This document provides information about Engro Foods Limited (EFL), a subsidiary of Engro Chemicals Pakistan Limited. It discusses EFL's plants in Sahiwal and Sukkur, what products are manufactured at each plant, and the strict criteria for receiving raw milk at EFL plants. The criteria include organoleptic tests, qualitative tests like temperature and acidity, quantitative tests like fat percentage, and various adulteration tests to check for substances like hydrogen peroxide, sugar, or urea. If the milk meets all the criteria after full analysis, it is accepted, otherwise it is rejected.

1. Amber zafar
Lab champion
Engro foods Sahiwal

2. Companyprofile
Engro Chemical Pakistan Limited is the second largest producer of Urea
fertilizer in Pakistan. The company was incorporated in 1965 and was formerly
Exxon Chemical Pakistan Limited until 1991, when Exxon decided to divest their
fertilizer business on a global basis and sold off its equity of 75% shares in our
company. The Employees of Engro, in partnership with leading international and
local financial institutions bought out Exxon’s equity and the company was renamed
as Engro Chemical Pakistan Limited. Engro is a public limited company listed on the
Stock Exchanges of Karachi, Lahore and Islamabad.

3. ENGRO FOOD LIMITED (EFL):
Engro Foods Limited is subsidiary of Engro Chemical Pvt. Ltd. It has diversified
into the food business and with the successful launch of Olper’s Milk, Olper’s
Cream, Olwell, Owsum Milk, Tarka Ghee, Omore Ice cream. Engro Foods Limited
has established itself as a major player in the foods business. Their aim is to
dominate the food business. EFL has been established in 2005 as part of a
diversification process at the Engro Group.
SUKKUR PLANT:
The plant located at Sukkur on 23 acre land, has the raw milk reception capability
of 300,000 liters per day and UHT milk capacity of 200,000 liters per day. Owsam
Milk,
Olwell Milk, Tarka Ghee, olfrute and Olper’s Cream are being manufactured here.

4. SAHIWAL PLANT:
It is situated at 8 Km away from Sahiwal and while going to Pakpattan and when
coming from Pakpattan towards Sahiwal it is 32 Km away from Pakpattan at
North side of main road.
Sahiwal plant was installed in 2007 and at starts its production at the end of
same year. It comprises of 33 acres that contains plant portion, parking areas,
landscaping areas, waste water treatment plant and neat and clean roads. It has
8 raw milk silos, 2 of them having capacity of 125000 liters and the 5 of them
having 150000 liters capacity. Here in Sahiwal olpers ,Tarang,Tarang elachi
Omore, and Omung are manufactured.
CERTIFICATES OWNED BY ENGRO FOODS (PVT.) LTD

5. MILK RECEPTION CRITERIA ON THE PLANT ENTRY:
when tanker reach at plant gate an inbound and out
bound security check list is filled by the security guard
. When milk tankers entered into EFL then proper
record of their entrance is maintained on security slip
that includes
Driver name
Vehicle number
Size of vehicle
Commodity it carry and first weight
After first weight company driver who drives the tanker
Up to first automatic weighting parking hand over
these three slips to reception operator in admin
building who attach a office copy with these and call to
lab for collect sample from respective vehicle ,as soon
the phone call receives at reception lab a sample boy
sent for milk sampling, who is trained for this .once
sampling done and results compile after analysis
sample boy bring back these slips with QA Accepted
stamp to reception operator ,now sample boy compile
QA lab results on Other two dispatches which are plant
copy and FOM copy signed by APM .

6. Dispatch note office copy carries information about D/s point
,area office ,name of the driver , tanker capacity
Factory time in
truck number , Date ,D/s time Seal number .
After QA accepted stamp and Shift chemist and APM sign
dispatch note tanker will receive and after milk receiving CIP
will start the time of CIP start and end time and than final
weight will display and print again on a slip through receiving
operator .after CIP these dispatch slips and all other slips
hand over to LCO
(logistic Coordinator ) except one dispatch who handed over
to production dept. and truck will out from second gate .
WEIGHING:
Where milk tanker pass through the weighed that is
automatically operated. Here weight is recorded in tons and
dispatch is given to driver.
Weight of milk = Total Weight - Empty tanker weight
Volume in liters of milk = weight in kilogram /specific gravity
of that milk. Once its weighted the driver will hand over this
dispatch note and security slip to production department
sitting in admin building .
The reception operator will give third copy to driver
Who will hand over this to line lab through line lab window .
Where lab analyst receive this and inform to shift chemist
shift chemist will instruct to sample boy of particular shift for
sampling .

7. sampling of Milk
Sampling is very crucial because all quality tests depend upon accuracy of
sampling. If samples are not true representatives of whole tanker then this
misleads the result that’s why EFL appointed trained persons for collection of
samples.
SAMPLING PROCEDURE:
Following steps are taken by the person who is taking sample:
Seals of the tanker are checked (either broken or not) . After this check he will take
plunger and knoppy and will wash them with 70% Ethanol dry them than he will
hook up the safety harness within the sides of trucks and ensure that it is hooked
properly . Than he will start Agitation with the help of plunger for about two to three
minutes for representative sample . He will take about a liter sample from each
portion of the tanker in washed and labelled utensils. Samples are brought to
reception lab immediately where these are analyzed for various parameters. At the
time samples received in lab temperature . sample analysis will done and results
announces Within 45 minutes .

8. ANALYSIS OF FRESH MILK:
Analysis comprises of following types of tests:
A. Organoleptic Tests
B. Qualitative Tests
C. Quantitative Test
D. Adulteration Tests
A. ORGANOLEPTIC TESTS:
Organoleptic evaluation of the milk includes, taste, odor, smell and
color. Normal milk has slightly sweet, no objectionable odor and
pleasant taste. If milk is not fresh its lactose content is converted into
lactic acid due to bacterial activity. Color of milk is white due to
dispersion of casein and fat which does not permits light to pass
through it. For Organoleptic evaluation milk is first heated to 40oC
because of the fact that molecules become active and volatile
compound present in milk are evaporated and make the evaluation
easy.

9. B. QUALITATIVE TEST.
1. TEMPERATURE:
After taking sample, immediately temperature of the milk is noted. The temperature
of the milk should not be more than 10oC. If it varies from this, warning should be
issued to the milk supplier or respective area collection center.
2. COB
When normal milk is heated it does not form clots. However if milk is abnormal,
milked from diseased animal (mastitis), rich in colostrum, very high in salts (NaCl) or
high in acidity (>0.30% lactic acid) it forms clots or curdles on gentle boiling. Such milk
cannot stand the heat temperature in milk processing. 2-4ml milk in test tube is
heated and clotting, coagulation or precipitation is observed. If any of above
mentioned property is observed it means milk sample has failed the test and milk is
suitable for further processing.

10. 3. pH OF MILK:
pH of fresh milk ranges 6.65-6.85 but when
milk comes in contact with environment
bacterial activity starts and due to production
of certain acids pH of milk decrease. pH of milk
is measured at EFL with the help of digital
WTW pH meter. Acceptable range of pH at EFL
plant is 6.6-6.9.
4. ACIDITY OF MILK:
Majority of the bacteria that grows in milk develop acidity through lactic acid
fermentation leading to souring, curdling of milk. In the acidity test the acid is
neutralized with 0.1 N Sodium Hydroxide and the amount of alkaline is
measured. From this, the percentage of lactic acid can be calculated. Fresh milk
contains in this test tube also” natural acidity” which is due to the natural ability
to resist pH changes. The natural acidity of the milk is 0.110-0.150%. Figure
higher than this signifies developed acidity due to the action of the bacteria on
the milk sugar.
At EFL milk reception criteria allow only milk to be received of it has acidity in
range of 0.110-0.150% (as a lactic acid); values higher than this are not
entertained for reception.

11. 5. APT @ 60 APT @90
PURPOSE:
To test the quality of raw milk for processing .
PRINCIPLE:
Alcohol precipitate test (APT) is quick and simple, based on in stability of
the protein when the levels of the acid and/or rennet are increased and
the aqueous alcoholic solution of known concentration is added an
insoluble precipitate is formed.
C. QUANTITATIVE TESTS:
1-FAT % DETERMINATION It( includes fat%, protein %, SNF % )
PURPOSE:
To determine fat content in milk since the fat content of the milk and
cream is the most important single factor in determining the price to
be paid for milk supplied by farmers in Pakistan. Fat test are also done
on milk products in order to make accurate adjustment of the butterfat
percentage in the standardized milk products. Fat determination at
plant is also calculated for loss/gain calculation of plant for production
strategies and in procurement.

12. 2-PROTEIN DETERMINATION:
PURPOSE:
Proteins are the most vital component of milk and part of SNF component of milk. Lactose, Proteins, Ash is
present in a fixed ratio know as Vieth’s ratio that is 13: 9: 2. We can infer quality of milk by observing any
change in the Vieth’s ratio through the determination of protein content of milk and not only monitor
quality of milk, avoid adulteration such as SNF forging with the addition of Sugar, salt etc) but can also
develop a multi component fresh milk payment formula based on SNF, Protein and Fat instead of
prevailing practices of milk payment on the basis of Fat alone. Formal titration is one of the quickest and
semi quantitative methods to determine protein percent of milk in field. It does not require high skill,
specialized equipment and is reasonably inexpensive. In this test it is assumed that the formalin used in
this test binds all the acids present in milk and remaining acidity is due to proteins in milk.
3. MSNF CALCULATION:
PURPOSE:
Determination of milk solids non fat (MSNF) and total solids in liquid milk for
material balance and some time for pricing of milk as well.

13. CALCULATION AND EXPRESSION OF THE RESULTS
MSNF % = (0.25 x CLR) + (0.22 x Fat %) + 0.72
TC % = Fat %+MSNF %
Where
LR=lactometer reading
Fat = Fat % in milk sample
MSNF= Milk solids non fat
TC=Total solid content

14. D. ADULTERATION TESTS:
1. TEST FOR DETECTION OF HYDROGEN PEROXID
2. TEST FOR DETECTION OF SUGAR IN MILK
3. TEST FOR DETECTION OF STARCH
4. TEST FOR DETECTION OF GLUCOSE
5. TEST FOR DETECTION OF UREA
6. TEST FOR DETECTION OF SALT
7. DETECTION OF VEGETABLE FAT IN MILK
8. TEST FOR DETECTION OF SORBITOL1
9. AMMONIUM SULPHATE
10. AMMONIUM NITRATE
11. FORMALINE
12. BARFORD
13. DETERGENT TEST

15. 1. DETERGENT TEST:
In milk neutralizers like hydrated lime, sodium hydroxide, sodium
carbonate or sodium bicarbonate are added which are generally
prohibited.
HOW TO DETECT?
Take 2ml of milk in a test tube and add 2 ml alcohol (95% ethanol)
followed by 2-3 drops of rosalic acid. If the color of milk changes to
pinkish red, then it is inferred that the milk is adulterated with sodium
carbonate / sodium bicarbonate and hence unfit for human
consumption.
This test will be effective only if the neutralizers are present in milk.
2. TEST FOR DETECTION OF HYDROGEN PEROXIDE:
For the determination of hydrogen peroxide strips are used which
develop color on presence of H2O2.

16. 3. TEST FOR DETECTION OF SUGAR IN MILK:
Generally sugar is mixed in the milk to increase the solid not fat
content of milk i.e. to increase the lactometer reading of milk, which is
already diluted with water.
HOW TO DETECT?
0.5ml milk + 3ml 37% HCl+ few drops of 10% alpha-naphthol, boil for
10 second and observe color, if no color sugar absent, blue violet color
indicate added sugars in milk.
4. TEST FOR DETECTION OF STARCH:
Addition of starch also increases the SNF content of milk. Apart from
the starch, wheat flour, arrowroot, rice flour is also added.
HOW TO DETECT?
2-4ml of milk sample + few drops of 0.1% iodine solution and observes
color, if blue color appears, starches are present.

17. 5. TEST FOR DETECTION OF GLUCOSE:
Usually poor quality glucose is added to milk to increase the lactometer
reading. There are two tests available to detect the adulteration of milk
with glucose.
HOW TO PROCEED?
Glucose strips are used to detect the glucose in milk. Color scale on the
pack indicates the amount of glucose.
BARFORD TEST:
2.5ml milk + 5ml barford reagent (copper acetate), dip in boiling water
for 3 minutes and observe color, if no color change then glucose is
absent, and if greenish color with brownish sedimentation appears
glucose is present in milk.

18. 5. TEST FOR DETECTION OF GLUCOSE:
Usually poor quality glucose is added to milk to increase the lactometer
reading. There are two tests available to detect the adulteration of milk
with glucose.
HOW TO PROCEED?
Glucose strips are used to detect the glucose in milk. Color scale on the
pack indicates the amount of glucose.
BARFORD TEST:
2.5ml milk + 5ml barford reagent (copper acetate), dip in boiling water
for 3 minutes and observe color, if no color change then glucose is
absent, and if greenish color with brownish sedimentation appears
glucose is present in milk.
6. TEST FOR DETECTION OF UREA:
1. Urea is generally added in the preparation of synthetic milk to
raise the SNF value. Strips are used to detect urea in milk sample.
2. 2ml milk sample + 2 ml DMAB solution, observe the color.
Yellowish color shows the presence of urea.

19. 7. TEST FOR DETECTION OF SALT:
Addition of salt in milk is mainly resorted to with the aim of increasing
the corrected lactometer reading.
HOW TO DETECT?
9ml milk sample + few drops of K2Cr2O5 (10%) and titrate against 0.1 N
AgNO3 and note the BR and multiply against 0.00584 to calculate salts
% (as NaCl).
8. TEST FOR DETECTION OF SORBITOL:
Generally sorbitol is mixed in the milk to increase the solid not fat
content of milk i.e. to increase the lactometer reading of milk, which is
already diluted with water.
HOW TO DETECT?
1 ml milk sample + 2ml, 10% NaOH sol. + 2ml, 10% iron sulphate sol.
Mix well and note the color and gel formation, if yellow green color and
gel formation appears then test is +ve.

20. 9. DETECTION OF VEGETABLE FAT IN MILK:
The characteristic feature of milk is its fatty acid composition, which
mainly consists of short chain fatty acids such as butyric, caproic,
caprylic acid; whereas the vegetable fats consist mainly of long chain
fatty acids and hence adulteration of vegetable fat in milk can be easily
found out by analyzing the fatty acid profile by gas chromatography.
At EFL vegetable fats are detected by using Butyro-refrective Index
meter which is calibrated at 41 with liquid paraffin at 40oC. Fat from
the milk sample is collected in spoon.
after centrifugation and heated on sprit lamp to evaporate moisture. A
drop of fat is spread on stage of BR meter and reading is noted from the
scale. The acceptable range of EFL is 39 to 43 and Values more than this
indicates that the milk has been adulterated with vegetable fat.
After complete analysis a sheet is prepared known as Raw Milk
Reception Sheet. If entire milk fulfills all criteria then, it is mentioned as
accepted otherwise rejected. Analyst then (May be more than one with
one supervisor) put his signature on this sheet. Then these results are
compared with results of analysis made at area collection center before
its dispatch from area and variation is mentioned on raw milk reception
sheet. Now milk tankers are weighed on a Weigh Bridge and are hooked
to reception point of plant where loading hose of silo pump is attached
to outlet of tank.

21. MILK PROCESSING:
Milk processing steps are these in EFL
Milk Reception
Milk Storage
Milk Pasteurization
UHT
Aseptic Packaging
Packaging Materials
Farmer Dairy
Production
Retailer
Dairy
Raw Material, Packaging, Service
Wholesaler
Dist. Centers
Broker
Sell Raw Material and Ingredients
Supplier
Add. Purchase of Raw Material / Raw Milk
Consumer

22. Reception Tanker Flexible
pipe
Raw Milk silos
(Temp >10)
Raw Milk Silos
Plate Heated
Exchanger
55 C
Separator
Sluge
Cream
45%
Skim
Milk fat
0.05%
Raw Cream
storage tank
Premix
Premix Additives Sugar
Raw milk Silos
Temp >10 c
Holding
Tube 3c
Main
heater
75c
Deaerator
65-70
Homogenization
1st Stage 100 bar
2nd 50 Bar
60c – 65c
Hydrogenated
palm oil

23. Pasturize
milk silos
>10
Thermal heat
exchanger 92 c+-3
Protein
stabilizer120 c
Thermal
exchange
exchanger
Main heater
140c + -4 c
Holding Tube
2 seconds
THE 25 c ATS
Filling
Machines

24. Total Five ATS at Packaging with capacity and machines .
ATS 1 (35000)
ATS 2 (40000)
A,B.D,omung (T 20 ) Tarang , Tarang Elachi
ATS -3 (50000)
X,Y,Z,Ecolan,F,V,A2,B2,C2
ATS4 (50000)
G,H,I,J,L,M,N, Tarang F2
ATS -5 (50000)
O,P,Q,R,S,T, Tarang One Step
ATS-6 (50000)
E2,D2,G2

25. Raw milk
silos
RMT 1
125,000 LTRS
RMT 2
125,000 LTRS
RMT 3
150,000
LTRS
RMT 5
150,000
LTRS
RMT 6
150,000
LTRS
RMT 6
150,000
LTRS
RMT 7
150,000
LTRS
RMT 8
150,000
LTRS

26. RCT 1
10,000 Kg
RCT 2
10,000Kg
RCT 3
20,000 kg
RCT 4
7500 Kg
RCT 5
7500 Kg
Raw Cream Storage Tanks

27. PC 1
10,000 Kg
PC 2
10,000 Kg
PC 3
10,000 Kg
PC 4
10,000Kg
PC 5
10,000Kg
PC 6
30,000 Kg
PC 6
30,000Kg
PC 7
30,000 Kg
PC 8
30,000 Kg
Pasteurized Cream Tanks

28. Premixes
Tanks
M2 20,000
LTRS
M3 20,000
LTRS
M4
20,000LTRS
SM1
20,000LTRS
SM2
20,000
LTRS
SM3
20,000
LTRS

29. PMT 1 75,000
LTRS
PMT 2
75,000LTRS
PMT 3
75,000LTRS
PMT 4 75,000
LTRS
PMT 5
75,000LTRS
PMT 6
75,000 LTRS
PMT 7 75,000
LTRS
PMT 8
10,0000 LTRS
PMT 9
10,0000 LTRS
PMT 10
10,0000 LTRS
Pasteurize Milk Tanks

30. Micro Lab orientation starts from 14-09-15 to
Portions
1- wet lab (For washing purpose of utensils and drying of utensils )
(Equipment's) 1-Oven 2-auto clave 121 c for 15 minutes )
3-water bath (37c)
2-Sterlization Room
Fridges <10 c <20c
Micro wave oven
Auto clave (out of order)
PH meter
Somatic cell counter
Weight balance 3200 g-0.5 g
Oven170 c
3-Inoculation Room
Laminar flow (purpose for inoculation of plates and having UV light)
It is also termed as Laminar Flow Clean Bench.
Here UV rays were used to sterilize surrounding air.
Thermometers wet bulb dry bulb
Fridge.

31. Incubation Room
1- incubators
MICROBIOLOGICAL LAB:
This Microbiological Lab was very important lab of the quality assurance
department. In this lab, the microbiological quality of the Ice cream, UHT milk,
pasteurized milk and raw milk is measured by following techniques,
Pour plate method
Spread plate method
Streak plate method
There were several incubators which were favorable to growth as they have
Moist Air.

32. MICROBIOLOGICAL TESTS:
Different tests are performed for different products in EFL and these are given here below:
Raw milk:
MBRT
TPC(5th or 6th dilution)
EB’s(4th dilution)
Somatic Cell
Antibiotics
Yeast and mold(Special case and on 4th dilution)
Pasteurized Milk:
TPC(2nd dilution)
EB’s(2nd dilution)
Phosphatase
UHT Milk(1st dilution):
TPC
EB’
Milk powder:
EB’s(1st dilution)
TPC(2nd dilution)
Yeast and mold (1st dilution)
Ice cream(1st dilution):
TPC
Coliform
Environmental monitoring:
Swab test( Machine+ person on 1st dilution))

33. MICROBIOLOGY ROOM HAS THE FOLLOWING EQUIPMENT’S AND SECTIONS:
AUTOCLAVE ROOM
This room is used for Media preparation.
Temperature =121oC
Pressure=15psi
Set time=15 minutes
In this room there is an oven operated at 170oC and used for sterilization of
equipment's.
Another oven that operates on 100oC and used for sterilization of stainless
steel and plastic equipment's
A water bath having temperature 52oC.
Hygiene auditing.
INOCULATION ROOM
It is also termed as Laminar Flow Clean Bench.
Here UV rays were used to sterilize surrounding air.

34. INCUBATION ROOM
There were several incubators which were favorable to growth as they have Moist Air.
MICROBIOLOGICAL TESTS:
Different tests are performed for different products in EFL and these are given here below:
Raw milk:
MBRT
TPC(5th or 6th dilution)
EB’s(4th dilution)
Somatic Cell
Antibiotics
Yeast and mold(Special case and on 4th dilution)
Pasteurized Milk:
TPC(2nd dilution)
EB’s(2nd dilution)
Phosphatase
UHT Milk(1st dilution):
TPC
EB’
Milk powder:
by the dilution technique

35. UHT Milk(1st dilution):
TPC
EB’
Milk powder:
EB’s(1st dilution)
TPC(2nd dilution)
Yeast and mold (1st dilution)
Ice cream(1st dilution):
TPC/Coliform
Environmental monitoring:
Swab test( Machine+ person on 1st dilution))
DILUTION PREPARATIONS:
Purpose:
To prepare an appropriate dilution of a sample so that 1ml will contain 30-300 colonies when
inoculated in a Petri dish.
Principle:
In determining the microbial content of milk, milk products, water and rinse and swab from
dairy utensils and equipment, serial dilutions of the sample is prepared. The measured
amount of the prepared dilution when inoculated in a Petri dish and grown on agar medium
should contain 30-300 colonies. The ten-fold serial dilution (1ml of sample diluted with 09 ml
diluting solution) can be prepared by the dilution technique

36. UHT Milk(1st dilution):
TPC
EB’
Milk powder:
EB’s(1st dilution)
TPC(2nd dilution)
Yeast and mold (1st dilution)
Ice cream(1st dilution):
TPC
Coliform
Environmental monitoring:
Swab test( Machine+ person on 1st dilution))
DILUTION PREPARATIONS:
Purpose:
To prepare an appropriate dilution of a sample so that 1ml will contain 30-300 colonies when
inoculated in a Petri dish.
Principle:
In determining the microbial content of milk, milk products, water and rinse and swab from
dairy utensils and equipment, serial dilutions of the sample is prepared. The measured
amount of the prepared dilution when inoculated in a Petri dish and grown on agar medium

37. should contain 30-300 colonies. The ten-fold serial dilution (1ml of
sample diluted with 09 ml diluting solution) can be prepared by the
dilution technique
MBRT:
Methylene Blue Reduction Test is used in order to check the keeping
quality of finished and raw milk. However this is mostly used for
finished product. Aerobic bacteria present in the milk reduce the color
of dye by oxidation reduction. More the aerobic form of bacteria less
will be time required for color to disappear.
10ml milk sample in sterile test tubes is taken and 1ml of MBRT
solution is added and were placed in water bath at 37°C After every
five minutes color change is observed and time is noted when whole
of the color disappears and is reported as” hours-methylene blue
reduction time”.
TPC-TOTAL PLATE COUNT:
It is done for Estimation of viable and non-viable microbes present in
fresh milk for microbiological quality, hygiene monitoring and
payment of quality characteristics of fresh milk. For this test, TPC
media is prepared and diluted milk sample inculcated and incubated.

38. EB’S - COLIFORM COUNT:
Purpose:
To detect the presence of Escherichia coli in milk, milk products, dairy
equipment and water supply.
Principle:
The group of coliform microorganisms includes the genera Escherichia
and Agrobacteria. The widespread distribution of coliform in nature,
feeding itself on available food of its habitat, permits a minimal
occurrence of these microorganisms in milk, milk products, and
surfaces of dairy equipment, air and water supply. A large number of
these bacteria indicate poor hygiene and negligence. Proper heat
treatment is sufficient to destroy the coliform bacteria, and its presence
in pasteurized milk and milk products serves as index of
recontamination or post pasteurization contamination largely due to
poor hygienic practices.
The coliform bacteria were a Gram-negative rod, and its ability to
produce acid and gas as products of lactose fermentation is the prime
basis of laboratory tests for detecting it in a sample. The medium used
contain a bile salt which prevents the growth of the Gram-positive
organism.

39. SOMATIC CELL COUNT:
Somatic cells were blood cells that fight infection and occur naturally in milk. The presence of
mastitis (an infection of the mammary gland) in the cow will increase the somatic cell count.
The somatic cell count can be determined by direct microscopic examination or by electronic
instruments designed to count somatic cells. The count can be measured on bulk tank milk or
on individual cow. California Mastitis Kit is used for this purpose by EFL microbiologist while
monitoring milk quality at root level, i.e. on individual cows. Normally count of somatic cells
found in milk is low (1, 00,000 cells/ml).
ANTIBIOTIC RESIDUES:
Antibiotics were commonly used to treat mastitis or other conditions in cows. Each antibiotic
preparation has a specific withdrawal time from meat and milk. The withdrawal time is time
from the last treatment with the antibiotic until the milk is permitted to be put in the bulk
tank for shipment to the processor. At EFL Standard Diffusion Test is used for the detection of
residual antibiotics.
0.2ml milk sample is transferred in special capped tube with the help of syringe provided in
test kit.
Now place at 65oC in water bath and observe color.
Results:
If purple or blue color appears, test is positive
If green color appears, test is negative.

40. ICE CREAM MANUFACTURING:
O’more Ice Cream is a famous ice cream brand in Pakistan. O’more
has a fully automatic ice cream manufacturing facility, and has a
production capacity capable of producing more than 4.5 million liters
of dairy ice cream a year. O’more Ice Cream produces a variety of
flavors, including chocolate, vanilla, mango, strawberry, orange, kulfi,
caramel as well as many more
Mixing of
igredients
Pasteurization
(85°C for 15min)
Homogenization
(1500-2000
bars)
Rapid Cooling
(7-8°C)
Aging (4°C)
Colour and
Flavoring Tank
Freezing
Filling
Hardening (-
28°C)
Cold Storage (-
18°C)

41. PHYSIOCHEMICAL LAB:
First of all I will discuss about physiochemical lab. Here different
projects are given to me. Now I will discuss these projects. These
projects are:
Water analysis
Wastewater analysis
Solution preparation
Equipment verification
Equipment calibration
PHYSIO LAB
WATER ANALYSIS:
In EFL Sahiwal, tape water comes after treatment so water analysis is
being done to checked the efficiency of water treatment. For this I
checked the water by using different chemical tests after every step of
water treatment. I performed water test for consecutive 10days.The
water treatment steps that efficiency I have checked . It includes

42. Sr. No.
Steps Tests
01
Raw water pH test, TDS test and Hardness test
02
Ro water pH test, TDS test and Hardness test
03
Chlorinated water pH test, TDS test and Hardness test
04
DE chlorinated water pH test, TDS test and Hardness test
05
Treated water pH test, TDS test and Hardness test

43. WATER ANALYSIS:
In EFL Sahiwal, tape water comes after treatment so water analysis is being done
to checked the efficiency of water treatment. For this I checked the water by using
different chemical tests after every step of water treatment. I performed water test
for consecutive 10days.The water treatment steps that efficiency I have checked
include.
pH AND TDS TEST:
pH is measured at EFL with the help of digital WTW pH meter. TDS is measured at
EFL with the help of TDS meter(HACH TDS 2C5).
HARDNESS TEST:
For hardness, Hardness kit is used. The hardness level as mg/L (ppm) calcium
carbonate is determined by an EDTA (ethylene-diamine-tetracetic acid) titration.
The solution is first adjusted to a pH of 10 using a buffer solution. The indicator
chelates with metal ions such as magnesium or calcium to form a red colored
complex. As EDTA
is added, metal ions complex with it. After all the free metal ions have been
complexed, an excess EDTA removes the metal ions complexed with the indicator to
form a blue colored solution. This color change from red to blue is the endpoint of
the titration and multiply the reading with 300.

44. WASTEWATER ANALYSIS:
In Engro food Sahiwal, before the disposal of wastewater different
tests are performed to meet the environmental regulatory authorities.
For wastewater treatment plant (WWTP) is made. Following
operations are done in this plant.
Waste water
Screening(to remove
coarse particles)
Equalization(maintain
the pH)
DAF(fat removed)
Aeration Basin(72hrs
stay time)
Clarifier(sludge settle on
bottom) Discharge of
wastewater(by
pump)

45. To check the efficiency of WWTP, samples are collected from different stages
and tested according to SOPs.Tests that I have performed are given here below:
Sr.
No.
Steps Tests
01 Clarifier pH, TDS, BOD, COD and FOG
02 After DAF pH, TDS, BOD, COD,phosphate, FOG
03 Aeration Basin pH,TDS, SV, SVI,TSS,MLSS, DO
04 Sludge(New) TSS,MLSS
05 Sludge(old) TSS,MLSS
COD:
COD is checked by number of steps. Firstly Clarifier and DAF samples
are filtered and then 2mL of sample Is added in Hanna COD reagents
vials and mix it. Then these are placed in COD reactor for 2hrs at 150
temperature for digestion. After this Vials are removed from reactor
and cooled at room temperature and then placed at millimeter
bench photometer and note the reading

46. BOD:
For BOD, 156 mL sample after filtration is placed in Lovibond BOD bootles and
add metallic tablet for stirring in BOD apperatus and placed in BOD apperatus for
incubation and check the reading the reading after 5 days.
EFFLUENT WATER STANDARD PARAMETERS (NEQS):
Parameter Units NEQS
pH ---- 6-9
TSS mg/l 200
BOD mg/l 80
COD mg/l 150

47. 1. SPECIAL WATER TESTS:
In addition to above these tests,Boiler and Ammonia condenser water is checked
to avoid the corrosion and any other trouble shooting in equipments.
These tests include:
Sr. No. Equipment Tests
01 Boiler feed water pH, TDS, Hardness
02 Boiler blow down water(3
boilers)
pH, TDS, Hardness,
Alkalinity,
sulfite, iron and Phosphorus
test.
03 Ammonia Condensor
water(3 condensors)
pH, TDS, Hardness

48. PHOSPHORUS AND IRON TEST:
Phosphorus is checked by addition of Hanna instruments HI 736-25
phosphorus and iron reagent in tube and it is compared with Hana
comparator. If phosphorus reading is multiplied with 0.326 then we get
phosphate reading.
ALKALINITY TEST:
The Alkalinity is determined by neutralizing the sample to a pH of 8.3
using a dilute hydrochloric acid solution, and a phenolphthalein
indicator. It is then titrated with HI 3811-0 solution. Read off the
milliliters of titration solution from the syringe scale, and multiply by
300 to obtain mg/L (ppm) CaCO3.
SOLUTION PREPARATION:
In physiochemical lab, solutions are also prepared. There are 3 kinds of
solutions thai I made.
PERCENT SOLUTION:
Except alcohol all chemicals are not 100% pure. Following formula is
used for percent solution:
C1V1=C2V2

49. by metallic stirrer.
NORMAL SOLUTION:
1 Normal solution is solution in which gram equivalent weight of
chemical dissolved in 1 liter. A number of normal solution is made in
physiochemical lab by following formula:
For Solids:
N=Required normality*gram equivalent weight of
compound*required volume/1000
For Liquids:
N=%purity of given solution*specific gravity*1000/gram equivalent
weight of compound*100
N1V1=N2V2
For example 0.1 N NaoH of 2liters is made by 80 grams of Noah in
volumetric flask and volume make up by distilled water up to 2litters

50. MOLAR SOLUTION:
Molar solutions are also frequently made in physiochemical lab. It is
made by weight equal to molecular weight added in volumetric flask
and volume make up to 1liter to made 1 molar solution. 3 molar KCL
solution is used for keeping the pH electrode in case of not use.
EQUIPMENT VERIFICATION:
In physiochemical I also verified different different labs equipment in
coordination with lab analyst. I have verified butyrometers, pipettes,
pH meters, lactometer, electric weighing balance etc. These are
checked with master piece of equipment that is certified by reputable
company. For example in case of butyrometer,it is verified with the
help of Dr. Gerber certified butyrometer by testing the fat with both
equipment's. If difference is major then rejected.
EQUIPMENT CALIBRATION:
I also verified different labs equipment in coordination with lab
analyst. I have calibrated pH meters and TDS meter. pH meter error
is cleared by proper cleaning of electrode or by changing the
electrode

51. RAW PACKAGING AND TECHNICAL MATERIALS LAB
Here packaging material that is used for raw packing is checked with the technical point of view.
Packaging lab falls under the quality assurance lab.
In this lab following tests were performed.
Analyze the design of the package
•Analyze the reel width
•Analyze the reel diameter (external)
•Analyze the core diameter (internal)
•Analyze the length of the sign detected by the photocell
•Analyze the width of the sign detected by the photocell
•Gramm age (g/m2) determination
•Aroma test

52. MILK POWDER ANALYSIS:
There are two types of milk powder which are tested; Skim milk
powder and Full cream milk powder. On powder following tests are
conducted;
Fat %age
Moisture %age
Bulk Density
Acidity
PH & OR-P
FAT DETERMINATION OF MILK POWDER:
Fat is determined by Gerber method, i.e. 10ml conc. H2SO4 (92%)
+1.69g powder (in case of using 8% butyrometer) or 2.50g (in case of
using butyrometer of 35%) + 1ml Iso-amyl alcohol. Centrifugation at
1180rpm for 5-6mintes at 65 oC is given to separate the fat from milk.
Reading of the butyrometer gives fat in percent's.
If butyrometer of 8% is used then final reading is multiplied with
20/3.
In Glorious Skim Milk Powder fat appears as 25-27% while in Glorious
Full Cream Milk Powder appears as 1-1.5%.

53. MOISTURE %AGE:
Moisture %age in final product is very important because of the fact
that shelf life of the product in storage is greatly influenced by the
amount of moisture present in that food article. In case of milk
powder moisture in the final product is kept in range of 1.2% to
1.70%.
Procedure: 2.5g milk powder is weighed in aluminum boat from
which moisture already has been removed. The temperature of
moisture of moisture analyzer is set to auto (101-104 oC for 3-4 min)
or at 90oC for 6min. Moisture analyzer directly gives the moisture in
percent's.
BULK DENSITY:
Weight by volume ratio of powder is called as bulk density of powder. It
shows degree of compactness of powder.
Procedure: 28g of powder is weighed into a graduated plastic cylinder
of 250ml capacity. Now place cap on the cylinder and tap the cylinder
25 times on shelf and note volume from the top level. Divide the
weight by volume to get bulk density of powder.

54. ACIDITY OF POWDER:
Acidity of powder is measured as lactic acid activity.
Sample Preparation: 10g of SMP or 13g of ISMP is dissolved in 100ml
distilled water in beaker and is kept for an hour. After sample
preparation proceed in the same way as in liquid milk.
Procedure:
8.8ml of sample solution is taken in beaker. Then add 2-3 drops of
phenolphthalein as an indicator. Titrate against 0.1N NaOH until light
pink color appears or pH meter shows reading of 8.4.
Calculation: No. of ml of NaOH used / 10 = % as Lactic Acid pH &
OR-P: Digital pH meter is used to measure pH and OR-Potential of
prepared sample of powder.
WETTABILITY:
Apparatus: Balance (.01 Sensitivity), Hollow Plastic Cylinder, Beaker
500 ml, Stop watch.
Procedure:
250ml water is taken 500ml beaker.
A hard plastic sheet is placed on lower side of cylinder.
15g powder is weighed in cylinder blocked at one end by plastic sheet
clumped with stand.

55. Remove plastic sheet and start stop watch. Stop the stop watched
when all powder has been wetted.
Calculations:
Wettability = Time taken in second for complete wetting.
SOLUBILITY INDEX OF MILK POWDER:
Apparatus:
Balance (0.01 sensitivity)
Solubility index tubes, Centrifuge machine, Funnel
Procedure:
Weight about 10g of skim milk powder or 13g of full cream milk
powder and transfer to 100ml beaker at 24 oC in 500ml beaker.
Mix the content and wait for 15 minutes.
Fill the solubility with this sample and place them in centrifuge
machine for 5 min by setting the solubility program of Gerber
machine.
After first centrifugation drain out sediment free liquid from tubes.
Again fill the tubes with distilled water up to mark and disperses
sediments with the help of thin wire.
Again place tubes in centrifuge for 5min and drop liquid portion of the
tubes.
Now measure the sedimentation in milliliters.

56. • SUGGESTIONS AND RECOMMENDATIONS:
• Following are the suggestions and recommendations for
improvement :
• The co-ordination between different departments should
increase in QA and QC.
• The activities like customer satisfaction day should be
performed on regular basis so the company should know the
feedback and satisfaction level of customers regarding the
product and the image of the company.
• EFL has documented the safety related documents but
continuous training ,incentive and grooming required for all lab
champions.
• The tiers of tankers coming to the plant should be dipped in
disinfectant first.
• With respect to Microbiology lab, tests for identification of
micro-organisms should also be performed. Because it is very
important to check the virulence.
• pH and Temperatures during testing should also be obtained
more consciously.

57. • There should minimize the mouth pipetting .
• A drain pipe should attach with fume hood to drain the but tyro
• meters waste in fume hood while fume hood on .
• Apt should take seriously in packet milk and performed .
• There should be sample bottles for water and waste water .
• There must be an oven for desiccation and drying in physio lab.
• There must be PH meter of Orion or met Rohm in physio lab .
• RPT Lab must have there own moisture analyzer .
• Sink should be provided in QA lab .
• A new spectrophotometer is required in KQ Lab .
• Burettes should be replace by auto measures .
• Thank you