Type of Industry

• Mahanand Dairy is the largest unprocessed milk

packing and distribution dairy in Asia.
• It is run by the MRSDMM ( Maharashtra Rajya
Sahakari Dudh Mahasangh, Maryadit)
• MRSDMM is a federation of milk unions established
to implement the Operation Flood programme
introduced in 1970 to help dairy farmers direct their
own development by placing control of the resources
they create in their own hands.
 Capacity
5 to 6 lakh litres ●
Milk Distribution

●
milk are used to prepare other products such as
4 Lakh Litres curd, paneer, ice cream, and buttermilk and so on.

174 ●
No. of Distributor

number of shop distributors, commission agents

548
●

etc.

Of pasteurized milk is together produced by 3 plants

●

54,000 litres per hour

 Location of Plants
• Mahanand dairy is located in Goregaon (East),Mumbai.
• Cattle feed is procured from four strategic locations.

Kud ●
Konkan
al region
●

Lat
Marathwada
ur region.

Mahanand Cattle Ahmednagar

●

Supa
for Pune &
Distric
t Nashik

Feed Plant Sola

region

pur
 Functional Groups
• MRSDMM manages the Mahanand Dairy plant at Goregaon,
Mumbai.
• Senior most authority : Chairman, vice chairman and managing
director
• Each of the individual departments of finance, marketing and
development is managed by the respective general managers.
• The department for Quality Control is led by a senior manager.
• The department for purchase and stores is handled by the
designated manager.
• The milk production and processing department is handled by
managers operating from a computerized control room.
 Production Strategy
• Products: Pasteurized milk , curd, lassi , flavored Milk, ghee,
etc
• The per capita consumption in the city of Mumbai is
approximately 250 ML per day.
• To satisfy this huge demand of milk Mahanand Dairy follows a
"Make to Stock" production strategy.
• Workers, work in shifts for 24 hours a day to ensure nonstop
production of various types of milk and milk products.
Layout of Plant and Machinery
 Layout of plant and machinery
• Raw Milk Reception Dock (RMRD) - consisting of can
conveyor, can washer, weighting balance, dump tank etc.
• Processing Hall - cream separator, chiller, homogenizer,
pasteurizer and other related machinery are installed.
• Storage area- for milk storage tanks.
• Products manufacturing area-depends upon the type of
products and the quantity of milk handled, the required
equipment needs to be installed.
• Packing area-for packing of liquid milk and other products.
• Cold storage-for keeping the milk and milk products before
sending to market.
 Layout of plant and machinery
• Quality Control Laboratory-for testing the quality of milk and
milk products.
• Utilities area-for installing boiler, generator set, water
treatment plant, maintenance and store area for spares.
• Waste water treatment plant area-for treating the dairy
effluents before releasing to the fields.
• Quarters and office area-for all the essential staff.
• Vehicle parking area-both for the milk procurement and
distribution vehicles.
• Input supply area- for providing veterinary service, supply of
feed, fodder seeds, etc.
Layout of plant and Machinery
 Planning and Scheduling
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 Planning and Scheduling
• The main processing operations conducted at Mahanand
Dairy are as follows:
– Liquid processing of unprocessed milk with cent percent
homogenization and clarification.
– Toned milk processing with cent percent homogenization
and clarification. Approximate processing capacity: 2.2
LLPD.
– Packaging and distribution of milk in pouch with cold
storage operation.
– Total Milk processing (pasteurization, homogenization and
clarification).
 Planning and Scheduling
• Sequence of operations in the processing of milk:
– Pasteurization : Aims to reduce the number of
viable pathogens so they are unlikely to cause
disease and increase the shelf life of milk.
– Homogenization : To ensure that more consistent
raw milk is produced prior to processing and also
to prevent or delay the natural separation of
cream from the rest of the emulsion.
– Clarification: Removes impurities like blood cells
from the milk that will be sold as whole milk
 Planning and Scheduling
• Packing of processed milk
– Milk is packed in bottles or cans.
– Packing material is supplied in rolls, is fed from a reel through on enclosed
sanitary chute to the top of vertically designed machine.
– The paper strip then travels downwards and is formed into a tube by guide
rods and forming rings.
– The edges of the strip forming the tube are sealed by heat and pressure.
– The vertical tube is filled with the product through a filling pipe extending in to
the tube.
– Electrically heated jaws, positioned at right angles to each other, alternatively
pinch the product – filled tube , forming a chain of individual tetra pack
containers.
– Then a cutter automatically divides the chain in to individual units.
– The individual packages are conveyed to an automatic packer which positions
the cartons in to a plastic case.
 Production Planning
• edoodh solutions
• There are 10 silos in Mahanand Dairy with each silo
having a capacity of 1 Lakh liters.
• A centralized computer system is located in a control
room. This computer system is called edoodh
solutions. Sensors are located at storage silos, cleaning
material storage tanks as well as other machines such
as pasteurizer, homogenizer and agitator. Data from
these sensors are stored in Programming Logic and
Control Unit (PLC) that is located in the control room.
• The data from the PLC is used by the computer system
managers to handle the processing of milk on a real time
basis. The computer system handlers can perform the
following set of activities:
• The amount of unprocessed milk that is to be transferred
from the transport tankers to the silos.
• Perform maintenance activity for the silos by conducting
cleaning procedures using caustic soda, acid and hot water.
• Perform pasteurization, homogenization, clarification and
agitation operations.
 Inventory Management
• Material : Raw Milk, Packaged Milk
• Stock on hand at a particular time: Packaged
Milk of different varieties, Milk Products such
as curd, ghee, Lassi etc.
 Inventory costs
• Ordering costs include
– Staff salaries of Milk testing department
– Traveling expenses
– Cost of inward inspection

• Inventory / carrying costs include

– Expenses on warehouse personnel salaries
– Cost of security for warehouses
– Cost of storage space for storing materials-Nil
Factors affecting Inventory Control
• Volume
– Large volume of Raw Milk need immediate
processing and packaging.
– Around 10 lakh litres of Milk is processed daily.
– 5 lakh litres for Milk and rest for milk Products
• Type of manufacturing
– Continuous, supply of raw material such as milk
happens in shifts throughout the day.
– Raw milk is Processed, pasteurized and packaged.
– Packaged Milk is initially stored in cold storage and
then distributed to various vendor locations.
Inventory management process

Milk is tested for

Pasteurized Milk its quality over a
is cooled and bridge using a
packed small sample.
Depending
upon the test
results, good
Packed Milk is milk is sent for
stored in cold processing
storage
Raw milk
before it is
Collected from transferred to
nearby villages, trucks for
carried in
insulated further
Tankers distribution
 Just In Time
• Conceptually, JIT means
– That virtually no inventories held at any stage of production.
– At Mahanand Dairy, packed milk is stored maximum for 2-3 hours and
not more than that.
– The storage time depends on the availability of trucks for distribution.
– Mostly, the packed milk is immediately filled in Cans and loaded in
Trucks
– Once the quantity check is performed, the trucks leave for their
respective distribution centres.
– Hence, Milk is stored for a very less time.
 Quality Management
Raw Milk from Tanker is collected in 4 bottles

B1=sent for chemical 2 bottles are stored in the

B2=sent for Physical analysis
analysis refrigerator
 Steps of Quality Management Process

Milk
Che Physi
Proc
mical cal Valve
essin
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g
sis sis
Unit
 chemical analysis
• Tests to detect adulteration of milk
• Test to ensure that the milk is in the required
specifications.
• There are 22 tests performed in chemical analysis.
• Some of the tests are as follows:

Acid =base test: to check the growth of microbes.

●

to check adulteration of urea and other fillers in

Urea test:
●

milk.

Salt test: ●
to check minute levels of salt if added
 CIP
cleaning in place
• Pre-rinsing –150 sec filling and emptying of
silos, tankers and processing machines.
• Hot water, caustic soda,nitric acid is used.
• The cleaning is monitored through computer
system
• All the equipments are checked for even
slightest traces of acid after cleaning.
 Physical analysis

• the milk sample is tested for:

• fat content,
• SNF,
• lactose,
• maltose,
• FPD etc.
• The machine which is used to check the density
of the milk sample is called “Milkoscan”
 Valve Test
• It detects any other particles such as hair or
dust that might not have been detected in the
chemical or physical analysis.
• The tested milk is then sent for Pasteurization
and final Packaging/Packing
• If the milk sample fails in either of the
physical, chemical or valve tests, the milk
tanker is rejected for processing.
 Quality Management
Acceptance Sampling:
• Lot accepted or rejected based on the number
of defects found in the sample
• No need to inspect the entire lot
• Risks of accepting bad lots or rejecting good
lots always associated while making decisions
based on sample evidence
 Environment management

Water Consumption:
• The reduction in water consumption helped
in:
– reducing the cost of milk handling
– reducing hydrological load of “Effluent Treatment
Plant” thereby reducing the waste water
treatment cost.
 Environment management

Non conventional energy use:

1. Solar Water Heating System:
• The water is used for boiler as feed water and crate cleaning
& general cleaning purpose.
• This has resulted into a saving of 200 - 250 liters of furnace
oil per day.
• Monetary savings of approximately Rs. 8/- Lakh per annum.

2. Electricity generation from bio gas

• used for running the electrical motors/ equipment at Effluent
Treatment Plant (ETP).
• annual savings of approximately Rs. 5 Lakh
• helps in reducing the pollution,
 Work Measurement
• Implementation of “Electronic attendance system”
at Mahanand Dairy.
• This system registers the attendance of an
employee by taking the
– employee code and
– the biometric fingerprint
• The employee details are stored in an online
system.
• These employee details are used by departments
such as payroll to pay the wages to the employees.
Thank you