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DAY 1 -2

ORIENTATION AND INSTRUCTION

Instruction to plant layot and safety guidelines,overview of the milk

procuremwnt network and co-operative structure

Every day, Aavin purchases 5 to 6.5 lakh litres milk, making it the third
largest buyer of milk among India’s daily cooperatives. The milk acquired by
cooperative is used to manufacture a variety of value-added milk products that they
sell under “Aavin” brand.

Aavin Salem was started in 1978 and started processing milk in

1984. Salem Aavin has grown to become one of the largest producers of milk and
milk products in the world. It has FSSAI and BSI permits, as well as certificates such
as AGMARK and HALAL for its products. The profits from the sale of milk and milk
products are immediately transferred. The profits from the sale of milk and milk
products are immediately transferred based on the quantity and quality of milk
produced by the milk producers; the milk value is later transferred to milk farmer’s
bank accounts.

Every morning and evening throughout the year, the milk producer’s
cooperative societies get milk from contributors.

PROCESSING UNIT:

Milk processing plant means a place, premises, or establishment

where milk or milk products are collected, handled, processed, stored, bottled,
pasteurized, aseptically processed, bottled, or prepared for distribution, except an
establishment that merely receives the processed milk products and serves them or
sells them at retail.
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The construction of a new fluid milk processing plant to serve

customers in either of the relevant geographic markets is very unlikely because of
the high costs of building a fluid milk processing plant especially as fluid milk
consumption continues to decline.

Food processing plant means a commercial operation that manufactures packages,

labels or stores food for human consumption and does not provide food directly to a
consumer.

DAY 3

MILK PROCUREMENT SECTION

Dairy processing stages: The raw milk container truck, having

passed the preliminary analytical test, proceeds to whole milk intake bays and the
milk houses are connected up by the driver.

The milk is pumped into bulk storage tanks called Milk Silos.

MILK SILOS
TYPES OF PROCESSED MILK:

• Skim milk:
o Milk which has no fat.
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• Toned milk:
o Fat milk is diluted with Skim milk and has fat upto 3
• Standardized milk:
o It has the fat of 4.5% minimum & SNF of 8.5%.
• Homogenized milk:
o Bigger size fat cream molecules is breaks down to small molecules and
easy to consume and adds color to milk   Evaporated milk:
o This milk is very thin and less creamy where 60% of water is removed
and then later condensed.
• Condensed milk:
o This milk is high sweet in taste and thick creamier & 40 – 55% sugar is
added.

RAW MILK RECEPTION:

The Raw Milk Reception dock (RMRD) is the primary in take point of liquid milk
entry in dairies/chilling centers. It is specifically meant for the reception of milk
brought in cans from village milk collection centers located over a wide area. It is
different from the bulk milk collection systems, which are also in operation in these
dairies. The collection process starts from the village milk collection centers, groups
of which are assigned to distinct milk truck routes.
The can of individual village milk collection centers from many such routes are
unloaded at the RMRD, after which their milk is weight & tested separately to issues
a milk receipt statement according to the measured parameters during the daily
shift.  Raw milk from the society is transported by the containers.

 Check the quality of the milk and smell of the milk.  Then finally milk weight
is calculated.
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“Convert the milk from kilogram to litres.” Milk can

washing is process in three units:

 Though the hot water at 65°c.

 Though the soda water at 65°c.
 Then through the normal water.

There the empty can is again sent to bring the milk from wide areas.

The raw milk is passed to raw milk silo to cool/chill the milk 5° c (in 100000 litres
silo). The milk is chilled and then it is processed.

Varieties of cow’s milk that is collected are:

• Naattu
• Sindhu
• Jersey

Raw milk fat for cow is,

 Minimum – 3.6%
 Maximum – 4.3%
Raw milk fat for buffalo is,

 Minimum – 4.1%
 Maximum – 5.2%

DAY 3

MILK PROCESSING SECTION:

The milk is brought from the society, BMC (Bulk Milk Coolers), chillers, etc.
to the plant where milk is cooled and stored at 4 degree celsius. The milk is then
tested for fat and SNF. The milk undergoes pasteurization and homogenized or cream
separated. The pasteurization occurs at 72°c for 15 seconds.

The Milk contains:

• Water
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• Fat
• SNF (Solid Non Fat )
• Proteins
Conventional method:

Total solids = fat +SNF.

The processed milk is standardized based on the requirement:

• Standardized milk:
FAT: 4.5%

SNF: 8.5%

• Full cream milk:

FAT: 6.0%

SNF: 9.0%

The standardization process includes:

 Homogenizer
 Cream separator
HOMOGENIZER: (20000 lit/Hr)

In raw milk, the diameter of fat globules ranges from 1 to 15 microns.

The fat has a specific gravity of 0.87. The fat globules are broken down into smaller
ones less than two microns in diameter by homogenization. Maintaining a
temperature around 70°c will result in satisfactory homogenization.
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The pumps in the homogenizer and it intakes milk and pushes the milk
at a high speed in a small area allowing the fat molecules to spread equally through
the milk in the needed requirement. This process is used for fat distribution in milk.
The milk is homogenized at 40-45°c and homogenization efficiency must be
maintained at 80-85%.The milk is separated into standardized milk and full cream
milk. Then it is transported to the silo, the silo stored the milk at 4°c to 6°c. Then it is
Pre packed and stored at the temp3°c to 5°c.

The raw milk is heats from 10°c to 85°c to kill the unknown bacteria.

Again chill the milk at 5°c to kill the microorganism present.

Then mix the fat and milk.

This milk is known as Standard Milk.

CREAM SEPERATOR: (20000 lit/Hr)

Milk cream separator is a device used to separate cream from whole milk, dividing
the milk into skim milk and cream. Cream and skim milk have dissimilar densities,
and therefore under the impact of gravity, they tend to get separated. This process is
used to remove cream from milk at 40-50°c using 5400rpm. The separated cream is
also pasteurized before further usages.

The cream separated machine contains 130 plates inside it.

Raw milk is directly taken and heated at 70°c.

While the milk passed in the machine it separates the milk into two, which is cream
milk and skimmed milk.
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Cream milk is used for a butter production which stores at (-20°c). Then, the butter
is used for ghee production.

Then the Skimmed milk is transported into the silo.

Finally, Skimmed milk is used for powder plant for milk powder production.

MILK PASTEURIZATION:

Milk pasteurization consists of 4 sections:

1. Regeneration section :
The chilled milk first enters the regeneration section and the temperature
of the milk raised to 40°c. In the section the raw milk is being heated by the
outgoing pasteurization milk.

2. Heating section :
The milk is delivered to the heating area immediately after the
regeneration section, where the temperature is 72.4°c. The milk is transferred to
the holding portion.

3. Holding section :
The milk enters the holding portion where the optimum holding time is
15 seconds. Milk is passed through a pipe and flow is arranged so that the
temperature is maintained at 72°c.
The temperature of the milk is decreased to 40°c in the regeneration
stage. As a result, the milk is cooled before proceeding to the cooling step.

4. Cooling section :
The milk is delivered to cooling area where the temperature is gradually
dropped from 24°c to 5°c.
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DAY 4

PRODUCT MANUFACTURUNG

BUTTER SECTION:

Butter section consists of Cream milk storage tanks which stores the
milk for 3 hours at 10°c, butter churner, butter storage at 16 degree celsius for
ripening. The butter collected is either converted into ghee or sold in gram or 20
kg bulk packs.
The cream milk is transported to the butter churn. The Pasteurized cream at
80.2% from cream storage tanks is obtained for butter preparation. The butter
churn which contains the capacity of 5000 litres as per the batch.
The cream is passed and grained in the machine.
Then it will transfer to the CBM butter machine (continuous butter machine).
Then the cream is converted into the butter and produced from the machine.

The remaining water is come as buttermilk.

From 2500 litres of cream 2200 kilo of butter is produced.
Composition:
 Fat - 80.2%
 Moisture not less than 16.3% having it between the range of 16.3% - 20%
salt- 2.5
 SNF of -1.0%

“Fat concentrates → Obtained by churning cream → Fat into compact mass

→Butter.”
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GHEE SECTION:

The butter with 81-83 percent fat is placed into a melting fat with a capacity of
1000 Litres. Melting is accomplished by running hot water through the tank.
Butter is melted to a temperature of 80 – 90 degree Celsius and transformed to
butter oil. By steaming the edges of the tank, it can be heated to 105°-110°C and
let to stand to stand for hour to achieve a gold brown color at 40°C. Here, the
boiler contain coil which flows the hot water in it.
Then it is passed to the kettle and heated at 110°C & it passed to the settled
tank.
Let cool it in the classifier and passed to another settle tank.
The clarifier capacity is 2000 litres.
Then fill the ghee in the bottle at 45°C.
Later, it is packed and sealed.

WEIGHT JAR PER MIN JAR PER HOUR

200 ML 30 1800
500 ML 25 1500
1000 ML 40 2400

RUPEES:
100 ml - RS.85
200 ml - RS.160
500 ml - RS.365
1000 ml - RS. 698
5 liter - RS.3250
15 kg ton - RS. 9680
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NEW PRIZE OF AAVIN PRODUCTS:

Butter milk (150 ml) - RS. 7
Curd (200G) - RS. 15 Curd
(500G) - RS.34
Ghee 1LIT JAR - RS.698
Ghee 500 ML JAR - RS.365
Ghee 200 ML JAR - RS.160
Ghee 5 LIT JARS - RS. 3250
Ghee 15 KG TIN - RS. 9680

PANEER SECTION:

Milk is boiled at 85° C to 90° C in the boiling tank and it is transferred

into big pan. Then, 0.4% of GDL (glucono delta lactone or gluconlatone) is diluted
in 85°C hot water for 5 to 6 minutes and adds the GDL water into the big pan
which contains the milk.

Leave it for 10 minutes till the milk is converting into the curdling.

Then, it is stirred for 20 minutes. Later the coagulation takes place. Take out the
curdled milk and put it into the small trays which are compressed for 15 minutes at
2.5 kg pressure.

After that keep the tray in the 4°C chill water for 1 hour to improve the texture. Then
it is get sliced and go for packaging.
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And paneer is ready to the distribution.

DAY 5

CURD SECTION:

The Skimmed milk heated at 92° C and again brings back the milk to 40° C to
add the culture. Culture is added to outlet milk at 40 - 45° C stirring for 15 minutes.
Here the culture used is citric acid powder which is from the lemon juice. Then filled it
in the cups and packets.

Incubation is given for 4hours in the incubation room when the acidity is
0.65 and after that process kept it into the deep freezer for 8hours.

When the acidity reaches 0.70 to 0.84, the curd is ready for the distribution.

The SNF is at 3.0%& Fat is at 9% in the curd. Its validity is only for 10 days.

BUTTER MILK:
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The remaining water from butter machine is stored in Storage tanks

for 3 hours at 10 deg C; enhancing the flavor is done in tanks.

The culture is mixed with the milk and left overnight to curdle. Curd is
mixed with 4 degree Celsius refrigerated water.

The ingredient used for butter milk is:

 Ginger
 Green chili
 Mint
 Coriander
 Salt are added for taste and further to packaging.

Packaging is done by keeping them at room temperature and packed and ready to
the distribution.

“Culture is directly added to milk and left over night for curding procees→4°C chilled
water is added to curd → addition of flavor →packaging.”

SWEET SECTION:

Variety of sweets is produced in Aavin and some are as follows:

 Milk khoa
 Mysorepak
 Ghee mysorepak
 Ice cream
 Badam milk cake
 Carrot mysorepak
 Soan papdi
 Badam milk powder
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MILK KHOA:

KHOA MAKING USING STEAM

Milk -160 liter is boiled at 65°C.

Sugar -14 -15 kg.

Adding of sugar is done when the temperature is 40°C.

After 3 and 1/2 hours 40 kg khoa is obtained. .

GHEE MYSORE PAK:

The ingredients added while preparing mysorepak are:

 Gram flour – 1300 kg

 Ghee – 4 liter
 Sugar – 5 kg
 Elaichi powder – 4 kg
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BADAM POWDER:

 Elaichi
 Badam
 Milk powder
 Sugar – 225 – 230

DAY 6

ASEPTIC PACKAGING STATION:

In pasteurized toned milk, the flavors are added at 8° C and homogenization

is done at for 65°C with 250 bar pressure.

Sterilization / UHT treatment is also done 137° C for 4 seconds and then
holding at 37°C during sterile packaging.
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Packing thickness is 7 layers, and the last layer is made up of sliver which helps to
prevent the contamination from the microorganisms.

Without opening the packets it can be stored for 180 days.

It expires after 6 months. Then, after packing it is sent to distribution. The presence
of Fat is 3.0 %.

JUICE PACKING MACHINE AT ASEPTIC PACKAGING STATION

The Different variety of milk flavors are:

 Pista
 Strawberry
 Chocolate
 Badam
 Cardamom
 Vanilla
 Apple
 Mango
 Mango
 Butter milk
 Carrot
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The presence of fat percent in juices:

 SNF – 8.5 %
 UHT Milk fat – 4.5%
 Exports UHT milk fat -3.3%

DAY 7

APS TEST:

Check the batch No’s., D.O.P., Volume, SNF%, FAT%, Acidity%, pH upto6.40 to6.60
Non-Alcohol 85% minimum, AflotoxinM1level –Below 250, PPT for export , MBRT,
Adulteration is negative.

The Physical test is color, flavor, and organoleptic test.

These are done at Temperature below 4°C.

The Aps transportation is done with an international license.

So, they are exporting the products over 4 other countries. They are:

 Singapore
 Malaysia
 Dubai
 Qatar

One lack litres is exported from the ship from Chennai.

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It takes one month to transport to Singapore, from that here 10 packets are taken
from the sample which we test the sample for two months once.

MILK PACKING MACHINE AT AAVIN

PACKED MILK MOVES TOWARDS PRE-COOLER SECTION BEFORE

TRANSPORTATION
The Different types of milk is filled by milk packaging machines with different
quantities and moves towards pre cooler section by belt conveyors and then taken to
places in need by trucks.

These packaging of milk is done both by machine and man for completion of
the work. The packed milk is sent all over tamilnadu and also some places of India.
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NUTRIENTS OF MILK:

CREAM MILK PER 100ML:

Fat - 6.0gm

Proteins - 3.4gm

Carbohydrates -4.9gm

Minerals -740mgms

Energy level -90.0Kcal

STANDARD MILK PER 100ML:

Fat -4.5gm

Proteins -3.2gm

Carbohydrates -4.6gm

Minerals -698gm

Energy levels -74Kcal

The packed milk is kept in the deep freezer (blast freezer) room it is until the
distribution.

The milk in storage is transported to the local areas and towns through the
containers and the truck for the future purposes.

The milk cover can be reused.

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DAY 8

QUALITY CONTROL LAB:

To find fat and SNF value of the milk using butyrometer:

Step1:

Take 10ml of sulphuric acid and pour into the butyrometer.

Step2:

Take 10.75ml of milk (raw milk) using the pipette and pour it into the butyrometer.

Step3:

Take 1ml of amyl alcohol and pour it into the pipette Step4:

Look the butyrometer and shake it well until it color change.

Step5:

It appears in reddish color.

Step6:

Keep the butyrometer in the centrifugal machine after shake it well.

Step7:

Kept for 4 minutes in the centrifugal machine which rotates 1500 times per min.

Step8:

After 4 minutes from the centrifugal machine take it out.

Step9:

The fat and the SNF were separated, where the fat is transparent color and the SNF in
the reddish color.

Step10:

Then finally calculate its measurements.

DAY 9

MICROBIOLOGY LAB:
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FOR MILK TESTING:

For 10ml milk, 10ml distilled water and phenolphthalein indicator is added and
titration is done with 0.1N (normal) sodium hydroxide.

The end point is appearance of pink color.

Formula:

=9×N×V÷weight of sample

Where,

9 is the lactic acid value.

FOR CURD TESTING:

For 10g of curd 10ml of distilled water and phenolphthalein indicator is added and
titration is done with 0.1N sodium hydroxide.

The end point is appearance of pink color.

Formula:

=9×N×V÷weight of sample

Where, 9 is the lactic acid value.

FOR GHEE TESTING:

To find the FFA (free fatty acid):

5g ghee is taken. In a separate beaker 25ml rectified spirit or ethanol and 1ml
phenolphthalein indicator is titrated with NaOH the end point is appearance of pink
color.

That pink solution is added with the 5g ghee and this mixture is hot plated and kept
for boiling.

That boiled ghee is titrated with sodium hydroxide and the end point is appearance of
slight pink color.

Formula:

=28.2×2.1×V÷weight of sample.

Then, we can find the free fatty acid value.

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DAY 10

WATER TREATMENT PLANT:

It is a destination where waste water which is not fit for the current purpose moves to
the sewage system through the pipes where wastewater flour to the treatment plant
for processing.

The waste water from the processing unit is carried out through pipes where the
water undergoes cleaning process for reuse.

Drinking water has 200 TDS (Total Dissolve Salt).

The tank has the capacity of 960litres .The input that comes from the production line
will have output must be 4TDS.

There are 3 types of filter can:

 Multi grade filter

 Activated carbon filter
 Resin (Softener)

MULTI GRADED FILTER:

This filter removes the dust from water and that is sent to the activated carbon filter.

ACTIVATED CARBON FILTER:

This filter converts the brownish water to clean water. (i.e.,) clean the color of the
water.

RESIN (SOFTEN):

In this filter salt (common salt) is used to remove the salt content in the water.

All these filtered water are stored in underground storage.

200kg of salt is added to 1000liters of water to this filtered water. Chlorine is added
to avoid the algae and insects and then stored.

The injected water is let out for 40minutes and from 41minutes the pure water starts
coming out.

2lakhs of water is collected from each plant.

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This treated water is used for washing and cleaning tanks while using this treated
water there is no resting formations in tank

DAY 11

DE-MINERALISING PLANT:

In this treatment plant, minerals are removed from the water.

This treatment is same as water treatment plant.

In this process, instead of salt hydrochloric acid and caustic acid is used.

In this treatment, when the pH value is reduced and raised the minerals and salts
decreases from the water.

BOILER SECTION:
The oil fire boiler is used in Aavin for steam production .It is separated as two parts.

4 TONS OIL FIRED BOILER

The two parts are,

 Water tube

 Fire tube

Here the oil is used is furnace oil. The firing point is at 90®C temperature. The output
pressure is 14kg.
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Per hour 4 tons of boiling production is produced. It is used to heat by using the
steam method. The milk powder is also prepared using the stream. 14kg pressure is
given at 240 degree Celsius temperature. For 12kg pressure, it is given at 197degree
Celsius temperature. This is simultaneous process.

The temperature is maintained at 107 degree celsius. If exceeds, the density of

the oil changes. So, it will not be fit for the spraying which is used for fire.

It is a small boiler. So, here FD (Forced Draft) is used.

DAY 12

COMPRESSOR SECTION:
Aavin uses two types of pressure receiver. They are:

 Low pressure receiver

 High pressure receiver
In low pressure receiver, four pumps using to pump the ammonia and it are pumped
at
-5 degree celsius and it sends it to the IBT (Ice bank tank) at
71.4pressure. There are 8 IBT which reduces the degree of the gas as,

IBT 1-(-1.1 deg C)

IBT2-(-1.1 deg C)

IBT3-(1.4 deg C) IBT4-(1.5 deg C) IBT5-

(1.8 deg C) IBT6-(1.9 deg C)

IBT7-(1.7 deg C)

IBT8-(2.9 deg C)
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SCREW COMPRESSOR WATER COOLED CHILLERS AT DAIRY PLANT

This process is at 3.5 KG/CM

This contains 50000 liters of water were all are maintained at the same temperature.

CIBT tank contains special and vertical pipe to its full length.

Ammonia absorbs heat and converts to vapor and comes out.

The temperature of vapor is depends on the temperature of the water inside.

Those vapor again comes to low pressure receiver.

From this, the ammonia will not be weights in gas nor will liquid undergo boiling.

This will be sent to the compressor.

The compressor increases its temperature from 2.9 to 72.7 and pressure is changed
to 33.3 to 165.4. It is moved to the condenser where it will change its temperature.

After changing its temperature, it goes to the economizer. The economizer is chill the
ammonia by using another ammonia. The input ammonia is at 35 deg C. And the
output ammonia is at 8 deg C.
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In this container, the coils will be kept outside ammonia and chills the ammonia
inside the coils. Then it goes to the high pressure receiver. From the high pressure
receiver it goes to the 6 types of condenser at 33.6°C & it goes to the milk cold store.

It is to chill the water and send to the silo at 4°C.

Then, it sends to the compressor for the pasteurization or evaporation, where the
milk is raised in temperature by allowing the milk into the chamber through pipe
where it is surrounded by the steam so its temperature is measured.

DAY 13

ETP (EFFLUENT TREATMENT PLANT):

For 1 liter of milk 1.62 liter of water is used. Waste water is exists in the form of
floating sledge. It goes to the bar screen and sump storage. Then it goes to the FRU
(fat removal unit). 15 minutes once the fat removal takes place in the tank.

CLARIFIER & UASB DIGESTER

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Then it goes to the equalization to maintain the pH range. The pH range is

maintained. Then it is pumped into the buffer tank and foe the performance of UASB
digester and it absorb in the gas holder and the gas is used for the gas production.

The remaining water goes to the clarifier and it is mostly used for the recycle and
rarely used for separate sledge. The separated sledge is goes to the sledge drying
beds. The clarifier mostly recycles in two ways which is PSF (pressure standard filter)
and ACF (activator carbon filter).

In PSF and ACF they should maintain chlorine level below 600. Also maintain, BOD

(biological oxygen department) – intake is 2000, which it reduces into below 30.

COD (chemical oxygen department) – intake is 4000 which is reduced into below 25.

TDS (total dissolved solids) – intake is 2000 which is reduced into below 30.The PSF
and ACF processes continue until BOD, COD, and TDS reach its certain range.

Finally, recycled water is used in the agriculture filed. In Salem Aavin, 5 lakhs liters of
water is recycled and used for agriculture purpose daily.
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CONCLUSION

 For a Mechanical Engineering student, a learning combination of theory

and practical experience is an valuable asset which helps in understanding
the core principles of manufacturing by the way of first-hand experience.

 This training program is an excellent opportunity for us to the ground level

and experiences the things that would have never gained through going
Straight into a job.

 The main objective of the industrial training is to provide an opportunity to

undergraduates to identify, observe and practice how it is applicable in the
real industry. It is not only to get experience on technical practices but also
to observe management practices and to interact with fellow workers.

 It also helped us to understand the exact mechanism of working of the

various departments.

 This study has taught some innovative things in industrial process. Getting
experience in the way of work in an organization, the important of being
punctual, the importance of maximum commitment, and the importance of
team spirit.

 The experience I encountered during the internship allowed me to develop

many skills. It was a very good positive experience and everything I learned
will be useful in my future carrier in this field.
Thank you…!