P.S- View it after downloading since it has lots of effects and animations because of which some slides look crowded. Presentation based on the internship/training that we had at Dudhmansagar Dairy, Manesar, Gurgaon, under the aegis of Mr. Sahil Jain and Mr Satish Chikkara. Huge thanks to Ankita Mishra Ma'am for this beautiful oppurtunity.

1. 1
FT471,INDUSTRIAL SUMMER TRAINING
Presented by
Pallabi Das
Tanuva Das
Rangina Brahma
Meenakshi Kumari
B.Tech 7th semester
Food Engineering and Technology
Tezpur University
DUDHMANSAGAR DAIRY
1JUNE - 30JUNE,2018

2. Contents
Introduction
History
Processing
Packing and Dispatch
Quality Control Lab
List of products
UHT
Engineering section
Conclusion
2

3. I
N
T
R
O
D
U
C
T
I
O
N
Amul Dudhmansagar
Type Cooperative
Industry Milk Production
Founded 1963
Headquarters Mehsana,
Gujarat, India
Federation
limited
GCMMF
Slogan The pride of
India
• The Mehsana District Cooperative milk producers
union limited popularly known as Dudhsagar dairy.
• It is a member of the state level Gujarat
cooperative milk marketing federation.
• It is the largest dairy in Asia, processing on as
average 1.41 million kg of milk each day.it has
established a network for procuring milk from
4500000 milk producers through 1150 village milk
cooperatives.
• The union is ISO 9001:2000, so 14000: ISO 2004,
and ISO 22000:2005 certified and is and
environment friendly organization. All these
certification has been achieved from NABL
accredited lab i.e. DNV, Norway.
• Mission- “ We at GCMMF endeavor to satisfy the taste
and nutritional requirement of the customers of the world ,
through excellence and marketing by our committed
team. Through co-operative networking , we are
committed to offering quality products that provide best
value for money”.
• Vision – To provide more and more satisfaction to the
farmers employees and distributer.
3

4. HISTORY OF COMPANY
• On 8 November 1960, Dudhsagar dairy was registered
under Mumbai Co-operative societies act, 1925. Shri
Mansinhbhai Pruthviraj Patel laid the foundation stone on 2
April 1963.
• Gujarat Cooperative Milk Marketing Federation Ltd.
(GCMMF) is a body of Dairy Cooperatives in Gujarat.
• Thirteen dairy cooperatives work under GCMMF.
• Mehsana District Cooperative Milk Producer's Union Limited
is also a part of GCMMF and it contributes the highest
amount of milk collection for GCMMF.
Location
It is located at Plot no. 26D, Sector-3, IMT, Manesar, Gurgaon,
and Haryana. Unit started with the vision to fulfill the demand of
consumers of Delhi and NCR region.
4

5. Processing SEction
5

6. Various storage tanks
6
RMST
PMST
HMST
6 silos
Capacity:
1,00,000L
6 silos
Capacity:
30,000L,
1,00,000L
6 silos
Capacity:
15,000L

7. RECEPTION DOCK
7
Dudhmansagar Dairy receives chilled milk in
insulated tankers from Punjab, Uttar Pradesh,
Rajhasthan, Haryana.
A weigh bridge is maintained inside the
industry at the entry gate for weighing of the
tankers.
There are two lines for receiving milk through line 1
and line 2 through which two pumps are connected
which transfers milk to RMST tanks.
The capacity of pumps are 50,000ltr/hr and
45,000ltr/hr.

8. Processing Flow diagram at DMD
Reception of incoming milk in tanker weighing plunging Sampling QA rejection
Unloading
filtration
Storage of milk in RMSTQA
Filtration through duplex at 55 – 60 ˚
C
pasteurized milk at(80±2˚) 16 sec
Chilled at
< 4˚ C
Storage in PMST ≤ 5 ˚ C Storage in HMST ≤ 5˚ C
QAPacking machine
8

9. Packing and dispatch section
9

10. Milk packing &Dispatch
Around 9.6 litre per day, processed milk is packed in pouches for
city supply.
After processing, the milk from storage tanks is pumped to HMST
(15000 litre)
 There are 6 HMST (capacity 15000lit of each) from where milk is
send to packaging section
And then it goes to filling machines. The machines are
automated and adjustable for different sizes of pouches.
 The temp of milk is kept below 5°C during packing.
Total number of lines- 6.
 Number of machine in each line- 5.
 Total packaging machine- 30(29
Machine 2 headed, and 1 Machine (6lit)
1 headed.)
 Make: RMC (machine no. 11&21&31.),
SAMARPAN.
10

11. Collection of milk
to leaky pouch
tank
Filtration &
Collected in
RMST
Leaky pouches
Crate washer
Empty crates
Storage of
pasteurized milk in
HMST(≤5˚C)
Packing
Machine
Filling of pouches in
crates
UV light treatment
QA analysis
LLDPE film
Leaky
pouches
through
crates
Storage (<5°C)
11
Dispatch through vehicles Flowchart of
packing section

12. Machine Specification
[Samarpan
Fabrication Ltd.]
1. Power Consumption: 2
kW/hr
2. Compressed air:
6kg/cm2
3. Air Consumption: 50
m3/hr
4. Cooling water: 200lit/h
at 20oC
5. Capacity: 1000 ml
Total 30 pouch packing machine:
1. 27 machine from SAMARPAN
(India) having double headed.
2. 3 packaging machine from R.M.C
packaging systems Ltd.
3. 6 litre packaging machine having
one headed which from
SAMARPAN
12

13. S.n
o.
Type of milk M/C no. Make Size of
packing
Pouch
+milk
weight(g)
Actual
capacity(pouch/min)
A B
1
Amul Gold (Fat: 6%,
SNF:9%)
11 RMC 500ml 518 35 35
12 SAMARPAN 1lit 1034 34 34
13 SAMARPAN 200ml 207 80 80
14 SAMARPAN 500ml 518 45 45
15 SAMARPAN 6lit 6208 8
2
Amul Taaza(TM)
(Fat: 3%,SNF: 8.5%)
21 RMC 500ml 518 35 35
22 SAMARPAN 500ml 518 80 80
23 SAMARPAN 500ml 518 45 45
24 SAMARPAN 1lit 1034 35 35
25 SAMARPAN 1lit 1034 35 35
3
Amul slim ‘n’ Trim
(Fat:1.5%,SNF: 9%)
31 RMC 500ml 518 35 35
32 SAMARPAN 500ml 518 45 45
33 SAMARPAN 500ml 518 45 45
34 SAMARPAN 500ml 518 45 45
35 SAMARPAN 500ml 518 45 45
5 Amul Gold
( Fat : 6%,
SNF : 9%)
51 SAMARPAN 500ml 518 45 45
52 SAMARPAN 500ml 518 45 45
53 SAMARPAN 500ml 518 45 45
54 SAMARPAN 500ml 518 45 45
55 SAMARPAN 1lit 1034 35 35
6 Amul Gold
(Fat : 6%,
SNF : 9%)
61 SAMARPAN 500ml 518 45 45
62 SAMARPAN 500ml 518 45 45
63 SAMARPAN 500ml 518 45 45
64 SAMARPAN 1lit 1034 35 35
65 SAMARPAN 500ml 518 45 45
4 Amul Taaza
(TM)
(Fat : 3%,
SNF : 8.5%)
41 SAMARPAN 500ml 518 45 45
42 SAMARPAN 1lit 1034 35 35
43 SAMARPAN 500ml 518 45 45
44 SAMARPAN 500ml 518 45 45
45 SAMARPAN 500ml 518 45 45
13

14. Specification of different milk pouch
S .no Name of packing Type of packing Length (mm) Width (mm)
1 Amul Gold 200ml 105 323
2 Amul Gold 1lit 248 323
3 Amul Gold 500ml 155 323
4 Amul Gold 6lit 410 590
5 TM 500ml 155 323
6 TM 1lit 248 323
7 TM 6lit 410 590
8 DTM 300ml 115 323
9 DTM 500ml 155 323
14

15. DAHI PROCESSING
 Indian Curd, known as Dahi is well known fermented
milk product consumed by large sections of the
population throughout the Country, either as a part of
the Dairy or as Refreshing Beverage.
 According to FSSAI, Dahi or Curd is the product obtained
from pasteurized or boiled milk by souring, natural or
otherwise, by a harmless lactic acid or other bacterial
culture .
 Dahi may contain additional cane sugar. It should have
15

16. COMPOSITION
16

17. EQUIPMENTS
REQUIRED IN
PROCESSING
Dahi milk tank: 5000L
Pasteurizer: 2000 LPH
capacity
SMP reconstitute tank:
500L
Processed Dahi milk
storage tank: 5000L
Inoculation tank 1000L
Homogenizer:
2000LPH
Dahi filling
machine: 3
(2 for pouch filling
1 for cup filling)
17

18. Standardization of milk for
dahi
(F-3.5, SNF -11.5 for Masti
and prolife dahi)
F-0.5, SNF- 11.5 for lite dahi)
Homogenization &
pasteurization
chilling
storage
Heating
Inoculation with starter
culture
Packing in cups and
pouches
Crate filling and
transferring to incubation
room
Incubation till ph -4.9
Transferring to fast
cooling
Cold storage
Dispatch in insulated van
Temp
-7°C
2 stage
homogeni
zation
90°C in 5
min
Temp
<7°C
Temp
40-45°c
18

19. SOP of masti DAHI milk
1. Required quantity of R.O.
water is taken in Rinse
StorageTank.
2. Required SMP added
manually.
3. Required amount of Milk
taken from RMST (Raw Milk
StorageTank).
4. SMP admixture is
transferred from Rinse
Storage
Tank.(Standardization)
5. Pasteurization at 90±2°C for
5 min.
6. Dahi milk stored in PMST
(Pasteurized Milk Storage
Tank).
1. Required quantity of milk is
transferred in SMP
reconstitute tank for SMP
addition.
2. Required SMP slowly added
for reconstitution.
3. The admixture is transferred
into processed dahi milk
storage tank
4. Before being processed
through Pasteurizer .
5. Dahi Milk stored in Storage
Tank.
SOP of lite dahi milk
19

20. DAHI PACKAGING
LDPE film for Dahi pouch,
Thermoform Dahi cup,
Aluminium Foil for Dahi
cups,
Raw Materials
for packaging
20

21. MARKET QUALITIES for dahi
Keeping quality of Dahi: for pouch 7 day at refrigeration
COLOR : Yellowish, creamy white, free from
browning.
APPEARANCE : Smooth and glossy surface,
creamy layer on top, free from extraneous
matter.
FLAVOUR: Acidic taste, free from off flavour.
BODY: Soft and firm, free from gas-holes and
whey pockets
ACIDITY : 0.75-0.85% L.A
21

22. Ice-cream section
22
Dudhmansagar Dairy has
a capacity of producing
25,000 litre ice-cream per
day.
There are 6 types of ice-creams
made which are Epic, Frozen
yoghurt, candies, cups, tri-
cones and Bricks.

23. 8.
Sop for ice cream mix
Agitate for 15 min and then take ice
cream mix is used into processing.
After 10 min add calculated amount of
stamucol (stabilizer for ice cream) with
remaining 10% of sugar at 60-65°C.
Calculated and add sugar (90% of
total quantity)
Further heated 60-65°C.
Quantity of SMP is added.
Heated at 40-45°C.
Calculated amount of raw cream is
added.
Required quantity of full cream
milk taken.
23

24. Standardized ice
cream mix
Homogenization
and
pasteurization
Transfer the mix
into ageing tank
for 4 hr-6hr at 4-
6°C
Pump
Transfer to FMT
tank
(19 RPM)
Addition of color
and flavor as per
recipe and
agitation for
mixing
Freezing the mix
to -5°C or below
in continuous
freezer
Packing in cone
Passing through
metal detector
Store in
hardening tunnel
(-25 to -40°֯C)
Cold storage -
18°c
Flowchart of cone Ice-
cream

25. EQUIPMENTS USED IN PROCESSING
Equipment Number Capaci
ty
Make
Mixing tank L11,L1
2
2500lt
r
Tetra Pack
Pasteurizer P3 2000 liter/hr Tetra Pack
Ageing
tank
M11 to
M16
4000lt
r
Tetra Pack
FMT 8 600ltr Tetra Pack
freeze
r
F2,F3,F
7
600ltr Tetra Pack
F6,F4,F1,
F5
1200lt
r
Gram Equipment
F8 400 Gram Equipment
Packi
ng
Machi
ne
IC30P(Swirl
machine)
3000cup/hr Panchal,Anand
IC2P(Small
cup machine)
3000
cup/hr
Panchal,Anand
IC60P(small
cone
6000
cone/hr
Panchal,Anand
25

26. FLOWCHART OF FROZEN YOGURT
Transfer of ice–cream and sweetened
probiotic yogurt to FMT.
Addition of color, flavor, fruit compound as
per recipe and agitation for mixing.
Freezing the product mix to <4°C in
continuous freezer
Passing through hardening tunnel (<-
37֯°c)
Passing through metal detector
Packing in cup/container then in CBX
Storage in cold store at<18°֯c
Crating
CCP
Waste
26
Rework
processing

27. Sop of juicy water
1. Required quantity of RO water.
2. Heated at 60-65°C.
3. Calculated amount of sugar,
liquid glucose and citric acid are
added.
4. After 10 min, pectin is added
with sugar.
5. Maintained the temperature
82±2°C for 25 sec.
6. Cool upto 6°C.
7. Plain juicy water is prepared.
Rework processing of ice
cream
1. Addition of the waste
into the rework tank
(800 ltr.).
2. Heat up to 80-85°C for
15 min
3. Cold water circulation
is done.
4. Then again filter this
content .
5. Then again give
sample to the Q.A lab.
6. If result are
satisfactory then it is
used for production.
27

28. OVERRUN
Over run = weight of unit volume of mix- weight of unit volume of ice
cream* 100
The over run of ice cream is defined as the
excess volume of ice cream .
Ice cream overrun refers to the amount of air
pushed into the ice-cream while it is being
made.
28

29. List of Products
29

30. Types of ice cream products
30
AASLI GUAVA ASLI AAM CHOCOBAR
TRICONE FROOT
LICKZ
BRICKSEPIC
FROZEN
YOGHURT
Cup

31. AMUL GOLD(FCM),
FAT- 6.0 % SNF- 9.0%
AMUL TAZZA(TM)
FAT – 3% SNF – 8.5%
AMUL DTM(SLIM & TRIM)
FAT – 1.5% SNF- 9.0%
AMUL DIAMOND
FAT- 7.0% SNF- 9.0%
AMUL BUTTERMILK
FAT- 1-2 % SNF – 7.5%
PASTEURISED COW MILK
FAT – 4% SNF – 8.5%
AMUL MOTI ( HOMOGENISED TONED
MILK)
FAT- 3.0% SNF- 8.5%
31
Milkproducts

32. Types of Dahi products
AMUL MASTI
FAT-3.50%,SNF-11.5%
AMUL PREMIUM
FAT-4.5%,SNF-11.5%
AMUL LITE
FAT-0.05%, SNF-11.5%
32

33. 33
CIP
1st rinse temp. 35°c for 180 sec
1) Lye temp. 75°c for 900 sec
2) Intermediate rinse 30°c for 180 sec
3) Acid temp. 65°c for 900 sec
4) Final rinse 240 sec
9 lines
Done to clean FMT, Ageing tank, RMST,
PMST, HMST etc

34. Ultra High Temperature
34

35. Ultra
High
Temperature
• Sterilization temperature - 135°C
(275°F).
• 3 lines are installed in DMD out of
which 2 has the capacity of
producing 6300 litre/hour and one
produces about 10,800 lit./hr.
• Variants are of 180 ml and 500 ml.
• Every packaging machine has 3
heads.
35
FAT- 3.0%
SNF- 8.5%

36. FlowchartforUHTmilk
36
PASTEURIZED
STANDARDIZED MILK
STORAGE IN MILK STORAGE
TANK
FILTRATION
Vitamin A, D added 0.05 % of
milk
1. Pre- heating at temp 65°C
2. Homogenization at min. 200bar
3. Temp raise upto 90°C
4. Protein stabilizer
5. Sterilization at 140-141°C
6. Holding for 5.3 secs
7. Chilling up to 45 to 50°C
8. Cooling upto 20-37°C
Filling in aseptic packing machines
Pouch packing
QA
analysis
Drain to
ETP
Pouch filling in crates
Sterilizati
on

37. Equipment used for UHT milk packing
37
Make: Elecster Packaging
Machine

38. Specification of pouch film materials
Raw Packaging Materials
• EVOH(5 layers) film for UHT
milk pouch
• CBX for UHT Milk pouch
500 ml
• CBX for UHT milk 180 ml
Structure of a 5 layer tube
38
Ethylene-vinyl
alcohol

39. Quality Control lab
39

40. QUALITY ASSURANCE LAB
1. Reception lab
2. Central lab
3. Microbiology lab
4. UHT lab (For UHT milk testing)
40

41. RECEPTION LAB
Raw milk sampling:Check the condition of the seal (must not
be broken).
1. Break the seal and open the lid.
2. The plunger is inserted in the manhole and is thrust
forward and pulled back, thrust downwards and pulled
back and thrust backwards and pulled back, for at least
15 min. After proper mixing the sample is taken through
the manhole.
3. Approximately 4 lits of milk is allowed to drain through
sampling cock in a plastic bucket &close the cock.
41
• After completion of 3-4 Delivery Challan.
Chemist shall inform sampler to get the sample
bottles ready as per the following:
No. 500 ml clean & dry plastic bottle for
detailed checking of adulteration.
No. 125 ml sterilized plastic bottle for
testing MBRT.
No. 500 ml clean dry SS container for
routine chemical testing.
No. 250 ml plastic bottle as control sample
at Security Gate in Refrigerator.

42. Tests carriedout in Central Lab
• DETERMINATION OF FAT IN MILK:
VOLUMETRIC METHOD
Gerber method.
GERBER METHOD
1) Into a clean dry butyrometer take 10 ml of Gerber sulphuric acid from
the automatic measure.
2) Mix the sample thoroughly and rise its temperature to 27 degree and
again cool down to 25°CTake 10.75 ml of milk with the pipette
4) Transfer the milk carefully into the butyrometer along the inside wall of
the butyrometer.
5) Pour in such a way that the milk should not mix with the acid but form a
separate layer on the top.
42
6) With the automatic tilt measure add 1 ml of iso amyl
alcohol on the top of milk.
7) Carefully Insert the stopper tightly and mix the contents by
shaking the butyrometer at an angle till all the curd has been
dissolved.
8) Bring the temperature of butyrometer at 65 degree
centigrade by placing it in water bath.
9) Centrifuge for 5 minutes at 1100-1200 rpm and again heat
the butyrometer to 65°C for 2 minutes.
10) Note the reading of the fat column inside the stem.

43. PLATFORM TESTS OF MILK
1. TEMPERATURE - MAX. 4°C
2. ORGANOLEPTIC TEST
3. TITRABLE ACIDITY (% LA)- MAX. 0.135
4. COB- NEGATIVE
5. ALCOHOL TEST (68%) - NEGATIVE.
6. MBRT TEST
7. SNF TESTING
8. GRAVIMETRIC TOTAL SOLIDS
(TS)
TEMPERATURE
1. It is basically checked by
thermometer.
GRAVIMETRIC TOTAL SOLIDS (TS)
1. Take petridish from hot air oven 7 keep
it in dessicator to cool.
2. Weigh the empty petridish (w1).Take
10ml milk as sample in it (w2).
3. keep it on boiling water bath for 30
Minutes till
4. completely dry.
Take weight as W3.
Moisture % = (w3 - w2) / (w2 - w1) X 100
% T.S. = 100 - % Moisture
SNF Test
1. Warm the milk sample to 40°C & maintain
at this temperature for 5 min.
2. Mix the contents by rotating & inverting
the bottle, taking care to avoid the formation
of air bubbles & froth. Cool the sample to 27
°C.
3. Take out 10.75 ml milk for fat
determination at 27 °C.
4. Allow the lactometer to remain steady in
the milk. Check the temp. of milk, take the
reading at 15.5°C within about 30 sec.
5. Note the corrected lactometer reading.
SNF Calculation at 15.5 °C –
SNF% = CLR/4 + 0.21×F + 0.29
Where, F= Fat %
CLR= Corrected Lactometer Reading
For cow milk, Lactometer reading is taken at
21°C .The SNF is calculated using the
formula.
%SNF = CLR/4 + 0.2F + 0.14
MBRT TEST
1. Taken 1 ml methylene blue
dye reduction reagent in
MBRT test tube.
2. Then taken 10 ml milk
sample in it by pipette which
should be dipped in spirit
3. Then stopper (cap) put on
test tube mouth. Stopper
should be dipped into ]spirit
and head clean with cotton.
4. Now test tube kept on water
bath at 37°C for 6-7 hrs.
5. After this period it turns into
white color (as it was blue in
initial stage).
ALCOHOL TEST
1. Taken 5 ml milk sample in
petriplate.
2. Added 68% alcohol drop by drop
into petriplate. Continuously mixing
during pouring of alcohol.
3. If there is no clotting observed,
then test is negative.
COB TEST
1. Transfer 5ml of milk sample to
the test tube.
2. Heat the tube on the flame of
burner, rotate in an almost
horizontal position and examine
the film of milk on side of the
test tube.
3. The formation of clot is
indicative of a positive test.
4. Size of COB test tube 15 x 1.9
cm.
Titrable acidity
1. Measured accurately 10 ml of milk.
2. Then Add an equal volume of distilled
water and 1 ml of phenolphthalein
indicator solution.
3. Titrate the contents against
standard 0.1N sodium hydroxide
solution added drop by drop from the
pipette until the color reaches the light
pink.
Titrable Acidity (% lactic acid) = End point
×0.09
Organoleptic test
It is done simply by tasting the milk or
looking at the colour of milk and
mostly done by experts .
43

44. ADULTERATIONTESTS
• Milk can be adulterated in two portions.
One is from fat portion and other is from
SNF portion.
• This can be checked by-
RM (REICHERT-
MEISSL) VALUE OF
MILK FAT
BORIC ACID TEST
44

45. RM Test
PROCEDURE:
1. Make Sulphuric acid solution such that 20ml of it can neutralize 1ml of 50% NaOH. Centrifuge milk to separate
the fat and then heat till get clear fat.
2. Take 5 ±0.1 gm of filtered fat sample in a clean & dry 300 ml Polenske flask.
3. Mix 20 ml glycerol + 2ml 50% NaOH.
4. Run a blank simultaneously without using fat sample.
5. Saponify the fat by heating with swirling over a flame until it becomes clear. Then cool it.
6. Add slowly 93 ml boiling distilled water (water vigorously boiled for ~15 minutes).
7. Add 50 ml of diluted H2SO4. Add 3-4 glass beads in flask to prevent bumping
&immediately connect the flask to the distillation apparatus.
8. First heat gently (until insoluble acid are completely melted) and then increase the heat and get 110 ml of filtrate
in 19 - 21 minutes.
9. Get required distillate (110 ml) in flaks & replace the flask by 25 ml measuring cylinders to collect draining.
10. Put the stopper & Keep 110ml flask in water bath (15 °C / 10 min.) without mixing.
11. Remove the flask from water bath and mix gently by inverting it 4 to 5 times.
12. Filter the distillate using Whatman filter paper No. 41. Pipette 100ml for titration.
13. Titrate against 0.1N NaOH using phenolphthalein as indicator till pink color appears, V1
Take blank reading as V2. .
45

46. BORIC ACID TEST
1. 10 ml milk in 50 ml beaker add 1 ml 1%
phenolphthalein titrate with 0.1N NaOH.
2. Add 3-4 drops of 0.1N NaOH pink colour
appear.
3. Divide it in two parts. Add 2ml of 50%
strength alcohol.
4. Pink colours disappearance shows +ve
46

47. CHECKING FOR COMMON ADULTERANTS
IN MILK
Name of
Adulterants
Reagent used Sample Quantity Reagent Qty. (ml) Procedure Observation
Sugar Modified Resorcinol 3 ml 5ml Mix well and keep
the test tube in
boiling bath for 5
minutes.
If positive: Red
Neutralizer Rosalic acid
reagent
2ml 2ml Mix well Rose red if positive
Starch Iodine Solution 3ml 1-2 drops Boil and cool.
Mix, add reagent
and mix well
Blue (Positive)
Slightly yellow
Salt 10%(w/v)
potassium
chromate,
0.1341%, silver
nitrate
1ml 3 drops potassium
chromate
Take salt reagent
and mix well
Yellow (Positive)
Chocolate brown
(Negative)
Ammonium
compound
Nessler Reagent 5ml 1ml Add slowly by side
wall of tube
Yellow, orange or
brown colour
(positive)
Formalin Ferric chloride,
Gerber sulphuric
acid
10ml
5ml 10ml Pour 10 ml Gerber
Sulphuric acid
Violet ring at
junction (Positive)
No colour at
junction ( Negative)
Pond water Diphenyl solution 5ml 2ml Mix well Blue colour(
Positive)
47

48. UHT LAB
Ph test
Alcohol
Test
COB H.I Test
Hydrogen
peroxide
test
pH of UHT milk- 6.45-6.50-By
ph meter
Alcohol Test
1. 4ml milk sample
2. 4 ml 74% alcohol
3. If no clot (-ve)
4. If clot(+ve)then not accepted
Heat stability test (COB)
1. 10 ml of milk sample
2. 0.5 ml of N/10 Hcl
3. Heat and boil
4. If bubbles appear
(positive)
Homogenization Index Test
1. In this test firstly done the separation of fat from
cream and then milk as the procedure of fat
separation of milk expect in REMI centrifuge at 1000
RPM for 15 minutes for cream fat.
2. Standard for cream fat is 3.5 or above.
3. Standard for milk fat 3.1 to 3.3
HYDROGEN PEROXIDE TEST
It is done by hydrometer .
Firstly, milk is taken in the measuring cylinder .Then,
hydrometer is dipped and noted the reading .
48
SL.NO
DENSITY OF
HYDROMTER(20DEGREE
CELSIUS)
CORRESPONDING
STRENGTH OF
H2O2
1 1.000 0.51
2 1.020 6.12
3 1.040 11.59
4 1.060 16.94
5 1.080 22.17
6 1.100 27.27
7 1.102 28.28
8 1.104 28.78
9 1.106 29.28
10 1.108 29.78
11 1.110 30.27
12 1.112 30.77
13 1.114 31.7
14 1.116 31.76

49. ENGINEERING SECTION
49

50. ENGINEERING SERVICES
O
B
J
E
C
T
I
V
E
S
To maintain the equipments in dairy in such a manner that ensures smooth running of all
the activities in dairy keeping in view the financial activities of dairy.
To keep the products such as Dahi, ice-cream and milk etc. at temperature at which it is
necessary for their perseveration.
To provide treated water from water treatment plant.
To remove the sludge after its treatment in Effluent Treatment Plant, and should meet
the standards.
To provide the compressed air at required pressure.
To maintain the electricity supply to different sections and also calculating the electricity
supplied individually to every section.
50

51. REFRIGERATION
WHY REFRIGERATION IS USED AND
WHAT IS ITS BENEFIT?
Refrigeration is the process of removing
heat from low temperature reservoir and
transferring it to the high temperature
reservoir.
To provide chilled water – This chilled water is
used for following:
a. Preparation of Ice-cream mix
b. Aging of cream
c. Pasteurization of milk
To maintain low temperature in the cold stores.
To harden ice cream in hardening tunnel and Bar
trade tunnel.
51

52. PROCESSING METHOD
HP Receiver
(Ammonia in liquid
form)
Economizer
Accumulator
-1 ֯C & -37°C
Milk and Dahi cold
storage, Dahi fast
cooling, ice-cream cold
store and hardening
tunnel, PHE Chiller
Compressor
206TR, 30TR
PHE OR Evaporative
Condensor
HP Receiver
52

53. BOILER
To provide
steam for
pasteurizat
ion of milk.
To
provide
steam for
CIP.
Why is boiler used?
53

54. Water Treatment Plant
The source of water includes water from lakes, rivers and surface wells or from
underground sources such as deep wells.
Hard water is containing dissolve salts of Ca &Mg.
WTP processes 9 lakhs litre /day.
54

55. Fire
hydran
t tank
•Capacity-
50,000 litre
•Year- 2 time
cleaning
Raw
water
tank
• Capacity-
2,25000 litre
• Yearly- 2 time
cleaning
Filtere
d
water
• Capacity-
75000 litre
Soft
water
tank
RO
water
tank-

Capacity-
75000 litre

Capacity-
10,000
litre
55

56. 3 Borewell
tank
Multi
grade
filter
Activated
carbon
filter
Filter
water tank
75000 litre
Softener
Soft water
tank
75000 litre
R.O plant
R.O water
tank
75,000 lit
56
Raw
water
tank-
2,25,000
litre
Fire Water
tank
-50,000
litre
Pump
Pump
pump

57. Effluent Treatment Plant (ETP)
• Initially importance is given to processing only,
the waste water produced was disposed in nearby
areas without any treatment and without facing
any significance resistance.
• Presently about 120 lakhs litre of milk is
produced daily in the country.
• The daily effluent discharge comes to 420 lakhs
litres.
• However, with the implementation of water
conservation measures being recommended
nowadays for the dairy plants this value is likely to
57

58. Source of Waste Water
Water coming from waste water, floors and other equipment's.
Spilled milk and milk products.
Spillage, leakage and overflow from pumps.
Boiler blow down and washed and regenerated water from water
softening plant.
CIP of Process, ice cream, packing section.
.
Drainage from QC lab.
58

59. Primary Treatment
Screening
Fat Separator
Equalization tank
Oil and grease trap (3chamber)
Buffer tank (Maintain pH)
UASB reactor
Hopper bottom tank
59

60. Secondary Treatment
Aeration – I
Aeration – II
Secondary Clarifier
Aeration – III
Final Clarifier
Final Discharge
Sludge Drying bed
60

61. Tertiary Treatment
Secondary treated water comes to tertiary
plant –
• Multigrade
filter filtrate
1
• Activated
carbon
filtrate
2 • Softening
feed tank
3
• Softwater
used in crate
washing
4
61

62. Underground waste
water
Bar screen
chamber
Equalization tank
(homogenous form)
Oil & grease trap
Dosing tank
(caustic , HCL)
Buffer tank
UASBR(Anaerobic
process) CH4, CO2
, H2O
Hopper bottom
(TSS is
maintained
Aeration tank
( Aerobic process ,
urea and nutrient
dosing)
Secondary clarifier
Garden outlet
ACF
MGF
Softener
CRATE
WASHIN
G
62

63. Description of Dairy ETP Plant
Sl No. Parameter Concentration
1 pH 6 to 9
2 COD 4000 – 5000 ppm
3 BOD 2000 – 2600 ppm
4 Oil and grease 100 to 150 ppm
5 Suspended solutes 300 to 500 ppm
6 Total dissolved
solutes
2000 to 3000 ppm
Design
characteristics of
Raw Effluent
63

64. Conclusion
On the whole, this internship was a useful
experience. We have gained new
knowledge, skills and met many new
people. We achieved several of our
learning goals. Furthermore, we can
confidently assert that the knowledge we
gained through this internship is suffiecient
to contribute towards our future
endeavours. At last this internship has
given us new insights and motivation to
pursue a career in core Dairy Industries.
64

65. Thank you
65