about verka milk plant

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L-2010-A-03-B.techFT

2. Industrial Training
TheLudhiana District Co-operativeMilk
Producer's Union Ltd.

3. Introduction
First Milk Plant, of the State was setup at Verka nearAmritsar.
The brand name of Milk and Milk Products was adopted as
Verka.
The Foundation stone of Milk Plant, Ludhiana was laid by Hon.
S. Parkash Singh Badal, the then Chief Minister of Punjab in
1970.
Commissioning of the Plant was done by Punjab Dairy
Development Corporation in 1974.
Inauguration was done by Late Smt. Indira Gandhi the Prime
Minister of India.
The capacity of the plant was 1.00 lac. Litre per day, and now
the milk handling capacity is 4.00 Lac Liter per day.

4. • Amritsar
• Bathinda
• Chandigar
h
• Faridkot
• Ferozpur
• Gurdaspu
r
• Horshiarpu
r
• Jalandhar
• Ludhiana
• Patiala
• Ropar
(Mohali)
• Sangrur
MILKFED has its milk unions in almost all the districts of Punjab.
These
district units are:-
These plants in all these unions are being run under the brand name
VERKA.

5. Present Status
No. of societies increased from 94 to 802 and its membership
from 5400 to 78500.
Milk Procurement has increased from 10200 LPD to 2,50,000 LPD.
Highest milk price is being paid to the milk producers as compare
to other plants in the states
Products being manufactured by Ludhiana Plant are sold at
premium rates through out of the country and in the
International Market.
City supply has increase from 66000 LPD to 1,98,000 LPD.
Turnover the plant touched to 283 crores Profit of the union has
increased manifold.
Capacity utilization of the plant is more than 85%.

6. Full name : The Ludhiana District Cooperative Milk Producers
Union Ltd.
Foundation : Laid by Hon. Sh. Prakash Singh Badal in 1970
Capacity : Then 1 lakh L/day, Now 6 lakh L/day
Head office : Punjab State Co-operative Milk Producers Federation
Ltd.
S.C.O.153-155, Sec. 34-A, Chd.
Inauguration date : 31stOctober, 1974
Chairman : Sh. Ajmer Singh
No. of societies : 816
No. of Chilling
centers
: 4
Brand name : VERKA
Products marketed
by
: The Punjab State Co-operative Milk Producers
Federation.
Ltd.
Quality certificates : International Quality Certificate ISO-9002 & IS-15000

7. • Verka milk plant (VMP), Ludhiana is known as The Ludhiana Dist.-
Co- operative Milk Producer’s Union Limited, Ludhiana . It is situated
on Ferozpur Road, about 5 km. away from both railway station and
main bus stand.
• The plant has bagged first position in Northern Zone
• It is fully equipped with modern fluid milk plant facilities. The latest
state of art technology in milk drying is available in this plant.
• The products manufactured by this Plant at present are STM, DTM,
FCM, SMP, WMP, Ghee, Butter, Paneer, Milk-Cake, Dahi, Kheer,
Lassi .

8. Some objectives of the Milk Plant are:-
• To uplift social and economic status of milk producers.
• To develop dairy as industry allied to agriculture.
• To provide better and remunerative prices for milk.
• To provide veterinary aids to animals of milk producers at their
doorstep.
• To provide better quality cattle feed at reasonable rates.
• To educate the milk producers about lowering down the cost of milk
without compromising quality.
• To create employment opportunities for rural youth by milk production
activities.
• To provide awareness among milk producers for socio-economic
change through co-operative set-up.

9. Product brand name : VERKA
Milk handling capacity : 6 lakh litres per day
Production of market milk : 2.5 lakh litres per day
Production of butter : 13000 Kg per day
Production of ghee : 14 MT per day
Production of powder : 30 MT per day
Production of paneer : 400-450 Kg per day
Production of kheer : 200 Kg per day
Production of milk cake : 30-40 Kg per day
Production of dahi : 1400 Kg per day
Production of lassi : 3000 Kg per day

10. POWDER
SECTION
• There are definite indication of greater
future productions of dried milk & milk
products due to their better keeping quality,
they require less storage space & lower
transportation costs. All these are
economically attractive.
• Dried milk provides a means of handling the
excess milk supply in a dairy factory during
flush season, while in lean season that
meant for the production of dry milk can be
diverted to market milk. Thus, dried milk is
called the balance wheel of dairy industry.
• VERKA MILK PLANT
, LUDHIANA has two
separate drying plants.

11. The Dairy has two separate drying plants, viz:
• Powder section with MVR unit & TVR unit
(30TPD)
• Powder section with TVR unit only (6.5TPD)
Compositional & other Standards maintained
:-
Parameters SMP Standard grade SMP Extra grade WMP
Moisture (%) 3.2-3.6 3.0-3.4 Max. 3
FAT (%) Max. 1.3 Max. 1.2 26.5-27.5
Acidity (%LA) 1.0-1.25 1.0-1.2.5 Max. 1
B.D. Agglomerated (gm/ml) 0.45-0.55 0.5-0.6 0.5-0.6
Insolubility Index (50ml) Max. 0.15 Max. 0.15 Max. 0.5
Ash content (%) Max. 8.2 Max. 8.2 Max. 0.5
Coliform Nil Nil Nil

12. PROCESS
CONTROL
Lumpiness in Powder
1. Ensure proper cooling of powder
2. Dehumidifier should be properly operating
Low moisture in Final Product 1. Increase flow rate
2. Adjust outlet temp
Burnt Powder Particles 1. Adjust inlet temp
2. Check the function of feed flow controller & feed
pump
3. Nozzle of jets are whether chocked partially
Sooty Powder 1. Clean or change the filter.
2. Check up air heater
Very Fine Powder A Particles 1. Increase in degree of concentration
2. Control the feed temp.
Solubility Index Increased 1. Check the outlet temp.
2. Control feed rate

13. OPERATING
PARAMETERS FOR
EVAPORATING
PLANT
PARAMETER STANDARD & EXTRA
GRADE
W.M.P CONCENTRATED MILK
Milk feed rate (lts/hr) 16000-17000 3500-14500 16000-17000
Steam pressure (kg/sq.cm) 5-6.5 5-6 5-6.5
Thermal vapor
recompression
(kg/sq.cm.)
2-2.5 2-2.5 1-1.5
High heater (temp oC) 90+/-2 95-100 90+/-2
Holding heater temp (oC) -Do- -Do-` -Do-
Flush vessel temp (oC) 73-85 73-85 73-85
Jacket temp (oC) 69+/-1 69+/-1 69+/-1
Vapor Separator I (oC) 66+/-2 66+/-1 66+/-1
Vapor Separator II (oC) 58+/-2 58+/-1 58+/-1
Vapor Separator III (oC) 50+/-2 50+/-1 50+/-1
Vacuum in condenser 0.9m bar 0.9m bar 0.9m bar
T.S. % of condenser 20+/-3 20+/-3 20+/-3

14. OPERATING PARAMETERS FOR
DRYING PLANT
PARAMETERS SMP WMP
Chamber inlet air temperature (oC) 170+/-10 165+/-5
180+/-10 170+/-5
Vibro fluidier air inlet temperature
(oC)
90+/-5 65+/-10
Chamber outlet temperature (oC) 80-90 80-90
Vibro fluidier outlet temperature
(oC)
64+/-2 65+/-2
Chamber vacuum (mm.w.c) 5+/-2 15+/-2
Atomizer load (amp) 55+/-5 55+/-5
Load on exhaust fan (amp) 95+/-5 95+/-5
Powder output (kg/hr) Min. 1375 Min. 1500

15. Powder
Plant

16. Drying
Chamber
Cyclon
e

17. Control
Panel

18. Processing
Operations
• Chilling: Milk is chilled below 4 ºC. The
raw chilled milk is utilized for the various
products processing operations. The
chilled milk is stored in tank called as Silo.
The chiller is plate heat exchanger type.
• Pasteurizing: Milk is heated at 63 ºC
for 30 minutes or 75-80 ºC for 15 sec
and then cooled immediately below 14
ºC.

19. Type of milk received :-
Cow Milk :- Fat Min. 3%, SNF Min. 7.9%
Buffalo Milk :- Fat Min. 6%, SNF Min. 8.6%
Mixed Milk :- Fat Min. 5.4-5.5%, SNF Min. 8-8.5%
Make : Cast iron grid tiles, edges are
planting
of cast iron
Width : To overcome heavy stresses
Types : 1.5mm
Slope : Open
Cans : 40 Liters capacity, weighing 6-6.5 kg
Material : Aluminum

20. • Starting the RMRD
• Unloading and Conveying
• Opening the lids
• Grading
• Weighing and Sampling
• Cleaning & Washing of cans
• Recording of cans
• Loading
• Closing down RMRD

22. Composition of
Milk
Characteristic Cow milk Buffalo milk
Fat 4.0-4.5 % 6.5-7.0%
Carbohydrates 4.5 % 4.7 %
SNF 8-8.5 % 8.5- 9.0%
Proteins 3.3 % 3.6 %
Minerals 0.6 % 0.7 %
Water 87-88 % 84-85 %

23. Milk
Fluid Milk
Packing
Given
Prefernce
Lassi
Milk-cake
Kheer
Dahi
Surplus
Fat
Table
Butter
White
Butter
Ghee
Skim Milk
Skim Milk
Powder

24. City Supply Section

25. Compositional & other Standards maintained :-
Equipments used are- Steam Jacketed Vat, T
rolleys, Sealing Machine, Hoops,
Automatic Machine For Processing.
• Cleaning of vats, hoops & muslin cloths is done manually, then they are
sanitized with 0.5% teepol & hot water at 55-60oC
Fat Not < 50% of dry
mater basis
Moisture Not > 70%
Texture Soft & spongy
Taste & flavor Pleasant

26. Whole milk
Heating (90oC)
for 15 min
Filtration (with
clean muslin
cloth)
Coagulation (1-
2% citric acid)
Separation of
whey
Hoping
Pressing
Cutting into
blocks
Dipped in
pasteurized &
chlorinated
chilled water (4-
10oC/45-60 min)
Cut into pieces
& weighing
(200gm
manually)
Packing in
polythene
sachets
Storage at butter
cold store Dispatching
Flow diagram for Paneer
manufacture

27. This dairy plant follows the ISI standard of dahi. Mostly it is manufactured
every two alternate days in flush seasons.
Compositional & other Standards maintained :-
Equipments used are- Steam Jacketed Vat, Weighing Balance, Cans, Incubation
Chamber, Dahi Packaging Machine.
Fat 4-5%
Protein 3.2 -3.4%
Acidity 0.8-1.0%
Taste Cream-sour
Flavor Acid

28. Milk is taken in
Vat For Dahi
Preparation
Standardization
&
Homogenization
Pasteurization
(80-90oc/15-30
Min)
Cooling (37°C)
Inoculation with
Lactic Culture
(from previous
day Dahi)
Filling by pipe
filler in
polystyrene cups
Sealing the Cups
Putting 12 Cups
in each Card
Board Box
Incubation
(37oc/1.5-2hr)
Dahi Prepared
Cooling &
Storage (5oc)
Dispatch
Flow diagram for Dahi manufacture

29. Ludhiana milk Plant is engaged in making two types of butter viz
 Table Butter
 White Butter (White Butter is made and stored as stock and is used
in lean season for recombination and is also used as base material
for ghee & often supplied for bulk demand).
The dairy produces butter by batch churn method. There is also a
provision for continuous butter making machine.
The packed butter is stored at -17 to -29oC till dispatch.

30. Loading of churn 1/3rd volume of drum capacity
Loading temp (oC) < 10-12 oC
Churning temp (oC) < 10-12 oC
Color addition 1ml/kg fat
Spray water temp (oC) Max 5
Speed of churning
28-30 rpm (1st gear)
14-18 rpm (2nd gear)
7-8 rpm (3rd gear)
Salt addition (dissolved in pasteurized warm
water)
22mg/kg of butter yield
Vacuum during operation 300-350mm
FAT% in cream 40-42

31. Cream from
separator
Cram
pasteurization
Storage in
cream tank for
ageing
Feeding to
butter churn
(In case of table
butter color is
added @
1ml/kg/fat)
Churning at 1st
gear up to
breaking point
(30-35min)
Churning at 2nd
gear (30-45
min)
Churning at 4th
gear of white
butter
Removal of
buttermilk
Washing at 2nd
gear (6-8oC/15
min after
adding water)
Equal in
volume of
buttermilk
removed)
Draining of
water
2nd washing
Salt @ 2.2% is
added (for table
butter)
Working &
controlling of
moisture at 2nd
gear
(25-30 min.
300-350mm)
Unloading
(before it rotate
at 2nd gear for5
min)
Packaging (500,
100, 10 gm)
Storage (-17 to
-29oC)
Package in card
board boxes
Flow diagram for Table Butter manufacture

32. Compositional & other Standards maintained :-
• Equipments used are- Butter Melting Vat, Pre-stratification Tank, Ghee
Boiler, Settling Tank, Filling/Storage Tank, Ghee Clarifier, Electronic
Weighing Balance, Closure Punching Machine, Pouch Filling Machine.
Flavor & color Pleasant & white or yellow
Moisture Max. 0.25%
F.F.A (% Oleic Acid) Max. 0.03%
B.R. reading at 40oC 40-43
Peroxide value Max. 1
Sediment Absent

33. Pre-melting temp (oC) 75-80
Cooking temp (oC) 105-112
Batch time (hr) Max. 4
Steam pressure in kettle (kg/sq.cm.) 2
Filtration Falalin cloth
Clarification temp (oC) 95+/-5
Setting time (hr) Min. 6
Ghee filling tank temp (oC) 43+/-5
Ghee filling temp (oC) 42+/-5 °C
After packaging the packed corrugated boxes are kept in
granulation room for 24 hrs. Then the boxes are transferred into
storage room till dispatch.

34. LASSI : Lassi is a drink made of standardized milk with 50:50
dilutions with water.
Receiving
milk
↓
Standardization
(4.5%fat and
8.5%snf)
Heating of milk
85°c /5min
Cooling down to 40°c
ulation with culture at 1% at 40 °c
Inoculation at 40 °c
(till acidity reach 0.67%)
Addition of pasteurized
chilled water 2%
Breaking of coagulum
( acidity o.54%)
Packaging
Cold storage less than 5°c

35. Kheer is concentrated heat desiccated
indigenous dairy product.
Taking milk in double jacketed
vat
Heating milk to desirable
reached with consistency with
continuous stirring
Addition of basmati rice in
boiling milk and stirring
Heating it till desired
consistency reached with
stirring
Addition of sugar
Addition of mixture of sodium
benzoate and Elaichi powder
Stirring for some time and
filling in cups(200 g)
Storing in cold room(below 8˚C)

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