TRAINING REPORT ON VERKA

TRAINING REPORT ON
VERKA MILK PLANT GURDASPUR

Submitted to-: Submitted by-:

Food Tech. Dept, Amarveer Singh
Khalsa college Roll no. 15511017
Amritsar MFST –IIIrd sem
 TRAINING REPORT ON VERKA

ACKNOWLEDGEMENT
I would like to thank our Head of department Prof. Manbir singh for all the
help he has provided in doing this In- plant Training.

  I would also like to thank S.BIKRAMJEET SINGH MAHAL (General

Manager), and Q.C. Manager Sri. Anil salaria for guiding  me throughout the
course of  my training in Verka.

  I also thank all the staff and workers of Verka for their understanding, care
and loving support throughout my training to make this work a great success.

 Finally I thank each and every one who helped me to complete my Inplant
training in a successful way.

AMARVEER SINGH

ROLL NO 15511020
 TRAINING REPORT ON VERKA

1) INTRODUCTION
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1.1 COMPANY PROFILE

The Plant was established in 1980 by The Punjab Dairy Development Corporation.
The Punjab Dairy Development Corp. and Milked are the two Government dairy
organizations which are running pay rolled to each other. In 1982 both these
organizations submerged into one which is now named as MILKFED. In the
beginning the capacity of the plant was 2,00,000 liters per day and the number of
workers was only 700. The products manufactured initially were liquid milk, lassi,
panner, kheer and curd. Paneer production started in 1990 and curd production
started in 1997. The Plant has introduced ISO-9001:2000 quality management
system and Indian standard of hazard analysis and critical points
(HACCP)/IS:15000-1998 to ensure highest quality products with built in safety to
the consumers.

1.2 PLANT PROFILE

Milk Plant, Gurdaspur is located at District Gurdspur in Punjab. It is located on
Mik plant, box no.5, Gurdaspur- 143521 (Punjab). There is a great advantage as it
is directly connected to National Highway which is facilitating all transportation
and allied facilities.
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1.3 MILK PLANT PRODUCTS

Milk Plant has to maintain company specifications for its milk and milk products
to provide standard and quality of products to consumers.

1) In Milk Plant Mohali four different kinds of milk are processed and packed.
(i) Standard Pasteurized Milk.

(ii) Pasteurized Double Tonned

(iii) Pasteurized Skimmed Milk

(iv) Premium (Full Cream) Milk

2) Paneer

3) Curd

4) Lassi

5) Kheer
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2) LABORATORY
SECTION
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2.1 DOC LAB

2.1.1 MAIN OBJECTIVES OF THE DOC LAB:-
1) Grading of the incoming raw milk.
2) Raw milk testing.
3) Testing of outgoing pasteurized milk.
4) Testing of processed milk stored in tanks.
5) Standardization of the milk. These include checking the fat % and SNF in
milk.
6) Checking the strength of detergents in can washer, can scrubber and crate
washer.
7) Checking the cleanliness of tankers after emptying and before filling milk.
8) Testing of cold storage pouches for city supply.

2.1.2 VARIOUS TESTS PERFORMED IN THE DOC LAB FOR

THE DETECTION OF ADULTERANTS:-
There are many methods known for detection of adulteration in milk but the
method discuss below are simple but rapid and sensitive methods to detect
adulteration.

1) TEST FOR DETECTION OF SALT:-

 Take 5ml of silver nitrate in test tube.
 Add 2 – 3 drops of 1% potassium chromate and mix.
 Add 1ml of milk and mix well.
 If the contents of the test tube turn yellow in color, then salt is present
(Test +ve). If the content of the test tube turn brown in color then salt
is absent (Test -ve).

2) TEST FOR DETECTION OF UREA:-

 TRAINING REPORT ON VERKA

Urea is generally added in the preparation of synthetic milk to raise the SNF
value.
 Take 2ml of milk in test tube.
 Add 2 ml of Urea reagent (4DMAB solution para dimethyl amino
benzaldehyde).
 If the solution turns yellow in color then the given sample of milk is
adulterated with urea.

3) DETECTION FOR NEUTRALIZERS IN MILK:-

In milk neutralizers like sodium hydroxide, sodium carbonate or sodium
bicarbonate are added which are generally prohibited.

ROSALIC ACID TEST (SODA TEST):-

 Take 2ml rosalic solution in test tube.
 Add 2ml of milk and mix well.
 If the color of sample changes to pinkish red, then it is inferred that
the milk is adulterated with sodium carbonate / sodium bicarbonate
and hence unfit for human consumption.
 If the color of sample changes to orange, then soda is not present (Test
–ve).

4) TEST FOR DETECTION OF SUGAR:-

Generally sugar is mixed in the milk to increase the solid not fat content of
milk i.e. to increase the lactometer reading of milk.
 Take 1ml of sugar reagent and 1ml of milk in test tube and mix.
 Place the test tube in boiling water bath for 3 – 5 minutes.
 Appearance of rose red / brick red color indicates the presence of add
sugar in milk.

5) TEST FOR DETECTION OF AMMONIA COMPOUNDS:-

 Take 5ml milk in a test tube.
 TRAINING REPORT ON VERKA

 Add 1ml of Nesslar’s reagent.

 Appearance of brown / dark yellow color indicates the presence of
ammonia compound in milk.

6) TEST FOR DETECTION OF STARCH:-

Addition of starch also increases the SNF content of milk. Apart from the
starch wheat flour and rice flour is also added.
 Take 3ml of milk in a test tube and boil it.
 Then milk is cooled to room temperature and added 2 – 3 drops of
1% iodine solution.
 Change of color to blue indicates that the milk is adulterated with
starch.

7) TEST FOR DETECTION OF GLUCOSE:-

Usually poor quality glucose is added to milk to increase the lactometer
reading.
 Take 1ml milk and 1ml fehling solution A. Mix it thoroughly.
 Then keep it in a boiling water bath for 3 minutes and then cool for 2
minutes by immersing in tap water without disturbance.
 Then add 1ml fehling solution B. If blue color is visible, then glucose
is present in the milk sample.

8) TEST FOR DETECTION OF HYDROGEN PEROXIDE:-

 Take 1ml milk.
 Add a few drops of hydrogen peroxide reagent and mix well.
 Orange color indicates that the milk is adulterated with hydrogen
peroxide.

9) TEST FOR DETECTION OF NITRATE FERTILIZER:-

 Rinse test tube with 5ml milk.
 Add 1ml nitrate reagent along the sides of the test tube.
 TRAINING REPORT ON VERKA

 Blue color indicates that the milk is adulterated with nitrate fertilizer.

MBR (METHYLENE BLUE REDUCTION) TEST

Principle:-

This test is based on the principle that methylene blue, which is blue in its oxidized
state is reduced to a colourless compound as a result of metabolic activities of
bacteria in milk. When solution of methylene blue is added, the organism present
in the milk consume the dissolved O2 and lower OR potential to a level when blue
is decolourised / reduced. The time taken for reduction of dye(methylene blue) is
influenced by number of bacteria in milk. the greater the number of organism,
greater their activity the more rapidly dye is reduced. MBR Test is therefore used
in milk for judging hygienic quality of milk. for assessing the probable quality of
milk and for detecting post pasteurization contamination.

PROCEDURE:-

 Take 10ml milk in sterilized test tube, add 1ml methylene blue dye and shake
well.
 Put in water bath of temperature 37°C blue color develops.
 Check the reduction of color periodically and reduction time is noted.
 Result lesser the total time, poor the quality of milk.

Each and every batch of processed milk should have a minimum MBRT time
of 5hrs. if MBRT is below 5hrs it should be reprocessed before pasteurization.

For Pasteurized milk = 6 Hours

For Fresh milk = Atleast 30 minutes

BIS standards for Pasteurized Milk:-

MBR Time Quality

5 and above very good

3-4hrs good
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1-2hrs fair

Determination of Fat Content by Gerber Method

Reagents required:- Gerber sulphuric acid (concentration 90-95%)

Iso amyl alcohol.

Procedure:-

 Take the butyrometer.

 Add 10ml Gerber sulphuric acid from tilt measure.
 Pipette out 10.75ml of well mixed milk sample and transfer it to butyrometer
gently without allowing it to mix with acid.
 Add 1ml amyl alcohol from tilt measure into same and tighten with stopper.
 Mix content by shaking butyrometer at a 450 angle until the curd has been
dissolved.
 Place the butyrometer in the centrifuge machine and allow the machine to run
for five minutes at 1100rpm.
 Take out the butyrometer and read the fat column. Reading should be taken
from lower meniscus. Adjust the fat column if needed and take the reading
which indicates direct fat percentage of milk.

Determination of SNF content in milk-Lactometer Method

Amar lactometer is used for finding lactometer reading. Lactometer reading is
taken at 290C. If the temperature of milk is above 29 0C, then a correction factor of
0.3 is added for each degree rise in temperature. If the temperature of milk is
below 290C, then correction factor of 0.3 is deducted for each degree of decrease
in temperature. Amar lactometer is calibrated at a temperature of 29±50C.
 TRAINING REPORT ON VERKA

PROCEDURE:-

 Adjust the temperature of milk sample to 15 0C or correction can be applied to

get lactometer reading to get CLR.
 Mix the milk sample well and pour sufficient quantity of milk in lactometer
jar and allow lactometer to float freely.
 Allow the lactometer to come to stationary position. Read the lactometer scale
and note the temperature of milk.
 Note the reading.
 Using formula, SNF and Total solids can be calculated.

%MSNF= (CLR/4)+0.2F+0.29 at 150C

%TS = (CLR/4)+1.2F+0.29 at 150C.

Pricing of milk is done based on the fat and SNF content present in milk. The
pricing of society milk are based on RMRD (Raw milk reception doc) package,
which is based on the analyzed fat and SNF contents by the milk analyzer.

2.2 QUALITY CONTROL LAB

2.2.1 MAIN OBJECTIVES OF THE QUALITY CONTROL LAB:-
1. Sensory evaluation of milk and milk products.
2. Testing of shelf life of milk for city supply.
3. Checking the quality of reagents, packing material, glass wares for testing
etc.
4. Hardness and chlorine content of water.
5. Controlling of cleanliness of dairy equipments as well as overall sanitization
of plant.
6. Checking the efficiency of waste treatment of plant.
7. Checking the weight, film thickness, prints and length of pouches for city
supply milk.
 TRAINING REPORT ON VERKA

2.2.2 VARIOUS TESTS PERFORMED IN THE QUALITY

CONTROL LAB:-
Raw milk:- The tests include organoleptic test, temperature, COB, acidity and
microbiological tests performed are Standard Plate Count and Coliform Plate
Count.

Processed milk:- The tests include temperature, acidity, FAT(Gerber method),

SNF, MBRT, phosphatase test, and microbiological tests performed are Standard
Plate Count and Coliform Plate Count.

Curd:- Total solids, acidity and microbial test performed is CPC.

Organoleptic evaluation of raw milk:- This platform test is conducted at

RMRD during milk reception. Each can of milk is carefully examined by smelling
the milk in the can immediately after removing the lid and observe each can of
milk for its appearance, colour and flavor. And then stir the milk thoroughly with
plunger and note the smell.

The flavor of milk should be normal mild aromatic flavor. In case of

doubtful milk cans, the milk is held for subjection to confirmation test. When there
is sourness or sour smell due to developed acidity, COB(Clot On Boiling) test is
conducted and milk is rejected is the test is positive.

Clot On Boiling Test:- This is a quick test to determine developed acidity and
helps in determining the keeping quality and suitability of milk for processing.

Procedure:- Transfer 5ml of milk sample to the test tube and place it over a flame
and stir the tube continuously in an almost horizontal position and examine the side
of test tube for any formation of clotting or flake formation. Formation of clot is
indicative of positive test.

Milk that gives a positive COB test has acidity generally above 0.17% as LA is not
suitable for processing
 TRAINING REPORT ON VERKA

Titrable Acidity:-
1. ACIDITY OF MILK:-
 Take 10ml milk in beaker and add an equal amount of water.
 Add 1 – 2 drops of phenolphthalein indicator.
 Titrate it against N/9 NaOH taken in a burette.
 Titrate it until the light pink color appears.
 Note the reading.
 It should be between 0.12 – 0.13% of normal milk.

2. ACIDITY OF LASSI:-
 Take 10ml lassi in beaker and add an equal amount of water.
 Add 1 – 2 drops of phenolphthalein indicator.
 Mix it well and titrate it against N/9 NaOH taken in a burette.
 Titrate it until the light pink color appears.
 Note the reading.
 It should be between 0.45 – 0.55%.

3. ACIDITY OF DAHI:-
 Take 10ml dahi in beaker and add an equal amount of water .
 Add 1 – 2 drops of phenolphthalein indicator.
 Mix it well and titrate it against N/9 NaOH taken in a burette.
 Titrate it until the light pink color appears.
 Note the reading.

Phosphatase test:-Phosphatase, an enzyme in milk is destroyed during

pasteurization. This test is used to judge the efficiency of pasteurization of milk.
To test whether the heat treatment properly carried out, the pasteurized milk is
subjected to phosphatase test, which helps to indicate the presence or absence of
the phosphatase enzyme. Phosphatase present in milk is destroyed by just about the
same heat treatment necessary for the destruction of Mycobacterium tuberculosis
 TRAINING REPORT ON VERKA

the most heat resistant pathogen likely to be present in milk. when heat treatment
less than specified some of the phosphatase remains active and will liberate phenol
from disodium phenyl phosphate. If the enzyme is present in milk, disodium p-
nitro phenyl phosphate is readily hydrolyzed to p-nitro phenol which is yellow in
alkaline solution.

Procedure:-

 Using a pipette transfer 5ml of the buffer substrate solution to a test tube
followed by 1ml of milk to be tested and put the stopper and bring to
temperature of 370C in a hot water bath and mix the contents of tube by
inverting it and incubate tube for exactly 2hrs at 370C.
 If the milk is properly pasteurized, then there will not be formation of yellow
colour and it indicates that phosphatase enzyme in milk is completely
inactivated by pasteurization temperature. Formation of yellow colour
indicates improper pasteurization.

MICROBIOLOGICAL TESTS:-
The microbiological tests performed includes Standard Plate Count (SPC) and
Coliform Plate Count (CPC). These tests are performed for both raw milk and
processed milk samples in the silos, tanks, sachets etc.

Standard Plate Count

This method is used for determining the total number of viable bacteria in milk
and consists of mixing appropriate quantity of milk with a suitable nutrient agar or
standard plate count agar in a petridish and counting bacterial colonies developed
after incubation at a specified temperature for a definite period of time. Incubation
period for SPC is for 48hrs at 370C.

The 1st dilution is made by adding 1ml milk to 9ml diluents in test tube. The serial
dilutions are made from 10-1 upto 10-5. 10-5 is plated for raw milk using standard
plate count agar. For processed milk 10-4 dilution is plated in the same media.

SPC for milk (As per BIS standards):-

Pasteurized milk - maximum 30000CFU/ml

 TRAINING REPORT ON VERKA

Raw milk

Not exceeding 2lakh - Very Good

2lakh to 10lakh - Good

10lakh to 50lakh - Fair

Over 50lakh - Poor

Coliform Count

This group of bacteria is important in quality control of milk as it is indicative of

possible fecal contamination and due to its ability to produce acid and taints in
milk. the presence of this group in milk is considered to be an indicator of the
degree of unhygienic practices during production, processing or storage and it is
intended to measure general care taken in handling this product. the members of
this group are generally destroyed during pasteurization treatments and therefore a
positive coliform test in the case of pasteurized milk is considered to indicate post
pasteurization contamination. The required dilution is plated in the media used for
CPC. The media used for CPC is Violet Red Bile Agar(VRBA). Incubation period
for CPC is for 24hrs at 370C. 10-4 dilution is plated for raw milk whereas for
processed milk 10-1 dilution is plated with VRBA media.

BIS standards:-

Raw milk:- Absence of coliforms in 1:100 dilution of raw milk is considered

satisfactory.

Pasteurized milk:- Coliform should be absent in first dilution 1:10.

Strength of cleaning solution

Acid strength:- Take 10ml acid solution in 100ml conical flask. Add 1-2drops of
phenolphthalein indicator solution. Mix and titrate against 0.1N NaOH. End point
 TRAINING REPORT ON VERKA

is appearance of pink colour.

Alkali strength:- Take 10ml alkali solution in 100ml conical flask. Add 1-2drops
of phenolphthalein indicator. Mix and titrate against 0.1N HCl. End point is
disappearance of pink colour.

The strength of cleaning solution used is calculated using the equation

N1V1=N2V2
 TRAINING REPORT ON VERKA

3) MILK PROCESSING

SECTION
 TRAINING REPORT ON VERKA

3.1 MILK PROCESSING SECTION

Milk after grading, testing, weighing and chilling goes to raw milk storage tanks
then it goes to processing unit. This is located next to reception Doc.

1. Milk from storage tank no. 1, 2, 3, 4, 5.

2. Flows to balance tank of pasteurizer because of gravity.
3. Pump to regeneration section 1.
4. Here incoming raw milk exchanges heat with outgoing pasteurized hot milk.
5. Temperature rises to 38°- 40°C. (Preheating)
6. It goes to filter for filtration.
7. Now 2 filters attached to regeneration section 1 for continuing pasteurization
even if 1 filter is cut off for cleaning purpose.
8. Regeneration section 2.
9. Exchange heat with hot pasteurized outgoing milk and temperature rises to
60°C
10. Heat fat milk passed to cream separator.
11. If fat not separated, milk goes to heating section where milk gets heated to
78° - 80°C by exchanging heat with hot water in alternate plates.
12. Milk goes to holding section at 75° - 80°C for 15 – 16 sec.
13. Exchanges heat with incoming raw chilled milk.
14. Chilling section 4 - 5°C.
15. Milk goes to storage tank no. 6, 7, 8, 9, 10

TYPE OF MILK PROCESSED HERE:

FAT% SNF%

Full Cream Milk 6.0 (max.) 9.0

 TRAINING REPORT ON VERKA

Standard Milk 4.5 8.5

Double Tonned Milk 1.5 9.0

Skim Milk 0.5 (min.) 8.7

Raw milk is the chief raw material for a dairy plant. Raw milk is collected
from farmers through villages. The villages which are located nearby the dairy, the
collection is made through cans. From the villages which are located away from
the dairy, the collection is made first in the BMC’s(Bulk Milk Coolers) and it is
transported to dairy using insulated tankers.

MILK PROCESSING
The processing of raw milk refers to subjecting it to different processes like
pasteurization, homogenization etc. in order to achieve good quality product and to
increase the marketable shelf life of the milk.

PASTEURIZATION
It is the process of heating the milk to such temperature and for such time periods
as required to destroy any pathogenic microorganisms which may be present in the
raw milk, whilst causing minimum changes in the composition flavor and nutritive
value. And such processes ensure the increased keeping quality of product and safe
for consumption.

The primary purpose of heat treatment is to kill all microorganisms capable

of causing disease. Apart from pathogens, milk may also contain other substances
and microorganisms which may spoil the taste and shelf life of milk and milk
products. The secondary purpose of pasteurization is therefore to destroy as many
as possible of these other organisms and enzymatic systems in order to safeguard
the product quality.

To ensure the destruction of all pathogenic microorganisms, it is necessary

 TRAINING REPORT ON VERKA

that the milk is to be heated to a certain specified temperature and holding it for
specified time before it is cooled again. Improper temperature-time combination
may affect the appearance, taste and nutritional quality of milk. To assure proper
pasteurization with a minimum of equipment, control and risk, nowadays milk is
pasteurized in the continuous HTST process.

The raw milk from storage tank is taken for processing. The raw milk is
heated to a temperature of 780C in 3 steps (1st regeneration, 2nd regeneration and
final heating section) and hold for a time period of at least 15 seconds and it is
cooled to a temperature below 70C .

MILK FLOW IN HTST SYSTEM

 Raw milk from storage tank is pumped to FCBT which is equipped with a float
which maintains the liquid level constant in FCBT and to supply milk to the
feed pump.
 The milk enters the 1st regeneration section where it is preheated and enters the
2nd regeneration section.
 From 2nd regeneration section, the milk enters the final heating section where it
is heated to temperature of 780C with the help of hot water.
 Milk enters the holding tube for at least 15seconds time period holding.
 Milk to FDV section, if the milk does not attained the preset temperature, flow
is diverted. If proper temperature is attained, the forward flow takes place.
 Milk enters the regeneration sections 2 and 1 for regenerative cooling.
 Milk enters the chilling section where it is chilled to 60C.
 Processed milk stored in storage tank.

STANDARDIZATION
Standardization refers to the adjustment of fat and SNF content in milk so as to
meet the legal standards required. As the fat and SNF content in the incoming milk
varies, the milk is required to be standardized. The fat and SNF content required
for milk varieties homogenized toned milk and toned milk is 3.0% and 8.5%
 TRAINING REPORT ON VERKA

respectively.

FAT STANDARDIZATION

Fat standardization is done by addition or removal of cream.

Amount of cream to be removed= (fat % in raw milk-fat % required)×Qty of milk processing

Fat % in cream

SNF STANDARDIZATION

SNF standardization is done by addition of skim milk or skim milk powder. The
raw milk enters the RC tank and is circulated using a pump. The calculated amount
of milk powder is dumped into the powder hooper. As a result of vacuum created
the powder in the hooper is sucked and it is mixed with milk circulating. After
proper mixing, the milk is pumped to FCBT (FLOOD CONTROL BALANCE
TANK) for pasteurization.

CREAM SEPARATION
The purpose of operation is either to liberate a liquid from strange particles or to
separate two intermixed liquids. The separation of cream is the process in which
the fat rich portion is separated from the serum portion of milk. The fat rich portion
is known as cream and serum portion is skim milk.

Working Principle

The separation process is based upon the density difference between the
milk fat in the globules and aqueous phase in which they are dispersed. The
specific gravity of skim milk is 1.036 and that of fat is 0.93. The separation is done
by means of subjecting it to centrifugal force. The milk flows through the
 TRAINING REPORT ON VERKA

distributor to the distribution holes of the rotating disc. The separation takes place
in the space between the discs. The lighter part or that part which is discharged as
cream is pressed towards the bowl center along the topsides of the disc and flow
out through the wear sleeve in the top disc ‘internal way’. The part discharged as
skim milk flows along the lower side of disc and out to the bowl periphery. The
skim milk flows along the upper side of the top disc and leaves the bowl via the
outlet sleeve (and discharge pump) ‘external way’.

 Prevent or delay the formation of cream layer in milk by reducing the diameter
of butter fat globules.

 Improve the flavor.

 Increase the whitening power.

 Increase in viscosity (sometimes).

HOMOGENIZATION
The homogenizing process has the specific function of reducing the treated
products particles to microns in order to improve the mixing process and stability
of product i.e. to homogenize the products components. Homogenization is done in
dairy industry principally to reduce the size of fat globules.

The non homogenized milk contains the fat particles having different sizes. To
avoid the cream layer formation during storage of milk, the fat particle size is
brought down to uniform size about 0.5-2microns. At this diameter, the fat
globules exhibits Brownian movement and prevent agglomeration.

Working Principle

Homogenizers are equipped with three stage piston pumps (having 1200 phase
shift of each working piston respectively) which sucks liquid while valves open on
their suction side and closed on their delivery side. The piston finally forces the
liquid through the homogenizer valve when the valve positions are reversed.
Homogenizer divides globules into smaller ones with diameter down to one
micron. This is done by forcing milk through narrow slit. The velocity of particle
in the narrow slits causes higher shearing stress, cavitation and micro-turbulence.
 TRAINING REPORT ON VERKA

The globules become deformed, wavy and finally break into smaller particles.

Two stage homogenization is usually done which avoids agglomeration of

broken fat particles. Homogenization is done at a temperature of 60 0C-700C.
Homogenization increase whitening power of milk and flavor becomes fuller
because of greater surface area of fat.

FINAL HEATING SYSTEM

The temperature of incoming milk to the final heating section is about 65 0C and it
is required to be heated to a temperature of minimum 78 0C. This is achieved by
means of circulating hot water in the final heating section of PHE system. In Verka
dairy, hot water having temperature about 800C is used for heating the incoming
milk in the final heating section. Hot water for this purpose is produced mixing
water and steam in the hot water tank.

HEATING SYSTEM

Hot steam produced in the boiler is used to heat water which heats the product to
the pasteurization temperature. In Verka Dairy, water is heated by injecting steam
to the hot water. Hot water produced in the hot water tank is having a temperature
of 850C and it is circulated in the HTST final heating section. The hot water in
gives off its heat to the product and as a result the product gets heated to required
temperature and temperature of water is reduced. The water coming out is again
taken to the hot water tank for reheating.

HOLDING OF MILK
The hot milk passes from final heating section to the holding tube which is a tube
having sufficient length and ensures the holding time of minimum 15seconds. The
temperature at the end of holding tube is determined and with the help of FDV, the
properly processed milk is forwarded through the unit, while that which is
unpasteurized is diverted to FCBT (FLOOD CONTROL BALANCE TANK).
 TRAINING REPORT ON VERKA

REGENERATION
Plate Heat Exchangers are used for heat transfer in the HTST system. Its
main advantage is regeneration. The re-use of heat is known as heat regeneration.
Regeneration process is particularly economical when the product is heated and
cooled. The cold incoming milk which is to be heated is partially heated indirectly
with hot outgoing product without the help of any heating medium. Similarly, the
hot outgoing product is partially cooled as it gives up its heat to the incoming
product. Thus the incoming product requires less additional heat for the
temperature to be raised and the outgoing product requires less cooling for the
temperature to be lowered.

CHILLING SECTION
The product is cooled to a temperature of 7 0C with the circulation of chilled water
having temperature of 00C in IBT. The processed milk is stored in the processed
milk storage tank

TYPE OF MILK PROCESSED HERE:

FAT% SNF%

Full Cream Milk 6.0 (max.) 9.0

Standard Milk 4.5 8.5

Double Tonned Milk 1.5 9.0

Skim Milk 0.5 (min.) 8.7

TRAINING REPORT ON VERKA
 TRAINING REPORT ON VERKA

4) PRODUCTION

4.1 KHEER SECTION

Kheer is a traditional South Asian sweet dish made by boiling rice, milk and
flavored with cardamom, raisins, saffron, pistachies or almonds.

4.1.1 REQUIREMENTS FOR KHEER MAKING:-

160lt. Milk

8.0kg Rice
 TRAINING REPORT ON VERKA

13.5kg Sugar

100g Elaichi (Powder form)

70g Sodium benzoate

4.1.2 NUTRITIONAL INFORMATION OF KHEER PER 100G

PACKAGING:-
Energy Value 125.0Kcal.

Carbohydrates 13.8g.

Sucrose 7.5g.

Lactose 6.3g.

Protein 4.0g.

Fat 3.8g.

4.1.3 FLOW CHART FOR KHEER:-

Milk for kheer

↓
Standardization and continuous boiling for about 10min. with stirring
cum scrapping.
↓
Addition of Basmati rice
 TRAINING REPORT ON VERKA

↓
Boiling gently with continuous cum scrapping till it attains desired
Concentration.
↓
Addition of required quantity of sugar, chotti elaichi (Powder form)
and sodium benzoate.
↓
Gentle boiling with continuous stirring cum scrapping for 10 – 15 mins.
↓
Filling into cups and sealing
↓
Storage 8°C max.
↓
Packaging in cardboard boxes
↓
Dispatch in insulated boxes

4.1.4 PROCESS OF KHEER MAKING:-

1. 16ol milk was taken in a utensil and heats it up to milk start vigorous boiling
with the steam provided up to 4kg. Milk is boiled until redness appears.
2. Then the milk is transferred to another utensil and 7.5 kg of rice were added
to it. The rice which was added was Basmati rice.
3. Boiling with continuous stirring cum scrapping till it attains the desired
concentration.
4. Addition of desired quantity of sugar, elaichi powder and sodium benzoate.
5. Now gentle boiling with continuous stirring cum scrapping for about 10 -
20mins. The steam provided for boiling kheer is 1 to 2kg.
6. Cool the kheer up to temperature of 48°C to 50°C.
 TRAINING REPORT ON VERKA

7. Now it is filled into cups before filling temperature is checked it should be

45°C.
8. Then after sealing cups packaging is done in cardboard boxes.
9. Now it is dispatch in insulated boxes.

4.2 LASSI SECTION

Lassi, also called chhas or matha, refers to desi butter milk, which is the by product
obtained when churning curdled whole milk with crude indigenous devices for the
production of desi butter (Makkhan).

4.2.1 NUTRITIONAL INFORMATION OF LASSI PER 100G

PACKAGING:-
 TRAINING REPORT ON VERKA

Fat 2.25g

Carbohydrates 2.20g

Protein 1.50g

Minerals 0.30g

Energy value 36.0kCal

4.2.2 FOOD AND NUTRITIVE VALUE:

Lassi contains appreciable amount of milk proteins and phospholipids, and is an
excellent beverage for quenching thirst by a reason of its lactic acidity.

4.2.3 FLOW CHART FOR LASSI:-

Receiving of milk
↓
Homogenization and Pasteurization
↓
Storage in tank below 7°C
↓
Pasteurization 88-90°C
 TRAINING REPORT ON VERKA

↓
Stored in storage tank
↓
Pre-heating (40-42°C)
↓
Take the milk in storage tank
↓
Addition of DVS culture @ 0.1%
↓
Setting of curd for 4-5 hours at 40-42°C
↓
Breaking of curd at 0.66-0.70% L.A.
↓
Mix the spices (cumin, green chillies, ginger all in powder form) and salt
↓
Package and Stored in cold store below 7°C

4.3 PANEER SECTION

It is fresh hard cheese. It does not melt and is made by coagulation of
hot milk with a food acid such as citric acid or lactic acid.

4.3.1 NUTRITIONAL INFORMATION OF PANEER PER 100G

PACKAGING:-
Energy Value 300Kcal.
 TRAINING REPORT ON VERKA

Carbohydrates 3g.

Mineral 0.9g.

Protein 18g.

Fat 23g.

4.3.2 FLOW CHART FOR PANEER:-

Receiving of pasteurized milk

Preheating at 85 ± 2°C

Cool down 10°C temp. of preheat temp.

↓
 TRAINING REPORT ON VERKA

Coagulation of milk by adding lactic acid or citric acid.

Collecting the coagulating mass in muslein cloth.

Placing the paneer mass into stainless steel hoops.

Paneer pressing in Pneumatic press 6kg/cm2 for 15 – 20mins.

Immersion of paneer block into chilled pasteurized water

0.5% iodized salt for 35 – 40mins.

Cutting paneer into 100g, 200g, 500g, 2kg and 5kg pack size and packaging.

Storage below 7°C.

Dispatch.

4.4 CURD SECTION

Curd is obtained by curdling (Coagulating) milk using microbial activity. In this
process lactose in milk is converted into lactic acid using several microorganisms.

4.4.1 NUTRITIONAL INFORMATION OF DAHI PER 100G

PACKAGING:-
Energy value 66.0kCal
 TRAINING REPORT ON VERKA

Carbohydrates 5.6g

Protein 3.8g

Fat 3.0g

Calcium 150mg

4.4.2 FLOW CHART FOR CURD:-

Receiving of milk

Standardization

Homogenization

Pasteurization (90 ± 2°C for 5mins.)

↓
 TRAINING REPORT ON VERKA

Stored in storage tank (Below 7°C)

Preheat 40°C

Transfer to milk balance tanks.

Addition of starter culture @ 1 – 1.5%

Machine filling (Cup – 200g, 400g, Sachets – 500g)

Placing curd cups in cartons

Keep in incubation room at 40 ± 2°C for 3hrs.

Settling of curd (0.60 – 0.66% lactic acid)

Shifting the cartons in cold store below -7°C for 7 – 10 hrs.

Dispatch.

4.4.3 PROCESS OF CURD MAKING:-

1. Fresh, sweet, good quality milk(cow, buffalo or mixed) is received, pre-
heated to 35-40°C, and subjected to filtration/clarification.
2. It is then standardize to 3.0% fat and 10.0% SNF(in order to improve the
body), pre-heated to 60°C and homogenized single stage at a pressure of
176kg /sq.cm.
3. The milk is pasteurized at 90°C for 5 mins, cool to 41-42°C and inoculated
with 1-1.5% specific starter culture.
4. It is then filled in plastic cups of the required capacity and incubated at 41-
42°C for 2-3hr., during which period the acidity reaches 0.66-0.70% and a
firm curd is formed.
 TRAINING REPORT ON VERKA

5. The curd is cooled and stored at <7°C for 7hrs or overnight in cold room.