College of Dairy Science and Food Technology,

Raipur (C.G.)
A REPORT
ON
Hands on Training and Experiential Learning
(DHT-411)
at

Chhattisgarh State Cooperative Dairy Federation Limited,

Raipur
From 13 july 2016 to 20 october 2016

Submitted to Submitted by
Dr S. Karthikeyan Anshul Nutan Kujur,
Prof and Head of Preeti Khunte,
Dept. of Food Technology Reshma Akhter Qureshi,
Shreshta Prakash Sahu,
 CERTIFICATE
Thisis to certify that Mr. Anshul Nutan Kujur, Ms. Preeti Khunte,
Ms. Reshma Akhter Qureshi& Mr. Shreshta Prakash Sahu
satudents of B.Tech (DT) Final year (2015-2016) College of Science
and Food Technology (Chhattisgarh kamdhenu Vishwavidalaya).
Raipur has successfully completed Training at Chhattisgarh State
Cooperative Dairy Federation Limited, Raipur from 13 July 2016
to 20 October 2016 as a part of their academic curriculum.

Their conduct during the training was good.

Mr. R.k. Singhdev

Asstt. Gen. Manager
CSCDFL, Raipur

Submitted by:
Anshul Nutan Kujur
Advisors: Preeti Khunte
Dr. A.K. Agrawal Reshma Akhter Qureshi
Er. R. Sahu Shreshta Prakash Sahu
Acknowledgement

We wish to express a deep sense of gratitude and regard to our advisor Dr. A.K
Agrawal (Professor and Head Department of Dairy Engineering) and Er. R Sahu
( Professor Department of Food Technology )for his valuable guidance and
help.

We would also like to express our gratitude to Dr. U.K. Mishra (Vice chancellor
of C.G.K.V), Dr. Sudhir Uprit (Dean C.O.D.S.F.T) and all the professors’ of
College of Dairy Science and Food Technology , Raipur who helped directly or
indirectly during the entire training period.

We heartily extent our sincere thanks to Dr. S. Kartikeyan Professor Incharge

hands on training and experiential learning and all for their kind cooperation.

We are heartily thanks to Mr. Mukul Tayal (general manager &Plant Incharge
of Devebhog) for their guidance and experimental knowledge for our business
plan.

At last we wish to convey our regards to all the staff, our friends and especially
our beloved parents whose moral support strengthen this hand on training and
experiential learning.
INTRODUCTION
Chhattisgarh State Cooperative Dairy Federation Limited, Raipur is a milk
processing plant at Dist. Durg. It is 21km from Raipur, begun on October 1,
1987 and was inaugurated by late Shri Madhav Rao Sindhia. It is spread over
approximately 24 acres area.

Chhattisgarh State Cooperative Dairy Federation Limited, Raipur tries to extent

to all kind of consumers by manufacturing products either by traditional
processing technique or by Modern Technologies. The milk requirement of
plant is met up by the different dairy cooperative societies ,which are located
nearby localities of Raipur, Durg or nearby village. The numbers of such
registered active societies are 693 covering 9 routes.

CHHATTISGARH SAHKARI DUGDH UTPADAK SANGH, offer milk

processing plant for processing of milk and milk products. The handling
capacity of Milk is 1 lakh litre per day. It produces a wide range of milk product
like Lassi, Buttermilk, Paneer, Shrikhand, Curd , Sweet curd, Ghee, Khoa,Peda ,
Flavoured milk, Toned milk, Double toned milk, Standardized milk. This wide
range of product is maintained by different departments of plant in which
approximately 165 employee work.

CSCDFL, like other industries follows certain standards for milk and milk
product processing. One of these standards is FSSAI Standard , which stand for
Food Safety And Standard Authority of India . CSCDFL is also ISO Certified .

Thus in short CSCDFL motive is to provide the best quality product to

customers, and with assistance of government and common people it is
performing well so far.

Formerly CSCDFL was known as SANCHI but after the division of Madhya
Pradesh and Chhattisgarh it was named as DEVBHOG. On September 11, 2011
it got its name.
OBJECTIVES OF CGSCDF :
The main objectives of CGSCDF are :-

 Producer Welfare
 Consumer Welfare
 Rural Development
 Maintain good quality
 Cooperation
 Educational and Training Programme

OVERVIEW OF PLANT PROFILE

Capacity 1 Lac litre/day

Total area 24 Acres

Constructed area 4 Acres

Total employee 165

Address Chhattisgarh State Cooperative Dairy Federation Limited

Village Urla

Post B.M.Y. Chroda, Disst. – Durg (C.G.)

Pin Code 490025

ORGANIZATION :-

GENERALMANAGER

Superintendent Asst.Finance Asst. Marketing

Manager Manager
SECTIONS IN RDS:-
 Production
RMRD Section Finance Marketing

 Manager
Processing Section
Manager Manager

 Product Section
 Engineering Section
 Quality Control
 Marketing Section
A brief Description of the each section is as follow:-
Formen
Sales
RMRD SECTION:- Accountant
Supervisor

Raw milk receiving dock is the most important section of dairy as milk is highly susceptible
Worker
to microbial deterioration and any delayClerks
in reception of raw milk favours the deterioration
Sales of
quality of milk. This is the place where raw milk is received by various modes of
transportation. RMRD is the section where the decision regarding the acceptance of milk is
taken.

The operations carried out at this section are as follows:

• Unloading: Here the cans are unloaded from the vehicles and lids are opened and after then
placed at conveyor.

• Before it reaches the Weighing tank through conveyor its organoleptic test is done and sample
is taken from each can for laboratory testing.

• Emptying and Weighing: Milk cans are emptied in the weighing tank (capacity 500 lit) and
the weight of milk is recorded. And then milk is dumped through strainer in the dump tank
(capacity – 1000litres) after emptying cans they are inverted on the drip saver with the
capacity of maximum 6 can at a time.

• Can washing is done manually with hot water and liquid soap solution then after it is washed
by normal water.

• Crates’ washing is done with the help of crate washer having capacity of 5 to 6 crates per
minute.
 • Operations occurring at RMRD section ends with the reloading of emptied washed cans in the
vehicles and in case of tankers they are washed after emptying and returns again for other
shift.

PROCUREMENT OF MILK:
The data regarding procurement of milk is as under:

Milk reception time in morning 10.30am – 11.30am

Avg. milk collection 6000 – 7000kg

Milk reception time in evng 10pm – 11pm

Avg. milk collection 5000 – 6000kg

Avg. Fat % 4.2

Avg. SNF % 8.3

Milk comes from 9 routes covering 120 societies and 5 chilling centers to the
plant.
Information regarding routes (9) is as follows:

Route Name of Routes Distance No. of societies on Time of

No. the route arrival

001 Raipur–Abhanpur 81 km 17 10:00

003 Raipur–Simga 170km 15 10:35

005 Raipur–Balouda bazar 127km 26 11:00

007 Raipur–Pithora 127km 28 10:50

008 Raipur–Ghamga, Berla 75km 17 10:30

009 Raipur–Pithora, bagabahara, 220km 12 10:45

mahasamund
019 Raipur–Rajnandgaon, risali 135km 1 9:45
0022 Raipur–Sahdevnagar 3 9:45

0023 Raipur–Khursiparchhawani 1 9:45

Information regarding chilling centers is as follows:
 DHAMTARI
 PENDRA
 BILASPUR
 PAKHILANJUR
 JAGDALPUR
 BASNA

PROCESSING SECTION:-
In processing section Milk is processed to obtained market milk and
various other milk products. In this section milk is received from the
RMRD section, then milk is chilled to 5⁰C and then stored into the
storage tank. From the storage tank it goes into the balance tank, where it
is standardized to obtain desired fat and SNF percentage, then from the
balance tank milk goes to the pasteurizer for pasteurization and then it
goes to the packaging section for packaging. In short, milk is chilled,
fore-warmed, filter/clarified, Homogenized, Pasteurized and Packed in
the processing section

Processing Section consist of :-

 STORAGE TANK

No. of Storage Tank 7

Capacity of each tank 15000 L

 MILK CHILLER
  Milk is chilled to 5⁰C in milk chiller.

Description about milk chiller is given below

Number 1
Type CM 20
Make HMT

Capacity 20,000 Liters per hour

Temperature range 4-50C
Weight 1510 kg
No. of plates 73
Cooling medium Chilling water 60,000 lts./hour

 PASTUERIZER
Milk Pasteurizer is used to pasteurized the milk. The pasteurization system
used in RDS is HTST Pasteurizer which gives a continues flow of milk ,
which is heated to72⁰C for 15 sec. Plate heat exchanger are used to heat the
milk. The steps or stages that are involved as milk passes through the
pasteurizer are
1. Balance tank
2. Pump
3. Regeneration section (heating)
4. Holding section
5. Regeneration section (cooling)
 Description about the Pasteurizer is as follow:-
Number 1

Type Plate heat exchanger (HTST)

Design Pressure 6 bar

Test Pressure 8 bar

Design temperature 1100C
Temperature range 5- 800C
Capacity 10,000 Liters per hour

Heating medium Hot water( 4500 Liters/hour at 830C)

Chilling medium Chilled water(4500 Liters/hours at 1.50C)
Steam pressure 4 kg/sq.cm
No. of plates in heating medium 39

No. of plates in chilling medium 23

Weight 2770 kg

 CREAM SEPARATOR

Cream separator is used to separate cream and skim milk from the milk .
Cream is obtained from the milk either by centrifugal method.
 The description about cream separator is given below:-

Number 2
Make Alfa level
Speed of motor shaft 1500 rpm
Capacity 10,000 Liters/hour

Maximum speed (bowl) 5925 rpm

Electric current frequency 50MHz
Max. density of feed 1100 kg/m3
Max. density of sediment 1600 kg/m3
No. of disk in separator 133

 HOMOGENIZER
Homogenizer is used to reduce the size of the fat globules .
 The description about the homogenizer is given below :-
Number 1

Working pressure In 1st stage 2500 psi

In 2nd stage 500 psi

Capacity 10,000 Liters/hr

Pump Triplex pump

No. of piston 3

Milk feeding temp. 60-65 °C

PRODUCT SECTION
In product section various dairy product are made. The products made in the
plant are as follows:

 Market milk (Toned, Double toned, Standardised)

 Butter

 Ghee
  Paneer

 Sweet curd

 Shrikhand

 Lassi

 Buttermilk

 Flavoured milk

 Khoa

 Peda

A brief description about them are as follows:

MARKET MILK

 Three types of market milk are manufactured in plant. They are as

follows:

1. Toned milk

2. Double toned milk

3. Standardised milk

The three kind of milk manufactured is sold in bellow form

TONNED MILK

FAT – 3 % SNF 8.5 %

DOUBLE TONNED MILK

FAT- 1.5 % SNF – 9 %

STANDARDISIED MILK

FAT – 4.5 % SNF – 8.5 %

FLOW DIAGRAM FOR MARKET MILK MANUFACTURE:

Recieving milk

Chilling milk ( 5 ᵒ C )
 Pre-heating (35-40°C)

Filtration/Clarification

Cooling & Storage (5°C)

Standardization

(Tonned milk Fat 3%, SNF 8.5%

Double Tonned milk Fat 1.5%, SNF 9%

Standardized milk Fat 4.5% , SNF 8.5%)

Homogenization (2500 & 500 psi)

Pasteurization (72°C/15 sec.)

Packaging

Storage (5°C)

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 it.

 At CGSCDF butter is prepared mainly for ghee making.

 The picture shows the manufacture of Butter in Chhattisgarh State

Cooperative Dairy Federation Limited, Raipur:

CONTINUES BUTTER MAKING MACHINE DETAIL

Make HMT ltd.

Type BM 08

Serial no. 1157

Weight of machine 1250 kg

Speed 1500 rpm

Capacity 325-340 kg/hours

FLOW DIAGRAM FOR BUTTER MANUFACTURE:

Receiving pasteurized cream

Cream feeded to the continuous butter making machine

Churning (at 9 to 11◦C for 40-45 minutes)

 ↓

Washing (with chilled water) → Butter milk

Working

Butter obtained

storage (at -23 to -29◦C)

GHEE:

 Ghee may be defined as clarified butter fat without any solid milk
particles

 Ghee prepared from cow or buffalo milk or desi (cooking) butter or

from cream to which no colouring matter is added.

 At CGSCDF, an avg. ghee production is about 7000 litres per month

 Ghee manufactured is sold as below:

FLOW DIAGRAM FOR GHEE MANUFACTURE:

Milk

Filtration & Clarification

Pasteurization (720C/ 15sec)

Cream separation (100 kg/hr) Skim Milk

CREAM

Churning (40-45 min) → White Butter (Cold store)

Transfer to ghee melting vat (55-600C)

Transfer to ghee boiler

Pre-stratification (75-800C)

Heating (106-1100C)
 ↓

Filtration → Ghee residue

Ghee storage cans

Packaging

PANEER:

 Paneer refers to the milk solids obtained by the acid coagulation of hot
milk and subsequent drainage of the whey. The acids commonly used
are citric, lactic, acetic etc. and sour whey or cultured whey can also
be used for coagulation of milk.

 At CGSCDF, an avg, production of paneer is 140 kg per day.

 Paneer manufactured at plant is sold in below form:

FLOW DIAGRAM OF PANEER MANUFACTURE:

Receiving Chilled milk

Heating ( 90 ˚C)

Cooling (70˚C)
 ↓

Addition of coagulant @ 1-2 %(citric acid)

Coagulation (70˚C)

Draining

Hooping

Pressing

Dipping in chilled water (4-5˚C)

Packaging

Storage

MISHTI DAHI:

 Mishti dahi is popular traditional sweetened fermented milk product. The

eastern parts of India, especially in West Bengal, Assam, Bihar and
Orissa. The sweetened variety of dahi is known as Mishti dahi.

 At CGSCDF, an avg. production of sweet curd is about 250 cups per

day.

 Mishti dahi manufactured at plant is sold in bellow form:

FLOW DIAGRAM FOR MISHTI DAHI MANUFACTURE:

Whole milk

Standardization (fat, 3.5%; SNF, 9.0 %)

Pre-heating (650C -700C)

Homogenization (56kg/ cm² at 650C )

Addition of sugar (approx. 15%)

Heating at 850C for 10 min.

Cooling to 40 0C

Inoculation (Culture @ 1.0%)

Filling in cups
 ↓

Incubation at 400C for 16-17h

Storage at 40C

SHRIKHAND:

 Shrikhand is a semi –solid, soft, sweetish, sour indigenous Dairy

product. It is prepared by lactic acid coagulation of whole milk and
explusion of whey from the curd, followed by mixing with sugar,
flavouring, colouring materials, fruits etc.

 Shrikhand manufactured at plant is sold as bellow form:

FLOW DIAGRAM SHRIKHAND FOR MANUFACTURE:

Milk (fat 6%, SNF 9%, pH 6.7)

Heat Treatment (90ºC/10min.)

Cooling (30ºC)
 ↓

Inoculation (@1% lactic culture)

Incubation

Dahi

Drainage of Whey

Chakka

Mixer

Shrikhand

Packaging at Room temp.

Storage

LASSI:

 Lassi is a fermented milk beverage popular in all parts of the country.

It is a white to yellowish in colour, viscous fluid with creamy mouth
feel, rich aroma and has a pleasant mild acidic taste. It is flavoured
either with salt or sugar and other condiments, depending on regional
preferences.

 CGSCDF an average production of lassi is 80 litres or 400 cups (200

ml each) per day.
  Lassi manufactured at plant is sold in bellow shown package.

FLOW DIAGRAM FOR LASSI MANUFACTURE:

Receiving plain curd (about 40 kg)

Put it into two cans (approx. 20 kg in each can)

Adding sugar (approx. 6 kg in each can)

Adding rose flavour

Adding chilled water (to make up the full volume of can)

↓
 Mixing by plunger properly

Filling in 200 ml cups

Sealing the cups

Storage & distribution

BUTTERMILK:

 Butter Milk is a by Product obtained during churning of curd which is

known as ‘chhach’ or ‘mattha’. The nutritional value of butter milk is as
high as fermented milk.

 At CGSCDF, an average butter milk production is 120 litres per day.

 Buttermilk(Matha) manufactured at plant is sold in bellow shown

package.

FLOW DIAGRAM FOR BUTTERMILK MANUFACTURE:

Receiving curd (about 40 kg)

↓
 Put it into three cans equally

Adding chilled water (to make up the full volume of each cans)

Adding salt (approx. 1 kg for all the three cans)

Adding Jeera & Black pepper (100 g of each in each can)

Mixing by plunger properly

Filling in 200 ml pouch (by FFS machine)

Storage & Distribution

FLAVOURED MILK:

 Flavoured milk is defined as a sweetened dairy drink made with milk,

sugar, colourings and artificial or natural flavourings.

 At CGSCDF, about 1500 litters double toned milk is used in one lot &
flavoured milk prepared about 700-750 bottles (200 ml each). It is
prepared according to the demand; not regularly.

 At CGSCDF three types of Flavoured Milk are prepared that is :-

Chocolate Flavoured Milk

Eliachi Flavoured Milk

Pista Flavoured Milk

 Flavoured milk manufactured at plant is sold in below form:

FLOW DIAGRAM FOR FLAVOURED MILK MANUFACTURE:

Pasteurized double toned milk

Mixing flavour (0.05%)

Colour (0.05%)

Sugar (7%)

Tri-sodium citrate

Filling in bottles

Capping

Sterilization (121⁰ C/20 min,15psi, 1000 bottles/batch)

Cooling
 ↓

Poly seal shrink packaging

Storage

KHOA:

 Khoa or mava refer to the partial dehydrated whole milk product prepared
by the continous heating over the direct flame in the karahi while
constantly stirring cum-scraping by using a khunti till it reaches semi
solid (Doughy) consistency. There after the pan content are removed
from the fire and worked up in to the solid mass.

 According to PFA (1976), Khoa is product obtained from cow or

buffaloes milk or combination there of the rapid drying the milk fat
content should not be less than 20% of the finished product.

 It is a new product being started in plant for both selling and making
Peda in plant.

 Machine installed at plant for khoa making is as below:

FLOW DIAGRAM FORKHOA MANUFACTURE:

Chilled milk (5°C)

Heated to 85°C in water bath

Pour in to the khoa making machine

Operating under steam

Stirring cum scraping

Dehydration to semi solid consistency

Cooling to room temp.

Packing and storage.

PEDA

 The quantity of peda produced in India exceeds any other indigenous

milk-based sweet using khoa as the raw material.

 Peda or doodh peda is prepared on a small scale by halwais using khoa as

the base material mixed with sugar and flavours.

 Peda is usually packed in paperboard cartons with a parchment paper of

grease proof paper liner. It is usually sold through confectionery shops
Peda is whitish yellow in colour and has a coarse grainy texture. Kesar
(saffron) peda is one of the preferred peda in which saffron is used for
added flavour and colour.

FLOW DIAGRAM FOR PEDA MANUFACTURE:

Receiving milk (5°C)

Fore warming

Pour in to the khoa making kettle

Continuous heating, stirring cum scraping to a semi solid consistency

 Addition of sugar and flavor and thoroughly mixed in pan

(Sugar@33% of yield khoa)

Peda mass is transferred to room temperature

Peda mass is fed to peda shaping machine

(Size 1.5 to 1.6 cm & weight 10-15gm)

Packaging & storage of Peda

MARKETING SECTION

 Chhattisgarh State Cooperative Dairy Federation Limited, Raipur follows

the following channels:

 Manufactures → Distributors → Retailer → Consumers

 The milk distribution vehicles reports at dock on 1.00 PM in day shift and
on 2.00 AM in night shift.

 Chhattisgarh Sahakari Dugdh Utpadak MahaSangh Limited is marketing

its milk and milk product through DEVBHOG brand.
 It’s the responsibility of this department to increase the sale of the
products made in plant for profit motive.

 Average Milk collection per day – 80000-85000ltr

 Milk collection price per liter – 1.60 Rs.

 Milk distribution price per liter – 0.75 Rs.

 Total turnover per year – 90 crore

 Total revenue per year – 73 crore

 Average milk sale in Raipur per day – 26000 ltr

 Milk products packaging material brand name and place - IDMC film &
Ahmedabad

 The total plant employees = 200

 Total vehical for dispetch is 18, but devbhog vehical is 2

MILK COLLECTION ROUTE

The milk collection society route in morning and evening table:-

ROUTE CODE ROUTE NAME

1 Raipur-Abhanpur
3 Raipuir- Sigma
5 Raipur –Balodabazar
8 Raipur – DhamdaBerla
13 Kawardha ( only morning)
20 Pipariya B.M.C (only evening)
22 Sahdevnagar
24 Tamasivani

MILK TRANSPORTATION ROUTE :-

The total milk transportation route is 18 in the table :-

 Route code Route name
1-8 Raipur
7-9 Bhilai
10 Durg
11 Balod
12 Rajnandgaon
13 Kawardha, bemetara
14 Kanker
15 Mahasamund
16 Rajim
17 Gariyaband
18 General

MILK CHILLING CENTRE :-

TOTAL MILK CHILLING CENTRE IS 18 SHOWN BELOW:-

1. Jagadalpur

2. Bhatagaon

3. Rawand

4. Raipur

5. Bilaspur

6. Basna

7. Raigarh

8. Kawardha

9. Rajnandgaon

10.Jashpur

11.Koriya

12.Ambikapur
13.Manpat

14.Sarangarh

15.Lendra

16.Tappa

17.Dhamtari

18.Pakhanjur

PRICE OF PRODUCT MANUFACTURE AT PLANT :-

Price of various product under different categories are shown in table:-

S PROD DISTRIBU RETAI CONSU

. UCT TOR LER MER
N NAME
O
.
Ghee 1 340 350 380
1 ltr
Ghee 175 180 195
2 500 ml
Ghee 75 80 85
3 200 ml
Ghee 5025 5150 6000
4 15 ltr
5 Milk 38.50 39 41
STD
Milk 33.50 34 36
6 TM
Milk 29.50 30 32
7 DTM
F. Milk 16.75 17.50 20
8 Bottle
Spicy 6.60 7 8
9 Butter
Milk
Sweet 9.30 10 12
1 curd
0
Lassi 16.75 17.50 20
1
1
White 280 290 310
1 butter
2
Peda 280 290 310
1 1kg
3
Peda 148 154 165
1 500gm
4
Peda 79 83 90
1 250gm
5
Khoa 264 276 300
1 1kg
6
Shrikha 16.75 17.50 20
1 nd
7 100gm
Paneer 200 210 240
1 1kg
8
Paneer 42 45 50
1 200gm
9
Plain 6.75 7.25 8
2 curd
0 100gm
Plain 8 8.50 10
2 curd
1 200gm

MILK PRODUCTS PACKAGING COST:-

S.No Packaging material Price(rupees)

. per packaging
material
1 Aluminium foil 100mm 0.36
2 Butter corrugated box 2.5kg 31
3 Milk pouch crate 191.80
4 Sweet F. milk crate 179.35
5 Crwon cork 0.30
6 SFM bottle 4.62
7 Ghee inner 1kg 165.35
8 Ghee inner 500gm 155.26
9 Lassi glass 200ml 1.50
10 Shrikhand 100ml cup 1.37
12 Plain curd cup 100ml 1.30
13 Khoa box 6.12
14 Cello tape 13.93
15 Ghee inner 500gm 154.54
16 Ghee inner 200gm 105.97
17 Ghee tin 15kg 131.21
18 Peda 500gm 7.29
19 Peda 1kg 13.63
20 Ghee duplex 1kg 4.07

MILK PRODUCTS DISPATCH PER MONTH ;-

S.No MILK QUANTITY AVG. /

. PRODUCTS MONTH
1 Ghee 15 ltr 404
2 Ghee 5 ltr 212
3 Ghee 1 ltr 233
4 Ghee 500ml 1850
5 Ghee 200ml 395
6 Milk STD 500ml 2475
7 Milk TM 500ml 873680
8 Milk DTM 500ml 234861
9 Flavoured 200ml 11340
milk bottle
10 Spicy butter 200ml 13599
milk
11 Sweet curd 100gm 9947
cup
12 Lassi 200ml 6662
 13 Peda 1kg 100
14 Peda 500gm 2821
15 Khoa 1kg 370
16 Shrikhand 100gm 6914
17 Paneer 1kg 11028
18 Paneer 200gm 11485
19 Plain curd 100gm 3416
20 Plaine curd 200gm 36115

AVERAGE UTILIZATION OF MILK :

UTILIZATION OF MILK QUANTITY ( ltr)

Milk pouch 30000 – 35000
UHT F. milk CG SOYA 20000 – 25000
TM Dispatch to Amul 15000 – 20000
For product 5000 – 7000

STAFF MEMBER

D.G.M - Mr. Mukul Tayar

General manager - Mr. Venkatram

Asst. General manager - Mr. T.S. Ahuja

S.P.O. - Mr. S.K. Soni

Mr. B.S. Patel

Mr. Vivel Temre

Mr. Umesh Sahu

Mr. Sanjay Rao

Junior assist. - Mr. Kamal Verma

Operator - Mr. Gaurav Shrivastava

Mr. Girish Bhagat

Mr. Vijesh Rao

QUALITY CONTROL SECTION

Quality control is a section where testing of milk and milk products is done,both
chemically and microbiologically to decide its suitability for further processing
and also to determine the shelf life. The tests carried out at this section
according to the need of the product and various quality test and its procedure
are describe below :-

A.MILK

1. RAW MILK TESTING

 Organoleptic test
 Fat
 SNF
 Temperature
 Acidity
 COB (Clot on boiling)
 Alcohol test
 MBRT (Methylene Blue Reduction Test)
 Adulteration test
1. Sugar Test
2. Neutraliser Test
3. Salt Test

2. PROCESSED MILK TESTING

  Phosphatase test
 MBRT test
 Standard Plate Count (SPC)
 Coliform count
 Creaming index (for homogenization efficiency)

B. PROUCT

1. PANEER TESTING
 Moisture Test
 Fat Test

2. BUTTER
 Fat Test
 Moisture Test

3. GHEE
 Free fatty Acid
 BR Test
 Moisture Test

4. SRIKHAND
 Fat test
 Acidity Test

5. DAHI
 Acidity Test

6. LASSI AND BUTTERMILK

 Acidity Test

7. KHOA AND PEDA

 Fat Test
 Moisture Test
 Acidity Test
  Total Solid content

Brief description to some of the tests are as follows: -

1. Methylene Blue Reduction Time (MBRT):-

In this test 1 ml of Methylene Blue is mixed in 10 ml of milk sample in a

serial test tube. After stopping the test tube, it is incubated at 37⁰C and the
length of time taken by milk to decolorize Methylene blue is recorded.

Grade Time
Excellent More than 5:30
Good 4:30 - 5:00
Fair 2:00 – 2:30
Poor Less than half hrs

2. Clot on Boiling (COB)

The procedure to be followed for this test is:

 Take 5 ml of milk in test tube.
 Boiling the sample in water bath 5-6 min.
 Examined for precipitate particles

A positive COB test indicates high developed acidity due to bacterial

growth.

3. Lactometer reading

There is two types of Lactometers are used:-

1) Small Lactometer (generally used for raw milk at 29⁰C)
2) Big Lactometer (generally used for processed milk at 27⁰C)

Milk
Filled in stainless steel cylinder
Lactometer dipped into the cylinder containing milk
Note the lactometer reading
4. Titratable acidity
The normal range of acidity of milk is 0.13-0.17% LA. In excess of
0.17% LA, it is regarded as sour milk.

Take 10 ml distilled water in a small beaker

Add 10 ml milk sample
Add few drops of phenolphthalein indicator
Titrate it by adding 0.1N NaOH solution till appearance of pink colour
Note the volume of NaOH used & calculate the titratable acidity

Formula for Calculation of Titratable acidity = (0.09×V) % LA

Where, V = volume of std. NaOH solution used for titration (in ml).
At RDS the normal range of acidity of different products are as follows:-
 Lassi → 0.72% LA (max)
 Butter milk → 0.4 – 0.7% LA
 Shrikhand → 1.4% LA (max)

Alcohol test

At CGSCDF, this test is done with three different ethyl alcohol

concentrations solution (50%, 55% and 60%). In this test, 2 ml of milk is
placed in a Petri plate and an equal amount of an ethyl alcohol solution
(of any one of above concentration).the mixture is shaken and any
formation of clots or flakes denotes a +ve test, i.e. the milk is susceptible
to heat coagulation.

Fat test

At CGSCDF, the fat test is done by following two methods:-

1) By Gerber method
2) By electronic milk tester

(1) By Gerber method:-

Take 10 ml conc. H₂SO₄ in milk butyrometer

Add 10.75 ml of milk sample
 Add 1 ml iso amyl alcohol
After capping with stopper mix it properly
Centrifuge it for about 5 minutes
Note the fat percentage

(2) By electronic milk tester (EMT)

This instrument works on the principle of photometric measurement of

light scattered by the fat globules of milk sample. Milk is diluted by a
solution of EDTA, NaOH, antifoaming agent and emulsifier (Triton X-
100). Homogenization is carried out because to increase the surface area
and uniform size of fat globules.

Measuring range of EMT 0 – 13% fat

Measuring temperature 5 - 45◦C
Sample volume 0.5 ml for each test
Range of fat globules size in EMT 0.5 – 1.5 micron
Weight of EMT 16 kg
NOTE: - On starting EMT, the first reading should be avoided and so the
first sample is tested two times.

SNF calculation

 For processed milk, % SNF = CLR/4 + Fat × 0.25 + 0.44

 For raw milk, %SNF = CLR/4 + Fat × 0.20 + 0

Adulteration tests

There is an adulterants detection kit at Chhattisgarh State Cooperative

Dairy Federation Limited in which the reagents for detection of
different adulterants in milk are kept. The test procedures of different
adulterants are as follows:-

1) For sugar:- Take 1 ml milk sample in a test tube & 1 ml sugar

reagent, place it in boiling water bath for 3-5 minutes. Red colour
gives +ve and black colour gives -ve sugar test.
 2) For salt: - Take 5 ml salt reagent-I in a test tube & add few drops of
salt reagent-II (red colour is developed). Now add 1 ml milk sample
and mix well, yellow colour gives +ve & red colour gives –ve salt
test.
3) For neutralizer:- Take 5 ml milk sample in a test tube & add 5 ml
neutralizer reagent-I and few drops of neutralizer reagent-II. After
mixing, rose red/pink colour gives +ve neutralizer test.

QUALITY CONTROL LAB. EQIPMENT:

1. Gerber centrifuge machine ( for Fat test)

2. Lactometer

3. Centrifuge machine ( Cream index test for homogenizer efficiency)

4. Milk-o-tester electronics machine

5. Heating mentle

6. Adultration test kit

7. Water bath

8. Weigh balance
9. Dessicator

10.Incubator
 STAFF MEMBER

A.G.M. - Mr. S.K.Mishra

General Manager - Mr. A.K. Varad Pandey
Senior technitian - Mr. G.N. Chandrakar
P.S. - Mrs. Ritu Baghel
Mr. Chandra Prakash Sahu
Mr. R.K. Gupta

CIP UNIT AT PLANT

This unit of plant is an important one as it allows the proper and
continuous working of machines without affecting the quality of
product being manufactured.
There are three vertical tanks of Capacity: 3,000 liters each
• Hot water
• Acid (Nitric acid with conc. 1.2%)
• Alkali (Caustic solution with conc. 1.5%)
The steps followed during this process are as follows:-

Rinsing with normal water

↓
Rinsing with hot water (80⁰C)
↓
Rinsing with caustic solution (75⁰C)
↓
Rinsing with normal water
CIP PUMP
Number 3
Make HMT Limited, Aurangabad
Flow 20 KLPH;
Electric Motor 3.8 Kw, 415V.50Hz.
CIP Return pump 2
Make: Vulcan Laval, HP-3.5, and RPM 2880
For storage tank
1. Rinsing with normal water 5 to 7 min.
2. Rinsing with hot water 80⁰C for 5 to 7 min.
3. Rinsing with caustic solution 75⁰C for 5 to 7 min.
4. Rinsing with hot water 80⁰C for 5 to 7 min.
5. Flushing with normal water for suitable time.
For equipments

1. Circulation of normal water for 10 to 15 min.

2. Circulation of hot water 80⁰Cfor 15 to 17 min.
3. Circulation of caustic solution 75⁰Cfor 15 to 20 min.
4. Circulation of hot water 80⁰Cfor 15 to 17 min.
5. Flushing with normal water for suitable time.
PACKAGING SECTION

Packaging of products

Pasteurized milk Standardized milk 500 ml

Toned milk 500 ml
Double toned milk 500 ml & 200 ml
Butter milk 200 ml
Flavoured milk 200 ml
Paneer 200 g, 500 g, 1 kg
Shrikhand 100 g
Lassi 200 ml
Sweet curd 100 g
Ghee 500 g, 1 kg, 15 kg
Khoa 500g, 1Kg

Packaging of pasteurized milk & Butter milk

Packaging machine: Automatic Polythene Film packaging machine
is used for their packaging. There are three FFS machines in plant.

Details of machine are as follows:

 Name 1. Samarpan Prepack Machine

2. Vijay Prepack Machine

 Max. Capacity 5000 Packets/hr

 Working Capacity 38 Packets/min. from one

head

 Air Consumption 50 m3/hr

 Compressed air 6 kg/cm2

Packaging material detail:

 Thickness 55 micron

 Weight of roll 20 – 22 kg

 Packs colour Red packet for tonned milk

Green packet for double tonned milk
Blue packet for standardised milk
Brown packet for butter milk

The packets are then collected in crates. The capacity of one crate is
20 packs of 500 ml
And 50 pack of 200 ml. Then these crates are forwarded to cold
storage (4⁰C).
Packaging of Paneer
Vacuum packaging machine is used for paneer packaging. First of
all paneer is taken in polythene and it is vacuum packed by the
machine.
Details of machine are as follows:

 Pressure 700 mm Hg

 Time 5 sec.

Packaging of Shrikhand, Mishti dahi, Lassi

It is packed in polypropylene cups with an Aluminium foil lid at its
top and this lid is sealed to the cup nicely with the help of manual
pressing machine and the packed cups are kept in carats and then sent
to storage room for dispatch.

Packaging of Flavoured milk

It is filled in the bottles of 200ml and capped manually with a hand
press machine. Then these bottles are sterilized (120⁰C for 20 min, 15
psi) 25 crates each consisting 30 bottles are kept overnight for cooling
under atmospheric condition.
Then these bottles are kept in the card
board crates and finally packed by poly seal shrink tunnel machine.
This type of packaging helps in proper handling and transportation.
  The packaging material for milk is the mixture of LLDPE
(20%) and LDPE (80%). The film width and pouch length of
½ litres milk pouch is about 325 mm and 150 mm
respectively.

UTILITY SECTION
The utility section of plant comprises of following:
1. Boiler section
2. Refrigeration section
3. Power

BOILER SECTION
• A boiler is a closed vessel made of steel. Its function is to
transfer the heat produced by the combustion of fuel to water and
ultimately generate the steam.
• In Chhattisgarh Rajya Sahkari Dugdh Mahasungh coal fired
smoke tube boiler is used. The number of boiler is two, one is used at
a time
Data regarding Boiler is as follows:-

No. of boiler 3
Boiler No. C-740
Type Fire tube
Type based on heating medium Coal fired
No. of tube 188
Height of boiler 3.1m
Length 5.8m
Diameter 2.7m

Fuel used Coal

Capacity 3000 kg/hr
Working Pressure 10.54 kg/cm2
Coal consumption 421 kg of coal/hr
Water storage capacity 5000 ltrs
Steam holding capacity 1.9 m2
Max. flue gas temperature 300-350⁰C

Total heating surface 117 m2

Boiler shell diameter 24.50 m (inside dia.)
Height of chimney 60ft
Steam pressure 10kg/cm2
Area of boiler section 200.2m2
Make Western work Engg. Ltd.

OTHER DETAILS:-

 100 kg of coal is required to generate 1kg steam.

 The coal consumption in this plant is 1-1.5 Tonne/day.
 Coal is marketed from Korba and Bilaspur..
 BLR 46 UNIS is used as scale and corrosion inhibitor and its
dosing quantity is 3.8kg per day.
 DREWPLEX 50S is used as online scaling cleaner and its dosing
quantity is 4.0 kg per day.
 Generally pressure is maintained around 5 kg/cm2.
 Water is treated in softener plant and its hardness should be below
8ppm.
 50 to 60 kg of NaCl is used at an interval of 2 to 3 days to prevent
scaling.
 A new modified boiler has been installed of capacity 4 tonnes
which has cyclone separator and water softener incorporated in it.

REFRIGERATION SECTION
  Refrigeration is known as the heart of the dairy plant.

 Refrigerant used is R-717 Ammonia (B.P. -33◦C $ F.P. -77⁰C).

 Lubricant used is Servo oil 68 no.

 Maximum amount of ammonia filled in cylinder is 50 kg.

 Cost of ammonia per kg is Rs 90 to Rs 95

 Near about 2 to 3 cylinder of ammonia is require per month.

 The capacity of refrigeration plant is 60Ton but at present the load is

about 44 Ton.

 In CGSCDF approx. 40% electricity is used in refrigeration section.

Different component of Refrigeration section are:-

COMPRESSOR – It consist of 3 pistons therefore it is called as KC3

compressor.

COMPRESSOR (Kirloskar pneumatic type KC3):-

Type Reciprocating
No. of compressor 5
Horse power 100
Max. design pressure 21 kg/cm2
No. of piston 3
Stoke 110 mm
 Bore 100 mm
Suction pressure 2 Kg/cm2
Discharge pressure 14 Kg/cm2
Operating pressure 4 Kg/cm2
Voltage 400
Ampere 120

Compressor system consists of :-

(1) Crank can and cylinders jackets.

(2) Cylinder liner.

(3) Valves.

(4) Piston.

(5) Connecting rods.

(6) Crank shaft.

(7) Oil pump.

(8) Safety valve.

(9) oil separator

MOTOR:-

Manufacturer Crompton Greaves ltd.

Type 3 phase induction motor

Voltage 415 V
Frequency 50Hz
Efficiency 93.5%
Rpm 1475
Ambient temp. 15
 Maximum two compressors are used at a time which depends on plant
requirement

 One compressor is not in working condition

 Cooling tower is used for head cooling of compressor

CONDENSER :-

It removes heat from the hot vapour refrigerant discharged from compressor.

Type Evaporative
No. of condenser 1
No. of tube 396
Material of tubes mild steel
No. of water circulation 3
Expansion device Hand operated expansion valve

 The condenser used is atmospheric water cooled condenser.

 To prevent algae from pipe lines they use CD BD HPA, 747M, AB AB1,
CD BD DS chemical reagents.
RECEIVER :-

It is a storage tank for Ammonia refrigerant

No. of unit 6 ( 2 in used)

Type Horizontal
Thickness 80 mm
Capacity 800 kg
Receiver Pressure 14 kg/cm2

Expansion Valve

It is connected between receiver and evaporator and its function is to reduce

high pressure refrigerant. Solenoid valve is used as expansion valve.

Evaporator

Its function is to absorb heat from the surrounding medium which is to be

cooled by-means of a refrigerant.

EVAPORATOR (IBT):-

 There is one ice bank tank having four section and each section has one
evaporator coil.

 Total number of accumulator tank- 4

 Normally the temperature of water is maintained below 00C

 Glycol is used as freezing point depressant

Total section of IBT 4

Total capacity 1 lakh ltrs

AIR COMPRESSOR

No. of units 1
Make K.G. khosla compressor ltd.
Speed 635 rpm
Discharge pressure 8.0 kg/cm2
Suction pressure 3 m3/mm
Discharge pressure 6.0 kg/cm2
Capacity 5 m3
THE REFRIGERATION CYCLE IS :-

Some important points:-

 The gravity of brine is checked by the hydrometer.

 The total weight of ammonia cylinder is 72.5 kg containing 50 k

WATER SOFTENER
Hard water is softened with the help of raisin. On the surface of raisin
impurities are sticked and sticked impurities are cleaned by brine solution. Hard
water causes scale formation and therefore reduces rate of heat transfer. Water
is softened before using it in the boiler.

 Amount of raisin used – 150 kg

 Amount of salt added -60 kg

 Hardness of water is kept below 8ppm

COLOUR CODE FOR PIPE LINES:-

 Safe product (Air & Water etc.). – Green
 Dangerous material(Ammonia, Fuel, Oil & High pressure steam
etc) - Yellow
 Protective material to minimize the hazards - Blue
 Fired control equipment – Red

POWER CONSUMPTION:-
 Transformer – 2,
 Electrical Connection - 33 KVA Sub Station, Step Down 440 Volt

 Connected load - 300 KVA

 Billing - 2 part tariff

 Units – depend upon load

 Monthly - 60,000 to 75,000 Units

 Bill - 3, 75,000 / month

 Generator – 200 KVA

 Fuel is diesel