Internship at Verka, Mohali in Production and quality control Internship

1. AN IN-PLANT

2. SUMMER TRAINING REPORT ON
“PRODUCTION AND QUALITY
CONTROL”
SUBMITTED BY: URVASHI KHURANA
( Msc 1st-year BIOCHEMISTRY)
Panjab University, Chandigarh
Acknowledgement
The training opportunity I had with “Verka Milk Plant, Mohali” was a great chance for learning
and professional development. Therefore, I consider myself as a very lucky individual as I was
provided with an opportunity to be a part of it. I am also grateful for having a chance to meet
so many wonderful people and professionals who led me through this training period. I perceive
this opportunity as a big milestone in my career development.
I am grateful to professor Archana bhatnagar (chairperson,dept. Of biochemistry (pu),for their
kind help to avail my training at Verka Milk Plant, Mohali. I am also thankful to all teaching
and non-teaching staffs at Verka mohali for their guidance in each & every step of acquiring
this opportunity of practical experience.

3. It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to
Last but not the least I with due respect pay my regard to My Parents and Almighty God who
have been the source of motivation, strength and support, which led me to attain success.
Urvashi khurana
Msc 1st-year biochemistry student
Panjab university, Chandigarh
CONTENTS
• Prologue
• Industry Detail {Dairy processing}
• Company detail
• Departments :
- Milk procurement section
- Production section
- Quality control lab
- Engineering section: -
● Detail of machinery installed
● Refrigeration plant
● Boiler section
● ETP section
• Conclusion

4. PROLOGUE
This document dwells upon my in plant training at Verka milk plant, Mohali From 17.06.2019
to 16.07.2019. The major purpose of this training to grasp the experience of industry as student
of BIOCHEMISTRY AT PANJAB UNIVERSITY,CHANDIGARH. The report commences
with company profile in which all the relevant details about the Mohali factory have been
included, avoiding the secrecy norms of the company.
My training in this esteemed organization helped me to know & learn the practical aspects of
industrial performance, theoretical part of which we studied in our course books. I was involved
in understanding the culture of company, learning various processes, way the people co-
ordinate with each other & effects of teamwork. Some other results of my training are better
communication, enhanced confidence & more practical outlook towards life.
In the end, I would like to say that my experience in this plant would be an indispensable one
throughout my life & I would like to thank all of them once again who have made it that way.

5. COMPANYDETAILS
MILKFED
“The Punjab State Co-operative milk Producers federation limited” popularly known as
MILKFED. It came into existence in 1973. It was backed by twin objective of providing
remunerative milk market to the milk producers of the state on the one hand and to provide
technical inputs to the milk producers for the enhancement of milk production on the other.
Although the federation was registered much earlier, it took the centre stage of Punjab dairy
scenario in 1983 when all the milk plants of Punjab Dairy development corporation Ltd were
handed over to Co-operative sector and the entire state was covered under OPERATION
FLOOD to give the farmers better value and to customers the better products.
The organizational set up of MILKFED is based on a three tier system:- •
Milk producers Co-operative societies at village level
• Milk Co-operative Unions at Districts level.
• Co-operative milk marketing federation as an apex body at State level {MILKFED}.
MILKFED with its network of over 5000 village’s milk producers Co-operative societies and
over 3 lakhs milk producers form a strong network providing assured market to milk producers.
MILKFED and its units have a workforce about 5000 employees and also provide regular
employment to about 600 transporters.
Milk production is a very important part of the agricultural economy in the state of Punjab.
Punjab is one of the smallest states in Indian union with a total area of 50362 Sq. kms which is
1.5% of the Indian landmass. Dairy-farming is an age-old subsidiary profession in the rural
areas of Punjab. Punjab is the fifth largest milk producing state in India, producing around
9.72% of the country’s milk production i.e. 146.31 million tons annually (2015-2016).
First milk plant of the state was setup near Amritsar. The brand name of milk and milk
products was adopted as Verka.
MILKFED has its milk unions in almost all the districts of Punjab. These district units are:-
• Amritsar
• Bathinda
• Chandigarh
• Gurdaspur
• Horshiarpur
• Jalandhar
• Ludhiana

6. • Patiala
• Ropar (Mohali)
These plants in all these unions are being run under the brand name VERKA.
VERKA MILK PLANT PROFILE
FULL NAME: THE ROPAR DISTRICT COOPERATIVE MILK PRODUCERS UNION LTD.
MOHALI.
REGISTERED OFFICE : Sector 56,Sas Nagar, Punjab 160055
FOUNDATION: Hon. S. Prakash Singh Badal In 1970
MILK HANDLING CAPACITY: Approximately 4.5 Lakh Litres Daily
PRODUCTION CAPACITY : APROXIMATELY 7.5 LAKH LTS DAILY
HEAD OFFICE: PUNJAB STATE CO-OPERATIVE MILK PRODUCERS FEDERATION
LTD. S.C.O.153-155, SEC. 34-A, CHD.
REGISTRATION
DATE OF PLANT: 5/7/1978 UNDER PUNJAB COOPERATIVES SOCIETIES ACT
1961

7. COMMENCEMENT OF PRODUCTION: SEPTEMBER , 1980
QUALITY : INTERNATIONAL QUALITY
CERTIFICATE ISO-9002 & IS-15000 (HACCP)
PRODUCTS MARKETED BY :THE PUNJAB STATE CO-OPERATIVE MILK
PRODUCERS FEDERATION. LTD.
NO. OF SOCIETIES : 1300(APPROXIMATELY)
BANKER
BANK
: PUNJAB STATE CENTRAL CO-OPERATIVE
BRAND NAME : VERKA
CHILLING CENTERS : 3
The machinery is available for the productions of following milk products:
• Pasteurized fluid milk
• Paneer
• Lassi
• Butter
• Dahi
• Kheer
NAME OF DIFFERENT SECTIONS OF THE PLANT
NAME OF SECTIONS NAME OF MANAGERS
Milk procurement Mr. A.k. mishra
Production Mr. Udham singh
Quality control lab Mr. Rakesh gupta
Marketing Mr. Mahajan singh
Engineering Mr. Hunardeep singh brar
Acoount Mr. Bhupinder singh
Administration Mr. Sukhdev singh
TRAINING SCHEDULE

8. S.No. Name Of Section Training Duraions
Start Date End Date
1. Production 08.08.2016 31.08.2016
2. Engineering 01.09.2016 15.09.2016
3. Quality Control Lab 16.09.2016 11.10.2016
4. Milk Procurement 12.10.2016 25.10.2016
5. Marketing 26.10.2016 08.11.2016
6. Accounting 09.11.2016 15.11.2016
7. Admin 16.11.2016 23.11.2016
8. Production 24.11.2016 07.12.2016
9. Engineering 08.12.2016 14.12.2016
DEPARTMENTS
MILK PROCUREMENT : MR. AK MISHRA
The "ANAND PATTERN" to procure the milk was started in punjab as earlier as 1978.the milk
is collected at village level societies and sand to milk chilling centre. The plant get milk from
these milk procurement village level societies. Villagers give surplus milk to societies. The
payment of milk is made according to fat, SNF, quantity and quality of milk.Milk procurement
system is the key factor behind the success of dairy. High quality milk is procured at village
level society twice in a day and chilled at <5o
c.the route of milk procurement at societies as:

9. At societies Fat, SNF, Protein and Lactose is calculated by lactoscan milk analyzer.machine is
attached to computer system and all the members of dairy are fed into computer.The chilled
milk is transported into Verka Milk Plant Mohali by insulated tankers.at verka milk milk plant
Mohali whole milk is received by tankers.
PRICING POLICY OF MILK PROCUREMENT
Raw Milk from Societies
1) For Fresh Milks (Buffalo Milk)
Policy of payment Single axis
Basis of payment Rs. 600 per kg fat
● Rs. 500/- basic rate +80 incentive+20 differential price.
● Differential price is given only on buffalo milk.
● This rate chart is based on 8.8 % SNF.
2)Cow Milk
Policy of payment Double axis
Price Rs. 285 per kg of fat Rs.
195 per kg SNF

10. This chart is based on 3.3 % Fat or 7.8 % SNF.
WELFARE PROGRAM FOR FARMERS
● Free veterinary service and consultancy is provided to each farmer.
● Camp is organized in villages, whatever we have established our collection cetre for
check- up of animals.
● Breed improvement program is also organized.
● Organized awareness programs to improve quality of milk.
RAW MILK RECEPTION DOCK (RMRD)
Raw milk is perishable in nature so the reception should be efficient and prompt with all
possible hygienic control to ensure best quality raw milk to produce equally good quality
products.
FLOW CHART OF MILK RECEPTION
WEIGHING
UNLOADING
PUMP
BALANCE TANK
PUMP
SAMPLING

11. FILTERS
CHILLERS
PUMP
STORAGE TANK(BELOW 5 0
C)
Sources of milk reception
• Three milk chilling centers:
• a) Morinda
• b) Nurpurbedi
• c) Jhinjari
• Co-operative societies: About 1300 societies supply milk through 37 routes throughout
the year.
MILK CHILLING SOCIETIES VISITED
DATE NAME OF
SOCIETY
DAILY MILK
COLLECTION
(Liters)
%FAT
(Avg.)
%SNF
(Avg.)
TEM. OF
INCOMING
MILK (O
C)
TEP. OF
STORAGE
TANK (O
C)
13.10.2016 DaduMajra 1800-1850 6.5 8.8 25-27 4
14.10.2016 Biro Majri 1900-1950 6.6 8.5 24-26 4
15.10.2016 Fatawa 1400-1450 5.9 8.5 25-27 5

12. 18.10.2016 KhooniMajr
a
1000-1050 5.7 8.7 26-30 4
19.10.2016 Dao
Majri
1800-1850 5.5 8.7 27-28 5
20.10.2016 M.C.C
Jhinjari
4000-4500 6.2 8.6 26-30 8
TEST PERFORMED IN LABORATORY ON RAW MILK:
TESTS METHOD STANDARD RANGE
Fat Gerber method -
SNF Lactometer
SNF=CLR/4+0.2 %f+0.29
-
( at 15.50
c)
SNF: Solid Not Fat
CLR: Correct Lactometer Reading
Acidity Titration with0.9 N NAOH 0.11-0.15 % la at 8 0
c
Adultration tests Using strips and solutions and match
the colour change
Negetive
MBRT By using test tube and water bath
at(37 o
c)
Good: 3-4hrs.
Fair:1-2 hrs.
Poor : 1/2 and below 1/2 hrs.
BR BR meter 40-43 at 400
c

13. Sodium Sodium analyzer 450-550 ppm
RM ISI method 28-31
PRODUCTION DEPARTMENT
HEAD OF DEPARTMENT: Mr. UDHAM SINGH
Production Department is headed by the Manager, Production and he is assisted by technical
officers, operators and dairymen. Production Department is responsible for –
• Proper Milk Reception
• Milk Processing
• Manufacturing of Milk Products- Dahi,Lassi, Butter, Ghee, Paneer, Kheer etc.
• Packing of all above mentioned products.
Production is done as per commitment made by marketing department depending on
requirement of products. Milk products are manufactured mostly by automatic machines with
best standards of sanitation. Production Manager is responsible for achieving production target
with minimum wastage and maintaining cordial relationship with the work force. He also
guides workers for better performance. Product Planning is managed by Production Manager
& accordingly the workforce produce. Generally product produced is as-

14. FLOW DIAGRAM OF MILK PROCESSING
MILK RECEPTION IN TANKERS
WEIGHMENT
UNLOADING THROUGH ONLINE STRAINER
CHILLING
SMP RMST WHITE BUTTER
RECONSTITUTION HOMOGENIZATION
PASTEURISATION (76+/-20
C/15 SECS) AND STANDARDIZATION

15. (OUTLET MILK MAX. TEMPERATURE 40
C)
PMST
POUCH FILLING MACHINE BALANCE TANK
POUCH FILLING POLYFILM
COLD STORAGE(5 C MAX.)
DESPATCH IN REFRIGERATED & INSULATED VAN
FSSAI STANDARDS FOR DIFFERENT TYPES OF MILK
TYPE OF MILK FAT %
(MIN.)
SNF %
(MIN.)
COLOUR OF
PACKING MATERIAL
FULL CREAM MILK 6 9 RED
STANDARD MILK 4.5 8.5 GREEN
DOUBLE TONED MILK 1.5 9 YELLOW
COW MILK 4 8.5 PINK
SKIM MILK 0.5 (MAX.) 8.7 PURPLE
CRATING CRATES
0

16. PASTEURIZATION
The flow of milk is heated continuously at 72 0
C for 15 seconds and promptly cooled
to 5 0
C or below.
OPERATION PARAMETERS FOR PASTEURIZATION
MILK PASTEURIZER
Temp of pasteurized milk 76-80o
C
Chilled milk temp Max 5o
C
Chilled water inlet temp Max 1.5o
C
Chilled water inlet pressure Min. 1.5kg/sq.cm
Flow rate of milk 20000 lit/hr
Steam pressure Min 1.5-3.0 kg/sq.cm.
CLEANING OF PASTEURIZER (CIP)
S.NO. MEDIA
USED
TEMP
(0
C)
START
TIME
(MINUTE
)
END
TIME
(MINUTE
)
TIME
TAKEN(MI
N)
CONCEN.
OF
SOLUTON
1. Rinse 40 10AM 10.05AM 5 -
2. Hot water 89 10.05AM 10.10AM 5 -
3. Alkali 90 10.10AM 10.45 AM 35 1.63%
4. Hot water
rinse
85 10.45 10.55AM 10 -
5. Acid 90 10.55AM 11.30AM 35 1.6%
6. Hot water 87 11.30AM 11.40AM 10 -
7. Akali 91 11.40AM 12.15PM 35 1.9%
8. Hot water 88 12.15PM 12.25PM 10 -
9. Cooling 5 12.25 PM 12.30PM 5 -

17. TOTAL TIME TAKEN:- 2.30 HOURS.
HOMOGENIZATION
Homogenization is the process of forcing the milk through a homogenizer with the objective of
sub-dividing the fat globules to 2mm or less.it does not allow to separate fat layer.in the plant
the dahi milk and cow milk is homogenized. In preparation of city supply milk homogenization
is optional.
OPERATING PARAMETERS:
Temperature : 60 o
C
Pressure : 1st
stage - 2000psi
: 2nd
stage - 500psi
POSITION OF HOMOGENIZER
In this dairy Homogenizer has been placed between Regeneration 2 and 3 sections. It is
connected to a filter before the milk enters into it.
REQUIREMENT FOR EFFEICIENT OPERATION
• The temperature should be above 550
C.
• Feed pressure should be above 10 psi and more depending upon product temperature,
viscosity and flow rate.
• Machine must run under pressure.
• Air-machine must be kept to absolute minimum possible 2% or less to avoid serious
damage.
• Uninterrupted supply is required.
• Until the machine is pumping smoothly, pressure is not applying.
• Putting on the cooling water on the plunger and oil cooler is essential.
• Before starting the homogenizer everyday open the petcock at the back of oil pump to
drain any condensation.
CREAM PASTEURIZERS
Pasteurized cream temp 85-88 o
C
Chilled cream temp Max. 10o
C
Chilled water inlet temp Max. 1.5o
C
Chilled water inlet pressure Max. 1.5kg/sq.cm.
Steam pressure Min. 1.5-3.0 kg/sq.cm

18. Flow rate of cream 5000lit/hr
CREAM SEPARATION
Complete parts of cream separators
• Handle connecting piece.
• Cream discharge.
• Skim milk discharge
• Clamp ring
• Hood
• Centripetal pump chamber lock ring
• Centripetal pump chamber look cover
• Skim milk pump
• Blow top • Blow lock ring
• Separator disc.
• Cream pump
• Feed tube
• Retaining ring
• Upper disc
• Disc set with distributor
• Spindle nut
• Bowl bottom
• Frame
• CHECKS FOR SEPARATOR
Before starting separator following checks are followed:-
• Ensure that separator is properly assembled with required number of pipelines.
• Check the oil level (5.5 litres of well refined lubricating oil)
• Bowl hood filled with water.
• Locking of separator

19. PANEER SECTION
According to PFA paneer is the product obtained from cow or buffalo milk or combination
thereof by precipitation with sour milk,lactic acid, citric acid.
INGREDIENTS: Milk and Citric Acid.
FSSAI STANDARDS FOR PANEER
TYPE OF MILK PRODUCT FAT % MOISTURE %
MIXED MILK PANEER NLT 50% (DMB) NMT 70%
SKIM MILK PANEER NMT 13% (DMB) NMT 70%
NLT:-Not less than
NMT:-Not more than
DMB:-Dry mater basis
SENSORY CHARACTERISTICS OF PANEER
PRODUCT FLAVOUR BODY AND
TEXTURE
COLOUR AND
APPEARANCE
Paneer Pleasant mildly acidic
and sweet nutty
Firm body and
compact close knit
texture
Uniform white
pleasing colour
Spc for paneer should not be more than 50,000/gm and coliform count should be not more
than 90/gm.Acc. toPFA the fat % in paneen should not be less than 50% on dry mater basis
and moisture content should not be more than 60%.
FLO W DIAGRAM OF PANEER MANUFACTURING

20. WEIGHT OF
PACKING
(200 Gm)
203-
204
203-
20
4
202-
20
4
202-2
04
203-2
04
202-
20
4
203-
20
4
203-
20
4

21. PACKING TEM.
(*C)
22-2
30
C
20-2
2
0
C
20-2
1
0
C
19-21
0
C
20-21
0
C
19-2
0
0
C
19-2
1
0
C
19-2
0
0
C
DIPPING TIME
(*C)
1.30 1.30 1.30 1.30 1.30 1.30 1.30 1.30
.
TEM. OF CHILLED
WATER
(*C)
8-10
0
C
12-1
4
0
C
8-10
0
C
10-12
0
C
13-14
0
C
12-1
3
0
C
9-11
0
C
10-1
1
0
C
PRESSING
PRESSURE/TIME
(Kg.Cm-2
/ Min.)
5.1/8 5.1/
8
5.1/
8
5.1/8 4.7/8 4.7/
8
4.5/
8
4.5/
8
TEMP. OF
COAGULATION
(*C)
76-7
90
C
75-7
6
0
C
75-7
6
0
C
79-82
0
C
79-81
0
C
80-8
2
0
C
79-8
0
0
C
79-8
0
0
C
TEM. OF HEATING
MILK
(*C)
90-9
3
0C
/5
MI
N.
89-9
0
0
C/
5
MI
N.
90-9
1
0
C
/5
MI
N.
87-90
0
C/5
MIN
.
88-90
0
C/5
MIN
.
89-9
0
0
C/
5
MI
N.
90-9
1
0
C
/5
MI
N.
90-9
1
0
C/
5
MI
N.
QUANTITY OF
CITRIC ACID
(Gm.)
800 800 800 800 800 800 800 800
QUANTITY OF
MILK
(Kg.)
500 500 500 500 500 500 500 500
DATE 17.8.
201
6
18.8
.20
16
19.8
.20
16
20.8.2
016
22.8.2
016
23.8
.20
16
24.8
.20
16
26.8
.20
16

22. KHEER
Kheer is also known as Basundi, is an Indian Dessert prepared by the partial dehydration of
whole milk in a karahi over fire together with sugar and usually rice or occasionally semolina.
It is very popular in Punjab and whole northern region.
INGREDIENTS: Milk, Rice, Sugar, Elachi Powder and Sodium Benzoate As Preservative

23. COMPOSITION OF KHEER
Moisture Fat Protein Lactose Ash Sugar (added)
67.02 % 7.83 % 6.34 % 8.45 % 1.41 % 8.95 %
FLOW CHART FOR KHEER MANUFACTURING
PASTEURIZED STANDARDIZED MILK IN KETTLE(FAT-3%, SNF-10%)
HEATING WITH VIGOROUS BOILING FOR ABOUT 10 MINS WITH CONTINUOUS
STIRRING CUM SCRAPPING
ADDITION OF RICE AFTER PROPER WASHING(ADDED
@4.5%)
BOILING
WITH CONTINUOUS STIRRING AND
SUGAR+ CARDAMOM POWDER
N SCRAPPING TILL IT ATTAINS DESIRED CONC.
GENTLE BOILING WITH CONTINUOUS STIRRING CUM SCRAPPING IS CONTINUED
FOR ABOUT 10-15 MINS TILL FINAL CONC. (WHEN TS IS AROUND
25.5-28% AS PER REFRACTOMETER READING)
TRANSFER TO DOUBLE JACKETED HOPPER WITH FACILITY OF COOLING
PRODUCT TO 50-600
C
KHEER FILLING MACHINE FOR FILLING AND SEALING
STORAGE AT 50
C IN COLD STORE AND DISPATCH
WEIGHT OF
PACKING
(200GM)
208-209 207-208 207-208

24. TEMP. OF COLD
STORE
(0
C)
2-3 2-3 2-3
TEMP. OF
PACKING
PRODUCT (0
C)
48-500
C 50-510
C 46-490
C
STEAM
PRESSURE OF
COOKING
(KG/CM2
)
3-4 KG/CM2
3-4
KG/CM2
3-4 KG/CM2
TEMP. OF
SEALING (0
C)
242-246 244-246 244-245
TEMP
OF HEATING
MILK (0
C)
98-990
C/0.2-
1.5KG/CM2
99-99.70
C/
0.2-1.5K
G/CM2
98-990
C/0.2-1.5KG/
CM2
SODIUM
BENZOATE
(GM)
30 30 30
ELACHI (GM) 100 100 100
SUGAR (KG) 12.8 12.8 12.8
RICE(KG) 7.2 7.2 7.2
MILK (KG) 160 160 160
DATE 29.8.2016 30.8.2016 31.8.2016

26. DAHI SECTION
Indian curd is known as dahi, which is very popular fermented milk product all over
India. In Punjab generally sour dahi is consumed. This dairy plant follows the FSSAI standards
ofdahi .Freezed dried cultures are used for culturing of milk for dahi.
INGREDIENTS: Milk and Dahi Culture.
CULTURES USED: Dahi 2,CIT-01, CIT-02,STI-13
COMPANIES PROVIDING CULTURES: CHR Denmark, ECOMILK Ludhiana, Gujrat
enterprises.
COMPOSITION MAINTAINED BY VERKA MILK PLANT MOHALI:
Fat Not less than 3%
Protein 3.2-3.4%
Acidity 0.8-1.0% LA
Taste Creamery-sour
Flavour Acidic

28. FLOW DIAGRAM FOR MANUFACTURING DAHI

29. WEIGHT OF
PACKING
(400gm,200gm,1
00gm.)
412-414
(gm)
107-108
(gm)
205-206 (gm) 412-413
(gm)
412-413
(gm)
COLD ROOM
TEM.
(0
C)
0.5-0.8 0
C 0.5-0.7 0
C 0.4-0.6 0
C 0.4-0.6 0
C 0.4-0.8 0
C
CURD
SETTING
TIME
(HRS.)
3-4 3-3.30 3-4 3-4 3-4
INCUBA-TION
ROOM TEM.
(*C)
43-44 0
C 43-44 0C 43-44 0
C 43-44 0
C 43-44 0
C
PACKING TEM.
(0
C)
43-44 0
C 43-44 0
C 43-440
C 43-44 0
C 43-44 0
C
AGITATION
TEM./TIME
(0
C/MIN.)
43-44 0
C/ 20
MIN.
43-44 0
C/ 20
MIN.
43-44 0
C/ 20
MIN.
43-44 0
C/ 20
MIN.
43-44 0
C/
20 MIN.
CULTURE USED STA IDC
703
STA IDC
701
STI 13 DAHI-2 DAHI-2
OUTLET TEM.
OF MILK.
(0
C)
44-45 0
C 44-45 0
C 45-46 0
C 44-45 0
C 44 -450
C
HOMOGE-NIZ
ATION
PRESSURE/T
EM.
(PSI/0
C)
1900-I,
500-II/84
0
C
1800-I,
500-II/83-8
4 0
C
1900-I,
500-II/84 0
C
2000-I,
500-II/87
0
C
2000-I,
500-II
/880
C
PASTEURI-SA
TION TEM.
OF MILK
(*C)
90-91 0
C/5
MIN.
90 0
C /5
MIN.
89-900
C/5 MIN. 900
C /5
MIN.
90 0
C/ 5
MIN.
DATE 13.10.2016 14.10.2016 28.11.2016 29.11.2016 30.11.2016

30. PACKING MATERIALS OF DAHI
Pack material Polystyrene cups
Size of cups 100,200 & 400ml
Thickness of cups 200+/-10mm
Lassi is also called chhas. Lassi refers to desi butter milk which is by product obtained when
churning curdle milk which is crude indigeneous device for production of desi butter.
Types of lassi:
- Plain Lassi
- Sweet Lassi
- Spiced Lassi
STANDARDS FOR VARIOUS TYPES OF LASSI
FLOW
CHART
FOR PLAIN LASSI
Standardized pasteurized milk(fat-4.5%, snf-8.5%) for curd from PMST
Heating of milk by PHE at 90+/-2*c/5mins with outlet temperature of milk at 44*c with
homogenization at 2500psi/500psi.
Inoculation with culture in MPST vat @ 200 units/2000 lts of milk at 42-44*c & setting the
curd LA acidity 0.80-0.90%
TYPE FAT ACIDITY TS
PLAIN LASSI NLT 2.2% NLT 0.4% NLT 6.5%
SWEET LASSI NLT 1.2% NLT 0.35% NLT 14.5%
SPICED LASSI NLT 1.2% NLT 0.35% NLT 5.5%
LASSI

31. Adding 1000kg of past. Water & agitation with circulationof chilled water in jacket to arrest
acidity development
Chilling/thermization at 65+/-2*c and addition of remaining past. Chilled water (5000 kg)
HMST for packing in pouches
Packing
Cold storage at max 5*c
Dispatched in insulated van
NOTE: In manufacturing of sweet and namkeenlassi, sugar and masala are added after
chilling/ thermization.
1) For sweet lassi , sugar is added @ 10%.
2) For spicedlassi, salt is added @ 4% and masala is added @ 5% i.e. 5kg/1000kg.
FLUID MILK PACKAGING SECTION FOR CITY SUPPLY
The vital role of the packaging material is to prevent the post processing contamination as well
as to create an attractive appearance and protect the product. Packaging Shift
There are 3 shifts i.e. from 6am-2pm, 2pm-10pm and 10pm-6am.

32. SPECIFICATION OF MACHINE IN POUCH FILLING Pouch filling
No 26
Make STAINLESS STEEL
Operating 5000 poches/hr
500ml:-40-42Pouches/min-head
1000ml:-26-28 pouches/min-head
Electricity 440V,3-phase, 4 wire, 50 Circle/sec
Compressed Air 6kg/sq.cm.
Head Tank Capacity 40lts
BUTTER SECTION
Acc. to PFA butter is the product obtained from cow or buffalo or combination thereof or cream
with or without addition of common salt and annatto or carotene as colouring matter. It
should be free from other animal fats, wax, mineral oils and vegetable fats.it must contain
not less than 80 % of milk fat, not more than 1.5 % curd and not more than 3% common
salt content. Diacetyl content may be added but not exceed 4 ppm. Surplus milk is
converted into butter while during scarcity the milk intended for butter making is used
for more essential products.
TYPES OF BUTTER
• Table Butter
• White Butter
COMPOSITIONAL & OTHER STANDARDS
PARTICULARS TABLE BUTTER WHITE BUTTER
Fat (%) 80.5-81.5 Min. 82
Moisture (%) Max.16 Max. 16
Curd (%) Max. 1 Max. 1.0
Coliform Nil Nil
Yeast & Molds (cfu/gm) Max. 10 Max. 20

33. Fat in butter milk (%) Max. 1.0 Max. 1.0
Salt 2.0+/-0.2 ----
Fat% in cream 37-42
Acidity (%LA) 0.15 Max
Temp ( o
C ) 10-12
Flavor Sweet
Ageing time (hrs) Min 6
Wash water for table butter & white butter for recombination
Treatment Past. Chilled water chlorinated with 10-24
ppm chlorine
Washing Temp. (1st
& 2nd
Wash) 6-8o
C
OPERATING PARAMETER (FOR TABLE BUTTER)
Loading of churn 1/3rd
volume of drum capacity
Loading temp (o
C) < 10-12 o
C
Churning temp (o
C) < 10-12 o
C
Colour addition 1ml/kg fat
Spray water temp (o
C) Max 5
Speed of churning granulation pre-working 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
FLOW DIAGRAM OF BUTTER MANUFACTURING

34. PACKAGING
Butter is packed in polythene bags (upto15kg ) and then cartons before washing with
chlorinated water of concentration 10-24 ppm.

35. White butter is generally converted into Ghee. It is stored as butter stock of fat to be used for
recantation or for Ghee in lean season.
STORAGE
The packed butter is stored at -17to-29o
C .
OVERRUN
The Overrun of butter is about 20%. The yield of butter is thus calculated as;
Y= Fat In Cream (Kg.) X (100 + % Overrun)/100
Y=fat ×1.02 (Y = Yield)
%OR =(B-F) X 100/F
B= butter made in kg, F=
fat in churn in kg.
GHEE SECTION
Acc. to the PFA ghee is the pure clarified fat derived from milk or from desi butter or
from cream to which no colouring matter is added. Ghee ranks as the largest produced milk
product in our country. Roughly 33% of total milk production of India is converted to Ghee.
COMPOSITIONAL & OTHER STANDARDS OF GHEE MAINTAINED BY THIS DAIRY
Milk fat NLT 99.6%
Flavour&colour Pleasant & white or yellow
Moisture NMT 0.4%
F.F.A (% Oleic Acid) NMT 0.4%
B.R. reading at 40o
C 40-43
Baoudin test Negative
Peroxide value( milli equivalent of
oxygen/kg fat)
NMT 0.6%
RM value NLT 24
Sediment Polenske
value
Absent
1.0 – 2.0
FLOW DIAGRAM OF GHEE MANUFACTURING
PASTUERIZED CREAM CHURNING AND WASHING WITH CHILLED WATER
WHITE BUTTER IN TROLLEYS BUTTER MILK REMOVAL

36. BUTTER MELTING VAT PACKING AND STORAGE(-5TO-100
C)
PRE-STRATIFICATION TANK FOR 1.5-2 HRS
COOKING IN GHEE KETTLE(105-1100
C )
FILTRATION/CLARIFICATION
SETTLING TANK FOR 4 HRS
GHEE BALANCE/BUFFER TANK
FILLING
TRANSFER FOR GRANULATION AT 20-260
CIN COLD STORE
STORAGE AND DESPATCH
OPERATING PARAMETERS
Pre-melting temp (o
C) 75-80
Cooking temp (o
C) 105-112
Batch time (hr) Max. 4
ONE LITRE TIN FILLING AND SEAMING 15 KG TIN FILLING AND SEAMING
POLYPACK FILLING
CARTONING

37. Steam pressure in kettle (kg/sq.cm.) 2
Clarification temp (o
C) 95+/-5
Setting time (hr) 4 hr
Ghee filling tank temp (o
C) 43+/-5
GRANULATION
Temp o
C : < 20o
C
Time (hr) : 8 (min)
STORAGE
After packaging the packed corrugated boxes are kept in granulation room for 24 hrs. Then the
boxes are transferred into storage room till dispatch.
PARAMETERS OF GHEE MANUFACTURING
LO
T
NO.
KETTL
E NO.
COOKIN
G
STARTED
STEAM
PRESSUR
E
(KG/CM2
)
COOKING
TEMP(MAX.
)
COOKIN
G
OVER
PUMPING
TIME
1 2 11 AM 2.6 1080
C 1 PM 1.45 PM
2 1 12PM 2.6 1080
C 3.10 PM 4.00 PM
3 1 4.20 PM 2.6 1070
C 7.15 PM 7.45PM

38. QUALITY CONTROL DEPARTMENT
HEAD OF DEPARTMENT: Mr. Rakesh Gupta
ISO-9002: Milk Plant Mohali is certified to ISO standards. It is provided to a concern, which
has established specialization in quality and prices and able to use its full installation production
capacity.
IS-15000(HACCP): Milk Plant Mohali has also get this international quality certificate, which
allows it to sell its products at international levels. It actually called “International Standard-
15000 (Hazard Analysis and Critical Control Point).The staff also keeps a strict watch on
cleanliness of equipment and pipelines etc. with a view to avoid contamination.
Here Q.A. section ensures triple aspect of quality of milk and milk products up to
consumer satisfaction level.
• Organoleptic
• Chemical
• Bacteriological
LABORATORIES OF Q.A. SECTION

39. FUNCTIONS OF DIFFERENT SECTIONS OF Q.A.
Dock lab
• Grading of incoming raw milk.
• Raw milk testing.
• Testing of outgoing pasteurized milk
• Testing of processed milk stored in storage tank of silo.
• Cream testing
• Butter milk testing.
• Standardization of fluid milk.
• Testing of fat in ghee residue
• Checking of strength of detergent for CIP.
• Checking of cleanliness.
• Testing of cold store pouches.
CHEMICAL LAB
• Sensory evolution of milk products.
• Checking of the composition of milk products.
• Hardness and chlorine content of water for butter washing
• Checking the quality of regents, packing materials glassware for testing etc.
• Checking the efficiency of wastewater treatment.
• Controlling the cleanliness of dairy equipments as well as overall sanitization of the
plant.
BACTERIOLOGICAL LAB
• Checking the bacteriological quality of various types of milk and milk products.
• Determine the types and number of micro flora in air, water and various dairy
equipments and pipelines etc.
• To check efficiency of pasteurization.
• Testing of shelf life of milk of city supply.
AGMARK LAB
-Testing of fat rich products: Ghee and Butter.
FLUID MILK ANALYSIS
SAMPLING: 1. mix the all milk properly with plunger and then take the sample with sterilized
dipper.
2. rinse the sample bottles and then take the two samples from each tanker one for testing and
one for custody.

40. TEST PERFORMED IN LABORATORY ON RAW MILK:
TESTS METHOD STANDARD RANGE
Fat Gerber method -
SNF Lactometer
SNF=CLR/4+0.2 %f+0.29
( at 15.50
c)
SNF: Solid Not Fat
CLR: Correct Lactometer Reading
-
Acidity Titration with 0.9 N NAOH 0.12-0.16 % la at 8 0
c
Adulteration
Tests:Salt,Urea,Neuta
lizer,
Glucose,Starchetc
Using strips and solutions and match
the colour change
Negative
MBRT By using test tube and water bath
at(37 o
c)
Good: 3-4hrs.
Fair:1-2 hrs.
Poor : 1/2 and below 1/2 hrs.
BR BR meter 40-43 at 400
c
Sodium Sodium analyzer 450-550 ppm
RM ISI method 28-31

41. TESTING REPORT OF RAW MILK SAMLES.
E
016 r sample eration test
ol test
y
oleptic test
ive
ive
.13 %L.A.
ive
016 r sample ading test 1.8
013 r sample m test 50 ppm
016 r sample alue testing 28.5
016 r sample ading test m
test
1.8 50
ppm
2.)Test performed on milk after pasteurization and before dispatch into market:
● Performing alkaline phosphatase test of pasteurized milk. (To check the efficiency of
pasteurization)
● MBRT TEST of pasteurized milk. (for good quality milk, time should be 6hrs)
● Fat test (by Gerber’s method)
● Total solids of milk (by gravimetric method) ● Titrable acidity of milk.
● Weight of pouch should also be checked. ● Seal testing (droping from 1.5 meter height) ●
Sensory evaluation of market milk.
DUCT PERFORMED ULTS
RAGE)
016 r sample T Hrs
016 r sample y ol
test
.13 %L.A.
ve
016 r sample erature of milk
eration test
*C
5 %
ive

42. 2)DAHI
1) Test performed on Dahi milk:
● Fat and SNF of milk used for dahi making. (fat-3.1%, SNF-10.5%) ● Titrable acidity of
milk as %LA.
● Creaming index of dahi milk after homogenisation. (value of CI should be below 10).
● pH and titrable acidity of dahi measured during incubation, when pH and %LA reaches
4.6 and 0.71%, then dahi is transferred to cold store.
2) Final dahi testing:
● Total solids of dahi.
● Fat Testing
● Plating of final dahi for checking coliforms.
● Sensory evaluation of final dahi before dispatch.
TESTING REPOT OF DAHI SAMPLES
OK
OK OK
3)LASSI
Milk used for making lassi should have fat and SNF of 4.5% &8.5%.
Test performed on final lassi:
● Fat test
● TS of lassi by gravimetric method.
● Titrable acidity as %LA.
● Sensory evaluation i.e. taste and flavour.
STANDARDS FOR VARIOUS TYPES OF LASSI
TYPE FAT ACIDITY TS
FAT
% IN
MILK
SNF%
IN
MILK
ACIDITY
IN MILK
(% L.A.)
CULTURE CREAMING
INDEX
pH % L.A. of
DAHI
PACKING
WEIGHT
TAS
3.1 10.5 0.17 STA IDC 703 4.52 4.5-4.7 0.70-0.71 400 gm
3.1 10.51 0.18 STA IDC 701 3.72 4.7-4.8 0.68-0.69 100 gm
3.2 10.52 0.17 DAHI 2 3.45-3.70 4.6-4.7 0.70-0.72 400 gm

43. PLAIN LASSI NLT 2.2% NLT 0.4% NLT 6.5%
SWEET LASSI NLT 1.2% NLT 0.35% NLT 14.5%
NAMKEEN LASSI NLT 1.2% NLT 0.35% NLT 5.5%
5)Paneer
Milk used for making paneer having minimum fat and SNF of 5% and 8.6%.
Test performed on final paneer:
● Fat test same as that of kheer.
● TS of paneer by gravimetric method.
● Taste and flavour
● Shelf life testing
DATE AT IN
MILK
NF IN
MILK
%FAT
PANEER
MOISTURE
IN
PANEER
%TS
PANEER
FAT IN
WHEY
NF IN
WHE
Y
TS IN
WHEY
8.8.2016 5.0 8.6 5.5-26.5 49-50 48-49 0.9 - -
9.8.2016 0-5.1 6-8.7 6.4-26.6 49-51 48-50 0.8 - -
0.8.2016 0-5.1 6-8.7 5.4-26.4 51-52 47-48 7-0.8 - .3-7.4
-8-2016 0-5.1 6-8.7 5.4-26.2 50-52 47-49 4-0.6 5-6.6 .8-7.2
23.8.16 0-5.1 6-8.7 4.8-25.2 51-52 46-47 5-0.45 7-6.8 .6-6.8

44. ● Weight
TESTING OF PANEER SAMPLES

45. 4)Kheer
Milk used for making kheer should have fat andSNFof minimum 3.1% and 10.5%.
Test performed on kheer:
● Fat by Gerber’s method.
Fat = buytrometer reading * 11.2/weight of kheer taken ● TS of
final kheer by gravimetric method or by using refractometer.
● Sensory evaluation i.e. taste and flavour.
● Plating of kheer contents.
TESTING REPORT OF KHEER SAMPLES
DATE %FAT
N MILK
%SNF
MILK
CIDITY
N MILK
% L.A.)
T IN KHEER TS IN KHEER
29.8.2016 3.0% 0.14% 0.17% 3.4-3.6 26.4-6.5
30.8.16 3.0% 0.16% 0.18% 3.5-3.6 25.625.7
24.8.16 0-5.1 6-8.7 25-26 51-52 47-48 5-0.35 6-6.8 .3-6.5
6.8.2016 1-5.2 6-8.7 23-24 52-53 46-47 5-0.35 6-6.8 .7-6.8

46. 31.8.2016 3.0% 0.19% 0.18% 3.4-3.5 26.626.8
BUTTER
After pre-working
Test Observation Method
Temperature 12-15o
C Thermometer
Moisture 16.2+/-0.2% Hot air oven
Salt Max. 2.2% Adding potassium chromate
indicator and titrate against
silver nitrate
After Production& During Packaging
TEST OBSERVATION METHOD
Organoleptic Normal Smell and taste
Moisture 16.2+/-0.2% By drying
Salt content Max. 2.2% Titration against silver
nitrate
Curd content Max. 1% Washing by petroleum ether
and trying
Fat content 80.5-81.5% Evaporation of petroleum
ether
Coliform count Nil VRBA Plating
Appearance Glossy and good At a glance
TESTING OF BUTTER
DATE %FAT %M0ISTUR
E
%CURD
CONTEN
T
2.12.2016 82.74 15.91 1.35
3.12.2016 83.46 15.15 1.39
6.12.2016 82.26 16.53 1.21

47. 7.12.2016 82.39 16.29 1.32
GHEE
There is separate AGMARK laboratory in which ghee samples are tested for following:
TEST METHOD RESULT
Free fatty acid(% oelic acid) Titration with N/9NaOH
after dissolving in alcohol
0.18-0.24 %
RM value ISI method 28-30
P Value -do- 0.4-0.6
BR reading Measure refractive index
(RI) in butyrometer and
convert RI into BR
41.8-42.8
Moisture Drying in hot air oven 0.42-0.44 %
Fat % 100-% Moistute 99.5 %
Adulterant Baudouin test NEGETIVE
Flavour Smell PLEASANT
TEST PERFORMED ON PACKAGING MATERIALS
st
HOD ULT
ness meter 2 microns
8
by dipping method
0
c/24 hrs)
ave hould be not
remove)

48. est
OTHER TESTS
- Calculating strength of solutions used for CIP cleaning.
- CIP of tankers after every 12 hrs.
Solutions of CIP
- Caustic
soda - Nitric
acid.
STRENGTH OF SOLUTIONS
NAME OF
SOLUTION
CONCENTRATION
(%)
CIP
CAUSTIC 1% (MIN.) RMST
ITRIC ACID 0.8 % (MIN.) RMST
By cellotape
ngstrengh chine Pressure wearing 6.0kg/cm2
per square meter (gsm) ight method e
10x10cm)
-4 gm
ure of cardboard ight method %
test rch solution olour: negetive colour:
positive
htment test hing balance min. 6gm./400ml cup,
12gm./800ml cup
ing method reak the seal when drop from 1.5 meter
height
er test for ghee tin pper solution rinse method
m copper sulphate+70 ml
HCL)
er layer should not remove

49. CAUSTIC 1.5-2.0 % PMST
ITRIC ACID 1.0-1.5 % PMST
● Strength of caustic= titre volume x0.4/ weight of caustic taken
● Strength of HCl = titre volume x 0.3654/ weight of sample
● Strength of nitric acid = titre volumex0.63/weight of sample
● Strength of citric acid used in Paneer making = titre volume x
0.70/ weight of sample The normality of titrate solution is 0.1 N - Testing
hardness of water samples.
- Testing strength of chlorine in chlorine water used for washing of butter to prevent
mould growth.
● Strength of chlorine = 0.71 X titre volume X 100
● Range of chlorine strength = 10-24 ppm
ENGINEERING DEPARTMENT
HEAD OF DEPARTMENT: Mr. Hunardeep Singh Brar
Sections under the engineering department:
● Detail of machinary installed.
• Refrigeration Section
• Boiler Section
• Electrical Section
MACHINARY USED ON RMRD SECTION
Sr.
No
Section Name Of Machinery Make Qty. Capacity
1. RMRD • Balance tank
• Pump
• Filters
• Chillers
• Storage tanks
IDMC
IDMC
IDMC
IDMC
IDMC
One
Four
Four
Two
Four
200 lts
167 lts/min
20000 lts/min
20KL/hr
60KL/hr

50. MACHINARY USED IN NEW DAIRY
Sr.
No
Section Name Of Machinery Make Qty. Capacity
1. Milk
Processing
(New
Dairy)
• HTST Milk
Pasteurizer
• Cream Separators
• Cream
Pasteurizer
• Homogeniser
• PMST
• Pumps
• Filters
• Cream chiller
• Cream ripening
tanks
IDMC
GEA
Tetra Pak
GEA
IDMC
IDMC
IDMC
IDMC
IDMC
2
2
1
1
4
4
4
1
2
20KL/hr(each)
20KL/hr(each)
5KL/hr
20KL/hr
60KL(each)
20KL/hr
20KL/hr
5KL/hr
10KL/hr(each)
Milk Pouch
Filling
• FFS (pneumatic) RMC
PACKAGIN
G SYSTEMS
LIMITED
26 heads 5000
packets/hour
( it may be 38
pouches per min
or 60 pouches per
min)
MACHINARY USED IN OLD DAIRY
S.NO. Section Name Of Machinery Make Qty. Capacity

51. 1. Milk
Processing(ol
d dairy)
•
•
•
•
•
•
•
HTST Milk
Pasteurizer
Balance tank
Cream Separator
Storage Tanks
Filters
Pumps
Homogeniser
IDMC
IDMC
Alfa Laval
IDMC
IDMC
IDMC
RANNIE
COPENHAGE
N Denmark
2
2
4
4
4
4
1
10KL/hr
100lts
10KL/hr
15KL
(each)
10KL/hr
10KL/hr
10KL/hr
MACHINARY USED IN PANEER SECTION
S.
N
O.
Section Name Of Machinery Make Qty. Capacity
1. Paneer • PHE
• STRAINING
VATS
• CHILLED
WATER TANK
• PACKING
AND
SEALING
MACHINE(200g)
HMT
HMT
IDMC
MULTIVAC
One
TWO
ONE
ONE
5000 LTS/HR
500 LTS
5000 LTS
5000 POUCHES
PER HR
SPECIFICATION OF EQUIPMENTS IN PANEER SECTION
STRAINING VAT
No. 2
Make HMT Ltd
Capacity 500kg
Working pressure 2.5kg/sq.cm.
Design pressure 3.8kg/sq.cm

52. AUTOMATIC MACHINE FOR PRESSING
No. 4
Pressure (kg/sq.cm) 6.5
PACKING OF PANEER
Packing material Polypacks
Packing size Brick wt. as per requirement 200 gm
Sealing Vacuum packaging is done manually
Storage Paneer is stored in cold store at below 5o
C
Make Multivac
Speed 1800-1900 pouches/hr
MACHINARY USED IN KHEER SECTION
S.
N
O.
Section Name Of Machinery Make Qty. Capacity
10. Kheer
section
• Boiling kettle
• Kheer kettle
• Hopper
• Filling and sealing
machine
IDMC
HMT
HMT
IDMC
1
1
1
1
160 kg
200 kg
60 kg
1500 cups/hr
MACHINARY USED IN DAHI SECTION
S.NO. Section Name Of EQUPMENT Make Qty. Capacity

53. 1. Dahi • STORAGE TANK
• Filters (simplex
filter)
• homogenizer
• PHE
• INOCULATION
VAT
• DAHI PACKING
MACHINE (100 g)
• DAHI PACKING
MACHINE
IDMC
GOMA
GOMA
GOMA
IDMC
IDMC
OYSTAR
CASTI
DOGATHERM
2
1
1
1
5
2
1
15000 LTS.
5000 LTS./HRS.
3000 LTR./MIN.
5000 LTR./HRS.
1000 lts (4 VAT)
400 lts (1VAT)
1500-2000
CUPS/HRS.
10000-15000 cups/hr
-for 500g pouch filling of dahi: SAMARPAN FAB LTD.(speed 40-45 pouches/min)
MACHINARY USED IN LASSI SECTION
S.
N
O.
Section Name Of Machinery Make Qty. Capacity
5. Lassi • FFS (for packing)
pneumatic
• Vertical
storage
tank
• PHE
SAMARPAN
Fab
IDMC
HMT
8 heads
3
1
1
5000
pouches/hr(49
pouches/min)
7000 lts each
5000 lts/hr
MACHINARY USED IN BUTTER SECTION
S.NO. Section Name Of Machinery Make Qty
.
Capacity
1. Butter • Butter Churn
• Continuous Butter
Making
Machine(CBM)
Larson
&Toburo
HMT Limited
1
1
2000Kg (Loading
Capacity)
800 kg

54. CREAM STORAGE TANK
About Old plant New plant
No. ` 4 2
Make KPSAR Engg. Works IDMC
Capacity 3000 lts 10000lts
MACHINARY USED IN GHEE SECTION
S.NO. Section Name Of Machinery Make Qty. Capacity
8. Ghee
Section
• Butter Churn
• CBM
• Butter Melting
Vat
• Pre-stratification
tank (double
jackated)
• Kettle/ghee
boiler
• ghee Clarifier
• ghee-Settling
tank
• Storage Tank
• Rotary Ghee
Filler
L & T
HMT
IDMC
IDMC
BANSAL
Tetra Pak
IDMC
IDMC
IDMC
1
1
2
3
2
One
3
3
One
2000Kg (Loading
Capacity)
800kg
5000 lts
3000 lts
1200 lts (each)/40
agitator rpm.
2000 LPH
3000 lts (2)
1000 lts (1)
3000Kg (2)
1000 lts (1)
1200 Tins/hr
(720 l)
SPECIFICATION OF EQUIPMENTS IN GHEE SECTION
FOR 1 LITRE GHEE FILLING
NUMBER 1

55. MAKE SHUBHAM FFLEXIBLE PACKAGING
PVT. LIMITED
MODEL NUMBER 12
SPEED 800-900 CARTONS/HR(1 LT.),
16 PACKETS/MIN
SPECIFICATIONS 50HZ, 3 PHASE, 440V
REFRIGERATION SECTION
FORMEN OF SECTION: MR. ROSHAN LAL
Refrigeration means process of absorbing undesirable heat from one substance &
transporting this heat to atmosphere through the cooling media. Dairy products are seasonal &
perishable in nature requiring preservation. For transportation, processing and storage of milk
and milk products, refrigeration is essential. At the ambient temperature, micro-organisms grow
well and spoil the milk and milk products easily, so as to increase the shelf life is almost
important to keep the milk & milk products at a very low temperature. For producing a cooling
medium (chilled water) refrigeration section is essential. In this plant there is a well – equipped
& large refrigeration section, which meets the entire refrigeration load of the plant.
TYPE OF REFRIGERATION PLANT:- SCREW COMPRESSOR REFRIGERATION SYSTEM
CAPACITY OF REFRIGERATION PLANT:-3600 TR REFRIGERANT USED:-LIQUID AMMONIA
VARIOUS PARTS OF REFRIGERATION SYSTEM
1. Low pressure liquid line
2. Suction line

56. 3. Discharge line or hot gas line
4.high pressure liquid line
1) COMPRESSOR: Its function is to increase the pressure and corresponding saturation
temperature of a refrigerant to a level enough to condense to a high pressure warm
liquid.
E
OR
SPEED (1/MIN)
USED FOR LUBRICATION O-FRIZ 68
F EACH COMPRESSOR
2) CONDENSOR:ITSFunction is to provide heat transfer surface.The refrigerant is
condense to a high pressure warm liquid by removing its heat.
W COMPRESSOR
BER
K MICROTEK
P
GN PRESSURE(MPAG)
PRESSURE(MPAG)
SWEPT VOLUME (CUBIC METER PER
HOUR)

57. E
3) EXPANSION VALVE: when liq. Pass through this valve, it lowers its pressure and
pressure drop also lowers the saturation temp to a point, where the refrigerant is ready
to enter the evaporator.
4) EVAPORATOR: It is a type of heat exchanger that receives cold refrigerant. The
refrigerant evaporates from a liquid to a low temperature vapour.It constitutes of two
equipments:
- Plate heat Chiller (capacity 50KL/hr) - Two
Ice bank tanks (1 lakh lts capacity each) Ice
bank tanks are equipped with agitators.
OTHER IMPORTANT EQUIPMENTS OF REFRIGRATION SECTION
1) Oil separator
2) Low pressure receiver
3) High pressure receiver: It is equipped with economiser to increase economy of process
and safety valve for safety purposes.
4) Non return valve
5) Suction pressure (30-35PSIG)
6) Discharge pressure (150-180 PSIG)
Full maintenance of machinery is done after every 5000hrs.
MAINTENANCE SCHEDULE FOR REFRIGERATION PLANT
S.NO. Items Frequency
1. Cleaning of water tank of condenser Six months
2. Complete overhauling of all compressors Six months
3. Overhauling of C.W. agitator & C.W. tank Six months
4. Complete overhauling of condenser & water Six months
5. Complete overhauling of cooling water pumps. Six months
6. Greasing of agitator & pumps Half-yearly
7. Greasing of air blower of different cold store Half-yearly
8. Air purging of plant Quarterly
9. Changing of oil in compressor & coil checks Quarterly
AND WATER COOLED
BER
PCO
D(TR) ACH)

58. 10. Inspection maintenance of refrigeration controls Quarterly
11. Oil purging of cold store, cooling water tank & brine tank 2 monthly
12. Cleaning of condenser Weekly
13. Cleaning of oil separators Nil
14. Cleaning of water header holes Nil
15. Check oil level in oil tank of compressor Daily
16. Check the valve in line & working pressure Daily
BOILER SECTION
FOREMEN OF SECTION: MR. AJAIB SINGH
Since steam can be transported through pipelines, very conveniently from its source of
generation to all places of utilization. It is the most economical and common source of heat
energy that is utilized in very large quantities in dairy i.e. in products processing plant it is very
convenient heating media compared with other source of energy.
Boiler is the equipment that produces steam. There are two working boilers in this dairy plant.
All the heat treatments, heating, cleaning etc are done with the help of steam in the dairy plant.
Boilers are of two types:
1) Fire tube ( Inside- Fire, Outside- Water): It used at low pressure.
2) Water tube (Inside- Water, Outside- Fire): It is used at high pressure.
BOILER SPECIFICATIOS
er
L MAX
ity f 3 Tonnes and other one is of 4 Tonnes
sed Furnace oil
ure of steam (send to plant) /cm2
mum pressure cm2
ure of steam (reaches at different sections) /cm2
Fuel Consumption 150 lts/hr (avg)
Fuel ignition temp. 90-100o
C
Chimney Temp. 240-250o
C

59. OTHER EQUIPMENTS USED IN BOILER SECTION
1) OIL SERVICE TANK
No. 2
Capacity 1800ltr & 1200ltr
2) OIL STORAGE TANK
Number 2
capacity 28000 lts
3) FEED WATER TANK
No. 2
Capacity 6000ltr
4) BLOWER
No. 3
Motor 15 H.P, 3000 rpm, 50 Hz. Cycles
Initial fuel temperature : 80o
C
Final fuel temperature : 90-100o
C
Fuel pressure : 15-20kg/sq.cm
Fuel gas temperature : 240-350o
C
BOILER MOUNTINGS: These are mounted on boiler’s body for its proper and safe working.
● Water level indicator
● Pressure gauge
● Safety vales: Lever safety valves, Dead weight safety valve, Steam stop valve, Blow off
cock, Feed check valve, Fusible plug.
BOILER ACCESSORIES: These are used to increase boiler efficiency and to help in their
working.

60. ● Feed pump
● Superheater ● Economiser
● Air pre-heater
PROBLEMS OF OPERATING BOILER Clinker back: it is due to three reasons:-
● Nozzel chock
● Pressure not maintained
● Oil temp. is not maintained
Proper fuel consumption in boiler is checked from the smoke emitting from boiler chimney.
- If black smoke emitting :- fuel is not properly burnt so increase the rpm of air
motor
- If white smoke emitting:- more air is entered into the boiler, so decrease the rpm
of air.
- Brown Smoke:- It indicates the good combustion of fuel.
EFFLUENT TREATMENT PLANT
EFFLUENT: It is liquid waste flowing out of a factory,farm, commercial establishment, or a
household into a water body such as river, lake, sewage system or reservoir.
Water discharged into air is called emission.
NEED OF ETP
● Water is basic neccessity of life used for many purpose .
● Industries generally take water from rivers or lakes but they have to pay heavy taxes for
that.
● So it is necessery to recycle that to reduce cost and also conserve it.
● The treated water is further used for other purpose.
Constituents of Effluents
● Residues of milk & milk products.
● Washed water.
● Residual detergent 7 sanitizers.
● Several chemicals.
● Several microflora.
● Oil & grease etc.

61. In this dairy effluent is treated in U.A.S.B. (Upper Anaerobic Sludge Blanket) method.
TYPE OF ETP PLANT: Anaerobic digestion plant
CAPACITY OF ETP PLANT: 7.5lakh lts/day
FLOW DIAGRAM OF TREATMENT OF EFFLUENTS
Effluents
Oil and grease chamber
Collection tank
Grip chamber
USAB feed pump
USAB tank
Aeration tank-1
Clarifier
Aeration tank-2
Secondary clarifier Sludge tank
Lagoon
Settling tank
V-notch dispatch tank
Parameters Maintained
The parameters maintained by this dairy are as follows:
PARAMETERS UNTREATED TREATED
H
P
8.07 7.99
Suspended
particles(mg/L)
492 74

62. Dissolved particles
(mg/L)
- -
B.O.D. (mg/L) 515 22
C.O.D. (mg/L) 504.4 80
Oil/Grease (mg/L) 34 3
ELECTRICAL SECTION
FORMEN OF SECTION: MR. ROSHAN LAL
Electric Supply is a very important factor for a dairy plant. Electric energy is mainly necessary
for:-
• Lighting
• Heating
• Equipmentscontroling
DESCRIPTION
The dairy receives high voltage electricity of 11 K.V. from P.S.E.B. through high
tension lines. At first electricity is received in metering unit. Then it goes either to O.C.B. or
A.C.B. through meter and then to the step-down transformers. The transformers convert the 11
K.V. supplies to 440 volts and transfer feeder. There is a local sub main distribution board in
L.T. side from where the electricity is supplied to various sections through a no. of capacitors
and provided in the lines are connected to BUS chamber control board and switch for isolating
in case of any breakdown.
1700A of current is used at a time when whole plant uses electicity.
ACCOUNTING SECTION
MANAGER ACCOUNTS
:
Mr. Bhupinderjit Singh
Here we studied the financial statements of Mohali plant for the financial year 2015-2016. Here
we studied account statements, which comprise of balance sheet as at 31/03/16, statement of
profit and loss, cash flow statement and accompanying notes to financial statements and other
explanatory information for the year ended.

63. MARKETING DEPARTMENT
HEAD OF DEPARTMENT- Mr. A.K Mahajan
Marketing Department is headed by Manager, Marketing, who is further assisted by Sales
Inspector and other supporting staff. Marketing department is responsible for ensuring
maximum possible returns to the organization. Sub-contractors/agents are appointed by
marketing department for supply of milk and milk products. At present, city supply is done
through almost 120 agents; surrounding areas are also covered through agents. Four milk bars
are being maintained by milk plant for customers. These milk bars are located at Milk Plant
Mohali, Morinda,Laldo and Jhinjari. There are 92 distributors of liquid milk and 25 product
distributors. There are approximately 102 booths of this plant in Chandigarh and 27 booths are
located in Mohali.
IMPORTANT POINTS REGARDING MARKETING OF VERKA PALNT MOHALI:
1) Total annual turnover of MILKFED is around 2800 crores.
2) Annual turnover of Verka Plant Mohali is around 800-850 crores.
3) There is vision to increase the annual turnover of MILKFED to 20000 crores/year in
2020.
4) There is vision to increase the turnover Mohali plant to 2000 crore/year in 2020.
5) One third share in annual turnover of MILKFED is of Mohali plant.
6) 80% market share in tricity (Chandigarh, mohali, panchkula) is of Verka.
7) Margin given by Verka to retailers, distributors and transport company are 1.26 Rs/lt,
80-90 paise/lt and 30-35 paise/lt.
MARKET SALE OF PLANT PRODUCTS:
Average quantity of milk received by Verka plant, Mohali is 4.5 to 5 lakhs liters per day.
Product Demand (approximately)
Liquid milk 4 lakh kg/day
Curd (dahi) 20000-25000 kg/day(winter), upto 50
tonnes/day in summers
Lassi 40000kg/day(winter), upto 150 tonnes in
summer
Kheer 1000-1100 kg/day
Ghee 2000kg/day
Paneer 4200 kg /day
MARKET COVERED BY MOHALI PLANT:

64. Chandigarh , Mohali, Panchkula, Ropar, Nangal, Kharar, Kalka, Pinjore, Shimla, Solan, Baddi,
Nalagarh, Poanta- Sahib, Mandi, Bilaspur.
ADMIN SECTION
SECTION INCHARGE:- Mr. Sukhdev Singh
It is one of the most important section of any factory/industry. This section provides rules or
establish rules on which plant works.
THE CO-OPERATIVE MILK PRODUCERS UNION EMPLOYEES SERVICE RULES, 1996
1) These rules shall be called “The Co-operative Milk Producers Union Employees
Service Rules, 1996.
2) These rules shall be applicable to all employees of the co-operative Milk producers
Union Ltd., except those who are covered by the Milkfed common Cadre Rules 1980.
3) These rules shall come into force from the date of approval of the Registrar, Co-
operative Societies, Punjab.
PUNISHMENTS FOR MAJOR MISCONDUCTS:-
1. Stoppage of one or more annual grade increment of pay with or without cumulative effect.
2. Recovery of damages or the amount of loss suffered by the establishment of the account of
misconduct of the employee.
3. Demotion to the lower post.
4.Termination of service.
5. Dismissed from the service.
PUNISHMENTS FOR MINOR MISCONDUCTS:-
1. Warning or censure.
2. Making an adverse entry in his service record.
3. Stoppage of one annual grade increment of pay with or without cummulative effect for a
period of six month.
4. Recovery of loss.
5. Recovery from his pay of the whole or part of any loss caused by him.
6. Suspension without pay o subsistence allowance for a period not exceeding 15 days.

65. CONCLUSION
The verka milk plant mohali is divided into two dairies. One is old dairy and second is new
dairy. In old dairy the production operations are doing manually as well as by machinery so it
is also called semi- automatic dairy. In new dairy all the operations are done by machines
automatically only sampling is taking manually. Due to automation of new dairy the quality of
our milk is improved and losses due to poor quality milk is reduced. Due to automation the
manpower cost is also reduced. The production is also increase because it consumes less time
to carryout the operations.
during my training at VERKA MILK PLANT, Mohali I concluded that the fluid milk products
manufactured here are of high quality and are highly acceptable to the consumer. The
management is dedicated to manage the affairs correctly and accurately. There is proper
coordination among the workers and management, which helps the plant to run smoothly. The
behavior of all workers and technical staff and official staff is appreciable.
In recent times plant has increased its earning and improved its position by creating innovative
approaches. Milk reception is computerized to eliminated weight variation and % of fat and
SNF variation so that producer can get correct amount of payment. Milko-scan is provided by
plant to its BMC’s and chilling centers for accurate fat and SNF measurements.
However there is scope for further improvement of marketing strategies. Market should be
made strong enough to cater more area within country and abroad. The plant should also use
the whey to produce the whey drinks.
There is a effluent treatment plant in which the water used for cleaning the equipments and
tankers is treated before being discharged in sewages.
As a trainee, it should be confessed that it is appropriate place conducting complete, practical
based training.I understand all the working of the plant and the department and the
interconnection between them. I felt very honored and privileged on doing my training for
such a reputed firm Verka Milk Plant, Mohali (Punjab).