m for 500ml and 1m for 1000 ml. No samples were rejected.
  • 47.
    Some Photos ofProduction Department Dahi Plant Set Up
  • 48.
    Some Photos ofInstruments used in QA Testing Department Centrifuge MBRT Lactometer
  • 49.
    Some Photos ofInstruments used in QA Testing Department Milkoscan Attached to Computer
  • 50.
    Some Photos ofPackaging Department Polypack Packaging And Final Packaging
  • 51.
    Mother Dairy, Kolkatais committed to the protection of environment by Prevention of Pollution and Continual Improvement in our processes and systems to Improve Environmental Performance. Minimize Waste generation Conservation of resources Use of renewable energy Recycling & re-use Environment and Safety: Storage Area
  • 52.
    o http://en.wikipedia.org/wiki/Mother_Dairy /Calcutta ohttp://www.mannventures.com/mother-dairy-kolkata- division.html o http://www.motherdairy.com/MotherDairyPages/home.aspx o http://www.motherdairy.com/MotherDairyPages/branddetailpag e.aspx.html o http://www.deccanherald.com/content/224908/mother-dairy- expand-operations.html o http://www.hrgms.com/news.html Bibliography