ICS Project Milk

Detailed Project Report on Milk and Milk Products
Prepared by:
Post Tamkor, Distt – Jhunjhunu, Rajasthan

Contents
Chapter 1: Introduction 2
Chapter 2: Process Flow of Milk and Milk Products 16
Chapter 3: Production and processing hubs/ clusters in Rajasthan 25
Chapter 4: Automation in Dairy Processing 26
Chapter 5: Product Benchmarking 31
Chapter 6: Appropriate Technology/ Plant and Machinery for Dairy Processing Unit 51
Chapter 7: Indicative Project Profile for Rajasthan 59
Chapter 8: Method of technology dissemination and adoption 91
Appendix 1: Dairy Technology Suppliers 93
Post Tamkor, Distt – Jhunjhunu, Rajasthan| Phone: 9810274608 Page 1 of 67

Chapter 1: Introduction
Global Scenario
Dairy is one of the major segments of this industry, greatly benefited by the emergence of dairy
processing as the fastest growing food producing sector in the world. However, over the years, with
emerging new markets and technologies, the sector has widened its scope. It has started producing
many new items like ready-to-eat and ready-to-cook, food products and frozen products.
Milk is one of the most valuable agriculture commodities and most produced across the world. Total
production in 2015 was around 806.70 million tonnes(NDDB). Milk contributes 27% to the global value
added of livestock and 10% to that of agriculture.
Major 5 Cow milk producing countries (in '000 (MT)
12%
United Staes (91300 ) India (60600)

36%
14% China (35700)
Brazil (34300) Germany(31100)
14%
24%
Figure 1: Major 5 Cow Milk producing countries
A steady rise in consumption demand for dairy and allied products has led to higher levels of technology
adoption among the major dairy producing countries in the world. With a Compound Annual Growth
Rate (CAGR) of 5 percent, the industry is expected to generate revenues worth USD 442.32 billion in
2019. Asia continues to dominate the global dairy market. China, India and countries in South East Asia
account for a major portion of the global dairy industry, but milk supply in these regions has not been
able to keep pace with the level of growing demand. These markets offer huge potential for dairy
companies that are looking to meet the global demand for dairy products.
Table 1: World Dairy Market at a Glance from 2015-2017
Change:2017 over
World Dairy Market At Glance
2016
World Balance
million tonnes. Milk equiv.
2015 2016 2017 %
Total milk production 812.1 819.3 830.5 1.4
Total trade 70 71.1 71.8 1
Supply and Demand Indicators
Per Caput Food Consumption
World(kg/yr.) 110.5 110.2 111.4 1.1
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Trade-share of production(%) 8.6 8.7 8.6 -0.3
Change: Jan-May 2017

FAO Dairy Price Index 2015 2016 2017 over Jan-May 2016 %
160 154 191 41.7
Source: FAO
During the first part of 2017 (January to May), prices remained generally stable overall, as recovery of
milk deliveries in the EU and continued growth in output in the United States lessened supply concerns.
Continued recovery in imports by China, following the substantial drop sustained in 2015, is forecast to
be the main engine for growth. The increase projected in world milk production is by 177 million tonnes
by 2025 (International Dairy Federation)
Apart from a few exceptions in Europe such as Russia and Ukraine, milk production has increased
significantly in almost all the countries around the world. Cow milk represents nearly 80 percent of
global milk production. As compared to cow milk, buffalo milk is produced in fewer countries; it is
estimated that more than 80 percent of the world's total buffalo milk is produced in India and Pakistan.
Major Milk Processing Global Companies

The top five countries in the world which process milk to manufacture various milk products such as
chocolates, milk powder, energy bars etc. are Nestle, Lactalis, Danone, Dairy Farmers of India and
Fonterra; in order of their market share for milk based products.
Nestle is known for its exceptional products which range from nourishment to snacks. The company is
incorporated in the Switzerland and is one of the oldest dairy companies in the world. Lactalis is mainly
a family run corporation in Laval, France, and is known for the best cheese in the world. It has
established a name in the dairy industry with its exquisite milk products. Danone is a multinational
corporation, which is incorporated in Paris, France. Danone is listed on the stock market of Paris,
Euronext Paris and deals in over 130 markets worldwide. The Dairy Farmers of America Inc. (DFA)
consumed 28.1 million tonnes of milk to fulfil its need. The corporation has 15,000 dairy farmers and
agriculturists who stake a claim. In 2016, the corporation recorded a turnover of $13.8 billion. The
Fonterra Co-dairy company is from New Zealand which is held by the around 11,000 farmers. Their milk
intake in the year 2016 stood to a whopping 22.1 million tonne with a turnover of $13.1 billion.
1st
2nd
3rd
4th
5th
Figure 2: Top Five Milk Processing Companies in the World
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New Zealand exports almost 49 % of the total dairy products manufactured in the world. Germany ranks
second in the global dairy products export, with a share of about 18% of global dairy products. Further,
Netherlands and France have almost same quantity of global; export which values US$ 1.9 and US$ 1.5
Billion respectively. United States exports dairy products worth 5.50% of the world’s total dairy product
manufactured.
Major Exporting Countries of Dairy Products
19% billion) Germany (US$2.6 billion) Netherlands (US$1.9 billion) France (US$1.
New Zealand (US$4.4
Rest countries
49%
11%
8%
7%
6%
Figure 3: Major Exporting Countries of dairy products, 2016
Major Importing Countries with quantity & Value of Dairy Products in 2016
Germany ranks first in the import of dairy products which was US$ 5,991 Million in 2016, followed by
Italy with a value of US$ 3,488. China ranks third whose import was valued at US $ 3,371 Million in
2016. Netherland and France ranked fourth & fifth respectively in the import of dairy products in 2016.
Major Importing Countries of Dairy Products

4,506,934.00 5,991 2,928,810.001,955,686.002,488,648.001,618,065.00
6,000.00
5,000.00
3,488
4,000.00 3,371 3,345 3,242
(000'MT)
3,000.00
2,000.00
1,000.00
-
Germany Italy China Netherland France
Quantity of Import ('000 MT) Value (US $ Million)
Figure 4: Major importing countries of dairy products
Global Opportunities and Challenges in the Dairy Sector

The following table shows the challenges and opportunities for all the stakeholders in the dairy sector
i.e. producers, processers and retailers. As it is imperative for the stakeholders to change the dynamics
of the sector with the market needs and challenges which originates with it.
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Producers
Opportunities
Taking advantage of new technologies
The professionalization of farming.
Challenges
Complementing technology with suitable process.
Enhancement of commercial skills.
Lack of skilled labours
Processors
Opportunities
Innovation on global scale.
Safe & secure supply chain
Challenges
Change in farm management.
Adapting to more informed consumer.
Demand for organic and GM-free products.
Page 5 of 67
Retailers
Opportunities
Demand for local produce
Growth of convenience stores.
Challenges
Adapting offerings tas per consumer demands.
Use of expensive technology in analysing purchasing behaviour.
Figure 5: Opportunities and Challenges for Stakeholders in Dairy sector
Indian Scenario
India now has indisputably the world's biggest dairy industry — in terms of milk production; In 2017,
India produced close to 165 million tons of milk, India also produces the biggest directory or
encyclopaedia of any world dairy industry. The dairy sector in the India has shown remarkable
development in the past decade and India has now become one of the largest producers of milk and
value-added milk products in the world.
The major Milk production zones in India are Uttar Pradesh, Maharashtra, Himachal Pradesh, Madhya
Pradesh, Punjab, Rajasthan, Tamil Nadu are the major production area of Dairy Products in India.
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Major Five Milk Producing States in India in 2015- 16
Uttar Pradesh (23.33 Million Tonnes)

14%
Rajasthan (13.90 Million
Tonnes)
33% Andhra Pradesh (18.22Million Tonnes)
15% Gujarat (14.72 Million Tonnes)
18%
Panjab (13.87 Million Tonnes)
20%
Figure 6: Major Five Milk Producing States in India in 2015-16
Production and Per Capita Availability of Milk

2016-2017 355
170 165.4 360
337
gram./day
In '000 MT
160 155.5
146.3 322 340
150
320
140
300
130
2016-2017
2014-2015 2015-2016
Years
Production(In Million Tonnes) Per Capita Availability(gram./day)
Figure 7: Milk Production & Per Capita Availability In India (2016-

17) Source: Department of Animal Husbandry, Dairying & Fisheries
The Indian dairy industry is divided into the organized and unorganized segment. The unorganized
segment consists of traditional milkmen, vendors and self-consumption at home and the organized
segment consists of cooperatives and private dairies. As per the Annual Report for FY17of Dept. of
Animal Husbandry, Dairying & Fisheries, Ministry of Agriculture & Farmers Welfare, GOI, co-Operatives
& private dairies still procure only about 20% of the milk produced in the country, while 34% is sold in
the unorganized market and about 46% is consumed locally. However, in most of the developed
nations, 90%of the surplus milk is processed through organized sector.
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Indian Dairy Industry
Oraganized Unorganized
Sector Sector
Private Companies
Milkmen/
10% Local Vendors 34%
Self Consumption
Co-operatives 10%
46%
Figure 8: Structure of an India Dairy Industry
There is immense room for the organized sector to gain market share of marketable milk from
unorganized sector by introducing standardization in milk quality testing and transparency in computing
remuneration being paid to farmers for their milk along with educating farmers on best dairy and animal
husbandry practices. This could also dovetail well with the shift of consumer preference from
unorganized to organized market. As per the Department of Animal Husbandry, Dairying and Fisheries,
the organized milk handling is expected to grow from 20% at present to 50% by 2022-23.
In India, animal husbandry and dairying are important economic activities accounting for approximately
33 percent of the agricultural Gross Domestic Product (GDP). India is the largest producer of milk
having achieved an annual production of 165.4 million tonnes in 2016-17. As the economy grows and
income increases, a World Bank study points out, per capita consumption for milk and milk products in
the country is projected to rise to more than 350 grams per day by 2020. The major Milk production
sector are Uttar Pradesh, Rajasthan, Madhya Pradesh, Gujarat and Andhra Pradesh are the major
production area of Dairy Products in India.
India’s milk production is expected to reach 180 million MT by 2020, from the current 163.7 million MT,
while NDDB has projected demand to touch 200 million MT. The Indian dairy market is amongst the
largest and fastest growing markets in the world. India has attained the top position in milk production
globally, owing to a huge bovine population. However, the full potential of Indian milch herd still remains
unattained. Per capita availability of milk in India has reached 352 grams per day.
An important milestone in the significant growth of the dairy sector in the past decades has been a
series of ‘Operation Flood Programs’ spearheaded by the National Dairy Development Board (NDDB)
through promotion of dairy cooperatives across the country. In addition, the World Bank funded National
Dairy Plan 1 (NDP) run by the NDDB for the period 2011-12 to 2017-18, is a scientifically planned multi-
state initiative. It aims at increasing the productivity of milch animals and providing rural milk producers
greater access to the organized milk-processing sector. It is estimated that only 30 percent of the
marketable surplus is sold to the organized sector. Small producers in rural areas, who account for 70
percent of milk production, are particularly affected.
Milk is one of the most important and most consumed commodity in India, and with considerable growth
in population the production of milk has also increased due to the demand. This sector is divided into
two
i.e. Organized Sector and Unorganized Sector. Unorganized sector is the milk that is sold by milkmen
(largely based in villages and small towns), vendors who collect the milk from local producers and sell it
directly to households and to sweet shops in both urban and rural areas. On the other hand, the
organized dairy sector represents milk that is processed using modern infrastructure and marketed
through the organized channels under their own brand names such as Amul, Mother Diary, and Parag
Dairy etc.
India’s dairy exports mainly include NFDM, fats and oils derived from milk, cheese, lactose products,
casein, butter, and ice-cream to countries such as Bangladesh, Pakistan, Nepal, Afghanistan, Bhutan,
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United Arab Emirates, United States and Singapore. In CY 2016, India’s dairy exports were valued at
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$172 million, up five percent in comparison to previous year. From CY 2011 to CY 2016, India’s dairy
exports value increased at a compound annual growth rate of 10.1 percent.
India's Export of dairy products were 39,397.62 MT of the world’s total, worth Rs. 910.44 crores during
the year 2016-17(APEDA). The graph below shows the top ten countries where India export its dairy
products.i
Export from India of Dairy Products 2016-17

Quantity of Export ('000 MT) Value (US $ Million)
20,322.35
12,459.53
10,923.45
8,521.93
7,092.68 7,264.83
5,733.87 4,364.67
4,362.75 5,055.48
U Arab Emts Bangladesh Pr Bhutan Pakistan Ir Nepal
Figure 9: Export from India of Dairy Products
United Arab Emirates imported maximum dairy products in 2016-17 followed by Bangladesh which
ranked second and imported dairy products worth about US$ 12,459.53 Million from India. Also, Bhutan,
Pakistan and Nepal among the major countries importing.
Major Indian companies in Dairy Products

Amul is the top dairy company in the country. Established in 1946 by Verghese Kurien (founder-
chairman of the GCMMF). Mother Dairy is a well-known dairy based company in India. The organization
was established in 1974 by National Dairy Development Board (NDDB) and has over 6 manufacturing
plants. Kwality Limited is a company which was established in 1992 and acquired by Dhingra Family in
2002. The federation offers Milk & Milk Products, Horticulture Products, Kandhamal Organic Products
and a lot more. One of the most famous industries in Orissa, Orissa State Cooperative Milk Producers
Federation (OMFED), is a well-known diary maker in country which was established in 1985. Andhra
Pradesh Dairy Development Cooperative Federation Ltd.is located in Lalapet, Hyderabad.
Table 2: Top 5 Indian companies in dairy products
Name of the
Rank Company Main Products
1st Amul Milk, Butter, Ghee, Milk Powder, Chocolate, Paneer, Curd
2nd Mother Dairy Milk, Ice- Creams, Dahl, Lassi and Flavoured Milk
3rd Kwality Limited Milk, Ghee, Curd, Lassi, Paneer and Ice Cream
Toned Milk, Ghee, Curd, Cheese, Lassi, Butter and Ice Cream
4th OMFED etc.
5th1 APDDCF Milk, Curd, Paneer and Ghee under brand name Vijaya
1 Source: http://www.trendingtopmost.com
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Emerging value-added categories
During the last five to ten years, India has seen dramatic shift towards consumption of value-added
products such as cheese, yoghurt, UHT (ultra-heat treatment) milk, flavoured milk, and whey. To tap the
advantages of the changing consumer food preferences, most organized players are expanding product
Ratings I Indian Dairy Industry -driven by value added products and portfolios in the value-added
segment. This segment offers high growth potential and better margins versus the liquid milk and
Skimmed Milk Powder (SMP) segment.
Figure 10: Average EBITDA margin for the value added products across categories, 2017
Current Market Scenario of Milk and Milk Products

Rising Urbanization Propelling Value‐Added Products
Increasing preference for value‐added products in India: In recent times, value‐added products (VADP)
have been gaining preference among customers due to apparent changes in demographic and dietary
patterns. The share of value‐added products has gradually increased and now stands at 34% of total
industry. However, contribution of milk and skimmed milk powder (SMP) combined stands at ~66% of
industry sales.
Indian dairy industry split (2016) – Value Added Products comprises just 34% of share
Butter SMP UHT MILK Cheese Others

4% Curd 1% 1% 1% 2%
5%
Paneer
7%
Ghee
15%
Liquid Milk
64%
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Indian dairy industry can be classified into commodity dairy products like: 1) Raw milk; 2) Skimmed milk
powders (SMP); and 3) Dairy whiteners (DW) which are low margin products. Further, milk products like
curd, buttermilk, ghee, butter, ice cream and paneer can be classified as traditional value‐added
products which have a huge unorganised market and driven by increasing nuclearisation of families.
With improving macroeconomic trends like rising consumerism, India is witnessing increasing
consumption of emerging value‐added products like UHT milk, cheese, flavoured milk, yogurt, Lassi,
whey, etc. These are hugely underpenetrated categories.
In 2004, Dairy Australia Seminar Series, a review of the epidemiological evidence on milk and
cardiovascular disease, showed that milk drinkers have a reduced risk of cardiovascular disease (CVD)
compared to those who drink little or no milk, despite the fact that most of the milk drank was regular fat
milk. The review further concluded that there was no evidence of an increase in vascular disease;
rather, the incidence of stroke and heart disease was about 15% lower in the subjects with the highest
intakes of milk. Evidence from cohort studies suggests that though milk consumption raises cholesterol
level, milk is protective against vascular disease.
The biggest setback to using milk and dairy products is that the public in general, and teenagers and
women in particular, tend to avoid milk and dairy products because of their fat content.
A 300 ml glass of full cream milk contains 10 g of fat, of which 6.3 g is saturated fat, and can contribute
about 770 kJ of energy. In contrast, a 300 ml glass of skim milk only contains 0.6 g of fat (a reduction of
94%), 0.3 g of saturated fat, and 440 kJ (a reduction of 43%). Therefore, consuming skim milk and low
fat yoghurt instead of whole milk will allay the fear of health risks associated with dairy fat.
Milk Production for 2017-18 (million tonnes)

World 830
India 164
Unorganised players 133
organised players 31*
Co-operatives 17
Private 14
Source: NDDB *Co-ops + Private
Evolution of key categories ‐ Consumption of value‐added products on the rise
Currently, due to conventional culture, commodity dairy products like liquid milk and SMP contribute
~66% of total dairy industry, followed by traditional dairy products (ghee, paneer, curd, buttermilk, butter
and ice‐cream) forming ~32%, and emerging (cheese, whey, UHT, flavoured milk, yogurt) accounting
for mere
~2% of market.
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Ergo, there is humungous growth opportunity in traditional milk products like ghee, curd and paneer due
to large industry size and unorganised presence, which we expect will lead to strong 20% CAGR in
organised players in these segments over 2016‐20E. Emerging value‐added products like UHT milk,
flavoured milk, cheese and whey have highly organised market presence, but are hugely
underpenetrated (small market size) which we believe will lead to strong 25% CAGR in growth for these
segments over 2016‐20E.
Humungous opportunity for organised segment led by high market growth, low penetration of
Value Added Products
Competitive Edge of Players
Strong procurement infrastructure, key to success: Companies with infrastructure for direct milk
procurement from farmers enjoy huge competitive edge as it assures steady milk supply and
consistency in milk quality at relatively lower prices. Heritage at ~95%, Hatsun ~100%, Parag ~80% and
Amul at 100% score high in terms of direct procurement and diversifying over the years.
Right product mix of milk and high‐growth Value Added Products: A right mix of milk ‐ Value
Added Products helps maximise growth, margins and return ratios. Companies with high milk sales
(Heritage and Hatsun at 65‐70% of sales) have seen their direct procurement network scale up resulting
in higher RoCE. It is these players that have been leveraging their established milk brands to expand
their Value Added Products share. Value Added Products is an attractive opportunity as: i) These
products are poised to grow at higher rate; and ii) Command ~1.5‐2x higher EBITDA margins.
For Heritage, while Value Added Products currently contributes 24% of sales it is well on way to touch
28% levels over FY17‐20E. While Heritage has the best product portfolio with majority of its sales from
high‐RoCE fresh dairy products, it is prudently increasing sales of high‐margin Value Added Products.
Parag derives ~64% of its sales from Value Added Products, which is expected to go to 70% over FY17‐
20. Emerging Value Added Products contributes ~27% of sales, however it has been ahead of the curve
in these high margin emerging Value Added Products with strong capex already incurred. Ergo, we
believe Parag is best placed to capture the advantages of high‐growth emerging Value Added Products,
which would offset the initial drag of lower RoCE of Value Added Products like cheese.
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Channel mix ‐ Strong branding and higher B2C sales: Heritage and Hatsun have a strong
procurement & distribution network which has led to creation of a strong B2C franchise (>90% of sales)
for them. Rising consumption of Value Added Products is seeing players expand their B2C mix.
However, there are certain Value Added Products like cheese which is consumed ~50% out of home.
Also, categories like butter, paneer and SMP are institutional in nature. Parag is strong in Value Added
Products due to its prowess in brand building in Value Added Products and B2C sales account for ~67%
of its mix.
Strong branding to scale the value curve: As competition intensifies and companies move up the
value curve to Value Added Products, it has become extremely critical to spruce up brand building
activities. Examples being national brands like Gowardhan ghee ‐ fetches better realisations and
commands brand premium. Parag offers an entire range of cheese products and variants leveraging
strength of its core Go cheese brand, while also devising a premiumisation strategy.
Product mix of Indian dairy companies
A mix of high‐RoCE milk segment, and leveraging established milk brands for high growth and margin
VADP is a theme prevailing across all Indian dairy companies, who have set their eyes on continuously
increasing the share of higher‐margin VADP. These companies include Heritage and Hatsun who derive
highest proportion of their revenues from milk (65‐68%), while for others majority of their revenue comes
from non‐milk products.
But, milk entails lower margins and scalability hinges on enhancing procurement reach, which takes
time to develop. Competition from cooperatives is also getting fiercer. To succeed it has become
imperative for players to leverage their procurement to extend into other VADP.
Penetration of organised players in VADP categories is comparatively lower than in liquid milk, with
many of these categories in low‐single digit penetration. However, over next 3 years, led by rising
income levels, increasing urbanisation and improving dietary habits, emerging (organised) VADP
categories are estimated to grow at 25% CAGR.
In the long run, we believe companies with higher share of VADP, strong branding, differentiated
products and distribution network for B2C channel will earn higher margins, record higher growth and
survive the cooperatives. In our view, Parag has the best scale in VADP at 64% of sales along with
strong branding and product mix. Heritage and Hatsun are also moving into traditional VADP, which will
lead to better margins and sustain high RoCE.
Revenue mix of Indian dairy players – Heritage, Hatsun strong in fresh milk, Parag best‐in‐class
in VADP
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Opportunities in Indian Dairy Industry
As mentioned earlier, India is the world’s largest producer of milk; however, the country’s dairy market is
highly fragmented, unorganized and is dominated by local milkmen, regional brands and milk
cooperatives. The sector has attracted several investors in the recent years, and has also seen
consolidations. Strong producer prices, a promising outlook for dairy consumption and government
incentives have been attracting robust investments to the dairy processing sector.
The recent investments by global companies in the Indian Dairy Companies are as under:
Indian Amount (Rs. In

Company Investing Company crore)
KKR India, the local arm of the New York based buyout
Kwality Ltd. 600
firm
Tirumala Milk Lactalis 1750
Anik Industries Lactalis 470
Creamline Dairy Godrej Agrovet Ltd. 150
Dodla Dairy Cargill Ventures 110
Table 3: Product wise EBIDTA Margin- VADP generate higher EBITDA Margins
Product EBITDA Margin (%)

Milk 3-5
Milk Powder 0-2
Curd 18-22
Paneer 18-22
Ghee 10-15
Butter 5-8
Ice-Cream 15-18
Cheese 14-18
Whey(consumer) 30-35
Flavoured Milk 16-18
Challenges in Milk and Dairy products production in India

However, there are challenges to dairy in India, mostly in the form of rapid urbanization, low interest of
younger generation in dairy farming and increasing real estate price that leads to loss of farm lands.
Due to these factors, some dairy regions may come under pressure. The preventive measures would be
to implement changes in the dairy production to make farming system more competitive. In addition,
there is a need to develop infrastructure to enhance production, followed by investment at farm level
and improving feeding methods. More importantly, Government could consider giving relaxation in tax
on farmer`s income from milk to encourage him to invest in dairy.
State Scenario
In Rajasthan, livestock sector plays major role in improving socio-economic status and fulfilling
nutritional needs of rural masses. The state is second highest in milk production in the country. Of the
total milk produced, 53 per cent is buffalo milk, 36 per cent is cattle milk and 11 per cent is goat milk.
Per capita availability of milk is highest in Jaisalmer district having 1,085 grams of milk per day per
person. Approximately, 50 per cent of the milk produced is sold in the market and only 25 per cent is
consumed at home as liquid milk. Remaining 25 per cent of the milk produced is converted into milk
products. Highest livestock density is in Rajsamand and Dausa district having 292 livestock per square
kilometre.
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Year wise goat and bovine milk production of Rajasthan (in '000 MT)
Goat MilkBovine MilkTotal Milk
14563
13512 13941
13234 12783
12330 11842 12238
11644
10882
1448 1590 1670 1703 1780
2006-07 2007-08 2008-09 2009-10 2010-11

Figure 11: Year wise goat and bovine milk production of Rajasthan (in '000 MT)
Source: Integrated Sample Survey Reports (2001-02 to 2013-14), Department of Animal Husbandry,
Govt. of Rajasthan
Animal Husbandry is a major economic activity of the rural people of Rajasthan, especially in the arid
and semi-arid regions. The State faces frequent droughts and famine which causes frequent crop failure
as most of the agriculture is rain fed. In this climatic scenario, dairy sector provides sustainable year-
round income to large number of farmers. Over a decade, there has been an incremental increase of 3
per cent in number of in-milk bovine with maximum increase in Jaisalmer and Pali districts.
Table 4: District wise milk production of Rajasthan (in '000 MT), 2014
Sr. No. District Bovine Milk Goat Milk Total Milk
1 Ajmer 588 91 679
2 Alwar 1,015 101 1116
3 Banswara 263 33 296
4 Baran 225 20 245
5 Barmer 454 142 596
6 Bharatpur 328 17 345
7 Bhilwara 433 54 487
8 Bikaner 420 67 487
9 Bundi 365 23 388
10 Chittaurgarh 415 40 455
11 Churu 278 80 358
12 Dausa 384 41 425
13 Dhaulpur 176 12 188
14 Dungarpur 217 31 248
15 Ganganagar 519 30 549
16 Hanumangarh 399 27 426
17 Jaipur 1,009 75 1084
18 Jaisalmer 148 107 255
19 Jalor 331 40 371
20 Jhalawar 278 35 313
21 Jhunjhunun 478 70 548
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Sr. No. District Bovine Milk Goat Milk Total Milk
22 Jodhpur 669 116 785
23 Karauli 236 37 273
24 Kota 206 20 226
25 Nagaur 447 122 569
26 Pali 544 70 614
27 Pratapgarh 0 0 0
28 Rajsamand 232 31 263
29 Sawai Madhopur 293 27 320
30 Sikar 628 87 715
31 Sirohi 167 38 205
32 Tonk 267 37 304
33 Udaipur 371 59 430
Total 12,783 1,780 14,563
Source: Integrated Sample Survey Reports (2001-02 to 2013-14), Department of Animal Husbandry,
Govt. of Rajasthan
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Chapter 2: Process Flow of Milk and Milk
Products
Dairy products are generally defined as food products that are produced from milk. They are rich
sources of energy. Raw milk for processing generally comes from cows and buffalo, but occasionally
from other mammals such as goats and sheep. Water is the main constituent of milk (about 90%). Milk
also contains fat, in the Indian dietary regimen, milk fat in the form of cream, butter and ghee contributes
significantly towards nourishment of people of almost all age groups these products are good sources of
fat soluble vitamins A, d, e and K. in the ancient Vedic literature it is mentioned that ghee derived from
cow milk has got excellent nutritional and tonic qualities especially beneficial to persons convalescing
after chronic illness and bone fracture. cream is a fat rich component and has been known from time
immemorial as the fatty layer that rises to the top portion of the milk when left undisturbed. cream is sold
in many varieties. Although used for several purposes, it is primarily something of a luxury because of its
excellent flavour, body and texture.
In this section following few milk and milk product process flow is described:
1. Pouch Milk
2. Curd
3. Paneer
4. Shrikhand
5. Lassi
6. Butter Milk
7. Butter
8. Ghee
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The clean and fresh cow milk having acidity less than 0.135% is received and chemical test is conducted on it. It is filtered thr
16 seconds and immediately chilled below 4°C store in the insulated storage tank. After the pasteurization process, the quali
Page 19 of 67
Name of
Flow Diagram Process
Product
Curd
Receiving of Cow Clean and fresh cow milk having acidity
Milk less than 0.135% is received and
chemical test is conducted. It is filtered
through nylon and online filter. After the
filtration, milk is chilled below 4° C by
Filtration using the plate heat exchanger and
then it is store in insulated storage tank
to prevent the growth of the harmful
bacteria. It is standardized to 3.8% milk
Chilling fat and 9.6% SNF by adding the
skimmed milk or removing the excess
fat from milk by using the online cream
separator. It is pasteurized at the
Standardization temperature 78° C for 16 seconds and
then immediately chilled below 4°C. It is
stored in an insulated storage tank after
the pasteurization process. The quality
Pasteurization is confirmed for MBR Test and is the
milk heated in the multipurpose
machine for the temperature 80°C for
20 minutes and is chilled at the
Storage temperature 40°C. After attaining the
temperature change, milk is inoculated
by 1% lactic acid culture and is mixed
Checking well with the milk by the agitation. It is
Quality packed in the cups or the pouches by
using the online automatic packing
machine. And it is incubated at 42°C for
Heating of 6 hours to get the solid settled mass in
Milk the cups. It is cooled at 4°C by using
the blast cooler to prevent the increase
in acidity and then it is stored
Inculation of immediately in the milk cold room
Culture having temperature less than 2°C.
Thereafter it is distributed in the
insulated vans to the market as per the
Packing in Cups schedule.
and Pouches
Incubation
Blast
Cooling
Storage
in cold
room
Distribution
Page 20 of 67
The clean and fresh cow milk having acidity less than 0.135% is received and the chemical test is conducted on it. It is filtered
Page 21 of 67
Name of Flow Diagram Process
Product
Shrikhand The clean and fresh cow milk having
Receiving of Cow Milk acidity less than 0.135% is received and
the chemical test is conducted. It is
Filtration filtered through the nylon and the online
filter. After the filtration, milk is chilled
below 4° C by using the plate heat
Chilling
exchanger. Then it is stored in the
insulated storage tanks to prevent the
Standardization growth of harmful bacteria. Thereby it is
standardized to 3.8% milk fat and 9.6%
SNF by adding the skimmed milk or
Pasteurization removing the excess fat from milk, by
using the online cream separator. Then
it is pasteurized at the temperature
Storage 78°C for 16 seconds and immediately
chilled below 4°C store in the insulated
storage tank. After the pasteurization
Checking Quality process, the quality is confirmed for
MBR Test and is heated in the
multipurpose machine for the
Heating of Milk temperature 80°C for 20 minutes and is
chilled at the temperature 40°C. Milk is
inoculated by 1% lactic acid and is
mixed well with the milk by agitation.
Inculation of Culture Then it is incubated as it is for 6 hours
after setting the curd then it is hung in
the muslin cloth and kept for 8 hours in
Hanging in musilin the hanging position to remove the
cloth whey and become the solid mass as
chakka. Chakka is kept in the cold room
for 12 hours and next day it is kneaded
Collection of Chakka with 70% sugar of chakka, and other
additives like mango pulp, nutmeg, ell
chi, cardamom, colors and flavor also
Additaion of Sugar, fruit verities as per the market demand
Addituage and
and packed in the cups or pouches
kneding
manually. Then it is kept in the deep
freezing temperature less than -15°C
Packing in Cup or and is distributed in the insulated vans
Pouch to the market as per the schedule.
Storage in Deep
Freeze
Distribution
Page 22 of 67
Name of
Flow Diagram Process
Product
Lassi
The clean and fresh cow milk having
Receiving of Cow Milk acidity less than 0.135% is achieved
after the receiving the other detail
chemical test. Then it is filtered through
Filtration the nylon and the online filter. After the
filtration, the milk is chilled below 4° C
by using the plate heat exchanger, then
Chilling it is stored in the insulated storage tank
to prevent the growth of harmful
bacteria. Then it is standardized to
Standardization 3.8% milk fat and 9.6% SNF by adding
the skimmed milk or removing the
excess fat from milk by using the online
Pasteurization cream separator. Then it is pasteurized
at the temperature 78°C for 16 seconds
and immediately chilled below 4°C store
Storage in the insulated storage tank. After the
pasteurization quality is confirmed for
MBR Test and is heated in the
Checking Quality multipurpose machine for the
temperature 80°C for 20 minutes and is
chilled at the temperature 40°C. After
attaining the temperature, milk is
Heating of Milk inoculated by 1% lactic Acid culture and
is mixed well with milk by the agitation.
Then it is incubated as it is for 6 hours
Inculation of Culture after setting of the curd, then 7% sugar
syrup is added and the mixture is
agitated with the high speed mixture. It
is homogenized along with pasteurized
Incubation lassi and chilled lassi is stored in the
insulated tank below 4°C. It is packed in
Addition of Sugar the pouches on the automatic packing
Syrup machine or in the cups manually and
then it is keep in cold room temperature
less than 2°C and it is distributed in
Homoginazation insulated vans to market as per
schedule.
Lassi Pasteurization
Storage
Packing in Cups and

Pouch
Storage in cold room
Distribution
Page 23 of 67
Product
Butter Milk Receiving of Cow The Clean and Fresh, Cow Milk having
Milk acidity less than 0.135% is received and
chemical test is conducted. Then It is
Filtration filtered through nylon and online filter.
After filtration, milk is chilled below 4° C
by using plate heat exchanger and then
it is store in an insulated storage tank to
Chilling
prevent the growth of harmful bacteria.
It is standardized to 3.8% milk fat and
9.6% SNF by adding skimmed milk and
Standardization removing excess fat from milk and by
using online cream separator. It is
pasteurized at the temperature 78° C
Pasteurization for
16 Seconds and immediately chilled
below 4°C store in insulated storage
Storage tank. After pasteurization the quality is
MBR Tested and is heated in
multipurpose machine at a temperature
80°C for 20 minutes and is chilled at a
Checking
Quality temperature 40°C. After this milk is
Heating of Milk inoculated by 1% lactic Acid Cultured
and is well mix with milk by agitation. It
is incubated as it is for 6 hours after
Inculation of setting the curd and then 1% salt and
Culture chilled water is added. And the mixture
is agitated with the high speed mixture
Incubation and it is then homogenized along with
the butter milk pasteurized. The chilled
butter milk is stored in the insulated
Addition of Salt and tank below 4°C and is packed in the
Child Water pouches on the automatic packing
machine or in the cups manually and
then it is kept in the cold room
Homoginazation temperature less than 4°C and it is
distributed in the insulated vans to the
market as per the schedule.
Butter Milk
Pasteurization
Storage
Packing in Cups
and Pouch
Storage in cold
room
Distribution
Page 24 of 67
Product
Butter Firstly, milk is received then the filtration
Receiving of Milk is done. The filtered milk is then chilled
below 40C and stored for some period
of time.
Filteration
The milk is then separated into two
parts- cream and skim milk.
Chilling below 40C The cream is pasteurized at 920C and

then chilled at 80C and ageing at 90C is
done for 8 hours. After that churning is
done in the butter churner. The churned
Storage milk is filtered and then butter milk is
removed.
Butter is ready; it is packed and stored

Seperation at 180C.
Cream gar
Pateurization at
920C/and chilling at
80C
Ageing 90C for 8

hrs
Churning in
Butter
churner
Removal of
butter milk
Washing
Working
Packaging
Storage
below 180C
Page 25 of 67
Product
Ghee Receiving of Cream Fresh cream is received from separator
from Separation is pasteurized at temperature of 90°C
for 20 Second and is chilled at 9°C and
keep ageing in insulated storage tank
Pasteurization
for 10 hours, after completion ageing
process cream is loaded in butter churn
where butter milk is separated where
Storage and Aging butter milk is separated from cream and
solid mass of butter is form then it is
worked to remove remaining butter milk
Butter Prepration from butter. Butter is melt in melting
tank where curd is removed from settled
butter oil, then butter oil is shifted in
Ghee Manufacture ghee boiler where it is heated at the
temperature 120°C with continues
starring, then it is settled for some time,
after this process berry is separated at
Remove of Berrey the bottom of ghee boiler. Pure Ghee is
again settled naturally and cool down to
Packing in 45°C and is clarified to remove minute
Tin/Jar/Pouch berry particles from ghee, then it is
packed in jar/tin/pouch and stored in
granulation room where temperature is
Granulation maintain 19°C for 12 hours, then ghee
is stored at room temperature and
distributed as per market schedule.
Store at Room
Temperature
Distribution
Page 26 of 67
Chapter 3: Production and processing
hubs/ clusters in Rajasthan
Rajasthan is 4th highest milk producing state in India. Within Rajasthan Alwar is ranks 1 st followed by
Jaipur, Jodhpur, Sikar and Ajmer with production of 11.16 Lakh MT, 10.84 Lakh MT, 7.85 Lakh MT, 7.15
Lakh MT and 6.79 Lakh MT respectively.
Table 5: Top 10 Milk Producing District of Rajasthan
Sr. No. District Milk Production (in ‘000 MT

1 Alwar 1,116
2 Jaipur 1,084
3 Jodhpur 785
4 Sikar 715
5 Ajmer 679
6 Pali 614
7 Barmer 596
8 Nagaur 569
9 Ganganagar 549
10 Jhunjhunun 548
In terms of RACP project cluster districts, Alwar ranks 1 st followed by Jaipur, Ajmer, Nagaur and
Ganganagar with production of 11.16 Lakh MT, 10.84 Lakh MT, 6.79 Lakh MT, 5.69 Lakh MT and 5.49
Lakh MT respectively.
Table 6: Top Milk Producing Cluster Districts of Rajasthan
Sr. No. District Milk Production (in ‘000 MT

1 Alwar 1,116
2 Jaipur 1,084
3 Ajmer 679
4 Nagaur 569
5 Ganganagar 549
6 Bikaner 487
7 Chittorgarh 455
8 Bundi 388
9 Sawai Madhopur 320
10 Jhalawar 313
Source: NDDB – Dairying Profile of Rajasthan
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Chapter 4:Automation in Dairy
processing
The first ideas about fully automating the milking process were generated in the mid-seventies. Cost of
labour in several countries was growing and this was one of the main reasons to start the development
of automation around milking. The first applications were automatic concentrate feeders. A further step
in the automation of milking parlours was the development of automatic cluster removers. In the early
eighties, automation in milking parlous was expanded with the development of milk yield recording
equipment and sensors to detect udder health problems. All these developments and new milking
technology reduces the labour input during milking, resulting in a higher output per man-hour. The final
step in the automation development seemed to be the development of automatic teat cup attachment
systems. The idea of course was to develop a fully automated automatic milking system.
An Automatic milking system is in use for 24 hours per day, needs adjusted cleaning and cooling
procedures, complicates visual control and the milking frequency varies from cow to cow and from day
to day.
One of the aspects affected by automatic milking is milk quality. The quality of milk is a very important
aspect of milk production. Milk payment systems and consumer acceptance are, to a great extent,
based on it. Automatic milking is a fully automated process. Visual control of the milk is not possible as
during conventional milking. Therefore, the milk quality needs to be managed in a different manner.
Several devices such as sensors for conductivity, color and temperature of the milk, yield measurement
and machine on time figures are integrated and inform the farmer on the status of the milk.
In India there are huge numbers of people depends on milk giving animals. Farmers supply milk to
Dairies and it reaches to consumers in the form of various milk products like pouch milk, ghee, butter,
curd, paneer, milk powder and so on. Actually what happens to the milk, how it is processed? What
makes the milk conducive to health? What treatment it receives? And how various milk products are
prepared?
Even though with modern automation in place, the need to configure design process itself, specifically
looking at methodologies for generating optimal dairy processing
Flow sheets over a range of scales, from raw milk to final product and packaging, are most sought after
Automation is delegation of human control functions to technical equipment for increasing productivity,
better quality, increase safety in working conditions reducing manpower & reduced cost. Manufacturing
of products under the control of computers and programmable controllers, manufacturing assembly lines
as well as stand-alone machine tools (CNC machines) and robotic devices can be used for dairy
automation. Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition
(SCADA) in combination attract the need of the project for its capability to provide over all fast and
reliable control for large process automation needs.
Automation in various process industries using PLC and SCADA has gained high importance due to
efficient & reliable control.
Dairy industry is one area in which automation plays an important role to control, automate and stream
line the process. Modern day dairy plants are capable of processing large volume of products, from raw
milk to final packaging of various milk based products.
The dairy industry is divided into two main production areas:
1. Primary production of milk in farms

2. Processing of milk The aim of this project is to study the dairy process automation, to suggest
any scope of improvement in the milk processing and packaging and to implement them using
PLC & SCADA
Automation
Automation is the use of various control system for operating equipment such as machinery, processes
in factories, boilers and heat treating ovens, switching in telephone networks, steering and stabilization
of
Page 28 of 67
ships or aircraft and other applications with minimal or reduced human intervention. Some processes
have been completely automated.
The biggest benefit of automation is that it saves labour; however, it is also used to save energy and
materials and to improve quality, accuracy and precision.
The term automation, inspired by the earlier word automatic was not widely used before 1947, when
General Motors established the automation department. It was during this time that industry was rapidly
adopting feedback controllers, which were introduced in the 1930s.
Automation has been achieved by various means including mechanical, hydraulic, pneumatic, electrical,
and electronic and computers, usually in combination. Complicated systems, such as modern factories,
airplanes and ships typically use all these combined techniques.
Types of Automation
a. Feedback Control
b. Sequential control and logical sequence control
c. Computer control.
Different Control Systems Used In Automation
a. HMI Controller based control system.
b. DCS based Control system.
c. PC based control system.
d. PLC Based automation system.
Human Machine Interface (HMI)

In complex systems, the human-machine interface is typically computerized. The term Human-computer
interface refers to this kind of systems.
The engineering of the human-machine interfaces is by considering ergonomics (Human Factors). The
corresponding disciplines are Human Factors Engineering (HFE) and Usability Engineering (UE), which
is part of Systems Engineering.
Tools used for incorporating the human factors in the interface design are developed based on
knowledge of computer science, such as computer graphics, operating systems, programming
languages. Nowadays, we use the expression Graphical User Interface for Human-Machine Interface on
computers, as nearly all of them are now using graphics. Primary methods used in the interface design
include prototyping and simulation.
Distributed Control System (DCS)

A distributed control system refers to a control system usually of a manufacturing system, process or
any kind of dynamic system, in which the controller elements are not central in location (like the brain)
but are distributed throughout the system with each component sub-system controlled by one or more
controllers.
PC Based Control System

Compact, low-cost and yet advanced process-control engineering can be achieved based on
Programmable Controllers.
PLC Based Automation System

PLC Automation panels are used in Process Control application in industries such as Dairy Industry/ Steel
/ Aluminium / Wire and Cable / Tyre & Tube / Packaging / Plastic / Polyfilms / Pharmaceuticals / Defence
/ Automobile / Power Plant / Marine / LPG Gas & Oil / Cement / In fracture / Crane Automation etc.
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About PLC
A Programmable Logic Controller, PLC or Programmable Controller is a digital computer used for
automation of electromechanical processes, such as control of machinery on factory assembly lines,
amusement rides, or light fixtures.
The abbreviation "PLC" and the term "Programmable Logic Controller" are registered trademarks of the
Allen-Bradley Company (Rockwell Automation). PLCs are used in many industries and machines.
Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements,
extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact.
In essence, a programmable logic controller reads its input signals and responds to them by turning the
output modules on or off. It functions under the classic "if/then" scenario, only on a much more
complicated scale since it controls multiple input and output devices, all of which must be responded to
immediately and constantly as designated by the user program. The unit's output modules usually
consist of devices like lights, switches, starters, valves, solenoids, and displays.
Programs to control machine operation are typically stored in battery-backed-up or non-volatile memory.
A PLC is an example of a hard real time system since output results must be produced in response to
input conditions within a limited time, otherwise unintended operation will result.
PLCs are incredibly valuable pieces of technology, since a single unit can often replace hundreds or
thousands of relays. Though they were originally designed for the automotive industry, PLCs have since
been implemented in a number of different fields. In large part, the automation processes in most
modern factories are facilitated by PLCs.
These devices are designed to follow their programming instructions precisely, which is especially vital
in a factory assembly line setting where a small mistake or miscalculation can result in costly errors.
Some PLCs function on a very basic level; others are capable of controlling higher-level, more
complicated processes. They can be used for a wide variety of input/output functions and timing
applications. They also offer motion control and complex networking capabilities.
History of PLC
The first PLC can be traced back to 1968 when Bedford Associates, a company in Bedford, MA,
developed a device called a Modular Digital Controller for General Motors (GM). The MODICON, as it
was known, was developed to help GM eliminate traditional relay-based machine control systems.
Because relays are mechanical devices, they have limited lifetimes. They are also cumbersome,
especially in large applications where thousands of them may exist. With so many relays to work with,
wiring and troubleshooting could be quite complicated.
Since the MODICON was an electronic device, not a mechanical one, it was perfect for GM's
requirements, as well as for many other manufacturers and users of control equipment. With less wiring,
simpler troubleshooting, and easy programming, PLC technology caught on quickly.
PLCs are often defined as miniature industrial computers that contain hardware and software that is
used to perform control functions. A PLC consists of two basic sections: the central processing unit
(CPU) and the input/output interface system. The CPU, which controls all PLC activity, can further be
broken down into the processor and memory system. The input/output system is physically connected to
field devices (e.g., switches, sensors, etc.) and provides the interface between the CPU and the
information providers (inputs) and controllable devices (outputs).
PLCs can be divided into at least three categories:
Full size: Full-size, for top level applications requiring fast program execution with very short instruction
cycle times. They are capable of supporting several CPUs for multiprocessing to provide more
processing power. They offer the TCP/IP communication capability over general purpose networks to
the supervisory workstations, and support field bus data transmission with equipment controllers.
Middle Size: Middle-size, intended for industrial automated systems of medium power. They offer a
large choice of analog and digital input/output modules. They are usually connected to a field bus on
Page 30 of 67
one side
and to the equipment on the other side; their speed is not an important parameter, the amount of data
transferred is small and the average price per function is low
Small or micro-size: Small or micro-size, for direct interface with sensors and actuators. They are very
simple electrically and mechanically and are sometimes integrated with the intelligent sensor itself, they
are characterized by short reaction times and they transfer a small amount of data.
To operate, the CPU "reads" input data from connected field devices through the use of its input
interfaces, and then "executes", or performs the control program that has been stored in its memory
system. Programs are typically created in ladder logic, a language that closely resembles a relay-based
wiring schematic, and are entered into the CPU's memory prior to operation. Finally, based on the
program, the PLC "writes", or updates output devices via the output interfaces. This process, also
known as scanning, continues in the same sequence without interruption, and changes only when a
change is made to the control program.
As PLC technology has advanced, so have programming languages and communications capabilities,
along with many other important features. Today's PLCs offer faster scan times, space efficient high-
density input/output systems, and special interfaces to allow non-traditional devices to be attached
directly to the PLC. Not only can they communicate with other control systems, they can also perform
reporting functions and diagnose their own failures, as well as the failure of a machine or process.
When you consider all of the advances PLCs have made and all the benefits they offer, it's easy to see
how they've become a standard in the industry, and why they will most likely continue their success in
the future.
Benefit of PLC
PLC play a vital role in automaton, programmable logic controller device can manage and control entire
industry to produce better and quick Response.
A PLC is a digital computer used for automation of industrial processes, like controlling machinery or
factory assembly lines. Unlike desktop computers, PLCs are having multiple inputs and outputs, operate
under extended temperature ranges, have immunity to electrical noise, and have resistance to vibration
and impact. Programs to control machine operation are usually stored in battery-backed or non-volatile
memory.
The main difference between PLC and other computer is that PLC has multiple inputs and outputs then
can do multiple works at moments, you can produce more output quickly.
1. Less cost to implement: For the cost of relays and timers to automate about 3 lines for
conveying product from finishing machine to packaging machine, you could pay for a PLC to
do the same job. In general, a PLC system would make production more flexible and
responsive.
2. Reliability: Relays and Electro-mechanical timers (magnetic control), are susceptible to
electrical / mechanical failure. With PLCs the control logic is non-mechanical, (solid state). And
with the PLC, you can program extra logic to monitor and test itself for possible failure at no
extra cost. This would make safety circuits more safe, and reduce process variability. With PLC
control you could increase compatibility with existing equipment, scalability, improving ease of
use, and providing a common look and feel.
3. Speed: The PLC can speed up operation of machines that you could not obtain with that old
out dated relay logic. Control logic makes decisions more accurate and faster than a human
operator could hope to achieve. Timers can be set to hundredths of a second to compensate
for external variables, and enhance safety.
4. Greater functionality: PLCs have the ability to compare real-time values and make decisions
based on that comparison. They can do complex mathematical functions, and adjust the
machine accordingly. The greater functionality allows you to design logic that can automatically
adjust for different machine products, thereby reducing downtime for setups and machine
change over.
5. Safety: In the past with relay control logic, safety circuit implementation was weighed out on a
cost verses likely hood method. In other words, the basic emergency stop button, relying on
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operators to stop the machine before an accident occurred. Usually do to distractions and slow
reaction time of humans, the button wasn't pressed until after the damage was done. With
PLCs, you can cover 99% of all the possible safety risk, and the only cost is the time it takes to
add a few rungs of logic to your program. Safety curtains are about the most expensive item,
but well under the cost of an accident. Using the PLC to monitor safety risks is equivalent to
having a full time employee watching, but with quicker reaction time than any human.
6. Less downtime: Downtime can be broken down in to two separate areas. Scheduled and non-
scheduled. DuPont has been quoted as saying: "Maintenance is the single largest controllable
cost opportunity, representing $100-$300 million per year corporate-wide."
Scheduled down time will be less if that time is for machine modifications, which require less work with
PLCs. Some of the preventive maintenance can be automated through the PLC to even further reduce
down time.
Unscheduled downtime can be broken down (no pun intended), further into two groups: Troubleshooting
and repair. The more complex our systems become, the more beneficial it is to write logic that will not
only isolate failures but also indicate potential failures that may occur in the near future. The trouble
shooting down time can be reduced by 90%. This is accomplished by utilizing the sensors already in
place, to do testing through PLC logic to isolate where trouble is originating.
Repair is usually only a fraction of the time it takes to find the problem. It's not uncommon to spend
hours tracking down a limit switch that is bent, or a dirty proximity sensor. The cost to find the problem is
more expensive than the cost to repair it. With PLCs the cost to find the problem is greatly reduced.
Page 32 of 67
Chapter 5: Product Benchmarking
Standard for Milk
This Standard applies to “Species identified milk”, “Mixed Milk” and “Full Cream Milk, Standardised Milk,
Toned Milk, Double Toned Milk, or Skimmed Milk” as defined in the regulations
Essential Composition and Quality Factors
 Raw Material - Raw material used shall be as per the respective definitions in item 1 of this
sub- regulation.
 Composition – The milk of different classes shall conform to the requirements for milk fat and
milk solids-not-fat, independently, according to Class of Milk, Locality or State or Area, with
Minimum Milk fat and Minimum Milk Solids- not-fat (SNF). (These have been given in tabular
form in the regulations.)
Food Additives
Milk shall not contain any food additives:
 Except for some dairy products which may contain carry over food additives specified in the
Food Safety and Standards (Food Products Standards and Food Additives) Regulations, 2011:
 Provided further that in sterilised milk, the specific food additives permitted in Appendix ‘A’ of
these regulations may be used and only within the limits specified.
Contaminants, Toxins and Residues
 The products shall comply with the Food Safety and Standards (Contaminants, toxins and
Residues) Regulations, 2011.
 The total urea content in milk shall not be more than 700 ppm.
Labelling
The following details shall be declared on the label of pre-packaged milk or otherwise if the milk is not
pre-packaged and is offered for sale to the consumer, such declaration shall be given on the container
from which milk is offered for sale to the consumer:
 If the milk from any milch animal, mixed milk or skimmed milk is offered for sale to the
consumer without any heat treatment, the name of the milk shall be declared on the label of
pre-packaged milk; or otherwise if the milk is not pre-packaged, the name of the milk shall be
declared and mentioned on the container from which milk shall be offered for sale to the
consumer and shall be preceded with the term ‘Raw’.
 In addition to the labelling requirements mentioned above, the provisions of the Food Safety
and Standards (Packaging and Labelling) Regulations, 2011, shall apply to pre-packaged milk
 Provided that the list of ingredients may not be declared in descending order of usage since
the proportion of ingredients used may require change on a daily basis
 Provided further that where ‘reconstituted’ or ‘recombined’ milk is declared in the list of
ingredients; their components need not be declared separately.
Standard for flavour milk

This Standard applies to Flavoured Milk as defined in the regulations. Flavoured milk shall be subjected
to heat treatment as provided in General Standards for Milk and Milk Products. Where flavoured milk is
dried or concentrated, the dried or concentrated product on addition of prescribed amount of water shall
give a product conforming to the requirements of flavoured milk.
Page 33 of 67
a. Raw Material
 Milk
 Concentrated and dried milk
 Milk fat, cream, butter and butter oil
 Potable water for use in reconstitution or recombination
b. Permitted ingredients
 Sugar or other nutritive sweeteners or both;

 Other non-dairy ingredients like nuts (whole, fragmented or ground), cocoa solids, chocolate,
coffee, fruits and vegetables and products thereof including juices, purees, pulps, preparations
and preserves derived therefrom, cereals, and cereal products and cereal based extracts,
honey, spices, condiments, salt, and other natural flavouring foods and flavours;
 Potable water.
c. Composition
Flavoured Milk shall have the same minimum percentage of milk fat and milk solids-not-fat as that of the
milk, as provided for in the Standard for Milk, from which it is prepared.
d. Labelling:
 The name of the product shall be ‘Flavoured Milk’.

 The following details shall be always declared on the label of pre-packaged product or
otherwise if the product is not pre-packaged, in respect of the product offered for sale
 the class of milk as per General Standard for Milk and Milk Products from which it is prepared
 the heat treatment, as per the General Standard for Milk and Milk Products, to which product
has been subjected to
 In addition to the labelling requirements mentioned above, the provisions of the Food Safety
and Standards (Packaging and Labelling) Regulations, 2011, shall apply to pre-packaged
products.
Standard for evaporated or concentrated milk

Evaporated Milk means the product obtained by partial removal of water from milk by heat or any other
process which leads to a product of the same composition and characteristics. The fat and protein
content of the milk may be adjusted, only to comply with the compositional requirements as given in the
regulation by addition or withdrawal of milk constituents in such a way as not to alter the whey protein to
casein ratio of the milk being adjusted.
a. Raw materials
 Milk and milk powders, cream and cream powders, milk fat products;
 The following milk products are allowed for protein adjustment purposes, only in product
covered by these regulations
 “Milk retentate” means the product obtained by concentrating milk protein by ultrafiltration of
milk, partly skimmed milk, or skimmed milk;
 Potable water
 Sodium chloride
c. Composition
The product shall conform to the compositional specifications provided in the table below
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Table 7: Standard Composition of Evaporated Milk
Evaporated Evaporated partly Evaporated Evaporated

Parameter
milk skimmed milk skimmed milk high fat milk
Milk fat, %, (m/m) 7.5 More than 1 and
1.0 (maximum) 15.0 (minimum)
(minimum) less than 7.5
Milk solids, minimum,
%, (m/m) 25.0 20.0 20.0 26.5
Milk protein* in milk

solids - not fat, 34.0 34.0 34.0 34.0
minimum, %, (m/m)
Labelling
According to the definitions in item 1 and composition in sub-item (c) of item 2, the name of the food shall
be
 evaporated milk, or
 evaporated partly skimmed milk, or
 evaporated skimmed milk, or
 evaporated high fat milk, and as appropriate
Provided that the “evaporated partly skimmed milk” may be designated “evaporated semi-skimmed milk”
when the content of milk fat is between 4.0 – 4.5 % (m/m) and minimum milk solids is 24% (m/m).
Standard for Sweetened Condensed Milk

Sweetened Condensed Milk is the product obtained by partial removal of water from milk with the
addition of sugar or a combination of sucrose with other sugars, or by any other process which leads to
a product of the same composition and characteristics. The fat or protein content or both of the milk may
be adjusted, only to comply with the compositional requirements given in the regulation by addition or
withdrawal of milk constituents in such a way as not to alter the whey protein to casein ratio of the milk
being adjusted.
a. Raw materials
 Milk and milk powders, cream and cream powders, milk fat products;
 Lactose (for seeding purposes);
 Milk products are allowed for protein adjustment purposes like Milk retentate: Milk retentate is
the product obtained by concentrating milk protein by processes like ultrafiltration of milk, partly
skimmed milk, or skimmed milk.
 potable water
 sugar (In this product, sugar is generally considered to be sucrose, but a combination of
sucrose with other sugars, consistent with Good Manufacturing Practice, may be used)
 Sodium chloride.
c. Composition
Page 35 of 67
Table 8: Standard for Sweetened Condensed Milk
Sweetened
Sweetened
Sweetened condensed Sweetened
condensed
Parameter condensed partly condensed
skimmed
milk skimmed high fat milk
milk
milk
More than
8.0 1.0 16.0
Milk fat, %, (m/m) 1.0 and less
(minimum) (maximum) (minimum)
than 8.0
Milk solids, minimum, %, (m/m) 28.0 24.0 24.0 -
Milk solid not fat, minimum, %, (m/m) - 20.0 - 14.0
Milk protein in milk solids - not fat,

34.0 34.0 34.0 34.0
minimum, %, (m/m)
d. Labelling
The name of the food shall be
 Sweetened condensed milk, or

 Sweetened condensed partly skimmed milk, or
 Sweetened condensed skimmed milk, or
 Sweetened condensed high fat milk, as appropriate:
Provided that the “Sweetened condensed partly skimmed milk” may be designated “Sweetened
condensed semi-skimmed milk”, if the content of milk fat is between 4.0 – 4.5 % (m/m) and minimum
milk solids is 28 % (m/m);
Sweetened condensed milks which are not suitable for infant feeding shall not contain any instruction of
modifying them for infant feeding.
Standard for Khoa

Khoa by whatever name it is sold such as Khoa or Mawa or any other region specific popular name
means the product obtained by partial removal of water from any variant of milk with or without added
milk solids by heating under controlled conditions.
a. Raw materials
Milk and milk powders, cream and cream powder and milk fat products.
b. Composition
 It shall be free from added starch and added sugar.

 The extracted fat from Khoa shall meet the standards for Reichert Meissl value, Polenske
value and Butyro-refractometer reading as prescribed for ghee.
Table 9: Standard for Khoa

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Parameter Khoa
Total solids, minimum, %, (m/m) 55.0
Milk fat, minimum, %, (m/m), dry matter basis 30.0
Total ash, maximum, %, (m/m) 6.0
Titratable acidity (as % lactic acid), maximum, % 0.9
Labelling
The name of the food shall be ‘Khoa’ or ‘Mawa’ or any other region specific popular name.
Standard for Cream and Malai

This Standard applies to Cream and Malai as defined in this regulation and refers to
Cream, Reconstituted cream, Recombined Cream, “Prepared creams” “pre-packaged liquid cream,
“whipping cream” “cream packed under pressure” “whipped cream” “fermented/cultured/sour cream”
“acidified cream” “Malai”
a. Raw Material
 All creams, prepared creams and malai

 Milk, which may have been subjected to mechanical and physical treatments prior to cream
processing
Additionally, for creams made by reconstitution or recombination- Butter, milk fat products, milk
powders, cream powders, and potable water. The milk product should
conform to the relevant Food Safety Standards or Regulations;
Additionally, product that remains after the removal of milk fat by churning milk and cream to
manufacture butter and milk fat products (often referred to as buttermilk) and that may have been
concentrated or dried.
 Only those ingredients listed below may be used for the purposes and product categories
specified, and only within the limitations specified.
 The product shall be free from any ingredient foreign to milk except otherwise provided in this
standard. For use in products only for which stabilizers or thickeners, or both, are justified.
 Products derived exclusively from milk or whey and containing 35.0% (m/m) or more of milk
protein of any type (including casein and whey protein products and concentrates and any
combinations thereof) and milk powders; these products can be used in the same function as
thickeners and stabilizers, provided they are added only in amounts functionally necessary not
exceeding 20.0 g/kg, taking into account any use of the stabilizers and thickeners permitted as
per the Food Safety and Standards (Food Products Standards and Food Additives) Regulation,
2011
 Additionally, for use in fermented cream, only- Starter cultures of harmless micro-organisms
 Additionally, for use in fermented cream and acidified cream, only – Non-animal rennet and
other safe and suitable coagulating enzymes to improve texture without achieving enzymatic
coagulation
 Sodium chloride.
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c. Composition
 The product shall contain minimum 10.0 per cent (m/m) milk fat.
 Acidity of the finished products, other than fermented and acidified creams, should not be more
than 0.15 % (as lactic acid).
d. Food Additives
 For products covered under this standard, specific food additives permitted in Appendix ‘A’ of
these regulations may be used and only within the limits specified:
 Provided that stabilizers, acidity regulators, thickeners and emulsifiers may be used when
needed to ensure product stability and integrity of the emulsion, taking into consideration the
fat content and durability of the product. With regard to the durability, special consideration
should be given to the level of heat treatment applied since some minimally pasteurized
products do not require the use of certain additives.
e. Labelling
 The name of the food shall be as specified in standards in this regulation as appropriate.
 However, “pre-packaged liquid cream” may be designated as “cream” and “cream packed
under pressure” may be designated by another descriptive term that refers to its nature or
intended use or as “Whipped Cream”.
 The term “prepared cream” should not apply as a designation.
 The type of cream and the fat content in cream shall be always indicated on the label or in
case of non-pre-packaged product; such declaration to be given on the container from which
product will be offered for sale to the consumer.
 Creams which have been manufactured by the recombination or reconstitution of dairy
ingredients shall be qualified with the term “Recombined” or “Reconstituted” as appropriate.
 If the product conforms to the description of malai as given in the standards the name of the
product shall be ‘Malai’.
Cream may be labelled according to milk fat content (m/m) along with product name as specified
 Low fat cream: Minimum 10 per cent and less than 40 per cent
 Medium fat cream: Minimum 40 per cent and less than 60 per cent
 High fat cream: Minimum 60 percent
 Labels on packages of fermented creams may include reference to the starter culture used for
fermentation.
 The heat treatment (refer General Standards for Milk and Milk Products), to which the product
has been subjected to, shall be declared on the label.
A standard for Milk Fat Products

This Standard applies Milk fat, ghee, butter oil, anhydrous milk fat and anhydrous butter oil are fatty
products derived exclusively from milk or products obtained from milk, or both, by means of processes
which result in almost total removal of water and milk solids-not-fat. Ghee has specially developed flavor
and physical structure as a result of its method of manufacturing.
a. Raw Material
Milk and products obtained from milk. The raw material used shall be free from added flavor, color or
preservative.
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b. Composition
The standards of quality of milk fat, butter oil, anhydrous milk fat, anhydrous butter oil, and ghee shall
conform to the following requirements:
Table 10: Standard for Milk Fat Products
Anhydrous Milk Fat,

Parameter Milk Fat, Butter Oil Khoa
Anhydrous Butter Oil
Moisture, maximum, %, (m/m) 0.4 0.1 0.5
Milk fat, minimum, %, (m/m) 99.6 99.8 99.5
Butyro-refractometer Reading at
40.0 to 44.0 40.0 to 44.0
400C As per table
for Ghee
Reichert Meissl Value, minimum 28 28
Polenske Value 1.0 - 2.0 1.0 - 2.0 -
FFA as Oleic Acid, maximum, % 0.4 0.3 3
Peroxide Value (Milli-equivalent of

0.6 0.3 -
Oxygen/Kg fat), maximum
Baudouin Test Negative Negative Negative
Additionally, the Butyro- refractometer reading and Reichert Meissl value of ghee will be different for
different States or Union territories which are given in Tabular form in the regulation on pages 90 -92.
c. Labelling
The name of the food shall be:
 Milk fat or Butter Oil

 Anhydrous Milk fat or Anhydrous Butter Oil
 Ghee
Standard for Butter

“Butter” means the fatty product principally in the form of an emulsion of the type water-in-oil derived
exclusively from milk or milk products, or both,
Butter may be of following types
 Table butter (Table butter shall be made from pasteurised cream)

 White butter/ Cooking butter
Essential composition and quality factors
a. Raw materials
Milk and/or milk fat based products obtained from milk.
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 Sodium chloride and food grade salt (only in table butter)

 Starter cultures of harmless lactic acid and flavour producing bacteria
 Potable water
c. Composition
Table 11: Standard for Butter
Parameter Table Butter White Butter/ Cooking Butter
Moisture, maximum, %, (m/m) 16.0 -
Milk fat, minimum, %, (m/m) 80.0 76.0
Milk solids-not-fat, maximum, %, (m/m) 2.0 -
Common salt, maximum, %, (m/m) 3.0 -
Note: Where butter is sold or offered for sale without any indication as to whether it is table butter or white
butter, the Standards of table butter shall apply.
The extracted fat from butter shall meet the standards for Reichert Meissl value and Butyro-refractometer
reading as prescribed for ghee.
d. Labelling
 The name of the product shall be “Pasteurized Table butter” or “White butter/ Cooking Butter”,
as appropriate, in conformance to the composition specified in regulations.
 Additionally, in case of white/cooking butter, the name should be preceded by the term
‘Pasteurised’ if the product has been prepared from pasteurised cream.
NOTE
In all these products the following requirement will be applicable. Where different it has been mentioned
in the specified standards for each product.
e. Food Additives
For products covered under this standard, specific food additives specified in Appendix ‘A’ of these
regulations may be used and only within the limits specified.
f. Contaminants, Toxins and Residues
The products shall comply with the limits for contaminants, toxins and residues stipulated under the Food
Safety and Standards (Contaminants, toxins and Residues) Regulations, 2011.
g. Hygiene
 The product shall be prepared and handled in accordance with the requirements specified in
Schedule 4, as applicable, of the Food Safety and Standards (Licensing and Registration of
Food Businesses) Regulations, 2011 and such other guidelines as specified from time to time
under the provisions of the Food Safety and Standard Act, 2006
 The products covered under this standard shall conform to the microbiological requirements
specified in Appendix ‘B’ of these regulations.
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h. Labelling
In addition to specific labelling requirements mentioned against each product, the provisions of the Food
Safety and Standards (Packaging and Labelling) Regulations, 2011 shall apply to pre-packaged
products.
i. Method of Sampling and Analysis
The methods of sampling and analysis mentioned in the manuals as specified by the Food Safety and
Standards Authority of India from time to time shall be applicable.
Standard for Milk Powders and Cream Powder

Milk powders and cream powder are milk products which can be obtained by partial removal of water
from milk or cream. The fat or protein content, or both of the milk or cream may be adjusted, only to
comply with the compositional requirements in regulations by addition or withdrawal of milk constituents
in such a way as not to alter the whey protein to casein ratio of the milk or cream being adjusted.
Product shall be free from added whey and whey preparations.
a. Raw materials
 Milk and cream

 The following milk products are allowed for protein adjustment purposes-
Milk retentate: Milk retentate is the product obtained by concentrating milk protein by ultrafiltration of
milk, partly skimmed milk, or skimmed milk;
b. Composition
Table 12: Standard for Milk Powder and Cream Powder
Whole Milk Skimmed Cream

Parameter Partly Skimmed Milk Powder
Powder Milk Powder Powder
Moisture,
maximum, 5.0 5.0 5.0 5.0
%, (m/m)
Milk solids,
minimum, %, 28.0 24.0 24.0 -
(m/m)
Minimum 26.
More than 1.5 and less than 1.5 42.0
Milk fat, %, (m/m) 0 and less
26.0 (maximum) (minimum)
than 42.0
Milk protein in
milk solids not fat,
34.0 34.0 34.0 34.0
minimum, %,
(m/m)
Titratable acidity,
maximum (ml 0.1
18.0 18.0 18.0 -
NaOH for 10 g –
solids-not-fat)
Insolubility Index,
2.0 2.0 2.0 -
maximum, ml
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Whole Milk Skimmed Cream
Parameter Partly Skimmed Milk Powder
Powder Milk Powder Powder
Total ash,
maximum,
% (m/m), on 9.3 9.3 9.3 -
moisture and fat
free basis
Scorched
particles, maximu Disc B Disc B Disc B Disc B
m
The moisture content does not include water of crystallization of the lactose; the milk solids-not-fat
content includes water of crystallization of the lactose.
** Protein content is 6.38 multiplied by the total nitrogen determined.
c. Labelling
 whole milk powder, or

 partly skimmed milk powder, or
 skimmed milk powder, or
 cream powder, as appropriate:
Provided that the “partly skimmed milk powder” may be designated “semi-skimmed milk powder” if the
content of milk fat does not exceed 16% (m/m) and is not less than 14% (m/m).
Wherever the word “milk” appears on the label of a package of skimmed milk powder as the description
or part of the description of the contents, it shall be immediately preceded or followed by the word
“skimmed or partly skimmed”, as the case may be.
There shall not be placed on any package containing the product covered under this Standard any
comment on, explanation of, or reference to either the statement of equivalence, contained in the
prescribed declaration or on the word “skimmed” [or “unsuitable for babies”] except instructions as to
dilution as follows:
“To make a fluid not below the composition of (here insert type of milk – toned milk or skimmed milk as
the case may be) with the contents of this package, add (here insert the number of parts) of water by
volume to one part by volume of this product”
Standard for Dairy Whitener

Dairy Whitener is a milk product prepared through an appropriate processing of cow milk, buffalo milk or
milk of any other species as defined under this regulation or a mixture thereof, and contains added
carbohydrates such as sucrose, dextrose and maltodextrin, singly or in combination. The fat or protein
content, or both, of the milk may be adjusted by addition or withdrawal of milk constituents in such a way
as not to alter the whey protein to casein ratio of milk.
The product shall be
 white or light cream in colour, uniform in composition and free from lumps except those that
break up readily under slight pressure
 free from extraneous matters and added colours
 free from off flavours
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The flavour of the product before or after reconstitution shall be pleasant and sweet. It is recommended
that the flavour and taste may be judged on the basis of their sensory characteristics.
The product shall conform to the compositional specifications provided in the table below:
Table 13: Standard for Dairy Whitener
Sr. No. Characteristics Requirements

Skimmed Low Fat Medium Fat High Fat
Dairy Dairy Dairy Dairy
Whitener Whitener Whitener Whitener
Moisture, maximum,
1 4.0 4.0 4.0 4.0
%, (m/m)
More
Minimum
1.5 than 1.5 and 20.0
2 Milk Fat, %, (m/m) 10.0 and less
(maximum) less than minimum
10.0 than 20.0
Milk protein (in solids-not-

3 34.0 34.0 34.0 34.0
fat), minimum, %, (m/m)
Insolubility Index, ml,

4 1.5 1.5 1.5 1.5
maximum
Total ash (on moisture,
added sugar and fat free
5 9.3 9.3 9.3 9.3
basis), maximum, %,
(m/m)
Acid Insoluble ash

6 0.1 0.1 0.1 0.1
maximum, %, (m/m)
Added sugar (as sucrose),

7 18.00 18.00 18.00 18.00
maximum, %, (m/m)
Acid Insoluble ash,

8 0.1 0.1 0.1 0.1
maximum, %, (m/m)
Added sugar (as sucrose),

9 18.00 18.00 18.00 18.00
maximum, %, (m/m)
** Protein content is 6.38 multiplied by the total nitrogen determined
*** Added sugar up to a level of 24% shall be permissible up to two years from the date of final notification.
a. Labelling
The name of the food shall be
 Skimmed Milk Dairy Whitener, or

 Low Fat Dairy Whitener, or
 Medium Fat Dairy Whitener, or
 High Fat Dairy Whitener, as appropriate
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A standard for Whey Powder
 Whey powders are milk products obtained by drying Whey or Acid Whey.
 Whey is the fluid milk product obtained during the manufacture of cheese, casein or similar
products by separation from the curd after coagulation of milk or of products obtained from
milk, or both. Coagulation is obtained through the action of, principally, suitable enzymes of
non- animal origin.
 Acid whey is the fluid milk product obtained during the manufacture of cheese, casein, paneer,
channa or similar products by separation from the curd after coagulation of milk and of
products obtained from milk. Coagulation is obtained, principally, by acidification and heating.
a. Raw materials
Whey or Acid whey, as appropriate.
b. Ingredients
Seed lactose in the manufacture of pre-crystallized Whey Powder
c. Composition
Table 14: Standard for Whey Powder
Parameter Whey Powder Acid Whey Powder
Moisture, maximum, %, (m/m) 5.0 4.5
Milk fat, maximum, %, (m/m) 2.0 2.0
Milk protein, minimum, %, (m/m) 10.0 7.0
Lactose content, as anhydrous lactose, minimum, %, (m/m) 61.0 61.0
pH (in 10% solution) more than 5.1 5.1 (maximum)
Total ash, maximum, %, (m/m) (on dry basis) 9.5 15.0
Note(s):
(i) The water content does not include water of crystallization of the lactose.
(ii) Protein content is 6.38 multiplied by the total nitrogen determined.
(iii) Although the powders may contain both anhydrous lactose and lactose monohydrates, the lactose
content is expressed as anhydrous lactose. 100 parts of lactose monohydrate contain 95 parts of
anhydrous lactose.
(iv) Or titratable acidity (calculated as lactic acid) <0.35%.
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(v) Or titratable acidity (calculated as lactic acid) ≥ 0.35%.
In accordance with the provisions of the regulations, whey powders may be modified in composition to
meet the desired end-product composition, for instance, neutralization or demineralization. However,
compositional modifications beyond the minimum or maximum specified above for milk protein and
water are not permitted.
d. Labelling
 Whey Powder, or
 Acid Whey Powder, as appropriate
A standard for Fermented Milk Products

This Standard applies to fermented milk, including, heat-treated fermented milk, concentrated fermented
milk and composite milk products based on these products in conformity with the definitions given in the
regulations.
Fermented Milk is a milk product obtained by fermentation of milk, which may have been manufactured
using other permitted raw material, by the action of suitable microorganisms and resulting in lowering of
pH with or without coagulation (iso-electric precipitation). Fermented milk may be heat treated after
fermentation. The raw material used shall be subjected to a heat treatment as defined in the General
Standard for Milk and Milk Products.
Certain fermented milks are characterised by specific starter culture(s) used for fermentation as follows
Table 15: Standard for Fermented Milk Products
Dahi Lactic Acid Bacteria
Symbiotic cultures of Streptococcus thermophilus and Lactobacillus

Yoghurt
delbrueckii sub sp. bulgaricus
Alternate Culture
Cultures of Streptococcus thermophilus and Lactobacillus species
Yoghurt
Acidophilus Milk Lactobacillus acidophilus
Other harmless microorganisms than those constituting the specific starter cultures specified above may
also be added.
Descriptions have been provided for
 Flavoured fermented milk

 Drinks based on fermented milk
 Concentrated Fermented Milk Chakka and Shrikhand
a. Raw materials
 milk
 concentrated milk and dried milk
 cream, butter, butter oil and anhydrous milk fat
 potable water for use in reconstitution or recombination or drinks based on fermented milks
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 starter cultures of harmless microorganisms, including those specified in regulations

 other suitable and harmless microorganisms
 salt
 sugar (only in Flavoured Fermented Milks, Drinks based on Fermented Milks, Yoghurt, Dahi
and Shrikhand)
 nutritive sweeteners other than sugar (only in Flavoured Fermented Milks, Drinks based on
Fermented Milks, Yoghurt and pre-packaged Dahi)
 non-dairy ingredients such as fruits and vegetables and their products thereof such as juices,
purees, pulps, preparations and preserves derived therefrom, cereals and cereal products,
coconut and coconut products, honey, chocolate, nuts, coffee, spices, condiments, culinary
herbs and other harmless natural flavouring foods (only in Flavoured Fermented Milks, Drinks
based on Fermented Milks and Shrikhand)
 milk and milk products (only in Drinks based on Fermented Milks)
 Prebiotics and Probiotics
 Starch (only in fermented milks heat treated after fermentation, flavoured fermented milks and
drinks based on fermented milks) Provided that it is added only in amounts functionally
necessary as governed by Good Manufacturing Practice, taking into account any use of the
stabilizers or thickeners as specified in Appendix ‘A’ of these regulations. Starch may be added
either before or after adding the non-dairy ingredients.
c. Composition
 The starter microorganisms shall be viable, active and abundant in the product up to the date
of minimum durability. The sum of microorganisms constituting the starter culture defined in
sub- item (a) of item 1 shall not be less than 107cfu/g. The labelled microorganisms, when
specific microorganisms other than those specified in sub-item (a) of item 1are added and a
content claim is made on label, shall not be less than 106cfu/g. If the product is heat treated
after fermentation these requirements for viable microorganisms do not apply
 Fermented milks shall have a minimum milk protein content of 2.9 % (m/m) and minimum titrable
acidity of 0.45% (m/m as lactic acid) unless otherwise specified. In case of Flavoured
Fermented Milks and Drinks based on Fermented Milks, these specifications apply to the
Fermented Milk Part unless otherwise specified
 Plain Dahi shall have the same minimum percentage of milk fat and milk solids-not-fat as that of
the milk, as provided for in the Standard for Milk, from which it is prepared. Where plain Dahi is
sold or offered for sale without any indication of class of milk, the Standards prescribed for
Dahi prepared from mixed milk shall apply
 Yoghurt (including Flavoured Yoghurt) and Flavoured Dahi, Chakka and Shrikhand shall all
conform to the compositional specifications as have been given in tabular form on pages 102
and 103 of the regulation.
Essential manufacturing characteristic
Whey removal after fermentation is not permitted in the manufacture of fermented milks, except for
concentrated fermented milk.
d. Labelling
Name of the food-
 The name of the products shall be ‘Fermented Milk’

 Provided that the name ‘Fermented Milk’ may be replaced with designations Dahi, Curd and
Yoghurt if the product complies with the relevant provisions of this Standard.
The designation ‘Yoghurt or Dahi’ may be used in connection with the term “frozen” Provided that
 the product submitted to freezing complies with the requirements in this Standard
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 the specific starter cultures can be reactivated in the specified numbers by thawing
 the frozen product is named as such and is sold for direct consumption only.
 Yoghurt or Dahi containing non-dairy ingredients may be designated as ‘Sweetened or
Flavoured Yoghurt or Dahi’, as appropriate. Yoghurt or Dahi containing fruits may be
designated as ‘Fruit Yoghurt or Dahi’, as appropriate.
Standard for Ice Cream, Kulfi, Chocolate Ice

Cream, Softy Ice-Cream, Milk Ice, Milk Lolly
and Dried Ice Cream Mix
This Standard applies to Ice Cream and Kulfi and their variants, milk ice and milk lolly, and dried ice-
cream mix in conformity with the definitions given in the regulation
Description has been given for the following
 Ice-Cream, Kulfi, Chocolate Ice Cream or Softy Ice-Cream

 Milk Ice or Milk Lolly
 Dried Ice-Cream Mix
a. Raw Material
Milk and milk products
 sugar and other nutritive sweeteners (e.g. jaggery, dextrose, fructose, liquid glucose, dried
liquid glucose, high maltose corn syrup, honey etc.)
 potable water
 starch, provided it is added only in amounts functionally necessary as governed by Good
Manufacturing Practice, taking into account any use of the stabilizers or thickeners as specified
in Appendix ‘A’ of these regulations.
 other non-dairy ingredients – fruit and fruit products, eggs and egg products, coffee, cocoa,
chocolate, confectionary, condiments, spices, ginger and nuts; bakery products such as cake
or cookies.
c. Composition
Compositional specifications have been provided in the tabular form separately for each category
 Ice cream, Kulfi, Chocolate Ice cream and Softy Ice Cream
 Milk Ice or Milk Lolly
 Dried Ice Cream Mix
d. Labelling
The name of the product shall be
 ‘Ice Cream’, ‘Kulfi’, ‘Chocolate Ice Cream’ or ‘Softy Ice Cream’.

 ‘Milk Ice’ or ‘Milk Lolly’.
 ‘Dried Ice Cream Mix’.
 The type of ice cream, kulfi, chocolate ice cream or softy ice cream shall always be indicated
on the label of the product.
 For softy ice cream offered for sale directly from the freezer without pre-packaging, the type of
Page 47 of 67
product shall be displayed in a manner and at a place that is clearly visible to the consumer.
Page 48 of 67
 Every package of ice cream, kulfi, chocolate ice cream and softy ice cream containing starch
shall have a declaration on its label as specified in sub- regulation 2.7.1 (2) of Food Safety and
Standards (Packaging and Labelling) Regulations, 2011.
Standard for Frozen Desserts or Confections with Added Vegetable Oil/ Fat or Vegetable Protein, or both
This Standard applies to Frozen Desserts or Confections. The regulations have defined the terms to which
these standards apply.
 Frozen Dessert or Frozen Confection
 Dried Frozen Dessert Mix or Dried Frozen Confection
Mix Essential Composition and Quality Factors
a. Raw Material
 Milk and/or milk products

 Vegetable oils or fats
 Vegetable protein products
 sugar and other nutritive sweeteners (e.g. jaggery, dextrose, fructose, liquid glucose, dried
liquid glucose, high maltose corn syrup, honey etc.)
 potable water
 starch, provided it is added only in amounts functionally necessary as governed by Good
Manufacturing Practice, taking into account any use of the stabilizers or thickeners as specified
in Appendix ‘A’ of these regulations
 other non-dairy ingredients – fruit and fruit products, eggs and egg products, coffee, cocoa,
chocolate, confectionary, condiments, spices, ginger and nuts; bakery products such as cake
or cookies.
c. Composition
Compositional specifications for Frozen Dessert or Frozen Confection

Table 16: Standard for Ice Cream, Kulfi, Chocolate Ice Cream, Softy Ice-Cream, Milk Ice, Milk Lolly and
Dried Ice Cream Mix
Medium fat Frozen

Frozen Dessert or Low fat Frozen Dessert
Parameter Dessert or Frozen
Frozen Confection or Frozen Confection
Confection
Total Solids,
minimum, 36.0 30.0 26.0
%,(m/m)
Weight, minimum,
525.0 475.0 475.0
(g/l)
Total Fat, %, More than 2.5 and less

10.0 (minimum) 2.5 (maximum)
(m/m) than 10.0
Protein*,
minimum, % 3.5 3.5 3.0
(m/m)
* Protein content is 6.25 multiplied by the total nitrogen
determined
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* Note
 In case where coating, base or layer of non-dairy ingredients forms a separate part of the
product, only the Frozen Dessert or Frozen Confection portion shall conform to the respective
composition.
 When any type of Frozen Dessert or Frozen Confection is offered for sale in contravention of
the requirements as stated, the Standards prescribed for these types of Frozen Desserts or
Frozen Confections as per this item shall apply.
Dried Frozen Dessert Mix or Dried Frozen Confection Mix
The product on addition of water shall give a product conforming to the composition, except the ‘weight’,
as specified in the regulation. The moisture content of the dried product shall not be more than 4.0 %
(m/m).
d. Labelling
Name of the foods shall be
‘Frozen Dessert or Frozen Confection’.
‘Dried Frozen Dessert or Dried Frozen Confection’
 The type of Frozen Dessert or Frozen Confection shall be indicated on the label of the product.
 For soft consistency products offered for sale directly from the freezer without any pre-
packaging, the type of product shall be displayed in a manner and at a place that is clearly
visible to the consumer.
 Every package of Frozen Desert or Frozen Confection shall bear the following label, namely:
“Contains........................% Milk Fat* Edible Vegetable Oil* and Vegetable Fat* and Vegetable
Protein Product” (*strike out whatever is not applicable)
Standard for Chhana and Paneer

Chhana or Paneer means the product obtained from any variant of milk**, with or without added milk
solids, by precipitation with permitted acidulants and heating.
a. Raw materials
 Milk
 Milk solids
 Acidulants such as lactic acid, citric acid, malic acid, vinegar, glucono delta lactone, sour whey
 spices and condiments (for flavoured paneer only)
 salt (for flavoured paneer only).
c. Composition
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The product shall conform to the compositional specifications provided in the table below:
Table 17: Standard for Chhana and Paneer
Parameter Channa or Paneer Low fat Channa or Paneer
65.0 (for Channa) 65.0 (for Channa)

Moisture, maximum, %, (m/m)
60.0 (for Paneer) 60.0 (for Paneer)
Milk fat, %, (m/m), dry matter basis 50.0 (minimum) 15.0 (maximum)
d. Labelling
The name of the product shall be ‘Chhana’, ‘Paneer’, ‘Low Fat Chhana’ or ‘Low Fat Paneer’ depending
upon the composition
Low Fat Channa and Low Fat Paneer shall be sold in sealed package only and shall bear the following
label declaration:
“LOW FAT PANEER or LOW FAT CHHANA”
Standard for Cheese and Cheese Products

This Standard applies to Cheese, Processed Cheese and Processed Cheese Spreads as defined in the
regulation. The regulations have described in detail the methods of making cheese.
 ‘Ripened Cheese’ means cheese which is not ready for consumption shortly after manufacture
but which must be held for some time at such temperature and under such other conditions as
will result in necessary biochemical and physical changes characterizing the cheese in
question.
 ‘Mould Ripened Cheese’ means ripened cheese in which the ripening has been accomplished
primarily by the development of characteristic mould growth through the interior and/ or on the
surface of the cheese.
 ‘Unripened Cheese including fresh cheese’ means cheese which is ready for consumption
shortly after manufacture.
These standards are applicable to all types of cheese defined individually in the regulations and
includes cheddar cheese, Danbo cheese, ‘Edam Cheese, ‘Gouda Cheese, Havarti Cheese, ‘Tilsiter,
Cottage Cheese, ‘Cream Cheese’ (Rahmfrischkase), ‘Coulommiers Cheese, ‘Camembert Cheese, Brie
cheese, Saint Paulin, Samsoe, Emmental, ‘Provolone, Extra Hard Grating Cheese.
 “Cheese Products” are the products prepared from cheese(s) with other milk products and may
contain permitted non-dairy ingredients.
 ‘Processed Cheese’ means the product obtained by grinding, mixing, melting and emulsifying
one or more varieties of cheeses with the aid of heat and emulsifying agents and may contain
cream, butter, butter oil and other milk products. It may also contain non-dairy ingredients not
exceeding one sixth of the weight of the total solids of the final product on dry matter basis.
 ‘Processed Cheese’ Spread means the product obtained by grinding, mixing, melting and
emulsifying one or more varieties of cheese with emulsifying agents with the aid of heat and
may contain cream, butter oil and other dairy products. It may also contain natural
carbohydrate sweetening agents and other non-dairy ingredients not exceeding one sixth of
the weight of total solids of the final product on dry weight basis.
a. Raw materials
Milk and products obtained from milk.
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 Starter cultures of harmless lactic acid, and flavour producing bacteria and cultures of other
harmless microorganisms
 Safe and suitable enzymes (non-animal origin) Sodium chloride
 Potable water
 Non-dairy ingredients: Vinegar or acetic acid, spices, condiments and other vegetable
seasoning and foods, other than sugars, properly cooked or prepared for flavouring and
characterization of the product (In Cheese Products only
 Natural carbohydrate sweetening agents: Sucrose, dextrose, corn syrup, corn syrup solids,
honey, maltose, malt syrup and hydrolysed lactose (In Processed Cheese Spreads only).
The compositional specifications have been given in tabular form on pages 113 and 114 of the regulations.
c. Labelling
 The name of the food product shall be “Cheese”. However, the word “Cheese” may be omitted
in the designation of an individual cheese variety
 Every package of Cheese (hard), surface treated with Natamycin, shall bear the following label
SURFACE TREATED WITH NATAMYCIN
 Every package of Cheese(s), if coated or packed in food grade waxes polyfilm or wrapping of
cloth, shall bear the following label
REMOVE THE OUTER PACKING BEFORE CONSUMPTION
Standard for Edible Casein Products

 Edible Casein products mean the products obtained by separating, washing and drying the
coagulum of skimmed milk or of other products obtained from milk;
 Edible Acid Casein means the product obtained by separating, washing and drying the acid
precipitated coagulum of skimmed milk or of other products obtained from milk;
 Edible Rennet Casein means the product obtained after washing and drying the coagulum
remaining after separating the whey from the skimmed milk or of other products obtained from
milk, or both, which has been coagulated by non-animal rennet or by other coagulating
enzymes;
 Edible Caseinate means the dry product obtained by reaction of edible casein or casein curd
coagulum with food grade neutralising agents followed by drying.
a. Raw Material
Skimmed milk and other suitable products obtained from milk.
b. Ingredients
 edible acids
 starter cultures of harmless lactic acid producing bacteria
 non-animal rennet or other safe and suitable coagulating enzymes
 potable water
 neutralizing agents
c. Composition
The product shall conform to the compositional specifications provided in the table bon page 116.
d. Labelling
 The name of the product shall be Edible Acid Casein or Edible Rennet Casein or Edible
Caseinate.
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 Edible Caseinate shall also be qualified by the name of the cation in the neutralizing agent used.
Page 53 of 67
Chapter 6: Appropriate Technology/ Plant
and Machinery for Dairy Processing Unit
In this section, most appropriate technologies or plant and machinery will be described along with their
application. Following the is important technology used in any standard dairy processing unit:
1. Milk Milking Machine
2. Bulk Milk Coolers
3. Road Milk Tankers
4. Milk Storage Tank (Silo)
5. Milk Chiller (PHE Type)
6. Milk Pasteurizer
7. Milk Homogenizer
8. Cream Separator
9. Butter Making Machine
10. Ghee Making Machine
11. Curd Making Machine
12. Paneer Making Machine
13. IQF
Milk Milking Machine

The milking process is the collection of tasks specifically devoted to extracting milk from an animal
(rather than the broader field of dairy animal husbandry). This process may be broken down into several
sub- tasks: collecting animals before milking, routing animals into the parlour, inspection and cleaning of
teats,
attachment of milking equipment to teats, and often
massaging the back of the udder to relieve any held back
milk, extraction of milk, removal of milking equipment,
routing of animals out of the parlour.
Maintaining milk yield during the lactation period

(approximately 300 days) requires consistent milking
intervals, usually twice daily and with maximum time
spacing between milking. In fact all activities must be
scheduled around the milking process on the dairy farm.
Such a milking routine imposes restrictions on time
management and personal life of an individual farmer, as
the farmer is committed to milking in the early morning
and
in the evening for seven days a week regardless of personal
health, family responsibilities or social schedule. This time
Figure 12: Milking restriction is exacerbated for lone farmers and farm families if
Machine extra labour cannot easily or economically be obtained, and is a
factor in the decline in small-scale dairy
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farming. Techniques such as once-a-day milking and voluntary milking (see below) have been
investigated to reduce these time constraints.
Parts of a milking machine:
1. Pulsator
2. Teat cup shells and liners
3. Milk receptacle
4. Vacuum pump and gauge
5. Vacuum tank.
6. Regulator
Benefits of milking machine:
 Elimination of labour - The farmer is freed from the milking process and associated rigid
schedule, and labour is devoted to supervision of animals, feeding, etc.
 Milking consistency – The milking process is consistent for every cow and every visit, and is
not influenced by different persons milking the cows. The four separate milking cups are
removed individually, meaning that an empty quarter does not stay attached while the other
three are finishing, resulting in less threat of injury. The newest models of automatic milkers
can vary the pulsation rate and vacuum level based on milk flow from each quarter.
 Increased milking frequency – Milking frequency may increase to three times per day,
however typically 2.5 times per day is achieved. This may result in less stress on the udder and
increased comfort for the cow, as on average less milk is stored. Higher frequency milking
increases milk yield per cow, however much of this increase is water rather than solids.
 Perceived lower stress environment – There is a perception that elective milking schedules
reduce cow stress.
 Herd management – The use of computer control allows greater scope for data collection.
Such data allows the farmer to improve management through analysis of trends in the herd, for
example response of milk production to changes in feedstuffs. Individual cow histories may
also be examined, and alerts set to warn the farmer of unusual changes indicating illness or
injury. Information gathering provides added value for AMS, however correct interpretation and
use of such information is highly dependent on the skills of the user or the accuracy of
computer algorithms to create attention reports.
Bulk Milk Cooler

In dairy farming a bulk milk cooling tank is a large storage tank for cooling and holding milk at a cold
temperature until it can be picked up by a milk hauler. The bulk milk cooling tank is an important piece of
dairy farm equipment. It is usually made of stainless steel and used every day to store the raw milk on
the farm in good condition. It must be cleaned after each milk collection. The milk cooling tank can be
the property of the farmer or be rented from a dairy plant
A milk cooling tank, also known as a bulk tank
or milk cooler, consists of an inner and an
outer tank, both made of high quality stainless
steel.
The space between the outer tank and the
inner tank is isolated with polyurethane foam.
In case of a power failure with an outside
temperature of 30°C, the content of the tank
will warm up only 1°C in 24 hours.
To facilitate an adequate and rapid cooling of
the entire content of a tank, every tank is
equipped with at least one agitator. Stirring
Figure 13: Bulk Milk Cooler the milk ensures that all milk inside the tank is
of the same temperature and that the milk
stays homogeneous.
On top of every closed milk cooling tank is a manhole of about 40 centimetres diameter. This enables
thorough cleaning and inspection of the inner tank if necessary. The manhole is covered by a lid and
sealed watertight with a rubber ring. Also on top are 2 or 3 small inlets. One is covered with an air-vent,
the other(s) can be used to pump milk into the tank.
A milk cooling tank usually stands on 4, 6, or 8 adjustable legs. The built-in tilt of the inner tank ensures
that even the last drop of milk will eventually flow to the outlet.At the bottom, every milk cooling tank has
a threaded outlet, usually including a valve.
All tanks have a thermometer, allowing for immediate inspection of the inner temperature.
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Most tanks include an automatic cleaning system. Using hot and cold water, an acid and/or alkaline
cleaning fluid, a pump and a spray lance will clean the inner tank, ensuring an hygienic inner
environment each time the tank is emptied.
Almost every tank has a control box. It manages the cooling process by use of a thermostat. The user
can turn the system on and off, allow for extra and immediate stirring, start the cleaning routine, and
reset the entire system in case of a failure.
New and bigger milk cooling tanks are now being equipped with monitoring and alarm systems. These
systems guard temperature of the milk inside the tank, check the functioning of the agitator, the cooling
unit and temperature of the cleaning water. In case of malfunctioning of any of these functions, the
alarm will activate. The monitoring system will also keep a record of the temperature and of all
malfunctions for a given period.
Road Milk Tanker

Stainless Steel Road Milk Tankers are of double wall construction with 100mm PUF Insulation between
the inner tank and the outer tank. The inner tank will have high degree of polish finish for Milk storage
and transportation. The tank will be elliptical in shape with single or multi compartment construction.
Each compartment will have independent

manhole assembly, complete with manhole lid,
Pressure vacuum relief valve, air vent and CIP
cleaning arrangement. The manhole shall be
additionally covered with a Stainless Steel dust
cover. The milk discharge from the tank will be
at the bottom through a discharge cup, pipe line
and butterfly valves. Valve box will be located
at the rear platform.
The tank will be having ladder, catwalk, and

side protection rail and side protection
channels. The tank rear shall be provided with
Figure 14: Road Milk Tanker a Skirting and a platform arrangement. PUF
insulated tank is capable of transporting chilled
milk at 3°C to 4°C and the average
temperature drop of milk in a
fully filled tank in a day will be less than 2°C. The insulated tank will be integrated with the chassis with a
trapezoidal frame and will have adequate slope towards the rear for complete drainage of milk. CIP
cleaning arrangement will be provided for regular water cleaning and maintenance of the tank. Road
Milk tanker can be supplied with single/double/triple compartments and capacity in the range of 4000L
to 21000L based on the chassis selected.
Milk Storage Tank (Silo)

Silo tanks for milk reception belong to the storage category and have been described in Chapter 5,
Collection and reception of milk. They vary in size from 25 000 to about 150 000 litres and the wetted
surfaces are made of stainless steel. They are often placed outdoors to save on building costs. In these
cases, the tanks are insulated. They have a double shell with a minimum of 70 mm mineral wool
insulation in between.
The outer shell can be of stainless steel,

but for economic reasons, it is usually
made of mild steel and coated with anti-
corrosion paint. To make complete
drainage easy, the bottom of the tank
slopes downwards with an inclination of
about 6 % towards the outlet. This is a
statutory requirement in some countries.
Figure 15: Milk Storage Tanks Silo tanks are fitted with various types of
agitators and monitoring and control
equipment. The number and size of the
silo tanks are determined by such factors as the milk intake per day, the number of days per working
week, the number of hours per working day (one, two or three shifts), the number of different products to
be manufactured, and the quantities involved.
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Milk Chiller (PHE Type)
Milk is chilled by ice to a temperature of 4 0 C or below. It is an intermediate processing before heat
treatment of milk. Chilling of milk minimizes the souring and spoilage.
Figure 16: Milk Chiller (PHE Type)
Milk Pasteurizer
To increase milk safety for the consumer by destroying disease causing microorganisms (pathogens)
that may be present in milk. To increase keeping the quality of milk products by destroying spoilage
microorganisms and enzymes that contribute to the reduced quality and shelf life of milk.
Minimum pasteurization requirements for milk products are
based on regulations outlined in the Grade A Pasteurized Milk
Ordinance (PMO). These conditions were determined to be the
minimum processing conditions needed to kill Coxiella burnetii,
the organism that causes Q fever in humans, which is the most
heat resistant pathogen currently recognized in milk. Milk can
be pasteurized using processing times and temperatures
greater than the required minimums.
Pasteurization can be done as a batch or a continuous
process. A vat pasteurizer consists of a temperature-controlled,
closed vat. The milk is pumped into the vat, the milk is heated
to the appropriate temperature and held at that temperature for
the appropriate time and then cooled. The cooled milk is then
pumped out of the vat to the rest of the processing line, for
example to the bottling station or cheese vat. Batch
Figure 17: Milk Pasteurizer pasteurization is still used in some smaller processing plants.
The most common process used for fluid milk is the continuous
process. The milk is pumped from the raw milk silo to a holding tank that feeds into the continuous
pasteurization system. The milk continuously flows from the tank through a series of thin plates that heat
up the milk to the appropriate temperature. The milk flow system is set up to make sure that the milk
stays at the pasteurization temperature for the appropriate time before it flows through the cooling area
of the pasteurizer. The cooled milk then flows to the rest of the processing line, for example to the
bottling station. There are several options for temperatures and times available for continuous
processing of refrigerated fluid milk. Although processing conditions are defined for temperatures above
200°F, they are rarely used because they can impart an undesirable cooked flavour to milk.
Milk Homogenizer
"Homogenization is a process that gives milk its rich, white colour and smooth texture. Milk that has not
been homogenized contains a layer of cream that rises to the top of a glass.
Before the homogenization process was used, milk was shaken or mixed to achieve consistency in its
look and taste. The homogenization process involves reducing the size of the fat globules into miniscule
portions that are dispersed evenly throughout the milk. Homogenization usually is achieved by pumping
milk through small openings under very high pressure."
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"Homogenization today is usually a two-step
process. The first stage…pushes milk through
small, tapered tubes or pores. As the diameter
shrinks and the flow of milk remains constant,
pressure builds up and fat globules break apart in
the turbulence.
The higher the pressure, the smaller the particles.
How much pressure? Typically, 2,000-3,000
pounds per square inch (psi), although some
super homogenizers work at over 1000 times
atmospheric pressure- 14,500psi and higher!
You can jam milk through pretty small holes with
force like that. Before homogenization, fat
globules range in size from 1-10 microns (a
Figure 18: Milk Homogenizer micron =
~0.00004 inch). After, the size range is reduced to
0.2-2 microns.
As the much smaller fat globules begin to reassemble, they include fragments of whey and casein in
their walls. Some are completely surrounded by a layer of protein. The tendency is for these new,
chemically altered globules to clump together. Stage two of the homogenization process breaks up this
unwanted assembly and makes sure everything stays in solution."
Cream Separator
Cream separator, machine for separating and removing
cream from whole milk; its operation is based on the fact
that skim milk (milk with no butterfat) is heavier than
cream. The separator consists of a centrifuge in the form
of a rapidly revolving bowl containing a set of disks. The
bowl is mounted on a spindle situated underneath the milk
supply tank. As milk enters the bowl at the top, it is
distributed to the disks through a series of openings, the
distributor. Thin films of milk are generated as whole milk
is forced out between the disks; the milk assumes the
speed of the bowl,
Figure 19: Cream Separator approximately 6,000 to 8,000 revolutions per minute, and
the heavier skim milk is thrown to the outer edge of the
bowl
and led off through an opening. The cream concentrates in the interior and moves up to the cream outlet
near the centre of the bowl. The most efficient separators leave less than 0.01 percent fat in the skim
milk.
Butter Making Machine

Butter is defined is a fat concentrate product obtained by churning, cream, gathering fat into a compact
mass and working it. Butter is made exclusively from milk or cream with or without common salt and
colouring matter and contains not less than 80% fat. In butter, fat is present in continuous phase and
water is present in dispersed phase. This phenomenon is known as phase inversion.
The essential feature of churning involves
destabilization of lipid phase emulsion by
means of mechanical agitation. Churning
is initiated by agitation and the
incorporation of numerous small air
bubbles. Partially denatured fat globules
gather at the fat/plasms inter face, where
they form, small clumps. A portion of this
hydrophilic fat spreads over the surface of
air bubbles causing them to collapse.
Prior to working of butter granules in the
Figure 20: Butter Making Machine churn, approximately 80% of the fat phase
exists as globular fat. As the butter
Page 58 of 67
granules are worked more and more fat
globules are crushed causing the release of liquid fat. This free fat constitutes the continuous phase. Fat
globules and finely dispersed droplets of the aqueous. Phase represent the dispersed phase.
Page 59 of 67
Ghee Making Machine
Ghee is clarified butter fat. It is prepared on both small
and large scale, Deshi method of ghee making
comprises more than 90% if Indian Ghee production.
The Ghee is prepared b fermenting whole milk to curd,
churning the curd to butter and boiling down the latter to
ghee. Ghee is the richest source of animal fat in
vegetarian diet. It supplies 9 K. calorie energy/gm. It has
long keeping quality under tropical storage conditions.
In India, Ghee is prepared form Makhan (deshi butter).
This ghee has low keeping quality than ghee prepared
by other methods.
Figure 21: Ghee Making Machine
Ghee is being prepared by continuous method on large
scale. A new method of ghee making has been started
and named as pre-stratification method. Cream (ripened/un-ripened) can also be used for ghee
making. Ghee prepared form un-ripened cream has got longer keeping quality. Factory scale ghee is
prepared form un-ripened cream.
Yoghurt Making Machine

Yogurt is a fermented milk product that contains the characteristic bacterial cultures Lactobacillus
bulgaricus and Streptococcus thermophilus. All yogurt must contain at least 8.25% solids not fat. Full fat
yogurt must contain not less than 3.25% milk fat, low fat yogurt not more than 2% milk fat, and nonfat
yogurt less than 0.5% milk.
The two styles of yogurt commonly found in the grocery store are set type yogurt and swiss style yogurt.
Set type yogurt is when the yogurt is packaged with the fruit on the bottom of the cup and the yogurt on
top. Swiss style yogurt is when the fruit is blended into the yogurt prior to packaging.
The main ingredient in yogurt is milk. The type
of milk used depends on the type of yogurt –
whole milk for full fat yogurt, low fat milk for
low- fat yogurt, and skim milk for non-fat yogurt.
Other dairy ingredients are allowed in yogurt to
adjust the composition, such as cream to adjust
the fat content, and non-fat dry milk to adjust
the solids content. The solids content of yogurt
is often adjusted above the 8.25% minimum to
provide a better body and texture to the
finished
Figure 22: Yoghurt Making Machine yogurt. The CFR contains a list of the
permissible dairy ingredients for yogurt.
Stabilizers may also be used in yogurt to improve the body and texture by increasing firmness,
preventing separation of the whey (syneresis), and helping to keep the fruit uniformly mixed in the
yogurt. Stabilizers used in yogurt are alginates (carageenan), gelatins, gums (locust bean, guar),
pectins, and starch.
Sweeteners, flavours and fruit preparations are used in yogurt to provide variety to the consumer. A list
of permissible sweeteners for yogurt is found in the CFR.
The main (starter) cultures in yogurt are Lactobacillus bulgaricus and Streptococcus thermophilus. The
function of the starter cultures is to ferment lactose (milk sugar) to produce lactic acid. The increase in
lactic acid decreases pH and causes the milk to clot, or form the soft gel that is characteristic of yogurt.
The fermentation of lactose also produces the flavor compounds that are characteristic of yogurt.
Lactobacillus bulgaricus and Streptococcus thermophilus are the only 2 cultures required by law (CFR)
to be present in yogurt.
Other bacterial cultures, such as Lactobacillus acidophilus, Lactobacillus subsp. casei, and Bifido-
bacteria may be added to yogurt as probiotic cultures. Probiotic cultures benefit human health by
improving lactose digestion, gastrointestinal function, and stimulating the immune system.
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Paneer Making Machine
Paneer is a fresh cheese common in the Indian subcontinent, especially in India. It is an unaged, non-
melting farmer cheese made by curdling milk with a vegetable-derived acid, such as lemon juice. Its
acid- set form (cheese curd or acid-set cottage cheese) is called chhena.
Paneer is prepared by adding food acid, such as
lemon juice, vinegar, citric acid or dahi (yogurt), to
hot milk to separate the curds from the whey. The
curds are drained in muslin or cheesecloth and
the excess water is pressed out. The resulting
paneer is dipped in chilled water for 2–3 hours to
improve its texture and appearance. From this
point, the preparation of paneer diverges based
on its use and regional tradition.
In most Nepalese cuisines, the curds are
wrapped in cloth, placed under a heavy weight
such as a stone slab for two to three hours, and
then cut into cubes for use in curries. Pressing for
a shorter time (approximately 20 minutes) results
in a softer,
Figure 23: Paneer Making Machine fluffier cheese.
In Bengali and other east Indian cuisines, the
chhena are beaten or kneaded by hand into a dough-like consistency, heavily salted and hardened to
produce paneer (called ponir), which is typically eaten in slices at teatime with biscuits or various types
of bread, deep-fried in a light batter or used in cooking.
In the area surrounding the city of Surat in Gujarat, Surti Paneer is made by draining the curds and
ripening them in whey for 12 to 36 hours.
Individual Quick Freezer

IQF is used as a way to freeze seasonal products such as fruits and vegetables, but over the years the
technology has enabled other food products to be individually frozen.
In Today's world, food preservation is more important than ever before, historically there were many
Methods of food preservation, like drying, smoking, pickling, salting etc. These rather primitive methods
are still widely used today, not only in backward societies, where no other means are available, but also
in modern societies where they serve to supplement the more modern methods of food preservation like
refrigeration.
Figure 24: IQF
In the Individual Quick Freezing (IQF) process, unlike other freezing processes, the products are frozen
as individual pieces. This offers greater convenience to the consumers and hence adds more value to
the product. The Individual Quick Freezers (IQF) process is far superior to the conventional processes.
In Quick freezing, small ice crystals form within the product thus its own fresh quality is maintained even
after extended shelf life. Most foods can be preserved for a long time if they are frozen quickly and kept
at a low temperature until ready for use. Slow, natural freezing destroys food because the low
temperatures draw all the water from the tiny cells of the food, affecting color and flavour.
Quick freezing method prevents breakage of the cell walls as the freezing process is so quick. Thus, in
quick-frozen food most of the flavour, colour and firmness are retained.
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The IQF freezing uses a bed of super cooled air to suspend and separate solid food products, simultaneously
freezing them. Our IQF Conveyor design optimized for directing air evenly towards the product and ensures
better quality crust freezing by locking the product moisture before the final core freezing, as well as
preserving product weight, appearance and quality. Product Agitator in the pre-cooling section provided to
avoid lumping of product.
 The appeal of IQF frozen fruits and vegetables are near to the much-sought-after appearance, flavour and
nutrition as of fresh ones.
 Individually quick frozen products lock in the essential nutrients and flavour, with optimum colour, taste
and texture.
 The IQF process makes it possible to offer ’fresh picked’ flavours all year round, in packaging convenient
for today’s busy consumer.
 Two-Stage Fluidization System Gives Optimum Freezing Process: The crust freezing zone (belt 1) and
the deep freezing zone (belt 2).
Features of FREEZOLINE FST – Straight Belt Series

 Factory Finished SS Floor with built in Drain arrangement.
 Automatic air defrost system. Air Defrost system ensure beyond 18 hours of continuous operation without
water defrost.
 The electrical Control Panel includes extreme user friendly PLC touch screen control panel, emergency
stop system along with VFDs and UPS control power.
 Individually adjustable double Belt system for different product processing.
 High velocity airflow inside freezers ensures high quality of freezing. The air flow is controlled to perfectly
suit each product which gives an even temperature throughout the freezer and uniform high product
quality.
 Operate as complete standalone or option to operate in combination with other systems.
Air Defrost System [FROST BUSTER]

Straight line IQF units are equipped with automatic Air Defrost system, especially for processing vegetable &
fruit products which carry high water percentage. The continuous removal of frost considerably extends the
effective operation time and efficiency of freezing thus extending the time intervals between the defrost hence
increasing the total daily production capacity over 25-30 %. Air Defrost system runs automatic with help of
PLC based control system. The continuous air jet will remove frost from coil and prevent frost built- up during
working, which results better air flow through coil and enhanced heat transfer.
Chapter 7: Indicative Project Profile for

Tamkor Rajasthan
Proposal for Establishment of Dairy Unit
Dairy farming is an important source of main income in Urban/rural areas
1. Why do Dairy Farming

Dairying is an important source of main income to urban/rural unemployed youth and subsidiary income to
small/marginal farmers and agricultural laborers. The milk is a complete food which is consumed by all living
beings from birth to death or we may say that milk is a commodity which is consumed by everyone from morning
to evening there for, its demand particularly in Urban as well as in rural areas remains towards increasing side.
The surplus fodder and agriculture byproducts are gainfully utilized for feeding the animals. The manure from
animals provides a good source of organic matter for improving soil fertility and crop yields. The goober gas from
the dung is used as fuel for domestic & commercial purposes, as also for running engines for drawing water from
well. Now a day’s so many types of medicines are being manufactured by cow urine there for, rearing of cows in
Urban/rural areas shall be more economical in coming days. Almost all draught power for farm operations and
transportation can also be supplied by bullocks.
Since agriculture is seasonal which can’t provide round the year employment, whereas dairying provides
employment throughout the year along with daily income in cash. A youth of urban/rural area came earn a gross
surplus of about rupees 25000 to 40000 per year from a cow. Now a day’s concept of consumption of Indigenous
cow milk is gating momentum, as awareness has come in peoples that cow milk/ A2 milk is light and easily
digestible as compared to buffalo milk. Hence demand of Indian cow milk is increasing day by day. Further sweets
like rasgolla is being prepared by cow milk only; therefore, demand of cow milk remains more in urban areas.
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Hence dairy farming can be taken up as a main occupation around urban cities where the demand for milk
remains high.
2. Scope of dairy farming and its national importance India is the highest milk producer of the world. Even then it is
not in position to provide minimum recommended quantity of A2 milk to each and every people of India. At present
per capita availability of milk is 322 g per day as compared to 360 g per day recommended by Indian council of
medical research (ICM). Thus there is a tremendous scope/potential in the field of milk production and dairying,
particularly in urban areas where most of working people resides.
3. Marketing of fluid milk It is well known that milk is produced in villages and consumed in cities/urban areas.
Transportation of milk from villages to urban areas unnecessarily increases the cost and deteriorates the quality of
milk. By promoting production of milk in cities; urban areas transportation and selling cost can be saved and fresh
milk can be provided to the peoples of urban/rural areas. The dairy farm is planned to establish at Lakheri in Bundi
District which is a part of well known Haroti region of Rajasthan having plenty of water and all required resources
for rearing mulch animals, from where thousand liters of milk is sent to neighboring city Kota to full fill daily
requirement of fluid milk. Therefore, marketing of fresh fluid milk shall not be a problem. Provision of milking
machine, bulk cooler, khoa machine ,gobar gas plant and pasteurizing unit if required has also been made in this
project for fetching more amount per liter of milk by providing fresh milk in packing’s of 250, 500 and 1000 ml.,
other milk products like rasgulla, paneer, shrikhand, flavoured milk and khoa etc. can also be prepared and
supplied on order to multimarket also along with fluid milk.
4. Availability of good quality animals Good quality milch animals remains available at the Dushera Maidan of Kota
city throughout the year and Gir breed milch animals can also be purchased from Ajmer district of Rajasthan and
from Junagarh area of Gujarat state where good milch animals of Gir breed are available in plenty, therefore,
purchasing of quality mulch animals is not a problem.
5. Availability of breeding and veterinary aid facilities
Veterinary and Al breeding facilities at state govt. veterinary clinics and at private level aloso is available in plenty
at every Panchayat village, therefore, availability of breeding and veterinary facilities will not be a problem. Further
provision of breeding bull own Al kit with Liquid Nitrogen containers of required capacity has also been made in
this project.
6. Availability of green/dry fodder, concentrate/cattle feeds and medicines etc.
All required feed ingredients viz. cakes, grains, chury, rice bran, wheat bran and readymade brand cattle feeds
and feed supplements, quality green and dry fodder and medicines etc are available in abundance on competitive
prices throughout the year. Therefore, availability or regular supply of required ingredients shall not be a problem.
Further because of more return in green fodder production, farmers having good source of irrigation water in
nearby villages can also produce and supply green fodder round the year to milk producers. Therefore, contract
may be signed with reliable farmer to produce and supply green fodder regularly in required quantity @ of Rs
100 /- per quintal . Further because of wheat, soybean,maize and paddy growing area, wheat bhusa, soybean
strovar, jowar/maize karby etc. along with seasonal grasses remains available at nominal prices @ of Rs 150-200
per quintal at the time of harvesting. Therefore, required quantity of dry fodder can be purchased and stored at the
time of harvesting the crops.
8. Availability of technical knowhow.
Technical knowhow is available at Krishi Vigyan Kendras establish in each district. Therefore, availability of
technical knowhow shall not be a problem. Further technical services of KVK Scientist/vet. Doctors can be taken
on contract basis or scientist can be given responsibility to guide as a technical advisor.
Reasons of Failure in Dairying
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Thinking of most of the peoples entering in Dairy business all across (especially India) the country is quite evident
that the general beliefs are:-
1. Dairy Farming is an easy business.
This is because Dairy farming is done by a farmer, who in most cases is not much learned & has been doing this
business for quite a lot of years & is making money. However the main constraint in his Dairy farming is that he
has been following the traditional methods in everything viz. Feeding & management (which comprises more than
80% of the farming costs) by virtue of which he is not in profits but just making both ends meet along with little help
from his agricultural income.
This business is easy provided you are well aware of the basics & are able to apply scientific methods which can
help improve the overall profitability. At the same time it must be understood that Dairy has to be closely observed
day in & da ou dairy t as there is no holiday in Dairy Farming
2. Animal gives milk throughout the year.
The animal gives milk only after it gives a calf (offspring) & not otherwise. On an average a cow gives milk for 270-
300 days whereas the buffalo gives for 240-270 days. This period (called Lactation) is followed by a Dry period
(during which it does not give milk but just EATS) is called as Intercalving period after which she will give the next
calf. In India the average Intercalving period in cows is 450 around days & in buffaloes its 500 days or more also.
The main goal in successful Dairying will be to REDUCE this DRY period which eats into the profits & should be
given maximum importance.
3. Dairy Business breaks even in the first year. As in all businesses Dairy business does not break even in first
year. The main costs in dairy farming are ;-
A. Capital cost ; For purchase of animals, construction of Shed & purchase of machinery, cans etc. This cost
occurs only once & is depreciable over a Period of time totally.
B. Administrative Costs : includes appointment of a Farm manager, Supervisor, skilled & unskilled labours
depending upon the requirements as well as the size of the farm. This is a fixed cost for a certain period.
C. Recurring Cost: includes the Feeding & Management along with Vaccination, Insurance, treatment, AI & other
miscellaneous costs. This is required daily & is liable to fluctuate at all times. It will be essential to control these
costs which will have a direct bearing on the production (of milk) as well as Reproduction (birth of next calf). At the
same time balancing of feed will also determine the REDUCTION of the Intercalving period which has a bearing
on total profitability.
Dairy farmer is NOT AWARE of the Profit & loss account; as he does not pay attention to the Feeding &
management which actually accounts for more than 80% expenses in any Farm. At the same time Treatment
costs are less than 2% of the total costs; still the farmer pays more attention to TREATMENT than Management &
Feeding.
What is essential for the farmer to know that in case he is spending Re.1/- per day more than required; then in a
10 Buffalo/cow Farm then he is likely to incur a LOSS of Rs. Minimum Rs.4,500/- in one Lactation Cycle ( which is
minimum 450 days or 15 months).
4. Dairy business can be done by being dependent on labours.
This is possible provided the owner is aware of all the intricacies as well as the loop holes in Dairying. It is a well
known fact that any labour is not at all concerned with Profitability but (his) net Payments at the end of the month.
Page 64 of 67
As such he is likely to use his own parameters for optimizing the profitability of the farm. Thus it will be extremely
imperative for the owner to know & understand all the details of Dairy farming before starting the same. This will
enable him to guide his labours towards the right path & help in minimizing the losses. A small expense of extra
Re. 1 per animal per day can result into a loss of Rs. 130 per day in a farm of 100 cows (This farm; along with 100
cows will also have calves which will also account for Feeding expense).
5. Dairy Business can be learned from the Net & by getting hold of Project report.
Most of the Dairy farmers in India do not use the NET nor do they use computers. They do not have the records of
the animals kept by them & as such only a little information is available on the Net.
Dairy Farming as a business ; keeping large number of animals & following Scientific methods has just started a
few years ago but is picking up very fast due to its several advantages viz.
a. Steady business with steady income unaffected by Recession.
b. Milk can be sold directly from the farm (No Marketing setup needed)
c. No brokers; price is already declared by the Government.
d. Selling rate of milk has been consistently increasing over a period of time.
e. Consumption accepted by all religions, caste & creed. However most of the information available on the Net is
related to Foreign countries which sadly cannot be applied to the Indian conditions as we differ from them in many
ways viz. seasons, soil structure, temperature, greens (quality & availability), number of animals & their genetic
potential etc.
At the same time it must be noted that just getting the Project report will be insufficient as Practical knowledge is
equally necessary to start this business. This can be possible only after getting thorough training and visiting
several farms; staying on those for certain time which will be helpful in determining the mental as well as the
physical capacity of the person venturing into this Dairying business.
It will be ideal to visit the farms along with an expert (who knows about Dairy farming in detail) so as to understand
the correct & incorrect methods being followed in the dairy farm which being visited. This is important as the
person newly entering into Dairying will have a clean slate of mind & may Repeat all the mistakes committed by
the dairy farmer (A person will NOT admit his mistakes openly). This can safely be avoided by visiting dairy farms
along with an Expert and getting training on scientific dairy management.
Page 65 of 67

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Detailed Project Report on Milk and Milk Products

Post Tamkor, Distt – Jhunjhunu, Rajasthan

Chapter 2: Process Flow of Milk and Milk Products 16

Chapter 3: Production and processing hubs/ clusters in Rajasthan 25

Chapter 4: Automation in Dairy Processing 26

Chapter 5: Product Benchmarking 31

Chapter 7: Indicative Project Profile for Rajasthan 59

Chapter 8: Method of technology dissemination and adoption 91

Appendix 1: Dairy Technology Suppliers 93

Post Tamkor, Distt – Jhunjhunu, Rajasthan| Phone: 9810274608 Page 1 of 67

Major 5 Cow milk producing countries (in '000 (MT)

United Staes (91300 ) India (60600)

Figure 1: Major 5 Cow Milk producing countries

Table 1: World Dairy Market at a Glance from 2015-2017

Change: Jan-May 2017

Major Milk Processing Global Companies

Figure 2: Top Five Milk Processing Companies in the World

Major Exporting Countries of Dairy Products

Figure 3: Major Exporting Countries of dairy products, 2016

Major Importing Countries of Dairy Products

Quantity of Import ('000 MT) Value (US $ Million)

Figure 4: Major importing countries of dairy products

Global Opportunities and Challenges in the Dairy Sector

Figure 5: Opportunities and Challenges for Stakeholders in Dairy sector

Uttar Pradesh (23.33 Million Tonnes)

Figure 6: Major Five Milk Producing States in India in 2015-16

Production and Per Capita Availability of Milk

Production(In Million Tonnes) Per Capita Availability(gram./day)

Figure 7: Milk Production & Per Capita Availability In India (2016-

Figure 8: Structure of an India Dairy Industry

Export from India of Dairy Products 2016-17

U Arab Emts Bangladesh Pr Bhutan Pakistan Ir Nepal

Figure 9: Export from India of Dairy Products

Major Indian companies in Dairy Products

Table 2: Top 5 Indian companies in dairy products

Current Market Scenario of Milk and Milk Products

Butter SMP UHT MILK Cheese Others

Milk Production for 2017-18 (million tonnes)

Evolution of key categories ‐ Consumption of value‐added products on the rise

Competitive Edge of Players

Product mix of Indian dairy companies

Indian Amount (Rs. In

Product EBITDA Margin (%)

Challenges in Milk and Dairy products production in India

1448 1590 1670 1703 1780

2006-07 2007-08 2008-09 2009-10 2010-11

Packing in Cups and

Storage in cold room

Chilling below 40C The cream is pasteurized at 920C and

Butter is ready; it is packed and stored

Ageing 90C for 8

Table 5: Top 10 Milk Producing District of Rajasthan

Sr. No. District Milk Production (in ‘000 MT

Table 6: Top Milk Producing Cluster Districts of Rajasthan

Sr. No. District Milk Production (in ‘000 MT

Source: NDDB – Dairying Profile of Rajasthan

The dairy industry is divided into two main production areas:

1. Primary production of milk in farms