We the Integrated M.Sc students have visited the Aavin Industry, Tirunelveli on 8th March 2019. Here, is our Industrial visit report. Hope that it will be beneficial to you my dear readers!

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MILK AND MILK-BASED PROCESSING METHODS AND
EFFLUENT TREATMENT PLANT STUDIES OF AAVIN MILK
INDUSTRY, TIRUNELVELI.
A PROJECT REPORT
Submitted by
M. SHARMILA [361136]
S. SHARMILA [361137]
K. AJAY KALLAPIRAN [361139]
J. JENSON SAMRAJ [361147]
P. MANIKANDAN [361149]
E. MARIAPPAN [361150]
K. VETRI [361159]
(Integrated M.Sc in Environmental Science)
Sri Paramakalyani Centre for Excellence in Environmental Science
MANONMANIAM SUNDARANAR UNIVERSITY
Alwarkurichi-627 412.
Submitted to
General Manager i/c,
Tirunelveli District Co Operative,
Milk producers Union Ltd.
MARCH - 2019

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ACKNOWLEDGEMENT
With humble heart, we place our thoughtful sense of gratitude to Lord
Almighty who’s by grace, good health and well-being that were necessary to
cross all the hundreds to complete this project venture.
Generally, we wish to give our grateful acknowledgements to all
members of the Aavin milk Industry who provide a great atmosphere where we
spent our two days.
Firstly, we would like to express our sincere gratitude our advisor
Dr. G. Annadurai, Professor in Nanoscience, for suggesting the Industry which
helped us to enable this project destination.
Then, we would like to extend our heartfelt thanks to the General
Manager of Aavin Milk Industry, Tirunelveli.
We wish to place our sincere thanks to our Professor and Head, Sri
Paramakalyani Centre for Environmental sciences, Manonmaniam Sundaranar
University, Alwarkurichi.
We wish to pen our heartfelt gratitude to Mrs. ESWARI, Mrs.
SUBHASHINI, Mr. ESAKKI PANDI and Mr. ULAGUMANI, Aavin Milk
Industry, Tirunelveli. for their constant help, sensible suggestion and special
supplements of the dairy products and also interest in our project work.

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TABLE OF CONTENTS
CHAPTER TITILE PAGE NO.
NO.
I INTRODUCTION AND DESIGN OF THE STUDY [1-5]
1.1 INTRODUCTION
1.2. PRODUCTION LEVEL OF MILK
1.3. DISTRICT UNIONS OF FEDERATIONS
1.4. FUNCTIONS OF CO-OPERATIVE MILK PRODUCERS UNION
1.5. FOUR SMALL BRANCHES
II PROJECT DESIGN [6-14]
2.1. STATEMENT OF THE PROBLEM
2.2. SCOPE OF THE STUDY
2.3. PERIOD OF THE STUDY
2.4. METHODOLOGY
2.5. COLLECTION OF MILK
2.6. DAIRY PROCESSING

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2.7. TYPES OF MILK
2.8. COLOR INDICATION AND COMPOSITION OF MILK PACKET
2.9. QUALITY CONTROL LAB
3.0. PERCENTAGE OF FAT IN MILK
3.1. DIFFERENT PRODUCT
3.2. VAPOUR ADSORPTION COOLING SYSTEM
3.3. EFFLUENT TREATMENT PLANT OF AAVIN
3.4. MAINE USE OF EQUALIZATION TANK
3.5. CLARIFIERS
3.6. PRIMARY CLARIFIER
3.7. SECONDARY CLARIFIER
3.8. BALANCING TANK
3.9. THE OUTLET WASTEWATER
4.0. CONCLUSION

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CHAPTER 1
INTRODUCTION AND DESIGN OF THE STUDY
1.1. Introduction
About the Company
Aavin union is a Government union which was founded in the year 1958. It is a Tamil Nadu-based
milk producer's union. Milk is procured from the Village level societies twice a day. The milk cost
payment is made on the basis of a quality test which consists of Fat and Solid Non-fat content. It is
one of the 17 Milk Procurement Unions Plants across 30 districts in the State of Tamil Nadu. Aavin
Dairy is networked with around 12000 Milk Producer’s Cooperative societies, with daily milk
production of the order of 25 to 30 lakh liters
1.2. The production level of Milk
The Aavin Dairy industry produces about 65,000 liters of milk during the Summer period and
80,000 liters of milk during the Winter period. This happens because during the dry summer months
there will be a low availability of green fodder for the cattle for the fall in milk production.
1.3. District unions of federations
There are about 17 district Co-operative Milk Producers’ Unions functioning in Tamil Nadu,
covering 30 Districts. They are:
1. Kancheepuram-Tiruvallur
2. Villupuram
3. Vellore
4. Dharmapuri
5. Salem
6. Erode
7. Coimbatore
8. Nilgiris
9. Madurai
10. Dindigul
11. Trichy
12. Thanjavur
13. Pudukkottai

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14. Sivagangai
15. Virudhunagar
16. Tirunelveli
17. Kanyakumari
1.4. Functions of Co-Operative Milk Producers Union
1. Establishment of chilling centers
2. Formation of new milk routes to collect milk produced by the members of the societies.
3. Collection of milk from societies, process, and pack in modern dairy.
4. Supply of quality milk.
5. Fixation of procurement and selling price of milk.
6. Supply of inputs to the members of the societies.
1.5. Four small branches
Tirunelveli is the main branch of milk production and producing dairy products. Under Tirunelveli,
there are four small branches located as follows
1. Sankarankoil
2. Vallioor
3. Shathankulam
4. Kovilpatti.
These are also called as “Chilling center”
CHAPTER II
PROJECT DESIGN
2.1. Statement of The Problem
A study with the title “MILK AND MILK-BASED PROCESSING METHODS AND
EFFLUENT TREATMENT PLANT STUDIES OF AAVIN MILK INDUSTRY,
TIRUNELVELI”.
2.2 Scope of The Study
We have started this project to know about the Milk and milk-based processing methods of Aavin
situated at Tirunelveli. We have attained a lot of information which includes production, products,
sales, profit, loss etc. In this project, we also took effect to know about assessing the quality of the
milk via various test and also we have learned about the wastewater management.
2.2. Objectives
1. To obtain extra knowledge about the dairy center.

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2. To know about the function and activities of Aavin.
3. To know about the financial highlight of the dairy center.
4. To know about the process of a dairy product in the dairy center.
5. To know about the wastewater management in the dairy center.
2.3. Period of The Study
The duration of the study was from 08.03.20019-09.03.2019.
2.4. Methodology
The present report data was obtained from the staff member of the Aavin dairy center.
2.5. Collection of milk
Raw milk:
The milk is collected from many villages. The milkers give their milk through dairy form situated
on their village. Therefore, both societies and milk givers can earn money with some profits. The
collection of milk which is directly got from the milk-giver is known as the “Raw Milk”. The milk
can be collected in the morning and evening.
2.6 Dairy processing:
The milk collected from the chilling centers are brought to the dairy and are kept for assessing the
quality. Some of the types of milk viz., standardized milk, high fat, high protein milk, are being
produced for the requirements of the consumers; the surplus fat is converted into ghee.
The high fat and high protein milk are packed in 250ml and 500ml sachets. In the dairy, milk, ghee,
ice-cream flavored milk, rose milk, butter milk etc., are being manufacturing and marketing. 3.8
Processing of milk
In Tirunelveli depot, processing of milk is of two types as described. The process of pasteurization
is carried out. The process pasteurization involves streaming at about 78℃ and then chilling at 4℃ to
kill harmful bacteria. Then the bacteria-free milk is stored in a silo (Large Milk Storage Tank)at 6℃.
This milk is then packed in ¼, ½, 1-liter pockets and then stored about 7℃ to 8℃. Finally, these
pocket milk are distributed to various market places for sale.
Homogenization
Homogenization is a process that reduces the size of fat globules by forcing pressurized hot milk
through small whole causing turbulence, the break up the larger fat globules so that they remain
suspended rather than separating in a cream layer at the top. It may be total or partial. Partial
homogenization is a more economical solution because a smaller homogenizer can be used. It must
always be sufficiently efficient to prevent creaming. This tank comprises of 10,000-liter capacity.

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Pasteurization
It is a process by which the disease-causing bacteria in the milk are destroyed without losing its
nutritive values. The milk is boiled at 600℃ for thirty minutes and cooled quickly. Every milk was
pasteurized for avoiding mistakes. In milk, the coloration distinction between pasteurized and raw
milk is associated with the homogenization step that takes region prior to pasteurization. Before
pasteurization, milk is homogenized to separate the solids (fat) from the liquid, which ends within the
pasteurized milk having a whiter look as compared to raw milk Pasteurization destroys 100% of
pathogenic bacteria, yeast and mold and 95% to 99% of other bacteria.
2.7. Types of Milk
Full cream milk: Full cream milk, also called whole milk is usually given to children, teenagers, and
body builders. This milk is called so because it contains all the milk fat without adding or removing
anything. It is collected from the dairy herd and it undergoes various processing techniques like
pasteurization to kill potentially harmful bacteria before it reaches the general public. One glass
would generally contain 3.5% milk fat, which provides about 150 calories. Full cream milk is also
creamier and full of flavor. This further can be divided into two parts:
Whole standardized milk: In this milk, the fat is contained to a minimum of 3.5%.
Whole homogenized milk: Fat globules are broken down and made to spread throughout the milk to
prevent the formation of the creamy layer at the top.
Single toned milk: Adding skimmed milk powder and water to whole milk makes single toned milk.
It has about 3% fat and minimizes body’s absorption of cholesterol from the milk. It contains almost
the same nutrition as whole milk except the fat-soluble vitamins. One glass of toned milk provides
around 120 calories.
Double toned milk: This milk is obtained by adding skimmed milk powder to whole milk and has
about 1.5% fat content. Double toned milk is ideal for those trying to maintain weight as it keeps the
calorie intake under control and also helps in weight loss. It has least fat comparing other milk.
Skimmed milk: Skimmed milk has 0.3% to 0.1% fat content. Though skimmed milk contains all the
nutrients found in whole milk like the vitamins and minerals, it gives you just half the calories of full
cream milk (around 80 calories per glass of milk). It contains slightly more calcium than whole milk
and even lower levels of fat-soluble vitamins, particularly vitamin A, as this is lost when the fat is
removed.

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2.8. Color indication and Composition of Milk packet
Aavin Blue milk packet
Homogenized pasteurized STANDARDIZED MILK with 4.5% fat and 8.5% SNF content
Homogenized pasteurized full cream milk with Min. 6.0% fat and 9.0 % SNF content
Pasteurized toned milk with 3.0% fat and 8.5%SNF
Aavin Green milk packet
Homogenized pasteurized STANDARDIZED MILK with 3.5% fat and 8.5% SNF content
Aavin Brown milk packet
Pasteurized Double toned milk Homogenized milk with 1.5% Fat and 9.0 % SNF content
Aavin Orange milk packet
Homogenized pasteurized full cream milk with 6.0% fat and 8.5% SNF content
2.9. Quality control Lab
Different kinds of Test
A. Organoleptic tests
The appearance of the surface of the milk and the lid is observed and inspected right away after
disposing of the lid of the incoming milk can. Any strange coloration of the milk, seen dirt and
particles, changes in viscosity etc. are determined. Any strange odor if noticed by way of inhalation
of air status above the milk inside the upper part of the milk can also determined.
B. Lactometer test
If the milk appears during organoleptic inspections to be too thin and watery and its color is
"blue thin" it is suspected that milk contains added water. Lactometer test serves as a quick
method for determination of adulteration of milk by adding water. The lactometer test is based on
the fact that the specific gravity of whole milk, skim milk and water differ from each other.
C. Clot-on- boiling test
Also, this test is used for rapid testing of increased acidity of milk. As stated above heating will
precipitate proteins of milk if it is sour. This method is slower than alcohol test but very useful
where and when an alcohol test is not available. This test is performed simply by heating a small
amount of milk in a test tube over a flame or immersed in boiling water for five minutes. The
result can be seen immediately. If no coagulation occurs, it indicates that milk can stand heating
operations at the time of testing.

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D. Fat test
Gerber method
The Gerber Method is a primary and historic chemical test to determine the fat content of
substances, most commonly milk and cream. The Gerber Method is the primary testing method
in Europe and much of the world. But, the US is following the Babcock test primarily similar to
the Gerber Method. It was developed and patented by Dr. Niklaus Gerber of Switzerland in
1891.
Procedure:
 For performing this test we should take 10 ml 90% of Sulphuric acid and 10.75 ml of
Milk sample that may be Raw milk or any other milk.
 Then, add 1 ml of Amyl alcohol and shake it up and down.
 Centrifuge it by setting 1300 rpm.
 The appearance of the golden yellow proofs that the fat content is separated.
Fig.1.1.Schematic view of the Gerber method for the fat removal
E. Methylene Blue Dye Reduction Test
Methylene Blue Dye Reduction Test, commonly known as the MBRT test is used as a quick
method to assess the microbiological quality of raw and pasteurized milk. This test is based on
the fact that the blue color of the dye solution added to the milk get decolorized when the oxygen
present in the milk get exhausted due to microbial activity. The sooner the decolorization, more

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inferior is the bacteriological quality of milk assumed to be. This test is widely used at the dairy
reception dock, processing units and milk chilling centers where it is followed as
acceptance/rejection criteria for the raw and processed milk.
Procedure:
The test has to be done under sterile conditions. Take 10 ml milk sample in a sterile MBRT
test tube. Add 1 ml MBRT dye solution (dye concentration 0.005%). Stopper the tubes with a
sterilized rubber stopper and carefully place them in a test tube stand dipped in a serological
water bath maintained at 37±1⁰C. Record this time as the beginning of the incubation period.
Decolorization is considered complete when only a faint blue ring (about 5mm) persists at the
top.
3.0 Percentage of fat in milk
Milk Fat percentage SNF Percentage
Toned Milk 3.0 8.5
Standardized Milk 4.5 8.5
Double Toned Milk 2.0 9.0
Table 1.1. Showing the percentage of fat in milk
3.1 Different product:
The different product by Aavin is listed in the following list.
1. Butter
2. Milk Khoa
3. Ghee
4. Ice cream
5. Milk cake
6. Curd and butter milk
3.2. Vapor Adsorption Cooling system
The milk is cooled with the help of refrigeration compressor, the ammonia was cooled up
by the water. The water again cycles throughout the pipe and again it falls like rain.
Normally, water is a strong adsorbent of NH3. Water is a strong absorbent of NH3. If NH3 is
kept in a vessel that is exposed to another vessel containing water, the strong absorption

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potential of water will cause evaporation of NH3 requiring no compressor to drive the vapors.
A liquid pump is used to increase the pressure of a strong solution. The strong solution is then
heated in a generator and passed through a rectification column to separate the water from
ammonia. The ammonia vapor is then condensed and recycled. The ammonia vapor is then
condensed and recycled. The pump power is negligible hence; the system runs virtually on
low- grade energy used for heating the strong solution to separate the water from ammonia.
These systems were initially run on steam. Later on, oil and natural gas based systems were
introduced.
3.3. EFFLUENT TREATMENT PLANT OF AAVIN
The Effluent treatment plant studies show that how the Aavin industry is recycling the
wastewater for further use. Some of the water in the Balancing tank is utilized by the cow
indirectly by some process. Effluent from the collection tank comes to the equalization tank
in wastewater treatment. The main function is to act as a buffer. To collect the incoming raw
effluent that comes at widely fluctuating rates and position to the rest of the ETP at a steady
flow rate. During the peak hours, ETP comes at a high flow rate. The equalization tank stores
this effluent and lets it out during the noon peak time when there is no /little incoming
effluent. The inlet pipe of equalization tank carries filtered effluent from cooling tower. The
raw effluent in the industry includes the washing out of some instruments, milk pockets, milk,
and so on.
3.4. Maine use of Equalization tank
 To reduce the temperature in the Equalization tank
 For homogeneous mixing
 To give the optimum dosing of HCl for neutralizing
 To increase the Bacteria growth in FBBR
 To reduce the insoluble BOD and COD in the System
 To avoid the solids cloaking in the air distribution system in the Equalization tank
 To increase the air volume in the equalization tank in wastewater treatment
 To remove the odor in Equalization tank due to the anaerobic reaction
 To increase the efficiency of Biological system
 To reduce the current and electrode consumption in the EC system

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3.5. Clarifiers
Clarifiers are settling tanks built with a mechanical approach for non-stop removal of
solids being deposited with the aid of sedimentation. A Clarifier is commonly used to cast off
strong particulates or suspended solids from the liquid for explanation and (or) thickening.
Concentrated impurities, discharged from the lowest of the tank are referred to as sludge,
whilst the particles that waft to the surface of the liquid are referred to as scum.
3.6. Primary Clarifier
Primary wastewater treatment systems may include both clarification and physical-
chemical treatment equipment, depending on the components in the wastewater. Clarification,
through the process of sedimentation, is the separation of suspended particles by gravitational
settling. This operation can be used for grit and solids removal in the primary settling basin,
removal of oil and grease, removal of chemically treated solids when the chemical
coagulation process is used or solids concentration in sludge thickeners.
Primary Clarifiers reduce the content of suspended solids and pollution embedded in those
suspended solids. Because of the huge quantity of reagent necessary to treat home
wastewater, preliminary chemical coagulation and flocculation are generally no longer used,
last suspended solids being reduced through following ranges of the machine. However,
coagulation and flocculation can be used for constructing a compact treatment plant (also
called a "package deal treatment plant"), or for further polishing of the handled water.
3.7. Secondary clarifier
Secondary treatment is a treatment process for wastewater (or sewage) to achieve a certain
degree of effluent quality by using a sewage treatment plant with physical phase separation to
remove settleable solids and a biological process to remove dissolved and suspended organic
compounds. After this kind of treatment, the wastewater may be called secondary-treated
wastewater. Secondary treatment is the part of a sewage treatment series disposing of
dissolved and colloidal compounds measured as biochemical oxygen demand (BOD). The
secondary remedy is traditionally implemented to the liquid portion of sewage after number
one treatment has removed settleable solids and floating cloth. The secondary remedy is
generally performed by indigenous, aquatic microorganisms in a controlled cardio habitat.
Bacteria and protozoa consume biodegradable soluble organic contaminants (e.g., Sugars,

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fats, and natural quick-chain carbon molecules from human waste, meals waste, soaps, and
detergent) while reproducing to shape cells of organic solids.
3.8. Balancing tank
A balancing tank has enough volume to permit a non-uniform waft of wastewater to be
amassed, blended and pumped ahead to a treatment gadget at an extra uniform fee. Pumping
is controlled by using stage sensors and its price varies in step with the intensity of liquid in
the balancing tank. A balancing tank ought to be mixed to prevent the settlement of solids and
to ensure that the wastewater first-class is as uniform as possible. To save you anaerobic
situations and odors developing previous to remedy, the contents of balancing tanks may also
want to be aerated. Venturi aerators will mix and aerate, at the same time as excessive speed
propellers are used to preserve solids in suspension.
3.9. The Outlet wastewater
The water which is expelled from the industry is considered as non-toxic and purified from
harmful bacteria. The water from the outlet is used up for various purposes like washing or
even as helpful for studying the basic parameter. The pollution control board officers will
come there for the analysis of the inlet and outlet water sample. This is how wastewater is
recycled and managed.
4.0. Conclusion
We have started this project to know about Aavin milk processing and ETP. We have
observed how to treat the milk, produce the related product, quality materials, and ETP
management. Thus we have analyzed how the and for what the people bring this product.

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BIBILIOGRAPHY
1. Introduction of Aavin - Encyclopedia
2. Profile of the milk - Aavin milk nellai
3. Processing of milk - Aavin nellai
4. History - Wikipedia
5. Related products - www.aavin.com
6. Study area - www.aavinnellai.com
7. Gerber Method - Wikipedia
8.Aavin Milk packet - www.Quora.com
9. Quality of Milk - Teuvo V.A
10.Dairy Processing - Aavin milk nellai