Report

on
Agro-Industrial Attachment
(AGR-407)
SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT
FOR THE DEGREE OF
BACHELOR OF SCIENCE (HONS.) IN AGRICULTURE

Submitted by
Name: Khushi Agrawal
Registration Number:11901506

Under supervision of
Dr. Abhilash Singh Maurya

School of Agriculture, Lovely Professional

University,Phagwara-144401, Punjab,
India
2022
1
 DECLARATION

I hereby declare that the report presented herein is an authentic

record of my work carried out under Agro- Industrial Attachment at
Saras Milk Processing Plant, Jaipur as requirement for the degree
of Bachelor of Science (Hons.) in Agriculture and no part of this has
been copied from any other sources.

Khushi Agrawal
(Registration No.11901506)

For Agro-Industry

Official Name: Ankit Kumar

Designation : PR Cell

2
 ACKNOWLEDGEMENT
The training opportunity I had with Saras Milk Processing Plant 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 though
this training period.

I express my deepest thanks to Ankit Kumar for taking part in useful

decision & giving necessary advices and guidance and arranged all
facilities to make life easier. I choose this moment to acknowledge his/her
contribution gratefully.

It is my radiant sentiment to place on record my best regards, deepest

sense of gratitude to Mr. Rajendar Prasad Jangir( Milk processing),Mr.
Bhagchand Gurjar(Ghee and butter processing),Mr Tejpal Choudhary
(Milk packaging), Mr Rajendar(Buttermilk production), Mr. Laxman Lal
Jaat(Buttermilk packaging) , Shweta(Quality control) ,Mr. Vikas Sharma
( Engineering), Mr. Kamlesh Verma(ETP )for their careful and precious
guidance which were extremely valuable for my study both theoretically
and practically.

Last but not the least I would like to express my deepest thanks to Dr.
Abhilash Singh Maurya and Dr.Homraj Anandrao Sahare whose,
stimulating suggestions and encouragement helped me in all time of
fabrication process and in writing in this report .

I perceive as this opportunity as a big milestone in my career

development. I will strive to use gained skills and knowledge in the best
possible way, and I will continue to work on their improvement, in order
to attain desired career objectives.

Khushi Agrawal
11901506

3
 TABLE OF CONTENTS

Chapter No. Contents Page number

1 Introduction 5-10

2 Nature of attachment 11

3 Process outline 12-69

4 Observations 70-72

5 Certificate 73

4
 Introduction
Agro-Industrial Attachment

During Agro-industrial attachment the students involve themselves in

the activities and tasks for 3 Weeks duration viz. acquaintance with
industry and staff, study of structure, functioning, objective and
mandates of the industry, study of various processing units and hands-on
trainings under supervision of industry staff, ethics of industry,
employment generated by the industry, contribution of the industry
promoting environment, learning business network
including outlets of the industry, skill development in all crucial tasks of
the industry, documentation of the activities and task performed by the
students.

5
 SARAS DAIRY PLANT, JAIPUR, RAJASTHAN

JAIPUR DAIRY is also known as Jaipur Zila Dugdh Utpadak Sahakari Sangh
Ltd. It is situated near Gandhi Nagar Railway Station, Jaipur. It is fully
equipped with modern fluid milk plants facilities. It is a state level apex
cooperative organization. The federation has a 15 Board of directors develops
village milk cooperative network.

➢ Aims of dairy co-operative societies:-

• Democratically elected board of DCS, milk unions & Federation from
among their members.
• Adoption of such bye laws which ensure democratic process on the
principles of cooperation.
• Management & ownership of assets by the cooperatives.
• Autonomy in pricing, marketing &appointment of personnel.
• Employment of professional.
• Total control of the organization is in the hands of its members

HISTORY-
The federation has chief executive designed as managing director. It was
registered in March 1975 at Jalmahal in Jaipur under Cooperative Act 1965 to
work in then Jaipur District. In June 1981 it was shifted to JLN Marg, Malviya
Nagar.
Registration Date 22nd March 1975

Aseptic Packing Station (APS) was established in April 1984.

There are 21 plants of Saras in all over Raj Towards fulfillment of the national
objective of making India self-sufficient in milk production. Initially this union
did not have the processing facilities. It started with a modest beginning of
procuring 250 liters of milk per day.

The initial handling capacity of the dairy plant was 1.5 Lakh Lt. per day with a
powder plant of 10 MT per day capacity, which was commissioned in the year
1981 under Operation Flood Program 1 by National Dairy Development Board
for service of thousands of rural farmers families of Jaipur.

Over the years, there has not been looking back for Jaipur Dairy and the 6
significant growth has been made in all fields i.e. procurement, processing and
production of various milk and milk products and marketing thereof under the
brand name of SARAS.

The plant is managed and operated by well-qualified, competent and

experienced managerial cadre and highly motivated work force to provide
highest quality of products and best of the services to our esteemed
customers.

To further improve the efficiency and effectiveness of the plant performance,

Jaipur Dairy (Jaipur Zila Dugdh Utpadak Sahakari Sangh Ltd., Jaipur) had
earlier obtained the Quality Management Systems Certification as per ISO
9002:1994 in combination with IS: 15000 (HACCP) in the year 2000. Now the
dairy has upgraded the system in accordance with ISO: 9001: 2000 in
combination with (HACCP) as per IS: 15000: 1998.

Jaipur milk Union is having a very large network of about 700 Bulk Milk
Coolers at 2500 DCS.

SARAS dairy installed new plant with capacity of 10 lakh liters per day in 2018-19

➢ MISSION-”SARAS Dairy’s heritage is intrinsically linked to the cooperative

movement in India. With determination & pride we will continue to serve
our farmers, rural India & our customers.

➢ VISION- “Vision- Provide quality food and beverage to consumers at

affordable prices while ensuring fair returns to their producers”

➢ Key activities of the dairy-

• Organisation of dairy cooperative societies(DCS) at village level &
Procurement of milk through net works of DCS
• Processing , Manufacturing, Marketing of milk & milk products under the
brand name of “ SARAS”.
• Providing technical input facilities to milk producers .
• Animal health care – First Aid, Vaccination camps, Deworming
• Animal Breeding – Artificial insemination
• Balance cattle feed , feed supplement , fodder seeds
• Social security scheme i.e SARAS SURAKHSHA KAWACH
• SARAS SAMUHIK AROGYA BIMA YOJNA
• Clean milk production- Bulk milk coolers

➢ VARIOUS PRODUCTS OF SARAS:

The core product of Saras is milk. Rests of the products are co-products
obtained from milk. The dairy has a wastage treatment plant which helps in
reusing the waste milk in making the cattle feed 7
 Fresh Milk Long Shelf Life Milk Cattle Feed
Products Products
Chaach,Lassi,Dahi, Ghee,Cow Ghee Balanced Feed,High
Paneer,Shrikhand Table Butter,White Energy,Mineral
Ice cream,Rasgulla Butter,Cheese,Dairy Mixture,Calf Starter,
Flavored Milk,Mawa Whitener,SMP,WMP Urea Molasses Brick

➢ Milk processing plant-

The production process in the Jaipur dairy plant goes as follows:- In the
beginning, the milk is collected from the milk producers and is brought in the
dairy. Once the raw milk reaches the plant the production starts in the
following manner:
Raw milk

Chilling

Pasteurization

Chilling

Separating

Packing
Pasteurization is the process of heating the milk at 161F to kill the
microorganisms present in the milk, which may cause disease and the
Separating is the process where the milk is separated into different categories
based on the amount of fat in it.

The four variants of milk are:-

Milk type Fat content

Double Toned Milk (Smart) 1.5%

Toned Milk (Taaza) 3%

Standard Milk (Shakti) 4.5%

8
Full Cream Milk (Gold) 6%
➢ Marketing Strategy
Jaipur Dairy sells its milk & milk products through a network of over 5327 retail
outlets spread over Jaipur city and near by 100 towns where supply of liquid
milk is made twice a day. Retail outlets consist of a network of a mix of own,
shop agencies, various institutions and Saras Milk Parlours. These days they are
also selling their products through -Reliance Fresh, Metro, Easy day, Hyper
City, Big Bazar, D Mart
• As an consumers’ incentive and sale promotion many schemes like
‘Double Dhamaka’, ‘Triple Dhamaka’,Saras Dhoom, ‘Home Delivery
Schemes’ etc have been launched.
• Jaipur Dairy has also started marketing ghee in rural area through dairy
cooperative societies. They are selling about selling over 85 MT per month
of ghee through DCSs.

➢ Company value
According to the report, the Rajasthan dairy market reached a value of INR 852
Billion . Looking forward, the market is expected to grow at a
CAGR(Compound annual growth rate )of 14.7% during 2021-2026.

➢ SWOT ANALYSIS
1. Strength :
• Recognized brand name among all over the state.
• Quality control certification implied.
• Plant is ISO and HACCP certified.
• Strong distribution network.
• Wide range of products.
2. Weakness:
• No specialized training imparted to workers.
• Work assigned on contract basis.
• Low availability of raw milk.
• Reduced supply of milk in summers.
3. Opportunities:
• Milk is an essential commodity, which is consumed by almost all the
people.
• They deal in wide range of milk products.
• Covers the major market of Rajasthan.
• Popular brand name among the people.
4. Threats:
• Entry of competitors in the market.
• Meet the demand during the summers, as milk can be produced not
manufactured

9
 PRESENT STATUS OF PLANT

State RAJASTHAN

District JAIPUR
SARAS JAIPUR Dairy, NEAR GANDHINAGAE
Address
RAILWAY STATION JAIPUR-302015
Standardised Milk, Full Cream Milk, Double Toned
Milk, Toned Milk, Skimmed Milk, Ghee, Butter, plain
Lassi, aseptic packing, Paneer, Dahi, Lassi ( Sweet
Product Profile
and Spiced), WhiteButter , Powder(SMP),
shrikhand, flavoured
milk
Product Brand Name SARAS
The Jaipur zila District Co-operative Milk
Marketed By Producers Union Ltd.,
SARAS Milk Plant, (Jaipur) – 302015(RJ).
Milk Handling Capacity
15 Lakh litres
Average quantity of milk
13 lakhs liters//day (flush season)
procured per day
8.5 lakhs liters/day (lean season)

Powder Plant 15 MT/Day

capacity
Number of societies
under milk union
2500
Total BMC’s under milk
union 700

Farmers 80584

Farmer women 89075

Owned:- DAUSHA, KOTHPUTLI
Private:-DUDU, CHAKSHU, KALADERA, SAHAPURA
Milk Chilling Centers
ALL MCC are closed now.

Milk Shed area Jaipur and Dausa district

Chairman Om Prakash Punia 10
 Nature of Attachment
On the first day of my 21 days attachment at SARAS Dairy, I was given a
schedule covering different units the dairy , I was then trained according to the
schedule provided.
SCHEDULE
S.No Section Date

1 Process 27 Oct-30 Oct

2 Ghee-Butter 31 Oct - 1 Nov

3 Milk and Chhach Packing 2 Nov- 6 Nov

4 Quality control 7 Nov-13 Nov

5 Engineering & ETP 14 Nov-15 Nov

6 Report writing 16 Nov

1.Process= Learned about the processing of milk

2. Ghee – Butter= Learned about how the ghee and butter and produced in
the dairy.
4. Milk and Chhach packing = Learned about the process, machine ,
parameters for packing.
5. Quality control= Learned about the test performed to maintain the quality
of products produced in dairy.
6. Engineering& ETP= Learned about the boiler system, refrigeration, water
treatment plant , air compressor , electrical section and Effluent treatment
plant .

11
 Process outline
PROCUREMENT SECTION
The model of successful ANAND PATTERN dairy is followed in SARAS Jaipur Dairy.
Maximizing farmer profit and productivity through cooperative effort is the hallmark
of this Pattern.
The Anand Pattern is an integrated cooperative structure that procures, processes
and markets the produce. Supported by professional management, producers
decide their own business policies, adopt modern production and marketing
techniques and receive services that they can individually neither afford nor
manage.
Anand Pattern cooperatives have progressively, linked producers directly with
consumers.

• Village Society:-
An Anand Pattern village dairy cooperative society (DCS) is formed by milk
producers. Any producer can become a DCS member by buying a share and
committing to sell milk only to the society. Each DCS has a milk collection centre
where members pour milk every day. Each member's milk is tested for quality with
payments based on the percentage of fat and SNF. At the end of each year, a portion
of the DCS profits is used to pay each member a patronage bonus based on the
quantity of milk poured.

• The District Union:-

A District Cooperative Milk Producers' Union like The JAIPUR ZILA DUGDH
UTPADAK SHKARI SANGH LTD. is owned by dairy cooperative societies. The Union
buys all the societies' milk, then processes and markets fluid milk and products.
Union also provide a range of inputs and services to DCSs and their members: feed,
veterinary care, artificial insemination to sustain the growth of milk production and
the cooperatives' business. Union staff train and provide consulting services to
support DCS leaders and staff.

• The State Federation:-

The cooperative milk producer's unions in a state form, a State Federation like The
Rajasthan State Cooperative Milk Producer’s Federation Limited (RCDF) ,which is
responsible for marketing the fluid milk and products of member unions.

12
Milk is assembled from various local vendors by “VILLAGE SAMEYTI(Cooperative)”
From their it goes to BMC(Bulk Milk Cooling Centre) who collect milk from many
villages in cans of about 40 L capacity and then cool the procured milk to increase its
shelf life and to avoid bacterial growth. The temp of normal milk is 30-40C , it is
reduced to BMC to 7-9C depending on the unit capacity. After cooling they store the
milk in insulation tank( Have thermocol insulation to avoid outside heat) where
temperature of cooled milk is maintained .
➢ BMC RECEPTION:-

MILK RECIVING FROM INDIVIDUAL OR DCS

FILTER THROUGH MUSCLIN CLOTH

SAMPLE TESTING OF MILK (OK) RECORD ARRIVAL

BMC OPEN MAN HOLE

SWITCH ON BMC AGITATOR CONNECT HOSE PIPE

RECORD TEMPERATURE AND QUANTITY SWITCH ON PUMP

LOADING MILK IN TANKER

MONITER MILK LEVEL AND CLOSE PUMP

CLOSE TANKER VALVE

RECORD DISPATCH TIME

Record the milk temperature and KM reading when dispatch from BMC.

➢ Tests performed in BMC and MCC

1.Organoleptic tests
2.Temperature
3.Fat % (For individual producers of village by Lacto scan; for societies by Gerber
method)
4.SNF % (For individual producers of village by Lacto scan; for societies by Lactometer
reading)
5.Tests for adulterants using Lacto scan in Milk Chilling Centres.

➢ Activities carried out by milk procurement section:-

1. Milk Procurement
i. To encourage the milk producers to join dairy co-operative society.
ii. To guide working aspect of dairy co-operative society. 13
iii. To supervise the activity of milk collection from starting to dispatch.
2. Feed and Fodder
3. Animal Health care and input breeding
4. Training and Extension
a. To enhance milk procurement.
b. To impart training to D.C.S. secretaries
c. Village level extension
d. To bring socio-economic up liftmen of milk producers

➢ Facilities provided to milk producers:

1. Kissan dugdh swavalamban yojana
2. Milk producer insurance
3. Animal insurance
4. Medical facility up to 2 lakh cashless/family
5. Emergency services at farmer door step
6. Deworming facility
7. Free veterinary services
8. Cattle feed supply
9. Cattle feed mineral mixture
10Protein bypass at reasonable rates
11. Artificial insemination provided at lower rates for improvement in breeds

Pricing policy of milk procurement:-

On fat basis:- 750 Rs/kg fat + 2Rs/litres + 3 Rs/litres (from govt. )

14
 Raw milk reception dock (RMRD)

As the quality of raw milk is the most important controlling factor for production of
quality products, separate specially designed dock is built for operation of reception.

The Raw Milk Reception Dock (RMRD) is the primary intake point of liquid milk entry
in dairies/chilling centres. It is specifically meant for the reception of milk brought in
tankers from village BMC’S located over a wide area.
The collection process starts from the village milk collection centres, groups of which
are assigned to distinct milk truck routes.

➢ Type of milk received-1. Cow milk 2. Buffalo milk 3.Mixed milk

➢ Time of milk reception:-

Flush season: Morning 8:00 am-1:00 pm, Evening 8:00 pm-11:30 pm
Lean season: Morning 8:00 am-12:00 pm,Evening 8:00 pm-11:00 pm.

Jaipur Dairy has two 60MT weigh bridge for taking the incoming milk tanker gross
weight, tare weight, along with IDMC installed three automated reception line for
Jaipur dairy having capacity of 40KLPH.it means total reception capacity of dairy
plant is 40×3 KLPH = 120 KLPH.
Particular Number Capacity

Raw milk silo 3 150 KL

Pasteurized milk silo 5 150 KL

Reception is done by following way:

1.Firstly incoming tanker will be weighed on the weighbridge. Based on it, tanker id,
receipt will be generated with vendor details tanker no, date, time etc.

2.Before starting the milk reception, quality control lab will take the sample of the
milk from the tanker at sample dock and check the quality (fat, SNF, acidity etc)
,After satisfactory lab result lab will clear QC of the tanker for reception.
3.Milk will be unloaded in the tanker reception bay area. Generally tanker unloaded
done by local HMI(Human-Machine Interface) operator of the reception.
4.To start unloading of the first tanker to the respective RMST, HMI operator
communicates with SCADA(Supervisory Control and Data Acquisition)operator. Then
SCADA operator will open transfer popup from the reception screen and select the
RMST for reception after ensuring that all interlocks related to reception( destination,
15
transfer) are healthy as well as all precondition( like soft water pressure, chilled water
pressure , temperature etc)
5.If all the condition related to reception healthy, start button of the reception will be
accessible to the local HMI operator. After clicking the start button of the job, the
drain valve (corresponding with that line) of RMST valve battery will open and
followed by preceding valves of the transfer pump, then the pump will start with
reference of deaerator high level switch. The milk then flows through a sieve which
remove particle upto 1mm size and then passes through flowmeter which indicate
the amount of liquid moving through a pipe.
Tank reception site

Flow Meter
Deaerator

Pipe
attached to Pump
tank
Milk reception area

6.Product (Milk) PUSH will start (as pipe is fully filled with water) towards the RMST
drain valve (which is already in open condition) for a particular set time or set
quantity and of water in the line will be drained out.
7.When product push will gained the set timer or set quantity (pump and related
equipment will consider the first achieved running timer or transfer quantity),
transfer pump will stop for 5 seconds and the drain valve will close, at that time
destination RMST valves will open.
8.Then transfer pump will again start as a result product (milk) will go to the
destination (selected RMST) safely without any mixing of water with milk. After
emptying the tank, operator will start tanker flush for 15sec.
9.After finishing of the total reception, one operator will connect the hosepipe with
the soft water line through flow plate (proximity should give healthy signal) to give
water push in the line. Control room operator will select water push in the reception
pop-up followed by clicking start button.
10.After clicking the start button, transfer pump will start till dearator low level
becomes dry then soft water supply valve (preceding flow plate) will open and again
transfer pump will start with the reference of dearator low level switch as a result
water moves forward in the line and pushing the product (milk) remaining in the line
for a particular set time or set quantity till the remaining portion of milk enters into
the destination RMST.
11.When the water push will gained the set timer or set quantity, transfer pump will
stop and water supply valve will close and the dearator air release valve will open
followed by drain valve of that line opens for 20 second.
12.Once the tanker is empty it will processed to the tanker CIP bay for cleaning. Hose
will be fitted from tanker outlet to CIP return. Operator will ensure that all interlocks
related to tanker CIP are healthy and then start CIP.
16
(Noted, Jaipur Dairy generally not does tanker CIP-Clean in Place)
Tanker receiving process
Incoming tanker weight

Sampling plate-form
(2 samples of 200 ml each taken)

Lab testing for quality clearance

Visual check of critical equipment clearance

Tanker positioning

Hose fitting

Checking of all manual valve at proper position

Checking all the equipment and transfer interlock

Control room operator acknowledges the pup-up on, select the RMST from reception
and start the job by clicking the start button

Unloading tanker weighing and washing

Deareator

Transfer pump

Raw milk chillier (4ºC)-cold-water supply line

Raw milk storage tank(RMST)

When milk tanker is out its cleaning is done. When tanker empty its weight is taken
and note down to calculate weight received from tanker.
Cleaning is done in old plant cleaning station. Where water, caustic, water cleaning is
done.

Valves
Deaerator
Pump

Sieve
RMST
Tanker ID
17
EQUIPMENT LIST IN: RECEPTION AND RMST-
EQUIPMENT TYPE MAKE QTY CAPACITY
DEARATOR - IDMC 3 200 LTR
PIPE IN PIPE - IDMC 3 40 KLPH
STRAINER
PUMP(RECEPTION) CENTRIFUGAL FRISTAM 3 40KLPH
CHILLER PHE IDMC 3 40KLPH
RMST(SILO) - IDMC 3 1.5 LAKH LTR
PUMP ( RMST-MPL) CENTRIFUGAL FRISTAM 3 30KLPH
PUMP( RMST INTER CENTRIFUGAL FRISTAM 1 30KLPH
SILO/DISPATCH)
CIP RETURN SELF PRIMIMG IDMC 1 20KLPH

TRANSFER LINE IN RMST:-

1.RECEPTION 1 (RECEPTION 1 TO RMST 1/2/3)
2.RECEPTION 2 (RECEPTION 2 TO RMST 1/2/3)
3.RECEPTION 3 (RECEPTION 3 TO RMST 1/2/3)
4.MPL 1 (RMST 1/2/3 TO MPL1)-Milk pasteurization line
5.MPL2 (RMST 1/2/3 TO MPL2)
6.MPL3 (RMST 1/2/3 TO MPL3)
7.RMST INTERSILO
8.RMST DISPATCH
9.RINSE MILK TANK TO RMST (RNSM 1/2 TO RMST 1/2/3)
10.BUTTER MILK TANK TO RMST (BMT TO RMST 1/2/3)

18
 MILK PROCESSING

• Jaipur Dairy has 3 milk processing line having capacity of 30KLPH.

• It is used to make standardized milk ready for consumption.
• Each MPL consist of a self-cleaning cream separator of 30KLPH capacity used to
separate cream and skim milk.
• And for standardization purpose there is an ALFAST for each line.
• Milk is pasteurized at 80C in dairy but standard pasteurization temperature for
milk is 72.8 as at this temperature Mycobacterium tuberculosis (TB causing )
killed.

Operational sequence of Milk pasteurization line:-

1.Before starting any operation, operator should take a visit to the field to ensure all
valve and critical equipment in proper condition.
2.Then he ensured that all the valve, pump etc in programmable mode.
3.The operator will first open the respective MPL screen and its pop-up window.
4.Then, will start water recirculation mode.
5.When all the set points will be achieved, production mode will be accessible to the
operator and operator will select source, destination and transfer quantity as
required for production.(QC should be cleared before selecting the destination tank
as well CIP should be done before, for the operating transfer line)
6.Then operator will start the production by clicking start button.
7.Product push will start and the drain valve (corresponding with that Milk
Processing Line) of PMST valve battery will open followed by outlet valve of RMST &
valves of RMST valve battery. VFD(variable frequency drive) operated transfer pump
from RMST to MPL will get command to start.
8.Thereafter Product Push timer will start sequentially i.e. RMST outlet to Balance
tank inlet, balance tank emptying, balance tank outlet to cold diversion, cold
diversion to PMST .During balance tank emptying the VFD operated feed pump of
MPL and booster pump will get command to start.
9.After transfer quantity achieved, transfer pump of RMST will stop and process will
goes on product recirculation mode.
10.Now operator can do water push by selecting water push confirmation. Thereafter
water push start can accessible if transfer valve and line is healthy.
11.Thereafter water Push timer will start sequentially i.e. RMST outlet to Balance tank
inlet, balance tank emptying, balance tank outlet to cold diversion, cold diversion to
PMST and finally water push to drain.
12. The operator may again start production for different product or may start CIP.
19
 PROCESS FLOW CHART

Balance tank

Feed pump
CREAM BUFFER TANK
Duplex filter

Hydro cyclone CREAM

Regeneration 2
Separator CREAM CHILLER
Heating 2

Cream separator

ALFAST

Regenerating 1

Booster pump
Sludge holder
Heating
auto standardization
unit
Holding tubes

Flow diversion valve BALANCE TANK

Regenerating 1

Regeneration 2

Chilling

PMST (pasteurized milk storage tank )

MILK INLET TEMPERATURE: - 4ºC

TEMPERATURE AFTER REGENERATION 2:- 53ºC
AFTER HEATING 2:- - 55ºC
AFTER REGENERATIN 1:- 74ºC
AFTER HOLDING:- - 80ºC 20
AFTER CHILLING:- - 3ºC
Flowmeter

Tank
2 strainers
PID
2 Pump

Milk heat
transfer
Hydro cyclone with milk

Milk heated for

pasteurization
with
water

Equipment's in MPL

EQUIPMENTS TYPE MAKE QTY CAPACITY

BALANCE - IDMC 3 400 LTR
TANK
FEED PUMP CENTRIFUGAL FRISTAM 3 35 KLPH
BOOSTER PUMP CENTRIFUGAL FRISTAM 3 30 KLPH
PASTEURIZER PHE IDMC 3 30 KLPH
CREAM PHE IDMC 3 6 KLPH
CHILLER
WATER PHE IDMC 3 40 KLPH
HEATER
CREAM CENTRIFUGAL TETRA PACK 3 30 KLPH
SEPARATOR
SLUDGE - IDMC 3 100 LTR
BALANCE
TANK
SLUDGE CENTRIFUGAL FRISTAM 3 1 KLPH
TRANSFER
PUMP
SLUDGE - IDMC 1 500 LTR
COLLECTION
TANK
SLUDGE CENTRIFUGAL FRISTASM 1 5 KLPH
TRANSFER
PUMP TO DSI
21
Pumps in PMST line:-
1 CIP return pump: - 20 KLPH
2 P.M. dispatch pump: - 30 KLPH
3 Interchange silo: - 30 KLPH
4 PMST TO HMST: - 40KLPH
5 PMST to butter milk: - 30KLPH
Pasteurized milk transfer pump
HORIZONTAL MILK STORAGE TANK: - (6 HMST×15KL)
1.To fill the final standardized milk to the respective HMST operator will first open
transfer pop up from PMST/HMST.
2.Then select the respective transfer line (PMST L1 OR L2) and select the respective
PMST and HMST as source and destination. If all the transfer related interlocks is
healthy start button will be accessible and operator can start the job.
3.As the operator starts transfer process product push will start and the water in the
line will be drained at the drain valve in the HMST valve battery when the
timer/quantity will be achieved, milk will start to fill into the HMST.
4.After transfer of set quantity the operator may give water push to the line thus the
water coming from behind will push milk into the HMST for the set time/quantity.
5.Once the HMST is filled with milk, it can be transferred to either of packing lines or
leaky pouch tank by gravity.

RCM PROCESSING

•Reconstitution of milk means dissolving milk powder in water.

•Reconstituted milk is needed to balance SNF percentage in pasteurized milk to the
legal standard.
•Jaipur dairy has one RCM line to make reconstitute milk. They use skim milk powder
to make reconstitute milk with higher total solid content

SEQUENCE OF OPERATION:-
1.To prepare reconstituted milk, the operator need to decide the total solid content of
the reconstituted milk according to which RO water should be filled in one of the
RCM tank as require for the batch.
2.To start whole process an operator will open the RCM screen on the SCADA. Then
he will open the popup of RCM filling and after that he will select one RCM tank out
of two and set the amount of water to be taken in this tank.
3.Now to start the blending through 2 TPH turbo blender he will open the popup of
the preparation line and will make proper selection of source & destination tank
(source and destination both may be same tank), and will select the blending and
finally click start button to start the blending.
4.RCM tank outlet valve will open, preceding valve of the turbo blender will open,
then the recirculation pump will start, sequentially turbo blender will start and milk
powder will be poured in the blender hopper.
5.Blended product pushes the remaining water towards the drain valve for a
22
particular set timer/quantity. After completion of product push timer/quantity, drain
valve will close and product enters into the selected destination tank.
6.After finishing of blending, water push will be given to the system by clicking check
box of water push and then click start button. Water will enter in the line from soft
water valve of RCM valve battery.
7.Water pushes the product in the line to the selected product tank up to a set
time/quantity. After completion of set timer/quantity, the drain valve will be open
automatically for a particular set time/quantity to complete the water push to drain
step.
8.Before dosing Reconstituted milk in MPL balance tank, chilling of the milk is
essential, to chill the milk operator will select source and destination afterward he
will enable the chilling loop to bring down the temperature down to about
9.During chilling source tank outlet valve, drain valve will open and then recirculation
pump will start for product push.
10. When the product push will complete milk will enter to the destination tank and
circulation of milk will continue, finally the operator will give water push to the line

EQUIPMENT IN RCM PROCESSING

EQUIPMENT TYPE MAKE QTY CAPACITY
RECONSTITUTION - IDMC 2 15 KL
MILK TANK
RCM CENTRIFUGAL FRISTAM 1 20 KLPH
RECIRCULATION
PUMP
DUPLEX FILTER - IDMC 1 20 KLPH
RCM CHILLER PHE IDMC 1 20 KLPH
RCM HEATER PHE IDMC 1 20 KLPH
RCM TRANSFER CENTRIFUGAL FRISTAM 1 20 KLPH
PUMP TO MPL

CIP RETURN SELF PRIMING IDMC 1 20KLPH

PUMP

RECONSTITIED MILK FLOW CHART:-

Skim milk powder +water (calculated amount) Reconstitution tank

Pump

Balance tank

Pump (15KLPH)

Strainer

Pasteurization (80ºC/ 15sec.) (15 KLPH)

Cooling (4-5ºc)
23
Storage tank (30kL)
 CREAM PROCESSING LINE (CPL)

•The Cream which is separated in cream separator passes through cream chillier
where it is chilled by raw milk which is coming from pasteurizer milk balance tank.
•The chilled cream is stored in the cream buffer tank, from where it will go to the
cream pasteurizer and then stored in cream storage tank (CST).
•From CST it is transferred to MPL balance tank or transferred to Cream balance tank
of CBMM as per their required.

SEQUENCE OF OPERATION IN CPL

1.Before starting any operation, operator should take a visit to the field to ensure all
valve and critical equipment in proper condition.
2.Then he ensured that all the valve, pump etc in programmable mode.
3.The operator will first open the respective CPL screen and its pop-up window.
4.Then, will process with water recirculation mode.
5.When all the set points will be achieved, production mode will be accessible to the
operator and operator will select source, destination and transfer quantity as
required for production.(QC should be cleared before selecting the destination tank
as well CIP should be for the operating transfer line)
6.Then operator will start the production by clicking Forward button.
7.Product push will start and the drain valve (corresponding with that Milk
Processing Line) of CST valve battery will open followed by outlet valve of cream
buffer tank (CBT) & valves of CBT valve battery. VFD operated transfer pump from
CBT to CPL will get command to start.
8.Thereafter Product Push timer will start sequentially i.e. CBT outlet to Balance tank
inlet, balance tank emptying, balance tank outlet to cold diversion, cold diversion to
CST .During balance tank emptying the VFD operated feed pump of CPL will get
command to start.
9.After transfer quantity achieved, transfer pump will stop and process will goes on
product recirculation mode.
10.Now operator can do water push by selecting water push confirmation. Thereafter
water push start can accessible if transfer valve and line is healthy.
11.Thereafter water Push timer will start sequentially i.e. CBT outlet to Balance tank
inlet, balance tank emptying, balance tank outlet to cold diversion, cold diversion to
CST and finally water push to drain.
12.The operator may again start production for different product or may start CIP.

PROCESS FLOW CHART

Cream buffer tank Cream balance tank Screw pump Regeneration

Heating
IN CREAM PASTURIZATION NO HODING BECAUSE FLASH TIME HIGH TEMPERATURE
CREAM INLET TEMP. = 18ºC Chilling
TEMP. AFTER REG. = 81ºC
HEATING = 90ºC 24
CHILLING = 8ºC Cream storage tank
In CPL screw pump used to prevent churning in pumps.
EQUIPMENT IN CREAM PROCESSING
EQUIPMENT TYPE MAKE NO CAPACITY
CREAM - IDMC 2 3 KL
BUFFER
TANK
CREAM SACREW ROTO 2 5 KLPH
TRANSFER
PUMP
CIP RETURN SELF PRIMING IDMC 1 10 KLPH
BALANCE - IDMC 2 250 LTR
TANK
FEED PUMP SCREW ROTO 2 5 KLPH
CIP SUPPLY CENTRIFUGAL FRISTAM 2 7.5 KLPH
PUMP
CREAM PHE IDMC 2 5 KLPH
PASTEURIZE
WATER PHE IDMC 2 10 KLPH
HEATER
CST - IDMC 3 20 KL
CST TO SCREW ROTO 2 5 KLPH
CBMM AND
MPL By
PUMP
CIP RETURN SELF PRIMING IDMC 1 20 KLPH
PUMP

25
 PASTEURIZED MILK DISPATCH (TO OTHER MILK UNIONS)

JAIPUR dairy has 30KLPH Pasteurized milk dispatch line and dispatch an average
amount of 16000 liter of pasteurized milk per day by the road tanker through the 30
KLPH PM Dispatch line. with pasteurized milk dispatch SARAS dairy also dispatch
raw milk with 30 KLPH.

FLOW OF DISPATCH

Empty washed tanker on weighing balance

Arrival on dispatch dock (before filling check internal cleaning of tanker)

Connect hose pipe to tanker

In control room fill dispatch quantity and start

PMST

Transfer pump

PM dispatch chillier

Sample test if ok than transfer

Weighing bridge (final weight)

26
 CIP SECTION
As it’s an automatic plant and so, it becomes more vital to ensure the cleaning of all
equipment's, tanks, pipelines and all related components in less time without
dismantling the parts which are in direct contact with the milk and the product.

PIPE LINE CIP

S no Procedure Time
1 Pre rinse with tap water 7 – 10 Min
2 Caustic circulation 7 – 10 Min
3 Hot water circulation 7 – 10 Min
4 Acid circulation 7 – 10 Min
5 Tap water 7 – 10 Min
6 Caustic circulation 7 – 10 Min
7 Hot water sterilization 7 – 10 Min

STORAGE TANK CIP:-

Procedure Temperature Strength Time
Pre rinse with tap 40 – 420C 2 Min
water
Hot water
flashing 70 –720C 2 Min
Caustic circulation 70 –720C 2% 2 Min
Hot water
flashing 70 –720C 2 Min
Water + sanitizer 30 0C 2 Min

PASTEURIZER CIP
Procedure Temperature Strength Time
Pre rinse with tap 40 – 420C 10 Min
water
Acid circulation 55 – 600C 1% 20 Min
Low acid circulation 55 – 600C 0.5% 10 min
Caustic circulation 70 –720C 5% 20 Min
Low caustic 70 –720C 2% 10 Min
Hot water + sanitizer 70 –720C 10 Min

27
 BUTTER & GHEE SECTION

1. Jaipur Dairy used creamery butter method for preparation of ghee. Controlling is
done by the local HMI of the respective section. Firstly Cream is transferred to the
Cream balance tank of the CBMM from CST with a screw pump and it’s done by
SCADA operator.
2. Then CBMM operator switch on the Beater first then after stabilizing the speed
and frequency he starts the kneader and screw conveyer .After that, cream is fed
from the balance tank to the CBMM machine by switching on the transfer pump..
3. From this it is transferred to to molten butter storage tank from HMI.
4. In between there is a tubular heat exchanger and its heat the butter to about 80C.
Then it is transferred to serum separator.
5. After separating the serum, separated molten butter is transferred to ghee boiler
to boil the ghee to about 105 and its takes about 40-50mins for complete boiling.
6. Then it’s transferred to the ghee settling where its kept for about 30 mins and after
settling clarification is done and ghee transferred to the storage tank though a
tubular heat exchanger where it’s cool to around 40.

BUTTER
“Butter may be defined as a fat concentrate which is obtained by churning of cream,
gathering the fat into a compact mass and then working on it.its contains not less
than 80 percent of milk fat.”

There are two type of butter manufactured

1)Plain Butter ( continuous method)

•Production started from 2018- 2019
•Plain butter is manufactured by using CBMM (continuous butter making machine)
from the cream of 38-43 % fat
•Yield of butter is 40%
•Yield of butter milk is 60%
•Removal of butter milk is contain 0.4-0.5 % milk fat and 8.2-8.3 % milk SNF. It's used
for double toned milk (Saras lite) production
•Generally used of plain butter is ghee production and some Kg of plain butter is
packaging in parchment paper with packing in corrugated box for using ghee
production in lean season at 10C in 15kg box.

Cream Butter Ghee

Fat-40% Fat-84% Moisture-Below 0.3%
Temp-10 C Moisture- Less than 16% Fat-99.7%
Acidity- 0.09% Curd-1% Residue-negative
MBR( Methyl Blue ( Total 100 % only , now Acidity-0.3%
Reduction)-4-5 hr , tells us coming 101% because the Moisture + fat=
28
about the goodness for how value adjust accordingly) Always 100%
much time
Flow Diagram for Manufacturing of Plain Butter

Cream (40%) from Cream Storage tank

Cream transfer pump

Hot water tank Heating tube butter milk buffer tank PUMP
CBMM

Hard butter chillier

butter milk tank

Butter tank
TT( temp transmitter)
Butter transfer pump to melting tube
Heat exchanger
Melting tube

Molten butter storage tank

Serum separation serum collection tank

For ghee manufacturing plant

Serum is collected in trolley and in this hot water is

poured so that fat come on top ( not disturbed for 4-5
hrs). After that the fat is recovered, water removed and
in cold pasteurized water is added which causes fat to
clump. This fat can now be processed again

2)Table butter ( IN OLD PLANT)

• Salt + Yellow colour
• Packaging of this done at 5C in 100gm ,500gm packets
• Total production of Table butter is 1.5 – 2.0 tons
EQUIPMENTS FOR BUTTER MAKING
EQUIPMENT TYPE MAKE QTY CAPACITY
CREAM - IDMC 3 500 LTR
BALANCE
TANK
CREAM SCREW ROTO 3 2KLPH
TRANSFER
PUMP TO
CBMM
CBMM - HMT 3 800 KLPH
PWT TANK - IDMC 1 1 KL
CHILLER PHE IDMC 1 5 KLPH
BUTTER MILK - IDMC 1 10 KL
STORAG 29
E
TANK(BMT)
CBMM-( Continuous Butter Making Machine)
WORKING PRINCIPLE
In CBMM has a top from where cream comes . Then it goes for churning ( Done at
1500rpm though RAMPLER. Rampler rotates with the help of shaft which rotates
through belt which rotates through pump.
The rate of churning depends on fat in cream ; that is if more than churning rate less.
40% fat-----1700 to 1800rpm
36% fat--------2200rpm
After churning goes to hopper . Hopper consist of mixture of butter + Butter milk(has
nil or 0.5%fat) (Both are the product of churning process).Then goes to screw
conveyor which is inclined at 45degree angle and rotates the drum system . In
drum system the butter forms clumps Then goes to screw conveyor which is again
reclined at 45-degree angle and here the butter and buttermilk separate, and the
butter comes through the outlet .This all occurs within machine.

GHEE
“Ghee is defined as clarified butter fat without any solid milk particles or water,
prepared cow or buffalo milk or desi (cooking) butter or from cream to which no
colouring matter is added.”

PRODUCTION OF GHEE:-
•old plant ghee started from started
•Production started from 2018- 2019 in new automatic plant.
•Average ghee production is about 15,000 kg/day.
•Installed the Serum Separator between molten butter storage tank and ghee
boiler ( tetra pack )
•Installed the duplex filtration between ghee boiler and ghee settling tank.
•Over all 2 % losses in the form of Ghee residual and handling

Flow Diagram for Manufacturing of Ghee

Molten butter storage tank (80C)

Serum Separator (80 C)(Removal of serum)

Ghee boiler (105 C/1-11/2 Hours)

Ghee balance tank

Duplex filtration (3KLPH) Ghee residual 30

Ghee settling tank
 Molten
Ghee clarifier (90 C) Ghee
boiler
Ghee balance tank

Cooling of ghee (370C) 3KLPH

Serum
Ghee storage tank separator

Packaging (SIKA pouch & tin)

Serum residue
EQUIPMWNTS FOR GHEE PRODUCTION From separator
EQUIPMENT TYPE MAKE NO CAPACITY
MOLTEN - IDMC 1 3 KL
BUTTER
STORAGE
TANK
MOLTEN CENTRIFUGAL FRISTAM 1 3 KLPH
BUTTER
STORAGE
TANK TO
SERUM
SEPARATOR
PUMP
SERUM CENTRIFUGAL TETRA PACK 2 3000 RPM
SEPARATOR
GHEE BOILER - IDMC 3 2 KL
SERUM - IDMC 2 300 LTR
BALANCE
TANK
SERUM CENTRIFUGAL FRISTAM 2 3 KLPH
TRANSFER
PUMP
GHEE - IDMC 1 200 LTR
BALANCE
TANK
DUPLEX - IDMC 2 3 KLPH
FILTER
GHEE - IDMC 3 2 KL
SETTLING
TANK
GHEE CENTRIFUGAL TETRA PACK 2 1500 RPM
CLARIFIER
GHEE - IDMC 2 10 KL
STORAGE CUM
GRANULATION
TANK
CHILLER - IDMC 1 3 KLPH
FAT - IDMC 1 2 KL 31
RECOVERY
VAT
From storage when it goes for packing in between there are 2 filters ( Line
filter- in 3 layers)

Packaging Done in-

1. 15 kg(Tin packing , 12months validity ,More validity as compared to
pouch as the tin has ss coating inside –{Stainless steel})
2. 1L(905gm)(6 month validity)(Pouch packing-Sika packing)
3. 0.5L(452gm) (Pouch packing- Sika packing)
For different size packing different machine is their

Packing unit
1.Pouch packing process= Use Cika packing machine
There is stack of cartoon with aluminium sheet liner, machine takes one by
one cartoon with vacccum holder. Then it open the flaps from one side ,
seals the aluminium liner of one side at 140C. Then machines using fevicol
seals the one end of box outside liner .Then it proceeds to filling system
where it fills 905 gm( 1L) in one pouch , excluding the packet weight of
43gm.Thus combine weight is 948gm.Machine uses Sensor and fixed fixing
meaning it uses sensor to detect the box and fills it by fixing the box. From
here it goes to conveyor as fevicol not dries instantly so this conveyor
applies pressure.
This is further packed in 10 L cartoon . In 1 cartoon =9kg 700gm
Machine can pack upto 15-16 pouch /min

2. Tin packing process=Done in 15 kg tins . There are 2 machines in which

ghee poured in tin by weight and after that capping done. Finally sent to
cold storage.
In min machines packs 2-3 tins .

Coded information
There is a coding room ( MRP, Packing date , Aluminium liner
Lot No written on boxes printed here.)

All the residue, serum is collected in trolley and in this hot water is poured
so that fat come on top ( not disturbed for 4-5 hrs). After that the fat is
recovered, water removed and in cold pasteurized water is added which
causes fat to clump. This fat can now be processed again.

Fat floats on hot32water

Serum residue mixed with hot water to recover fat
After packaging ghee kept for a day to check for leakage at 25C.Then
transferred to Fully general store – That is a single place through which
all product sold(Not milk marketing as they don’t have cold storage and
milk stored at 4-6C).

Revised ghee rate list – From 1.11.2022

Size In RAJ Outside RAJ

15 kg TIN 8820/- 9345/-

5 LTR TIN 2675/- 2850/-

1LTR POUCH 538/- 573/-

½ LTR POUCH 270.5/- 288/-

33
 BUTTER MILK PREPRATION

1. Butter milk is a popular refreshing drink made from the curd or dahi.
2. SARAS plant installed 2 LLPD plain butter milk processing unit for Jaipur Dairy.
3. Jaipur dairy processed buttermilk having fat percentage of greater than 2%.
4. They used pasteurized standardized milk (not less than 4.5% fat and 8.5% SNF) for
curd preparation.
5. Firstly they re-pasteurized standardized milk at 90 for 5 min and cooled the milk
through regeneration to about 11-12 and again there is secondary heating
arrangement to get optimum curd settling temperature of about 40.
6. They add about 0. 5% culture for settling of curd and its take about 3 hours. Then
lab personal check the acidity of the curd if it’s more than 0 .7, operator starts
breaking the curd for about 10 minutes and then starts recirculation to cool the
temperature to about 15.
7. After that they transfer it to the BPT( Buttermilk preparation tank). Where they
add needed pasteurized water to adjust the Fat percentage .Then after proper
mixing, sampling is done to check and finalize fat percentage in Butter milk.
8. After that operator starts recirculation (via chiller) to cool the butter milk to around
5ºc .
9.Then they transfer the butter milk to HBMT for packaging

SEQUENCE OF OPERATION FOR PREPRATION:-

1. Standard milk comes in Curd Milk Silo( 3 in number, capacity=3KL).
2. From here it goes to balance tank via pump.
3. Then it goes pasteurizer unit ( 2 in number, Capacity=10KLPH, one for milk and
the other for water pasteurizer). The milk is pasteurized at 85-88C .
4. From here the milk goes to Chiller (which chills milk at about 40-44C).
5. Then goes to Curd setting tank (4 in number, capacity=10KL). Into this culture
(0.5%) is added . It has a agitator for mixing which works for 5-10min.After 3 hrs
checked for Acidity( should be 0.70)
Then cooled by Chiller till 10-15C .
6. From here goes to Buttermilk preparation tank( 3 in number, capacity=20KL)..In
this 10KL from curd setting tank + 10KL pasteurized water( tempereature-5-6C)
added in 50-50 ratio.
7..Then chilled again to 5C. From here sample goes to lab to check for acidity
(should be 0.38%) , fat(should be more than 2%).
8.. From here buttermilk goes to HORIZONTAL BUTTER MILK STORE TANK on first
floor for packaging(4 in number, capacity=20KL)

34
 PROCESS FLOW CHART:-

CURD MILK SILO

PUMP

CURD MILK PASTURIZER BALANCE TANK

FEED PUMP

STRAINER

PASTURIZER

HOLDING ( 5 min)

COOLING BY REGENERATION IN PASTURIZER

SECONDRY HEATING

CPT

PUMP
CDT

PUMP
DUPLEX FILTER
BPT
CHILLER
PUMP

HBMT (HORIZONTAL BUTTER MILK STORE TANK )

CURD MILK SILO (CMS)
CURD SETTLING TANK (CDT),
CULTURE PREPRATION TANK (CPT) 35
BUTTER MILK PREPRATION TANK(BPT)
MILK PASTURIZER IN BUTTER MILK MAKING SECTION:-

1.Milk inlet temp.=6ºc

2.Temp. After reg. 2=64ºC
3.Temp. After reg. 1=82ºC
4.HEATING=90ºC
5.Temp. Holding=89ºC
6.Temp after chilling=12ºC
7.Temp. Secondary heating = 41ºC

EQUIPMENT LIST CURD SECTION

EQUIPMENT TYPE MAKE NO. CAPACITY
CMS - IDMC 3 30 KL
PHE IDMC 2 10 KLPH
PASTEURIZER
FEED PUMP CENTRIFUGAL FRISTAM 2 10 KLPH

BOOSTER PUMP CENTRIFUGAL FRISTAM 2 10 KLPH

CDT - IDMC 5 10 KL(4) 40
KL(1)
CDT TO BPT CENTRIFUGAL FRISTAM 2 20 KLPH
TRANSFER PUMP
CDT CENTRIFUGAL FRISTAM 1 20 KLPH
RECIRCULATION
PUMP
CPT - IDMC 2 500 LTR
CPT TO CDT PUMP DIAPHRAM WILDEN 2 500 LPH
BPT - IDMC 2 20 KL
BPT TO HBMT CENTRIFUGAL FRISTAM 1 30 KLPH
PUMP
HBMT - IDMC 4 20 KL
CIP RETURN SELF PRIMING IDMC 1 20 KLPH

BPT AND HBMT SECTION:-

1.To fill the finalize Butter milk to the respective HBMT operator will first open transfer
pop up from BPT/HBMT. Then select the respective BPT and HBMT as source and
destination.
2.If all the transfer related interlocks is healthy, start button will be accessible and
operator can start the job.
3.As the operator starts transfer process, product push will start and the water in the
line will be drained at the drain valve in the HBMT valve battery when the
timer/quantity will be achieved, milk will start to fill into the HBMT.
4.After transfer of set quantity the operator may give water push to the line thus the
water coming from behind will push milk into the HBMT for the set time/quantity.
5.Once the HBMT is filled with milk, it can be transferred to either of packing lines 36 or
leaky pouch tank by gravity.
 MIILK AND CHHACH PACKING

MILK PACKING:-
• PACKING section is headed by the Manager, Production and he is assisted by
technical officers, operators and dairyman. Production department is responsible
for-crate washing , Packaging, cold storage
• The vital role of the packaging material is to prevent the post processing
contaminations as well as to create an attractive appeal to the customer &
facilities, the super security of milk flow till the distribution. There is Four type of
packages are used to differentiate four type of milk prepared in Jaipur dairy

Product Name Packing FAT SNF Content Packing

Colour Content
Full cream Gold Red 6.0% 9.0% ½, 1 and 6 liter
milk
Toned milk Taaza Blue 3.0% 8.5% ½, 1 and 6 liter
Double Smart Yellow 1.5% 9.0% ½ liter
toned milk
Standard Shakti Green 4.5% 8.5% ½ and 1 liter
milk
Skim milk Lite Purple 0.5% 8.7% ½ and 1 liter

MILK packing procedure:-

1.There are 16 no’s of packing machines of capacity 5000 PPH arranged in four rows
and in another row has 3no’s of machine having capacity of 720PPH each .
2. To start the job the operator will open the pop-up of HMST/ packaging. Then select
the HMST and packing line from transfer pop up If all parameters are ok then the
start button will be accessible to the operator and he can start the job.
3. The process will start with product push then all overhead balance tank of
packing machine will be filled with milk; then packing can be started. .
4. The pouch thus packed are arrange in crate (12 liters each) and conveyed to the
cold store with the help of a two tier conveyor, the upper tier is used for conveying
empty creates from crate washer and the lower one is used for conveying crates with
milk pouch to cold store.
5. Five no’s of crate washers of capacity 1600 CPH are supplied one for each packing
line, the crates to be cleaned are manually feed and the cleaned crates are conveyed
to packing machines.
6. When crate is fed to crate washer it undergoes three steps of cleaning first rinse,
detergent rinse and finally hot water rinse. Then the cleaned crates are forwarded to
packing machines on conveyor.
7.Then comes the jaw cooling system, its principle work is to ensure that the
temperature of horizontal as well as vertical seal does not exceed the set limit and
thus avoid the leakage. 37
8.The set temperature of jaw cooling is 15 , the whole system contains one 500L
balance tank where the water level is maintains automatically, one 10KLPH re-
circulation pump and one 5 KLPH chiller is there for cooling purposes.
9.There are two leaky pouch tanks (Leaky pouch1 for MPP1, 2 and Leaky pouch2 for
mpp3, 4, 5) for dumping the leaky pouch as well as excess milk from HMST.
10.From leaky pouch tank milk comes to Rinse milk balance tank through strainer,
pump and 3KLPH chiller.
This transfer is automatic on basis of leaky pouch tank high level switch.
Specification pf pre pack section:- Kg=1.068 x L
No of machine 19
No. of head 35
Operating 500ml:- 80 pouch/min –had (high speed
heads)
500ml:-40-45 pouches/min-head
1000ml:-30-35pouches/min-head
6000ml:-9-12 pouches/min-head
Balance tank capacity 40 lt
Height 3.5 Mt

Floor space 1.70 Mt X 0.84 Mt

Pouch/kg film 395 pouch/kg (1/2 ltrs)

245 pouch/kg (1 liters)
Thickness of film 55 µm (1/2 ltr)
Approx 110 µm (1 ltr)
Length of pouch 142-145 mm (1/2ltr)
220 mm (1 ltr )
Sealing temperature Vertical sealing (120-1400C)
Horizontal sealing (120-1400
C)

Crate washing
No 5
Type Continuous
Capacity 1600 CPH
Detergent used Caustic
Rinse water temp 40-450C
Hot water pump 65-700C
Detergent temp Above 600C
Steam pressure Max.4 kg/sq.cm
Alkali used Caustic soda:0.3-0.5%
Cold store
No. 4
MAKE Star Collers & Condensers Pvt. Ltd. 38
Cold Store temp 4-50C
Operating Function
1.Film supplied from back position of the machine.
2.Shaping the film into cylindrical tubes.
3.Vertical sealing on the overlap using a vertical electrode.
4.Injecting & filling the liquid milk into the tubes.
5.Horizontal sealing by horizontal electrodes subsequently cutting to predetermined
length, simultaneous cooling to reduce the temperature increased while sealing by
water. Also UV rays transmitted to remove any microorganisms.
6.Detaching the filling bags

Operating of pouch filling machine

The operating of pouch filling machine consists of:
1.Preliminary check
2.Starting
3.Running in attention
4.Stopping
5.Cleaning

➢ Preliminary check
Before starting the machine the following points be checked
• The rolls of cream are correctly routed & film slide freely on the following plates &
provides suitable overlap.
• All the switches are in OFF position
• The headed milk tank is full of milk & the supply tuned ON.
• Cooling water flow is 1000 lt/hr.
• Check the condition of Teflon cloth, rubber at condition of electrode jaws.
• Lubricate various moving parts of the machine..
• Check filters cloth over injection tube.

➢ Starting
After starting the machine-If sachet is not properly cut, increase the heat gradually
by heat control knob also the quantity of milk injected in the tube can be adjusted to
exact value by mean of volume control fine knob.

➢ Running attention
1.Film role should slide smoothly.
2. Weight of volume of milk should be checked at regular intervals.
3.The length of the pack is also checked from time to time.
4.Before a film roll is finished attach a new one & join it with the old with the adhesive
tape.
5.Check steady flow of milk in header tank.
6.Check the overlapping of the film before the vertical jaws.
7.Check the pouch for the corner creases & if required adjust spreader arm
8. Check the sealing strength of sachet by pressing & by dropping from 1 meter.
39
➢ Stopping
1.Turn the fill knob OFF to stop the milk coming from tank.
2.Switch the horizontal seal to OFF position.
3.Let the film tube be formed into tubular from about a meter.
4.Put the ends of film tubes in an empty can.
5. Stop the main valve of the milk tank.

➢ Cleaning
All the components, which are in direct contact with milk, can be dismantled &
washed manually by hot water or soap solution.
Cleaning parameters
Machine, Balance tank & filling heads Once in a day after operation
cleaning with caustic CIP rinse with cold
water & followed by manual cleaning
Rollers & other parts, which come in Once a day
direction contact with the filling to be
manually cleaned & sterilized with
Methylated spirit, diluted 50:50 with water
UV tube manual cleaning with methylated Once a week
spirit
Disinfect the machine with seal with water Immediate before start up
(0 C for 15 min) then areolation & add
chlorinated water 50ppm

Crate washer

Manual cleaning of nozzles, detergent Once in a day in morning start up

tank, fillers etc.

CHHACH PACKING
In new plant only plain chhach packing in half and one litres pouches.
In ‘LDPE’ pouches.

PACKING PROCEDURE FOR CHHACH

1. There are 8no’s of packing machines of capacity 5000 PPH arranged in two rows. ,
one 3KLPH re-circulation pump and one 3 KLPH chiller
2. To start the job the operator will open the pop-up of HBMT/ packaging. If all
parameters are ok then the start button will be accessible to the operator and he
can start the job.
3. The operator controlling the machine will select the pouch volume (500ml and
1000ml), bag length, and speed, and then will start the pouch packing.
40
4. Starts with Vertical sealing Jaw mechanism which has a element ( Thin/plate
like). This element is supplied 24 voltage which cause temperature rise to 80-85C
thus the high temperature helps in sealing the vertical length of packet. Thus rise in
temperature is responsible for sealing the packet.
5.After been vertically sealed the packet is filled with the packet is fixed by one by
one with milk from balance tank placed above machine . This tank has a ejection
tube which has a piston which is responsible for milk movement in packet.
6. Then goes to horizontal Jaw sealing mechanism which has a element (
Cylindrical shape). This element is also given 24 Voltage supply to increase its
temperature to 45-50C.The other side in this has rubber ( 3mm thickness,15cm
length, 6cm width). Due to pressure between rubber and element horizontal sealing
is done and also cause packet to cut one by one.
7 . This whole line of packet moves through a pulleys system. Then comes the jaw
cooling system, its principle work is to ensure that the temperature of horizontal as
well as vertical seal does not exceed the set limit and thus avoid the leakage. The set
temperature of jaw. cooling is 10ºC .
8. The pouch thus packed are arrange in crate (12 liters each) and conveyed to the
cold store with the help of a two tier conveyor, the upper tier is used for conveying
empty creates from crate washer and the lower one is used for conveying crates with
milk pouch to cold store.
9. Two no’s of crate washers of capacity 1200 CPH are supplied one for each packing
line, the crates to be cleaned are manually feed and the cleaned crates are conveyed
to packing machines. When crate is fed to crate washer it undergoes three steps of
cleaning first rinse, detergent rinse and finally hot water rinse. Then the cleaned
crates are forwarded to packing machines on conveyor.
10. There is one leaky pouch tanks for dumping the leaky pouch as well as excess
milk in HBMT.

Horizontal Jaw sealing

Overhead tank

Pulley One machine 2 heads

Rubber

Vertical Jaw sealing 41

PACKING MACHINE SPECIFICATION
No of machine 8
No. of head 16
Operating 500ml:- 80 pouch/min –had (high speed
heads)
500ml:-40-45 pouches/min-head
Balance tank capacity 40 lt
Height 3.5 Mt
Floor space 1.70 Mt X 0.84 Mt
Pouch/kg film 395 pouch/kg (1/2 ltrs)
245 pouch/kg (1 liters)
Thickness of film 55 µm (1/2 ltr)
Length of pouch 142-145 mm (1/2ltr)
Sealing temperature Vertical sealing (80-850C)
Horizontal sealing (45-500

COLD STORE
No. 2
MAKE StarCollers & Condensers Pvt.Ltd.
Cold Store temp 4-50C

CRATE WASHER
No 2
Type Continuous
Capacity 1600 cph
Detergent used Caustic
Rinse water temp 40-450C
Hot water pump 65-700C
Detergent temp Above 600C
Steam pressure Max.4 kg/sq.cm
Alkali used Caustic soda:0.3-0.5%
Cleaning
All the components, which are in direct contact with milk, can be dismantled &
washed manually by hot water or soap solution.
Cleaning parameters
Machine, Balance tank & filling heads Once in a day after operation
cleaning with caustic CIP rinse with cold
water & followed by manual cleaning
Rollers & other parts, which come in Once a day
direction contact with the filling to be
manually cleaned & sterilized with
Methylated spirit, diluted 50:50 with water
UV tube manual cleaning with methylated Once a week
spirit
Disinfect the machine with seal with water Immediate before start up 42
(0 C for 15 min) then areolation & add
chlorinated water 50ppm
Buttermilk Composition
Composition Chhach
Fat 2.0%(min)

SNF 8.5%(min)

Acidity 0.45%(max)
Shelf life 7 days
Salt / Sugar 0.75%(Salt)
Total Solid 6-7%
Price Rs.10

Stored at 6 C

Packaging of Chhach
The film shall be White Pigmented 2 to 3 color printing and manufactured out of
only Food grade virgin material with a blend of LDPE 50% and Octane based LLDEPE
50% with following specifications:-
PARTICULARS SPECIFICATION
Raw Material A blend of low density polyethylene(LDPE) with Linear
low density polyethylene(LLDPE)
Film thickness 45 / 60 micron for 250 ml; 55 / 60 micron for 500ml
Width of the film 323 mm
Yield 250 ml, 45 micron – 630 pouch/kg film
500 ml, 55 micron – 380 pouch/kg film

43
 APS (ASEPTIC PACKING STATION)
The first aseptic filling plant for milk was presented in Switzerland in1961. The Tetra
Pak Company later became one of the leading suppliers of processing and
packaging equipment for dairies.

SARAS dairy is major supplier of tetra pak milk to the armed force.

Packaging structure
The aseptic packages are typically a mix of paper (70%), polyethylene (LDPE) (24%),
and aluminium (6%), with a tight polyethylene inside layer

Top layer, adhesion layer & first layer are made up of Polyethylene

• Hydrogen peroxides used for sterilizes the packaging material and maintain
aseptic environment in machine. Hydrogen peroxide is not an efficient when
used at room temperature. Therefore, most aseptic packaging systems use
hydrogen peroxide (at concentrations of 35-48%) as a sterility for packaging
material followed by hot air (60 to 125°C) to dissipate residual hydrogen peroxide.

44
 QUALITY CONTROL SECTION

Quality is the product and service of the total satisfaction of consumer in a

continuous way for all these are the assembly of all planned and systematic actions
necessary to provide adequate confidence that a product, process, or service will
satisfy given quality requirements.

Quality control is the implementation of quality checks and procedures to

immediately correct any failure and mistake that is able to reduce the quality of
interim products at every production step. Thus the desired high quality of final
product is planned and obtained.

ISO-9001 Milk Plant Jaipur 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 Jaipur has also got 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:
1)Organoleptic
2)Chemical
3)Microbiological

FUNCTIONS OF DIFFERENT LABS

DOCK LAB
1)Grading of incoming raw milk
2)Raw milk testing
3)Testing of outgoing pasteurised milk
4)Testing of processed milk stored in storage tank or silo
5)Cream testing
6)Buttermilk testing
7)Standardisation of fluid milk
8)Checking of strength of detergent in crate washer

CHEMICAL LAB
1)Sensory evaluation of milk and milk products 45
2)Checking the composition of milk products
3)Hardness of water
4)Checking the quality of reagents, packaging materials, glass wares for testing
5)Checking efficiency of waste water treatment
6)Controlling the cleaning of dairy equipments as well as sanitation of plant.

MICROBIOLOGICAL LAB
1)Checking the bacteriological quality of various types of milk & milk products.
2)Determine the types and number of micro flora in air, water & various dairy
equipment's pipelines.
3)Testing of keeping of milk & milk products.

➢ TESTS FOR RAW MILK

1)Organoleptic test
2)In Dock Lab
i)Fat by Gerber or Milk-o-scan
ii)SNF by lactometer or Milk-o-scan
iii)Acidity
iv)Alcohol test
v)COB (Clot on Boiling)
vi)Adulterants
vii)Sediments
viii)MBRT
3)Main Lab
i)BR reading
ii)RM value
iii)Polanski Value
iv)Sodium ion content
v)Maltose

➢ TESTS FOR MILK AND POUCHES OF PACKED PASTEURISED MILK

a)Weight
b)Leakage
c)Drop test
d)Length
e)Bursting strength
f)For milk:
i.Temperature
ii.Acidity
iii.Fat
iv.SNF
v.Total Solids by gravimetric method
vi.Phosphatase
vii.MBRT
**Milk testing initially done by Delta Dairy Analyzer(Lactoscope) Machine which
46
tells the SNF, Fat, acidity, adulteration compounds with percent like vegetable
oil etc.**
➢ TESTS FOR CREAM

a)Acidity
b)Fat%
c)ORGANOLAPTIC
d)Temperature

➢ TESTS FOR GHEE

a)Colour
b)Flavour
c)FFA (Free Fatty Acid) as % Oleic Acid
d)RM Value
e)BR reading
h)Moisture

➢ TESTS FOR BUTTER

a)Fat %
b)Moisture
c)Curd
d)Acidity

➢ TESTS FOR DAHI

a)Acidity
b)Fat
c)Total Solids

➢ TEST FOR WATER

a)Estimate of hardness
b)TDS (Total Dissolved Solids)
c)Chloride content
d)Ph

SAMPLING

SAMPLING OF RAW MILK

• Sampling of raw milk at R.M.R.D. of B.M.C.: Sample of societies is taken from the
weighing bowl into 200 ml sample bottles.
• Sampling of raw milk from B.M.C. in tankers: Sampling is done after thorough
plungering by opening the upper lids of the tankers in a pan & sample is collected
in 200 ml sampling bottle
47
• Sampling of chilled raw from tank: Sampling is done from storage tanks & silo in
200 ml plastic bottle by opening the sampling cork
SAMPLING FROM STORAGE TANK
• Check whether the agitators of storage tank are running or not
• Place a crate or bucket under the outlet of storage tank
• Open the screw adjusts to main outlet of storage tanks
• Check temp. of milk by thermometer
• Place the bottle under the flow of milk and collect the sample

TESTS PERFORMED IN LAB

ACIDITY TEST
Bacteria that normally develop in raw milk produce more or less of lactic acid. In the
acidity test the acid is neutralised with Sodium hydroxide and the amount of alkaline
is measured. From this, the percentage of lactic acid can be calculated.

Procedure
•Take 10 ml of sample (can be milk, curd, buttermilk etc.) in 10 ml conical flask.
•Hold the flask against white surface.
•Add 4-5 drops of phenolphthalein(1ml) to the sample and stir gently
•Titrate against N/9NaOH solution
•Continue until the appearance of a light pink colouring which persists for 10-20
seconds and down the volume of NaOH used.

So,
%Acidity = 9×NORMALITY OF NaOH ×VOLUME OF NaOH USED (ml)
VOLUME OF SAMPLE USED
= 0.1 X volume of NaOH used
MILK – value will be less than 0.140, BUTTERMILK- Around 0.4 , CURD -Around 0.7

Procedure for acidity of butter sample:-

•Take 20 g of butter sample in volumetric flask
•Add 90 ml of boiling distilled water to butter sample in volumetric flask.
•Hold the flask against white surface.
•Add 4-5 drops of phenolphthalein to the sample and stir gently
•Titrate against N/10 NaOH solution
•Continue until the appearance of a light pink colouring which persists for 10-20
seconds and note down the volume of NaOH used.

So,
%Acidity = 9×NORMALITY OF NaOH ×VOLUME OF NaOH USED (ml)
WEIGHT OF SAMPLE USED

METHYLENE BLUE REDUCTION TEST (MBRT test)

It is indirect method of estimation of total bacterial content of milk. Instead of
counting bacteria directly, a correlation is made between the time required to reduce
dye to colourless in milk. 48
Procedure
1.To 10 ml of milk in a sterilized test tube add 10 ml of methylene blue dye. Plug with a
sterilized cork, invert the tube to mix the contents.
2.Incubate at 37°C in a water bath.
3.Note down the time in which the colour of dye gets disappear and that will give the
MBRT time.
TIME MILK
more than or equal to 5 hrs VERY GOOD
3-4 hrs GOOD
1-2 hrs FAIR
less than half hrs POOR

"In SARAS JAIPUR dairy pasteurized milk reduction time is 6 hrs and raw milk
reduction time is approx. 45-50 min.“

ESTIMATION OF FAT CONTENT

Fat can be determined using Gerber’s method or using a milk-o-scan which is sample
heated at 40ºC
Gerber Method:-
Principle: When a definite quantity of sulphuric acid and amyl alcohol are added to a
definite volume of milk, the proteins will be dissolved and the fat will be set free which
remains in liquid state due to heat produced by the acid. The amyl alcohol used
facilitates the separation of a clear fat column. On centrifugation, fat being lighter will
be separated on top of the solution.

Procedure for estimation (milk and chhach)

•Take about 10 ml of H2SO4(10% dilute for milk & 20% for chhach)in Butyrometer.
•Add slowly 10.75 ml sample (can be chhach or milk) in it.. Heat the milk sample or
water bath at 40C for 5min then bring it to 27C before adding it to butyrometer.
•Add 1 ml Isoamyl alcohol and adjust level with distilled water.
•Cap butyrometer with lock stopper and mix it at 45-degree angle until all curd
dissolves.
•Centrifuge at 1000-1200 rpm for 5 minutes or 2000rpm for 2 min.
•Take reading of the % fat by reading the butyrometer.. For reading take the difference
between the two levels.

Precautions- While putting milk in acid it shouldn’t mix.

Procedure for estimation (CREAM)
•Take about 10 ml of H2SO4 (10% diluted) in Butyrometer.
•Add a known amount of sample (note down the weight) in the butyrometer
•Add 1 ml Isoamyl alcohol and adjust level with distilled water.
•Cap butyrometer with lock stopper.
•Centrifuge for about 5 minutes. 49
•Take reading of the % fat by reading the butyrometer.
%Fat = 11.26×Fat % obtained in Butyrometer
Weight of sample taken

Procedure for estimation( DAHI)

•Take 100 g of dahi and add 5 ml of ammonia solution
•Take about 10 ml of H2SO4 (85%) in Butyrometer.
•Add slowly 10.75 ml sample in it.
•Add 1 ml isoamyl alcohol and adjust level with distilled water.
•Cap butyrometer with lock stopper.
•Centrifuge for about 5 minutes.
•Take reading of the % fat by reading the butyrometer.

ESTIMATION OF S.N.F. CONTENT BY LACTOMETER

S.N.F. % can also be estimated by using milk-o-scan before which the sample is
heated to a temperature of 40ºC

Principle:-The method is based on the Archimedes Principle, which states that when
a solid is immersed in a liquid it is subjected to upward thrust equal to the weight of
liquid displaced by it and acting vertically upwards. Lactometers are variable
immersion type hydrometers and calibrated beforehand with liquid of known
specific gravity.

Procedure-
•Warm milk in lactometer jar at about 40˚C then cool at 15.5˚C.
•Immerse lactometer in jar and take C.L.R.

%SNF = CLR/4+0.2×fat+0.40

ALCOHOL TEST
The alcohol test is used for rapid assessment of stability of milk to processing. This
test gives an indication of the mineral balance of milk. The test aids in detecting
abnormal milk such as colostrum, milk from the animal in the late lactation, milk
from animal suffering from mastitis and milk in which mineral balance has been
disturbed.

Procedure:
•Take 5.0 ml of milk in a test tube using graduated pipette.
•Add equal amount of 70% ethyl alcohol
•Close the mouth of the test tube with thumb and mix the contents well by inverting
the test tube several times. Formation of any flakes on the wall of the test tube
indicates positive test

ADULTERATION TESTING METHOD

1. Soda test= 2ml Milk sample + 0.05% Rosalic Acd + Ethanol . Then Mix. and observe
colour change 50
If, Pure milk= Orange colour
Adultered = Pink colour
2. Starch Test= Take 5 ml Milk sample , then boil it and then cool it , to it add 5 drop of
1% Iodine , then observe the colour.
If, Pure milk= Yellow colour
Adultered =Blue colour

3. H2O2 Test= Take 2 ml Milk sample, to it add 2ml Starch Iodide mix, then observe
the colour.
If, Pure milk= White colour
Adultered =Blue colour

4.Glucose test=Take 1 ml Milk sample in test tube, to it add 1ml Barfoed Reagent , put
this test tube boiling water for 3 min , Let it cool , then add 1ml Phosphomolyldic
acid then observe the colour.
If, Pure milk= Light Blue colour
Adultered =Dark blue colour

5 Sorbitol Test= Take 2 ml Milk sample, to it add 2ml Sorbitol to it , then mix, observe
the colour.
If, Pure milk= Light Green colour
Adultered =Yellow colour

6. Urea Test= Take 2ml 1.6% urea detecting agent (DMAB-Dimethyl Amino
Benzaldehyde reagent) and add 2ml milk. To it add ethanol and mix
If, Pure milk= Light yellow colour
Adultered =Dark yellow colour

7. Salt Test= Take 1ml of Silver Nitrate solution(1N) . Add few drops(2) of 1%potassium
chromate and 1 ml milk sample.
If, Pure milk= Brown colour
Adultered =Yellow colour

8. Sugar test=Take 10 ml milk sample in test tube to it add 0.1g of Resorcinol powder
and 1ml concentrated HCl .Place it in boiling water bath for 5 min.
If, Pure milk=White colour
Adultered =Dark red/ Brick red colour

9. Maltose test= Take 2ml milk sample to it add 1ml 18% lactic acid , then mix 0.5%
enzyme solution , then put it in boiling water for 5 min, then cool at 25 C then dip the
diasktik strip and observe colour.
If, Pure milk=Blue colour
Adultered =Brown colour

10. Test strip= Dip strip for 2minutes

• SODA= Pure = Orange , Adultered = Blue
• SALT= Pure = Orange , Adultered = Yellow 51
• H2O2= Pure = White , Adultered = Pink
• Sorbitol= Pure = Green , Adultered = Yellow
• Formalin=Pure = Red , Adultered = Yellow
• Soap/detergent=Pure = Pink , Adultered = Green

PHOSPHATASE TEST
Alkaline Phosphatase is an enzyme which is naturally present in milk, but is
destroyed at a temperature just near to the pasteurization temperature.
Alkaline Phosphatase test is used to indicate whether milk has been adequately
pasteurised or whether it has been contaminated with raw milk after pasteurisation..

Principle=Based on the principle that the alkaline phosphatase enzyme in raw milk
liberates phenol from a disodium Para-nitro phenyl phosphate and forms a yellow
coloured complex at alkaline ph. The intensity of yellow colour produced is
proportional to the activity of the enzyme.

Preparation of phosphatase solution=Add sodium carbonate 1.75 gm+ Sodium

hydrogen carbonate 0.75 gm+4 Nitrophenyl Phosphate disodium salt 0.75 gm + 500
ml water. Mix thoroughly.

PROCEDURE:
•Take 1 ml of milk sample.
•Put 5 ml of Phosphatase solution.
•Incubate it in water bath at temperature of about 37˚C
•Check for colour change after 15 minutes.
•If colour changes then the milk is not pasteurized

In the image Test tube on left side with pale yellow colour is showing pasteurised
milk which is having no alkaline phosphate activity and test tube on right side is
showing colour change in case raw milk having alkaline phosphate activity.

POLENSKE VALUE:-

It is number of millilitres of 0.1 N sodium hydroxide or alkali solution required to

neutralize the steam volatile water insoluble fatty acids distilled from 5 g of fat under
the precise conditions specified in the method. The caprylic and capric although
steam volatile, are insoluble in water are indicated mainly by P.V. 52
Since most of the steam volatile fatty acids in milk are water soluble this value helps
in identifying the presence of coconut oil content which contains higher proportion
of these acids.
Value should be 1 to 2.

1.After finishing RM Value experiment, detach still head and rinse it with water.
2.Rinse the condenser, collecting flask and filter paper with cold distilled water and
discard washings.
3.Wash still head, condenser, collecting flask and filter paper 3 times with 15 ml ethyl
alcohol.
4.Collect washings and titrate against N/10 NaOH using phenolphthalein as indicator.

Polanski Value = 10 x ml of NaOH used x Normality of NaOH

GHEE TEST

MOISTURE TEST
Procedure=Take samples of ghee from different size packaging (1/2kg,1L and 15 kg)
Weight an empty container (W1) and then add 10 g sample( all 3 in different
container) to it , then weigh it again(W2).
Then heat all the three containers with sample using hot plate , until all the bubbles
removed. The bubbles indicates moisture removal from sample.
After heating, keep the samples in in jar with CaCl2 pieces to cool it(W3).
Moisture %=W3-W2 X 100
W2-W1
Where W1= weight of empty container
W2=Weight of container with sample{ empty container + sample(10g)}
W3=Weight of container having sample after cooling

ESTIMATION OF FREE FATTY ACID (FFA) VALUE OF GHEE

This is the test to check the quality of ghee/fat in terms of acidity.
This value should be less than 3 (ghee)

Procedure
1.Take about 10 g of ghee sample( 3 samples from different container) in a conical
flask( 250 ml capacity)
2.Add 50 ml of neutralized spirit/Ethyl alcohol on ghee in the flask and mix the
content of the flask .Bring then to boil and which it is still hot.
3.Titrate with 0.1N (N/10)sodium hydroxide using phenolphthalein indicator, shaking
vigorously during the titration is reached when addition of a single drop produce a
slight but definite colour change persisting for atleast 15 sec.
4.The percentage of the fully acids is expressed as oleic acid.

F.F.A (% oleic acid).=TITRAION VALUE ×2.82 = Titration value x 0.282

WEIGHT OF SAMPLE

53
REICHERT-MEISSAL VALUE
It is the number of millilitres of 0.1 N sodium hydroxide or alkali solution required to
neutralize the steam volatile, water soluble fatty acids distilled from 5g fat under
precise conditions specified in the method.
This value is quite significant for milk fat, since it primarily measures the butyric acid
and caproic acid content in given fat.
When compared to other fats this value for milk fat is high. So this helps in
identification of milk fat from other fats.
Value should be 28 to 32.

1.Centrifuge the sample for 15 min

2.Separate the cream and heat it to make ghee.
3. Take 5g of ghee in flask.
4.Add 20 g glycerol, 2ml of 50% NaOH and 6 to 8 glass beads
5.Heat clarify the sample.
6.Add 93 ml boiling distilled water followed by 50 ml 1 N H2SO4.
7.Fix it with still head to distillation apparatus.
8.Mildly heat the flask so as to form the golden ring on top.
9. After that heat it properly so that distillation starts and 110 ml distillate is collected
in round bottom flask.
10.Distillate is filtered and chilled.
11.Titrate it against N/10 NaOH using phenolphthalein indicator.

RM Value = (ml of NaOH USED FOR SAMPLE – NaOH USED IN BLANK) x 1.1

ESTIMATION OF BR VALUE OF MILK SAMPLE

Vegetable oils, hydrogenated fats, animal body fats and their blends have been
reported as adulterants in milk and milk fat products.
The elevation of butyro-refractometer (BR) reading of milk fat by addition of different
vegetable oils is used to detect adulteration of milk.

Refractometer is the ratio of the velocity of light in vacuum to the velocity of light in
the sample medium it is expressed as the ratio between the sine of angle of
incidence to the sine of angle of refraction , when a ray of light of definite known
wavelength (usually 589.3Imu the mean of the D line of sodium) passes through air
into ghee.
It should be between 41-43 for milk fat with no adulteration.

Procedure: Place few drops od sample on the prism in Butero-refractometer .Allow

the sample instrument to sand for few minutes till it has attained constant
temperature (40c) after that note the reading.
.

54
TOTAL SOLID CONTENT OF MILK AND MILK PRODUCTS BY GRAVIMETRIC METHOD:-
For milk
Whole milk contains about 84 –87% water and remaining 13-16% are solids
comprising of fat, protein, carbohydrate and minerals.
By evaporating water from the milk under controlled conditions the total solid
content can be determined accurately.

Procedure
• Weigh accurately a clean and dry empty dish (W1).
• Transfer 1-2 ml of sample into dish and note the weight (W2).
• Place the dish on boiling water bath or hot plate for 20-30 minutes. Allow the
water to evaporate.
• Place dish in hot air oven at 105 ± 5°C for 3 hours. Transfer dish to desiccator and
allow cooling for 30 minutes.
• Weigh the contents and note the weight (W3). Repeat heating and cooling until
difference in two successive weights do not exceed 0.5 mg.

•Calculate % TS = (B/A)x 100, where, A = W2 – W1 , B = W3 – W1

•% Total Solids procedure for Dahi, is same as that of milk.

ESTIMATION OF BUTTER SAMPLES FOR MOISTURE%, CURD% AND FAT%

Procedure
• Note the empty weight of dish as W1
• Now take 10 gm of butter samples and note down the weight of dish with sample
as W2
• Now heat the butter sample so as to evaporate moisture. When brown residues
starts forming then note down the weight of dish as W3 after keeping it in
desiccator.
• Now 3 washings has to be done with petroleum ether so as to extract fat.
• Heat the sample so as to remove the petroleum ether residues.
• Note down the weight of dish as W4 after keeping it in desiccator.

%Moisture=W2- W3×100
W2- W1

%Curd= W4- W1×100

W2- W1

%Fat=100-(%curd+%moisture)

WATER TESTING IN LABORATORY

HARDNESS OF WATER:-
Hardness of two type Temporary ( CO3 2-, HCO3 2- s as they readily evolve C02 with
55
disintegration) and Permeant ( SO4 2-, NH2- For removing this we must for ion
complex by using a metal that will chelate the ions responsible for hardness – Like
AgNO3 used )
1)Take 50ml sample in volumetric flask
2)Add approximately 1 ml of Ammonia Buffer
3)Add few drops of indicator EBT (Erichrome Black T)
4)Titrate against N/50 standard EDTA (Ethylene Diamine Tetra Acetic acid) solution
5) End point: teal blue (from wine red)
Hardness = ml of EDTA solution used x 20

CHLORIDE OF WATER:
1)Take 25 ml sample in volumetric flask
2)Add 3-4 drops of potassium chromate.
3)Titrate with silver nitrate
4)Note down the reading of silver nitrate used.

Chloride content = used silver nitrate×0.1×35.45×40=Used silver nitrate x 141.8

PH TESTING OF WATER:-
1)For testing of water ph. universal indicator used
2)Take 10 ml of water in test tube
3)Add 2-3 drops of universal indicator( measures pH between 4-11) in water
4)Check the colour change and match with colourer chart for universal indicator for
ph.

Total dissolved solid(TDS)

Done using TDS meter . The value is in PPT. To convert it to PPM reading multiplied
with 1000.

TESTING FOR PACKAGING MATERIAL

• Thickness test by using Micrometer. ( range of thickness =46+/-2 microns for 500
ml)
• Ink test by using cello tape and by dipping in milk for 24 hrs, then rubbing.
• Printing test by matching printing code.
• Bursting strength of carton by using BS machine.
• Moisture test of card-board. (Moisture = 8+/-2%)
• Weightment of empty polystyrene cups.
• Drop test for crates.

MICROBIAL TESTING
• Sterilization of solution and media in autoclave (15 psi,/15 min,/121ºC)
• MEDIA USED:-
a)SPC/TPC = PLATE COUNT AGAR
Standard Plate Count(SPC)
Preparation= Take 4.7gm of agar in 1200 distilled water. After sample pouring , 56
incubate the plate for 48hrs
b.) Coli form = VRBA (violet red bile agar)
Preparation=Take 4.02gm milk(powder form) in 100gm distilled water, heat the
mixture obtained and then bring it to room temperature .After that do plating
,incubate the plate for 24hrs .
There is no need for autoclave for this media preparation.
Produce pink coloured colonies which can further be counted.

c.) E.COLI = CCA(chromogenic coli form count )

d.) Yeast and Mould = YGCA (yeast glucose chromophenicol agar)

Used to see the prescence of yeast mould in ghee, butter.
Preparation =Take 1ml sample ( ghee , butter) on YGCA media .Incubate the plate at
20-25 C for 5 days
Produce greyish/black coloured colony.

• Spores are two type: -ATS (aerobic thermopiles spore),AMS (aerobic mesophilic
spore).
• Product testing: -Sample can be poured in three ways on media-
a.) pore plant method used 57
b.) spread plate method
c.) striking method
• Pore plate method: -
1.1ml sample +15 ml poring media
2.Mix (solidification)
3.Incubation (37ºC/24 HRS)
4.SPC Incubation (37ºC/ 48HRS)
5.Yeast and mold (22ºC/ 5 day)

• SPREAD PLANT METHOD: -

a.) PLATE PREPRATION
b.) 1ML SAMPLE INCUBATE (SAME)
c.) SPREADER (SPREADING SAMPLE UNIFORM)

• STRIKING METHOD :-
1)PREAPRE PLATE
2)USE INOCULATING
3)INCUBATION (SAME TEMP TIME)

• COLONI COUNT :-Plate put on colony counter and sec in magnification glass than
count colonies by marker pen

STANDERDS MAINTAINED IN MILK PRODUCTS :-

CHHACH:- SALTED
1.FAT= NLT 2%( Not less than)
2.ACIDITY= NMT 0.5% ( Not more than)
3.TS = MORE THAN 6%
4.ORGANOLAPTIC CHARACTERSTICS = CLEAN FLAVOUR

DAHI:-
1)FAT = NLT 3%
2)SNF= NLT 8.5%
3)T.S. = NLT 11.5%
4)ACIDITY= 0.7-1% LA
5)ORGANOLEPTIC CHARACTER = CLEAN AND PLEASENT FLAVOUR

58
SARAS QUALITY CONTROL LAB
 ENGINEERING SECTION
Engineering Department is headed by the Manager Engineering who is assisted by
technical officer’s expert in one branch of engineering or other. Engineering
Department is divided into various sections viz

1.Boiler section
2.Refrigeration
3.Air compressor
4.Electrical section
5.Water treatment plant
6.Effluent treatment plant

BOILER SECTION:-
• 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.

Type of boiler
Horizontal type Fire tube boilers
Number 2
Make Energy process equipment
Capacity to generate steam by boiler 8 tonne/hr capacity
Fuel used One LDO(Light diesel oil ), One LPG gas
Furnace temperature 300-350 C
Pressure of steam (send to plant) 12 Kg/cm2
Fuel Consumption 230 kg/hr
Pressure required by plant Normally-8-10Kg/cm2 59
pH of feed water 8.5-9.5
Boiler mountings
These are mounted on boiler’s body for its proper and safe working.
1.Water level indicator
2.Pressure gauge
3.Safety vales

Process
In order to produce steam, mainly 3 constituents required air, fuel, water .The air and
fuel works combust together to produce flew gas which then goes through a three
way pipe channels in water is used to produce steam. The water in boiler goes
through the feed pump that is of 10tonne/ hr capacity , it is sprayed with perforated
pipes in boiler so that the influence on already heated water is minimum.. The
temperature of water is raised to about 190C. The steam produced is taken from the
top while the flew gas through a system of pipe goes to economizer , where the
incoming water( 30C) before going to boiler is heated by heat exchange from flew
gas thus increasing the overall efficiency . The temperature increased upto 70-80 C
thus reducing the demand to increase temperature on boiler . Then the cooled flew
gas is released in atmosphere through chimney.

Sequence of water flow= Water ( RO)------Economizer------Boiler

• On average the water in boiler is filled about 80 percent and rest 20 percent is
steam
• The water used is Ro type as normal water is hard and may corrosion and is of Ph
around 10.5.
• The water is treated with Phosphate( for swift movement ), Hydrazine ( it removes
O2 as it may cause corrosion), pH booster ( Their to increase pH).
• The water in the boiler comes from ETP

Boiler and steam distribution

1.Steam is supplied from boiler house having very high pressure @ 12 kg/ m2. This
high pressure is converted into desirable low pressure by pressure reducing system.
2.There are three pressures reducing station each for process (around 3.5 bar), CIP
(around 3.5 bar), and condensing plant (around 9 bar).
3.One vortex flow meter is present in each line for measurement of steam flow and
consumption.
4.These all data are recorded . Since the steam pressure is used as interlock for all
process and CIP, steam pressure should be at least 1.5bar less than that will hold any
process/CIP i.e. will not allow proceeding.
5.Low pressure steam is distributed in whole plant through a header from which
tapping is provided to indirect hot water generator or direct steam injection system.
6.All valves in both high pressure and low pressure lines are piston type.

Condensate recovery system

1.Condensate recovery is a very efficient way to recover energy. Steam converted
60 into
condensate after hot water generation.
2.This condensate is returned to the main header through Steam Operated Pumping
Trap (SOPT).
3.From main header, condensate returned to PUMP and pump discharge the
condensate to storage tank (5 KL).
4.Condensate from this tank is utilized in CIP kitchen as hot water as well as in boiler.

Economizer

Boiler

61
 REFRIGERATION SECTION:-

1.Refrigeration means process of absorbing undesirable heat from one substance &
transporting this heat to atmosphere through the cooling media.
2.Dairy products are seasonal & perishable in nature requiring preservation.
3.For transportation, processing and storage of milk and milk products, refrigeration
is essential.
4.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.
5.For producing a cooling medium (chilled water) refrigeration section is essential.
6. 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

REFRIGERANT USED:-LIQUID AMMONIA
Ammonia is liquid at -33 to -75 C and above this is in found in gaseous form.

VARIOUS PARTS OF REFRIGERATION SYSTEM

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.
TYPE SCREW COMPRESSOR
NUMBER 6
MAKE FRICK MICROTEK
MOTOR 335 HP
DESIGN PRESSURE(MPAG) 2.6
MAX. SWEPT VOLUME (CUBIC 1550
METER PER HOUR)
OIL USED FOR LUBRICATION SERVO-FRIZ 68
2)CONDENSOR:
In this gas is changed to liquid by decrease in temperature and same pressure.
This allows the refrigerant to condense to a high-pressure warm liquid by removing
its heat.
TYPE AIR AND WATER COOLED
NUMBER 5
MAKE EVAPCO
LOAD(TR) 300(EACH)

3)HP(High pressure) Receiver:

It is their for-storage purpose

4)LP (Low pressure) Receiver :

Has 2 parts the upper gas and lower liquid. The upper gas is again send to
compressor while lower liquid to silo to cool water.
62
5)Economizer
To increase the overall efficiency

6)ICE SILO/ EVAPORATOR:

It is a type of heat exchanger with continuous tubes ,that receives cold refrigerant.
The refrigerant from expansion valve evaporates from a liquid to a low temperature
vapour thus reducing the temp of refrigerant in tubes.

7)EXPANSION VALVE: When liquid(refrigerant) pass through this valve, it lowers .

This cooled liquid then enters the ice silo in droplet form where it takes the heat from
the refrigerant in the tubes of ice silo and convert itself to vapour form thus reducing
the temperature further . The vapour then goes back to condenser.

8) Silo
Has water inside with coils that ammonia which helps in cooling of water.
The silo also has expansion valve which reduce the temperature further.

Process
• Water first comes to Pre heat exchanger (PHE) which reduces its temperature to
around -2C then it goes to silo where the temperature is further reduced with the
help of ammonia gas.
• The whole process of cooling ammonia gas is a closed cycle.

63
 ELECTRICAL SECTION

1. Two types of panels in section high tension panel and low tension panel
2. IN HIGHT TENSION PANEL :-2 are receiver electricity,
3. 4 are transfer to transformer
4. 4 transformers are in the plant , these convert 33kv to 11kv (old plant) and 33 kv to
433 kv ( for new plant )
5. They used circuit breaks for 11kv (ACB(AIR CIRCIUT BREAK ) AND FOR 33KV
(VCB(VACCUME CIRCUIT BREAK)
6. And a bus coupler also their if one transformer is under service than used bus
coupler
7. A power factor controller to control power factor.
8. Power factor= KWH/KVH (mostly Approx. 0.996)
9. Plant using 550 KW/DAY and 550 KV/DAY

COMPRESSED AIR GENERATION AND DISTRIBUTION

Jaipur dairy has Altas Copco made two oil free air compressor of 590 CFM capacity,
two refrigerated air drying system, filters for ensuring the quality of air suitable for
instruments and one receiver (3KL) with automatic drain valve.

LED display screen is provided through which an operator can easily start or stop the
compressor; the operator can change the settings of the compressor and also check
the status of the compressor and receiver time to time. Refrigerated air drying
system has the facility of LED screen and manual switch through which the operator
can control the drying of air.

One Vortex flow meter for measurement of consumption and flow and pressure
transmitter ,present at the outlet of the compressed air generation system, these
data are available in the control room OS too and are recorded in the MIS. If air
pressure is less than 5 bar), any process/CIP cannot be performed.

USE- The air under pressure is then used for steam movement.
Sequence – Air is compressed then stored and then dried.

64
 WATER TREATMENT PLANT

• Jaipur dairy consumes about 9 to 10 Lakh Litre per day out of which about 5Lakh
comes from Bisalpur and rest from the tube well present in the dairy itself.
• All water comes into water treatment plant where it is used for four purposes –
1. RO water -2 tank of 1L capacity each
2. Soft water-2 tank of 1L capacity each
3. R.O. water-2 tank of 1L capacity each
4. Fire tank = Water is stored in this for emergency fire situation , this is then
connected to sprinklers Has 2 tank of 1L capacity each
• Raw water can cause scale formation in pipeline due to presence of high amount
of mineral. Hardness of water categorized in two type i.e. temporary and
permanent hardness.
• Temporary hardness removed by simple boiling method. But permanent
hardness due to chloride and sulphate of calcium and magnesium ions cannot
remove by boiling, for that water softening plant needed.
• Jaipur dairy has one Water Treatment Plant including Softener and RO plant
facility.
• Soft water generation with the water softening plant is very simple i.e. first water
will pass through from MGF (multi grade filter), then pass through the softener
and storage & distribution with hydro flow system trough out the dairy plant.
• There is dual pump (one working & one standby) provided for raw water feeding
in MGF and also dual pump (one working & one standby) present to feed MGF
water into softener.
• They have 4 MGF tank from where water then goes for soft and RO water
treatment.
• All soft water, RO storage tank have 50Lakh capacity.
WATER SOFTNING PLANT
Has capacity to treat about 45000L water per hr
Raw water storage tank NaOCl

Multigrade filter feed pump

Salt+ Raw water

(Mixed by agitator) MGF
(Has various sediments which helps in filtration)

Softener unit with resin( works for 2 hrs)

Soft water tank

65
The whole resin and soft water mixture can work for 11hrs , then again it has to be
changed .
RO SECTION

Reverse osmosis is a purification technology which removes all ions, contaminants,

microorganism and other larger particles form water to use the water directly into
the dairy products
Before doing process with RO membrane, the MGF water pass through the UF plant
then it will came forward to the RO plant.
Has capacity to treat about 25000 L water per hr.,50,000L in every 2hrs. Takes about
2hr to complete whole cycle .
PROCESS FLOW CHART

Raw milk inlet line

MGF(Multigrade filter)

Backfilter( Primary filter)

{Remove sediments}

UF membrane( Ultra filter)

8 in number

VERTICAL INLET PUMP TO RO

Cartage filter

RO feed pump

RO membrane
3 in number +1 common

DGT
(In this air is supplied to remove Co2)

PUMP

ROSTORAGE(50 Lakh capacity)

HYDRO FLOW

PLANT

66
 EFFLUENT TRARTMENT PLANT:-

• To control the environment pollution ETP plant has very important for only
industry
• Especially in dairy plant its effluent rich in organic matter, having high BOD.
• The dairy treats about 14-15 Lakh water everyday which later transferred to other
organizations(MNIT etc) and also used in dairy for watering pants.

Constituents of dairy waste water-

1.Residues of milk & milk products.
2.Water used for CIP.
3.Residual detergent & sanitizers.
4.Several chemicals.
5.Several micro-Flora.
6.Oil & grease etc.
Process flow chart

Raw effluent from plant

( Water that comes has pH=6-9, TS=1200mg/L, BOD=1500mg/L, COD{Chemical
oxygen demand}=4450mg/L, Oil/Grease=300mg/L)

Balance pit

Bar Screen with grit chamber

(Sieve like )
(Here to maintain pH , caustic soda added to increase pH and HCl added to decrease
it)

Equalization tanker
(Capacity =8 Lakh, 2in number)( For storage purpose)

Fat removal unit, Dissolved air floatation (DAF)

( These 2 unit works alternatively , at a time only one works)
( Here dozing of Coagulant (To remove fat ), Poly-Dosing( to bring fat on the upper
layer) is done
Fat collection tank
Fine screen
( All fat comes in this)
Acid Reactor phase
( Here lime added to maintain pH and gas evolution)
( Further connected via 2 lines to 2 USAB)

UASB (1,2) REACTOR

(UPFLOW AEROBIC SLUDGE BLANKET)
(Cow dung added here ) 67
 Settling tank
( Media settles fat)

Aeration tank (1,2)

(Here air formed by air compressor pump
and food for microorganisms in form of
urea, DAP, Bacteria culture is added )

Secondary clarifier (1,2)

(Here the sludge is settled and removed)

Sludge collection tank Treated water tank

Fat collection tank Treated water (gardening/ Reuse)

( Capacity 50000L)

Digestor
(Has black covering , produce BIOGAS)
( 56C maintained inside by hot water)

Treated water has pH of about 8.26, BOD=10.7, COD=37.4 and TSS=13.4

(As on 14 Nov 2022)

SPECIFICATION OF ETP PLANT INLET AND OUTLET WATER

Water inlet Outlet

TSS 1200 mg\lt Less than 100mg/lt

Ph 6-9 5.5-8.5

BOD 1500 mg\lt Less than 300mg/lt

COD 4450 mg/lt Less than 250 mg/lt

OIL/GAS 300 mg/lt Less than 10 mg/lt

68
 AUTOMATION SYSTEM

1.Jaipur dairy project is a semi-automatic dairy plant project of IDMC.

2.The entire process and control is done by the supervisory control and data
acquisition system (SCADA).
It uses computer, networked data communication and graphical user interfaces for
high level supervisory management.
4.It also uses programmable logic controller (PLC) and discrete PID to interface with
the process.
5.The entire automation system is programmed by ROCKWELL AUTOMATION for
SARAS.

1)There is generally two level of operating in the SCADA :

a)Operator (can operate all the production related process from OS.)
b)Engineer (Can able to configure and change the logic from OS, able to bypass
interlock can change recipe parameter of any process and can operate the process)

2)The whole control system has powerful visualization software installed in different
OS of dairy plant.

• The entire dairy plant’s network is based on Ethernet cables or Fiber optics.

• All analog and digital instruments are communicated with the controller through
the Remote input/output panel Instruments that are help in automation system
for measuring, controlling and recording variables are of temperature transmitter,
pressure transmitter, level transmitter flow switch, flow meter, level switch etc
including mix proof valve and pneumatic valve.

69
 Observations
➢ In the industrial visit to Jaipur Dairy (Saras) I found that-
• The industry is offering its services in all parts of Jaipur and Dausa.
• The employees are working on the contract basis.
• The marketing and distribution is given to the private parties on
contract.
• The employees are satisfied with their job.
• The management supervision and control over the lower management
is medium.
• The plant uses milk powder to produce the milk and fulfill the shortage
of milk .
According to the analysis, it was assessed that people have more faith in
Saras as compared to other brands. However, the competition may get
intense in the upcoming time by the entry of new competitors in the
market.

➢ Recommendation and Suggestion

After collecting the data and analysing the data, the following are there
commendations that can be helpful for the Saras:
• The industry should be focus on more states and districts.
• The industry should focus on providing quality service to the consumers
by improving their supply services and introducing new lucrative
schemes to increase the sales.
• They should try to improve their relation with the dealers and try to
give some benefits to them.
• The advertisements can be made more attractive.

➢ Conclusion :
The project of milk products with special reference to Jaipur Dairy have
been undertaken during the training period gave an opportunity to study
the system in detail and have an insight into the organization.
The organization has a very well thought out organizational structure,
streamlined procedure and well-motivated workforce.
The objectives are very clear and unambiguous. During the 21 days of my
training at Jaipur Dairy and I reached the following conclusions
• We came to know the nature and scope of the operation and
production capacity of the plant.
• We got an idea about the system of milk production and distribution of
the organization.
• They are focusing on expansion.
• The Saras is the more popular milk brand among the people. 70
• Saras tries to provide 100% customer satisfaction.
• Customers believe in the quality and services of Saras.
• Maximum consumers purchase the Saras milk from the nearest Saras
outlet

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PHOTO GALLERY

72
Certificate

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