2015

RASHID ALI
BFSF12E022

[INTERNSHIP REPORT]
(QUALITY DEPARTMENT)
INTERNSHIP REPORT

To whom it may concern

It is certified that RASHID ALI-BFSF12E022joined us for internship program from 22.06.2015 to

03.08.2015. He performed his work successfully and his report has been evaluated by;

External supervisor ______________

Babar Mahmood Tariq

Internal supervisor ______________

Dr. Tahir Mahmood

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DEDICATION

This humble effort,

The fruit of studies and thoughts are

Dedicated to

My Beloved

“Mother”
Who strongly believes that

Her prayers are always with me

And also My Caring

“Father”

Who always inspired and encouraged me

To get on the higher ideas of my life.

May Almighty Allah bless both of them with

Long, Happy &Healthy Life (Ameen)

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Table of Contents
1 Introduction ............................................................................................................................................... 4
1.1 History ................................................................................................................................................ 4
2 Products ..................................................................................................................................................... 7
2.1 Dairy .................................................................................................................................................... 7
2.2 Frozen desserts ................................................................................................................................... 8
3 Tasks ........................................................................................................................................................... 9
3.1 Tanker entry to exit in the EFL ............................................................................................................ 9
3.1.1 Sampling....................................................................................................................................... 9
3.2 Milk Analysis ..................................................................................................................................... 10
3.2.1 Organoleptic Evaluation Tests ................................................................................................... 10
3.2.2 Qualitative Tests ........................................................................................................................ 11
3.2.3 Quantitative Tests ...................................................................................................................... 15
3.2.4 Adulteration Tests ...................................................................................................................... 17
4 Reception unit .......................................................................................................................................... 24
4.1 Cleaning in Place (CIP) .................................................................................................................... 24
5 Overview of quality control labs.............................................................................................................. 25
5.1 Reception lab .................................................................................................................................... 25
5.2 Line/Processing lab ........................................................................................................................... 26
6 Overview of quality assurance labs ......................................................................................................... 26
6.1 Physiochemical lab ........................................................................................................................... 27
6.2 Keeping quality lab (KQ).................................................................................................................. 27
6.3 Raw, packaging and technical materials (RPT) ................................................................................ 27
6.4 Microbiology lab ............................................................................................................................... 27

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1 Introduction
Engro Foods (Pvt.) Limited (EFL) was recognized in 2005 and starts working as a
subsidiary of Engro corporation. Its plant is situated at Sukkur at 23 acre land and has the
capability of raw milk like 300,000 liters per day by using the UHT (Ultra High Temperature)
milk ability of 200,000 liters per day. The plant has been started by the cost of Rs. 1 billion
which offers direct employment to 550 people. The company has started their Food business
through the processing of the milk and selling milk with the company’s vision to follow growth
opportunities which are based on country essentials and own strength. It is also the company’s
duty to control its corporate social responsibility programs and try to work directly with rural
society to sponsor incorporated farming and livestock growth. This effort is playing a vital role
for the achievement of its goals and in minimizing the poverty level and improving the
employment level for the poor people by collecting milk from the villages.
1.1 History
From ESSO to ENGRO
An ESSO/Mobil is a joint venture in 1957, which was led to the discovery of Mari gas
field that is situated near Daharki that is a small township in Sindh province. ESSO was the first
firm to research on this expansion in detail and started to establish of a plant of urea in that area.
The suggestion was accepted by the government in 1964, after that which was led to a fertilizer
plant agreement signed in December of the same year. Later in 1965, the ESSO Pakistan
Fertilizer Company Limited was built-in with 75% of the shares owned by ESSO and 25% by the
common public. The urea plant was constructed and began for the production at Daharki the next
year with the annual capability of 173,000 tons and production originates in 1968. At US $ 43

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million, it was the single but the largest foreign investment by an Multinational Company in the
country.
A developed market organization was well-known which commenced agronomic
programs to teach the farmers of Pakistan. As the first fertilizer brand’s nation, ESSO (then
Engro) helped update conventional farming practices to improve farm yields, directly impacting
the quality of life both for farmers but also their families, but for the population at large. As a
result of these hard works, utilization of fertilizers increased in Pakistan, concrete the way for
the Company’s branded urea called "Engro", and the purpose for this name is "Energy for
Growth”. By taking part in the international name change program, ESSO became Exxon in
1978 and the company was secondly changed its named which is converted into Exxon Chemical
Pakistan Limited. The company nonstop to show a profit as it candidly pursued productivity
gains and made efforts to achieve specialized brilliance.
In 1991, Exxon decided to separate from its business of fertilizer on the basis of
globalization. The workers of Exxon Chemical Pakistan Ltd, partners with most important global
and local financial foundations bought out Exxon’s 75 percent equity. Renamed as Engro
Chemical Pakistan Limited, the Company has gone from vigor to more strength, reflected in its
reliable financial act and the growth of the main fertilizer businesses and diversification into
different fields. Investment of human asset, solutions of the processes and resource
protection projects has condensed the use of energy per ton of urea at every third part of four, yet
as rising urea production almost six-fold since 1968. It is not only for saving the money; it
extends non-renewable energy sources and sensible the impact of desecrate. By stepping on their
success path, a major high point in plant capacity promote corresponded with the employee led
buy-out; imaginatively optimizing our capital, Engro re-located the plants of
fertilizer manufacturing from the United Kingdom and USA to its Daharki plant site – an
international first.
Those years were very exciting and profitable for the company and its employees since
Exxon became Engro. Difficulties have been defeated, goals have been achieved and new goals
have been set. Engro today is known as a successful business operator and a vital platform for
doing foods business in Pakistan.
From EXXON TO ENGRO

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By taking part in the program of International name change, ESSO converted into Exxon
and company was known by a new name of Exxon chemical Pakistan limited. After that, Exxon
decided to distinguish its fertilizer business on worldwide level due to which the company name
was converted to Engro chemical Pakistan limited. Engro chemical Pakistan limited then started
spreading its self into other segments as energy, foods, PVC marketing and manufacturing,
chemical end and storage and manufacturing manage and automation. In 2009, plans were make
separate fertilizer business into self-governing operating company. Engro fertilizer business was
incorporated to manage fertilizer business. To replicate the change in the span of edict and scale
of operations, Engro Chemical Pakistan Limited has been changed their name as Engro
Corporation Limited.
TIMELINE OF ENGRO
Sr. Year Description
1 1957 Joint venture of ESSO and Mobil discovered the Mari gas
1. 1964 Fertilizer plant agreement signed and approved.
2. 1965 ESSO chemical fertilizer company limited was incorporated
3. 1968 Construction of Urea plant
4. 1978 Name changed from ESSO to EXXON
5. 1991 Expanded on a global basis
6. 2009 Engro was established as an independent corporation, named as Engro
Corporation LTD.

MISSION STATEMENT
“Build branded food business to improve quality of life by offering tasty, affordable and high
nutritional products to our consumers while maximizing stakeholder’s value.”

VISION:
“Elevating consumer delight worldwide”

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2 Products

2.1 Dairy

Olper's milk Our flagship premium dairy brand, Olper's Milk, is 100% Preservative
Free UHT milk.
Olper’s lite The ideal low-fat, hi-calcium milk for adults who want to stay healthy,
active and fit for life, Olper's Lite contains all the inherent nutrients of
milk that can boost energy, without the extra calories that cause weight
gain.

Olper’s cream Olper's cream continues to make meal-times, as well as breakfast and
afternoon rituals a rich, creamy celebration day after day.

Olper’s flavored milk Inspired by the traditional flavors of badam, zafran and rose, Olper's
flavored milk caters to a diverse cross-section of consumers, with a
penchant for natural ingredients infused in rich, creamy and aromatic
milk.

Olper’s tarrka Launched in 2007, Olper's Tarrka is our premium desi ghee distinct for
its pure flavor and aroma.

Olper’s y-frooter Olper's Y Frooter tastes the delicious fruits of your imagination running
wild.

Olper’s lassi Olper's Lassi is a refreshing liquid snack that combines the goodness of
milk & yoghurt.

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2.2 Frozen desserts

Cups
Stick

Family-packs

Cones

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3 Tasks
3.1 Tanker entry to exit in the EFL
The standard time for a tanker from entry to exit in EFL is 3 hours. Average time is about 4 -5
hours.
Before entering the tanker in the industry (EFL), following parameters are checked which are as
follow:
Checking of vehicle in start position
1. Handbrake
2. Horn
3. Seat belt
4. Seal no. (most important parameter, seal no. is compared with the deposit slip form the
collection center)
If the following parameters are fulfilled then tanker is moved to weighing bridge where weight
of the tanker is done. This is also called first weight. It takes about 2-5 minutes.
3.1.1 Sampling
The tanker then moves to the parking area where sampling is done. It is done in almost 2-3 minutes. Only
1 sample is taken form one portion of the tanker and the size of the sample is almost 1 liter. Before taking
sample, plunging is done. Samples are sending to the reception lab where 22 tests are performed.
Line lab consists of
a) reception lab
b) process lab
26 tests are performed and the standard time for performing all these test is 45 minutes which are:
1)APT
2) COB
3) Starch
4) Urea
5) Barfode
6) Glucose (strips are used)
7) BRV ( butter refractive value)
8) Peroxide
9) Salt
10) Acidity
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11) Protein
12) Whey protein
13) Detergents
14) Sorbitol
15) Sucrose/sugar
16) pH
17) Butter test
18) formalin
19) Ammonium sulphate
20) Ammonium nitrate
21) LR
22) Fat

3.2 Milk Analysis

1. Organoleptic Evaluation test
2. Qualitative tests
3. Quantitative tests
4. Adulteration tests
3.2.1 Organoleptic Evaluation Tests
Principle
The organoleptic properties of food, raw food, especially for oral use and others, having a
determent effect on consumption and commercial success. Organoleptic properties are described as:
1. Taste
2. Odor
3. Color
4. Texture
5. Flavor (taste + odor)
6. Aspect ( color + texture)
The normal flavor of raw milk cannot be easily defined in specific terms. It is characterized by milky
odor and taste, resulting from the complex mixture of various constituents. The fact that its organoleptic
characteristics are very marked is due to the following:
• No constituent is present in sufficient concentration to produce a dominant flavor.

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• The main constituents of milk in its natural state are not volatile, which accounts for its
characteristics slightly pronounced odor and flavor.
• Defects in milk flavor generally appear when the concentration of one constituent varies
considerably compared to its usual average content.
Because of the perishability of milk and the nature of milk production and handling procedures, the
changes in color, development of off-flavor or taste impairment is not uncommon with milk. Milk is
tested simply by Seeing, Smelling, Swirling, Sipping and/or swallowing (5 S’s) to pass a judgment on the
acceptability or rejection of milk.
Procedure
1. Open a can/lid of container and collect sample as per sampling work instruction of milk, observe
milk, organoleptic in below pattern.
2. To See: Immediately see the color of milk it should be white, creamy white or with no
dominating yellow color. Any other color will be considered as abnormality. See physical texture
of milk it should be free from floaters, broken fat oily layer or any other physical contamination.
Texture should be smooth and walls of containing beaker should be free from deposits of fat and
powder grains.
3. Swirl the sample and observe the appearance of the milk and note any clots/fine particles
adherence to sides of the glass. Any such particles or floaters are considered as abnormal. Now
heat the milk at 40ᵒC and see the texture, it should be also according to the standards that
mentioned above.
4. To Smell: Smell the milk immediately after sample reception at startup of organo activity after
seeing and note for any deviation from fresh milk. It should be having fresh and pleasant creamy
smell. It should not be flat (without smell), old milk smell, sour, pungent or any smell of an
adulterant or flavor. Now heat the milk at 40oC, then smelled, it should be also according to the
standards that mentioned above.
5. Taste, take a small sip of the sample and note any abnormality in taste of milk. Do not swallow;
it may contain pathogenic micro-organisms. It should be fresh, pleasant milky taste, any off taste
like old milk, rancid, pungent, sour, pinching, salty, bitter, powdery, oily flat(no taste), watery(no
creamy taste) or any other deviation from fresh milk will be considered as abnormality.
6. Split the milk sample into a bucket provided for the purpose or into a drain basin, flush with
water.

3.2.2 Qualitative Tests

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3.2.2.1 Determination of Total Protein by Formal Method

Proteins are the most vital component of milk and part of SNF component of milk. Lactose,
Protein, Ash is present in a fixed ratio known as Vieth’s ratio that is 13:9:2. Formal titration is one of the
quickest and semi quantitative methods to determine protein percentage in milk.
Apparatus & Reagents
1. Beaker
2. Phenolphthalein indicator
3. NaOH 0.1 N
4. Formalin solution 37%
Principle
Neutralize the sample with NaOH to release ammonia and back titration with formalin.
Procedure
1. Take 10 mL milk in a beaker.
2. Add 2-3 drops of phenolphthalein indicator
3. Then neutralize with 0.1 N NaOH until light pink color appears.
4. Add 2 mL formalin solution.
5. Wait for 5-8 minutes.
6. Then again neutralize with 0.1 N NaOH.
7. Note the reading.
Calculation
% Total Protein = (V1-V2) * 1.94
Where:
V1= Titrate value
V2= Blank reading of Formalin
3.2.2.2 Determination of Whey Protein
Apparatus & Reagents
1. Beaker
2. Water bath
3. Filter paper
4. Pipette
5. Citric acid
6. NaOH 0.1 N
7. Phenolphthalein indicator
8. Formaldehyde 37%
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Principle
HCl denature the protein and develop turbidity depending on the concentration of whey protein.
Casein and heat denature whey protein are removed by filtration after precipitation of the reconstituted
milk with NaCl. The filtrate contains all the undenaturated whey proteins.
Procedure
1. Take 100 mL milk sample in the beaker.
2. Place the sample at water bath till 90oc.
3. Add 1g citric acid and mix gently until curd formed
4. Then filter it.
5. Take 10 mL filter solution and chilled at 20ᵒC.
6. Add 2-3 drops of phenolphthalein indicator.
7. Then neutralize with NaOH 0.1 N till light pink color appears.
8. Add 1 mL formaldehyde 37% and wait for 5-8 minutes.
9. Then again neutralize with NaOH 0.1 N and note the reading.
Calculation
% Whey Protein = (V1-V2) * 1.94 * 100
T.P
Where:
T.P= Total Protein
3.2.2.3 COB Test
Apparatus & Reagents
1. Bunsen burner/ spirit lamp
2. Wooden test tubes holder
3. Heat proof gloves
4. Test tubes
Principle
When normal milk is heated it does not form clots. However if milk is abnormal, milked from
diseased animals (mastitis), rich in colostrum, very high in salts (NaCl) or high in acidity (<0.30% lactic
acid) it forms clots or curdles on gentle boiling. Acid develop in milk due to microbial activities during
processing, handling and transportation. This develop acid in milk make milk protein casein more heat
sensitive.
Procedure

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1. Boil 2-5 mL milk into a test tube.

2. Observe any changes in milk such as;
i. Fine grains sticking with the walls of test tube.
ii. Coagulation of milk
iii. Precipitation
Inference
If there is clotting, coagulation or precipitation as mentioned above, milk sample has failed the
test and milk is not suitable for further processing, hence rejected.

3.2.2.4 Determination of pH
Apparatus & Reagents
1. pH meter
2. Buffer solution 7.00 & 4.01
3. Distilled water
4. Tissue paper
5. Thermometer
6. Wash bottle
7. KCl (charge its electrodes)
Procedure
1. Verify the pH meter at least once in a day using buffer solution, according to the manufacturing
instructions.
2. Take sample in a beaker and the electrode of pH meter immerse in sample completely.
3. Maintain the temperature of sample at 20ᵒC.
4. Dip the electrode in the sample solution and wait for the reading to stabilize.
5. Note the reading on pH meter.
3.2.2.5 Determination of Acidity
Apparatus & Reagents
1. Conical flask/ Beaker
2. 10ml pipette
3. 1 mL pipette/Dropper
4. Phenolphthalein indicator solution 1%
Principle
Majority of bacteria that grows in milk, develop acidity through lactic acid fermentation leading
to souring, curding of milk. In the acidity test the acid is neutralized with 0.1 N NaOH and amount of

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alkaline is measured. For this the percentage of lactic acid can be calculated. Fresh milk also contains the
natural acidity, which is range of 0.16-0.18 figure higher than this developed acidity due to the action of
the bacteria in the milk.
Procedure
1. Take 9 mL milk sample in the beaker.
2. Add 3 drops of phenolphthalein indicator.
3. Neutralize with NaOH until light pink color appears.
4. Read the titrate value and note this.
Calculation
Acidity = Titrate value/10
3.2.2.6 Alcohol Precipitate Test
It is based on instability of the proteins, when the levels of acid and/or rennet are increased and
acted upon by the alcohol. Also increased levels of albumen (colostrum milk) and salt concentrates
(mastitis) results in positive test.
Apparatus & Reagents
1. Ethanol 60% for raw milk
2. Ethanol 68% for pasteurized milk
3. Ethanol 80% for UHT milk
4. Petri dish
5. Pipette 10 mL
Principle
Protein of milk and alcohol compete for water available in milk. The higher of the concentration
of alcohol used; greater will be its power to attract water. Consequently less water will be available to
keep the casein in suspension.
Procedure
1. Take 2 mL milk sample in the petri dish with the help of pipette.
2. Add 2 mL ethanol solution.
3. Mix well.
4. Carefully observe any fine or coarse precipitation is rejected.
3.2.3 Quantitative Tests
3.2.3.1 Determination of Fat
Apparatus & Reagents
1. Gerber butyrometer

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2. 10.94 mL pipettes for milk

3. 10 mL pipette for H₂SO₄
4. 1 mL pipette for iso-amyl alcohol
5. Rubber stoppers for butyrometer
6. Stand for butyrometer
7. Centrifuge machine (1100 rpm) known as Gerber machine
8. Water bath
9. H₂SO₄ 92%
10. Iso-amyl alcohol 1 mL
Principle
Milk sample is subjected to wet digestion to dissolve nonfat content (dissolution of suspensions
such as proteins with the help of sulphuric acid), in the sample and then total fats are extracted with the
help of amyl alcohol. Everything in milk except fat dissolves in sulphuric acid. The fat floats to the top.
The centrifuge ensures complete separation with no bubbles in the fat. Iso-amyl alcohol ensures the
complete separation of fat and fat contents can be measured using the butyrometer.
Procedure
1. Maintain temperature first 40ᵒC then cool at 20ᵒC.
2. Add 10 mL of H₂SO₄ in the butyrometer followed by 10.94 mL milk. Avoid wetting the neck of
the butyrometer.
3. Add 1 mL of Iso-amyl alcohol.
4. Insert stopper and shake the butyrometer carefully until curd dissolves and no white particles can
be seen.
5. The butyrometer must be placed in the centrifuge with the stem (scale) pointing towards the
center of centrifuge.
6. Spin 5 minutes for raw milk, 12 minutes for pasteurized milk and 15 minutes for UHT milk at
1100 rpm.
7. Remove the butyrometer from centrifuge and read the scale showing column of extracted it.
Results
The fat column should be read from the lowest point of meniscus of interface of the acid fat to ‘’
0 “mark of scale and then read butterfat percentage. The color of the fat column should be straw yellow.
3.2.3.2 Determination of MSNF & TS
Apparatus & Reagent
1. Lactometer

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2. Plastic cylinder
3. Thermometer
4. Water bath (upto 100ᵒC)
5. Beakers
Principle
Lactometer a specified hydro-densitometer, where dipped in milk at 20ᵒC temperature, floats and
measures the density of milk. The lactometer reading is then subjected to an equation for the calculation
of milk not fat (MSNF) and total solids (TS) in milk by addition method. The function of
lactometer/hydrometer is based on Archimedes principle that a solid suspended in a liquid will be buoyed
up by a force equal to the weight of the liquid displaced. Thus, the lower the density of the substance
lower the lactometer will sink.
Procedure
1. Pour about 500 mL milk in the 1000 mL beaker.
2. Gently mix until temperature reaches 40ᵒC.
3. Then reduced at 20ᵒC by chilled water.
4. Gently pour sample in cylinder. Fill it until milk overflows.
5. Let the lactometer sink slowly into the milk. Slowly let the lactometer down to the equilibrium
position.
6. Read and record the last lactometer degree, just below the surface.
Calculation
%MSNF = (0.25 * CLR) + (0.22 * Fat %) + 0.72
%TS = Fat% + MSNF%
Where:
LR = Lactometer reading
MSNF = Milk solids not fat
TS= Total solids in milk
3.2.4 Adulteration Tests
3.2.4.1 Determination of Starch
Apparatus & Reagents
1. Iodine solution 0.1 N
2. Pipettes 10 mL
3. Watch glasses/ Petri dish

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Principle
Iodine solution turns starch granules into bluish purple color by acting on amylase. Starch form a
complex with iodine that ranges from blue to blackish color depending upon the type of starch.
Procedure
1. Mix the milk sample thoroughly.
2. Place 10-15 drops of milk to be tested on the glass watch.
3. Add 1 drop of iodine solution.
4. Mix gently the glass watch and allow stand.
5. After 1 minute, examine the bottom of the watch glass.
6. Note any change and spot colored granules in the test sample.
Inference
Presence of bluish, purple or brownish grains or color is indicator of starch present in the milk.
3.2.4.2 Determination of Sucrose
Apparatus & Reagents
1. Alpha-napthol 10%
2. Boiling Water bath
3. HCl 35-37%
4. Test tubes
Principle
Cane sugar is most common adulterant in milk. It increases the specific gravity of milk so
increases lactometer reading. Formation of a violet coloration by reaction of sucrose with alpha-napthol in
presence of hot, concentrated HCl. HCl breaks down the sugar into its monosaccharide units (glucose and
fructose). Fructose such formed reacts with napthol and form violet color compound.
Procedure
1. Introduce half mL milk in test tube.
2. Add 2-3 drops of alpha-napthol indicator.
3. Add 3 mL conc.HCl 35-37% mix it well.
4. Put the test tube in boiling water bath for 10 seconds.
5. Note color change in the sample.
Inference
Appearance of light blue or dark violent within 15 minutes, the test will be positive. The
transparent or pink color indicates the test is negative.

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3.2.4.3 Determination of Salt

Apparatus & Reagents
1. Burette 25 mL
2. Pipette 10 mL
3. Beaker 100 mL
4. 0.1 N AgNO3 solution
5. 10% Potassium Chromate
Principle
To increase the lactometer reading of milk just like sugar, common salt NaCl is added in milk as
an adulterant this may also come in milk through ice used to chill the milk during storage and
transportation. Silver nitrate added, reacts with salts (chlorine) in the sample to form silver chlorine and
nitrates of sodium or potassium that result in light brown color in media containing potassium chromate
as an indicator.
Procedure
1. Take 9 mL of well mixed sample in a 100 mL beaker with the help of a pipette.
2. Add 3-4 drops of potassium chromate solution, being used as an indicator.
3. Titrate the sample against 0.1 N AgNO₃
4. Before titration make sure that level of 0.1 N AgNO3 solution in burette is at ‘0’ mark.
5. Add 0.1 N AgNO₃ solution drop by drop from burette until light brown color appears.
6. Note AgNO₃ reading from burette.
Calculation
% Salt = Titrate value of AgNO3 * 0.00584

3.2.4.4 Determination of Detergent

Apparatus & Reagents
1. Ethanol 95%
2. Rosalic acid 1%
3. Pipette 10 mL
4. Test tube
Principle
Soda means sodium bicarbonates, which acts as a preservative in milk. It neutralizes the
developed acidity of milk. Ethanol added in milk sample, coagulates the casein protein which is separated
from milk serum. The milk serum containing the carbonates and bicarbonates turns the color of Rosalic
acid added from the red to pink.
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Procedure
1. Take 2 mL of the milk in test tube.
2. Add 3 drops of Rosalic acid solution and mix well.
3. Add 2 mL of ethanol 95%
4. Gently mix and examine the color.
Inference
Presence of pinkish color is indication of test positive. While orange color shows the negative
color.
3.2.4.5 Determination of Hydrogen per oxide
Apparatus & Reagents
1. Per oxide strip
2. Beaker
Principle
Hydrogen per oxide reacts with per oxide and the organic redox indicator in the test field to form
a blue colored oxidation compound.
Procedure
1. Take the milk sample.
2. Dip the test stick in the milk sample.
3. When hydrogen peroxide is present, the test field forms a blue coloration.
4. Wait 5 sec and then compare the test field with the color scale.
3.2.4.6 Determination of Glucose
Apparatus & Reagents
1. Glucose strip
2. Beaker
Principle
Glucose is mostly added in fresh milk to increase its lactometer reading, so to increase SNF
contents of milk. This test is based on a double sequential enzymes reaction. One enzyme, glucose
oxidase, catalyzes the formation of gluconic acid and hydrogen peroxide from the oxidation of glucose.
Second enzyme peroxidase, catalyzes the reaction of hydrogen peroxide with potassium iodine
chromogen to oxidize the chromogen to colors ranging from blue green to greenish brown through brown
and dark brown.
Procedure
1. Dip the strip in milk sample for 5-10 second, wet reagent area of strip.

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2. While removing, run the edge of strip against the rim of beaker to remove excess milk.
3. Wait for 30 second.
4. Compare the test area with the color chart.
Inference
A color of greenish brown to dark brown indicates teat positive. While blue green after 30
second, indicates negative test.
3.2.4.7 Determination of Sorbitol
Apparatus & Reagents
1. Pipette 5 mL
2. Test tube
3. Sodium hydroxide 10%
4. Iron (lll) sulphates 0.8%
Procedure
1. Take 1 mL of milk sample in test tube.
2. Add 1 mL of NaOH 10%
3. Add 2 mL of Iron (lll) sulphates 0.8%
4. Mix well.
Inference
Appearance of bright yellow color gel formation indicates the test is positive.
3.2.4.8 Determination of Urea
Apparatus & Reagents
1. Pipette
2. Test tube
3. Di-methyl aminobenzaldehyde (DMAB) 10%
Principle
Urea or carbamide is an organic compound with chemical formula (NH2)2CO. Urea serve as
important role in the metabolism of nitrogen containing compound by animals. Urea is added in raw milk
by suppliers in order to increase the SNF.
Procedure
1. Take 2 mL milk sample in test tube.
2. Add 2 mL DMAB solution.
3. Note the color.
Inference

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If yellow color appears then the test is positive.

3.2.4.9 Determination of Formalin
Formalin is used as disinfectant or antibacterial. It contains 40% formaldehyde by volume and
small amount of stabilizer 10-12% methanol.
Apparatus & Reagents
1. 1% Phenyl Hydrazine hydrochloride
2. 1% Ferric Chloride (FeCl₃)
3. Hydrochloric acid
Procedure
1. Treat 15 mL of fresh milk with 1ml of phenyl hydrazine hydrochloride.
2. Add 3 drops of 1% FeCl3 and few mL HCl.
Inference
In the presence of formalin, a red color develops that change to orange yellow with the passage of
time.
3.2.4.10 Determination of Ammonium Sulfate
Ammonium sulfate is an inorganic salt. It contain 21% ‘N’ as ammonium cations and 24% ‘S’ as
sulfate anions. It is added in raw milk to increase the SNF.
Apparatus & Reagents
1. NaOH 2%
2. Sodium hypochloride 2%
3. Phenol 5%
Procedure
1. Take 1 mL sample in a test tube and add 0.5ml of each 2% NaOH and 2% sodium hypochloride
and an aqueous solution of 5% phenol.
2. Heat the mixture in the boiling water bath for 20 seconds.
Inference
In the presence of extraneous ammonium sulfate is indicated by appearance of rapidly deepening
of blue color.
3.2.4.11 Determination of BR
Apparatus & Reagents
1. BR Apparatus
2. Centrifuge machine
3. Water bath

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4. Spirit lamp
5. Steel petri dish
6. Match box
7. Test tube
8. Steel jug
9. Spatula
Procedure
1. Take 2 liter milk in steel jug.
2. Place the jug in water bath at 40ᵒC.
3. When the temperature of milk reaches at 40ᵒC, fill the test tube and put in to the centrifuge
machine for 10 minutes and put the upper layer of test tube on spatula.
4. Extract the oil by heating it.
5. Place a drop of butter oil on the prism of BR apparatus.
6. Make sure that water of 40ᵒC is passing through the BR apparatus.
7. Take the reading by placing eye on eyepiece.
8. Note the reading where black shade and clear shades divide.
3.2.4.12 Determination of Sodium by Ion Meter
Apparatus & Reagents
1. Sodium ion meter
2. Beaker 100 mL
3. ISA solution
4. Magnetic stirrer
Principle
The sodium ion-selective electrode has a solid state PVC polymer matrix membrane. The
electrode is designed for detection of sodium ions (Na+) in milk. The sodium ion is a monovalent cation.
Virtually all cations interfere with sodium electrode to some extent. Thus it is the best used for measuring
pure sodium solution, where sodium is far more concentrated than other components.
Procedure
1. Take 50 mL of milk sample having 25ᵒC temperature in a 100 mL beaker.
2. Add 2.5 mL of ISA solution.
3. Put magnetic stirrer for stirring.

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4. Remove the lid of electrode, rinse it with distilled water and press push button on the top of
electrode for gel pressing and then dip the electrode in the beaker (Ensure that electrode does not
touch with the walls and bottom of beaker).
5. On the (Exit) button of ion meter (Ensure the desired calibrated channel should be selected).
6. After beep note the reading.
Inference
The result will be displayed as ppm. Sodium in raw milk should be > 585.
4 Reception unit
Tanker is further move to the reception unit where weight is done again. After weighing, suction
of milk is carried out. Reception unit consist of:
• Filter
• Balance tank
• Filter
• Plate heat exchanger
After passing through these parts, raw milk is stored in silos where temperature of the milk is 3-
4oC. The temperature of the raw milk in the tanker is about 6-7oC.
There are 7 silos for storage of raw milk. The capacity of R1 and R2 silos is 1 lac and 25
thousand liters whereas the rest of the silos have the capacity of 1 lac and 50 thousand liters.
Flow rate of raw milk is 50,000 liters per hour in the reception unit. The time required or use for
empty of tanker is:

Capacity of tanker Decanting Time

20 tons 45 minutes
12 tons 25 minutes
8 tons 15 minutes

4.1 Cleaning in place (CIP)

Next portion is cleaning in place (CIP). The standard time is given in table.
Type Time
Tanker 30 minutes

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Silo 90 minutes
Reception unit 50 minutes

Procedure for CIP

1) Pre-rinsed water for 2 minutes and empty the tanker.
2) Caustic washing for 1 minute. For that purpose NaOH (1.5-2%) is used and empty the tanker.
3) Fresh water washing for 5 minutes.
There are 2 types of tankers
1) Raw milk tankers
2) HPO tankers.
Type of tanker Type of washing Time
Raw milk Caustic treatment (NaOH) 25-30 minutes
HPO Acid treatment (HNO3) 60 minutes

After CIP, tanker moves out of EFL from gate 3.

5 Overview of quality control labs
Two labs are associated with the quality control department;
1. Reception lab
2. Line/processing lab
5.1 Reception lab
It deals with the raw milk samples and report to production department for reception of raw
milk. It takes 45 minutes and performs 26 tests of raw milk.
The tests are:
1. Organo
2. Fat
3. LR
4. BRV
5. pH
6. Total protein
7. Whey protein

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8. Na test
9. Detergent
10. Sugar
11. Formalin
12. Bar ford test
13. APT (60%,90%)
14. Ammonia
15. Sorbitol
16. Starch
17. COB
18. Butter
19. Nestler test
20. TSS
21. Urea
22. Glucose
5.2 Line/Processing lab
It deals with the samples from production line. Deal with samples from ATS, Silo’s, and final
products (dairy).
Following tests are performed after UHT:
1. pH
2. APT
3. LR
4. Fat
5. Temperature
6 Overview of quality assurance labs
The quality assurance department deals with assurance of quality at every step i.e. raw
materials, chemicals, waste products, finish products etc.
Four labs are working under the umbrella of quality assurance;
1. Physiochemical lab
2. Keeping quality lab (KQ)
3. Raw, packaging and technical lab (RPT)
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4. Microbiology lab
6.1 Physiochemical lab
Main objective of Physiochemical lab are;
1. Inspection and standardization of chemicals (set dilutions)
2. Inspection and standardization of Glassware
3. Calibration of equipment’s
4. Raw water, filter water, boiler water (blow down), ammonia condenser (blow down)
water, and waste water analysis.
5. Provide chemicals to other labs i.e. line lab, micro. Lab, reception lab etc.
After analysis Physiochemical lab reports to the respective departments i.e. utility, purchase
etc.Raw water tests are pH, TDS, total hardness, M-value, P-value, caustic alkalinity, sulfite
phosphate, zinc iron, conductivity, and silica. And waste water tests includes pH (6-9), dissolved
oxygen (1.6), sludge volume, MLSS, TDS, BOD, COD, FOG.
6.2 Keeping quality lab (KQ)
It keeps the record of the quality of finish product. Samples are checked at different
temperature i.e.
At room temperature, 37◦C, 55 ◦C for 24 hours, 2 days, 3 days, 5 days and till expiry date.
1. Keep the records of quality.
2. Deals with the market claims.
6.3 Raw, packaging and technical materials (RPT)
It deals with the inspection of raw packaging material for all products, flavors, additives, and
preservatives, chemical.
• ICP raw and packaging materials
• Dairy packaging
• Butter packaging
• Primary and secondary packaging
• Chemicals
6.4 Microbiology lab
It deals with the microbiology of these samples;
1. Raw milk

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2. Pasteurized milk
3. Milk powder
4. Ice cream
5. Raw material
6. Water (raw, drinking, reverse osmosis, waste, canteen etc.)
7. Air
8. Environment
Following tests are performed;
1. Total plate count
2. Entero Bactreacea count
3. Yeast and Mold count
4. MBRT
5. Afla toxins
6. Antibiotic Count

Activity no. 6:

Dairy Processing:

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FLOW SHEET

RAW MILK

RECEIVING

FILTRATION

STORE IN SILOES

CENTRIFUGAION

STANDARDIZATION

PASTEURIZATION

HOMOGENIZATION

UHT TREATMENT

COOLING

PACKAGING

STORAGE

RAW MILK

• Out of Gate
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After collection of milk when trucks arrive at gate, security guard check the truck
according to check list like: hand break, seat belt, tiers, lights, driver license, truck screen etc.

NOTE : In case if truck is not according to check list and rejected then truck goes to gate no 3,
where truck mail is send to the admin office, if its approve then truck in, otherwise not in.

• In Gate

If all the things are correct then truck in and take initial weight. Then truck stand at
parking area.

RECEIVING
• There are 4 receiving units in industry.
• The receiving capacity of each pipe line is 50,000 L/hr.
• The truck arrives on receiving area; pipes are attached and receive the milk.
• Milk goes to the targeted siloes.
• When the truck complete empty remove pipes but pipe lines have some milk, to gain
this milk pass water through the pipe lines. In this way all the milk run forward to the
water and gain all the milk.

FILTRATION
• The milk during receiving passes through the filter media, to filter different particles.
• After filtration milk goes to balance tank, where two flow sensors are present.
• Then milk pass through the heat exchanger, where ice water is used to low down the
temperature at 4-6ᵒC.

STORE IN SILOES
• There are 7 receiving siloes present in industry.
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• Capacity of S1 and S2 is 1, 25,000 Liter and S3, S5, S6, S7 and S8 is 1, 50,000 Liter.
• Temperature of all the siloes is less than 10ᵒC.
• When all the receiving process complete milk store in siloes, then wash all the pipe
lines.

STANDARDIZATION
• The store milk goes to production area where first standardize the milk according to
standard.

PASTEURIZATION
• Heat treatment that kill pathogenic micro-organisms and also kill the enzymes.
• Pasteurization is done at 75ᵒC for 16 sec.
• 3 pasteurizer in industry, 2 Tetra pack and 1 Gea technology.
• Capacity of each pasteurizer is 25, 000 Liter.
• 10 pasteurized siloes are present in industry.
• 7 pasteurized siloes have capacity 75, 000 Liter and 3 pasteurized Siloes have capacity 1,
00,000 Liter.

HOMOGENIZATION

• Homogenization is done to create uniformity in fat molecules. Some molecules of fat are
bigger size and some are smaller, that are become equal after homogenization. If
homogenization is not done some fat molecules becomes on upper side and make layer
and some goes denser side.
• Homogenization is done at 65ᵒC and 150 bar pressure.

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UHT TREATMENT
• After homogenization temperature is gradually increase to done UHT treatment by
passing through 4 heat exchanger.
• UHT kill all types of micro-organisms and the bacterial spores.
• UHT done at 140ᵒC for 2-3 sec.
• 5 UHT tanks are present in industry.

TANKS CAPACITY
UHT 1 20, 000 L
UHT 2 16, 000 L
UHT 3, 4, 5 30, 000L

COOLING
• After UHT treatment cooling is done.
• Cooling temperature is 70ᵒC.
• After cooling again homogenization is done at 65ᵒC and 200 bar pressure.
• Again cooling is done that reduce product temperature at room level.

Activity no. 7:

TETRA PACK Machines Data

ATS M/C M/C quantity product packs/hr Lit/hr Silo's

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name type (SKU)

G 200ml 4,000
H TBA-22 250ml 5,000
20,000
N (STOP) 200ml 4,000
I 200ml 4,000 ONE
1 Tarang
J 125ml 3,000 STEP
L A3 250ml 6,000
24,000
M SPEED 125ml 3,000
F2 125ml 3,000
A 250ml 5,000
TBA-22 tarang+omung+olpers+ 20,000
2 B 250ml 5,000
elaichi
D TBA-08 1000ml 6,000 6,000
E (stop) 1000ml 6000 6,000
TBA-08
F 1500ml 5000 75,00 1 to 10
V (EDGE) A3 FLAX 1000ml 8000 8,000 (optiona
W l)
3 OLPERS
X
ECOLEA 9000 2,250
A2 250ml
N
B2
C2 (NEW) 12,000 3,000
4 NIL
O 200ml 4,800
P 250ml 6,000
Q A3
5 TARANG 24,000
R SPEED 200ml 4,800 ONE
S STEP
T 125ml 3,000
D2
6 TBA-19 125ml TARANG 6000 750
E2

Activity no. 8:

Ice cream Process Flow:

ICE CREAM
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Definition:
Ice cream is a complex colloidal system, comprised of ice crystals, air bubbles, partially
collesced fat globules and aggregates in frozen state and in discrete phase surrounded by
unfrozen continuous matrix of sugar, protein, salts, polysaccharides and water.

Introduction to Ice cream Plant:

Omore ice cream plant consists of 5 departments:

• Material store department

• Mixing department
• Production department
• Cold store department
• Cone baking department

Material Store Department:

The incoming raw packaging material is received by material store department and is
kept separately for QA inspection, analysis and clearance. Material store is divided into three
temperature zones.

• Ambient
• +22ᵒC
• Chill Storage (4ᵒC)

Mixing Department:
This department is divided into followings areas:

 Mix processing area

 Aging rooms & chilled rooms

 Mix Processing Area:

The followings tanks and equipment’s are available for different processes in this
area:

Tanks Capacity (liters)

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Mixing tank 1 2000

Mixing tank 2 2000
Rework tank 1000
Pasteurizer 5000 Lit/hr
Homogenizer 5000 Lit/hr

MIXING PROCESS FLOW DIAGRAM

Dosing
of Homog
Balance Pasteuri Pre- Aging
material enizatio chilling
Tank zation cooling Tanks
& n
Mixing

Start of Batch Process:

• First of all water (80ᵒC) is dosed automatically.
• After that solid 1 are dosed that containing sugar, stabilizer, emulsifier, and glucose.
• Solid 2 are added in mixing tank which includes sugar and SMP (skimmed milk powder).
• After that solid 3 is added which is fat.
• Mixing tank contains both solid and liquid ingredients when all the ingredients have
been dosed in the mixing tank then it is given 2 minutes agitation time at 1000-1100
rpm. After 2 minutes agitation, mixture is forwarded to the balance tank.

Pasteurization:
• Pasteurization is done at 79ᵒC for 29 sec.

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Pasteurizer consists of 5 compartments:

i. R1
ii. R2
iii. Heating
iv. Pre-cooling
v. Chilling

(Note): R1, R2 & Heating are heating sections and pre-cooling & chilling are cooling sections. In
heating part, mixture attains a temperature 80ᵒC.

Homogenizer:
After gaining temperature of 80ᵒC in heating chamber, mixture is transferred to
homogenizer for uniformity. When fats are added in mixing tank, fat size are 50 micro and after
homogenization, fat size reduced to less than 1 micro. If high fat (10-11) % is required then 150
bars pressured is applied. If low fat (8-9) % is required, then 180 bars pressure is applied.

Holding Tubes:
After homogenization, mixture is forward to holding tubes, where temperature 80ᵒC
for 29 sec.

Pre-cooling:
In pre-cooling part, heat is exchanged between water and mixture and the
temperature of the mixture decreases to 25-30ᵒC.

Chilling:
In chilling part, glycol is used as a coolant, the mixture is chilled at 4ᵒC and at least it is
forwarded to the aging tank present in aging room.

 Aging Rooms &Chilled Rooms:

Two aging rooms are presents, which have different aging tanks of different
capacities. Aging room 1 consists of 12 aging tanks and aging room 2 consists 8 aging tanks of
following capacity.

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Tanks Capacity (Liter)

4 Aging tanks 4000
4 Aging tanks 6000
4 Aging tanks 8000
8 Aging tanks 8000

Functions of Aging:
• Hydration of milk proteins
• Crystallization of liquid fats
• Protein desorption from fat globules surface

Chilled Rooms:
2 chilled rooms are presents. In chilled room 1 rework storage and in chilled room 2
color/flavors are store.

Liquid Ingredients Area:

LI area consists of 6 liquid ingredient tanks of following capacities:

LI Tanks Capacity (Liter)

2 Vegetable oil tanks 6000
2 Glucose tanks 8000
1 Milk tank 6000
1 Cream tank 6000

Ice Cream Production

Production Machines:
Production hall consist of 7 production machines:
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• ROLO 1 (Moulded stick Products)

• ROLO 2 (Moulded stick Products)
• Comet (Cups & Tubs)
• SL 800 (Extruded products)
• SL 900 (Extruded products)
• Big Drum (Cones Filling)

ROLO 1, 2 Process:
• Ice cream Mix from aging is transferred to the freezer after quality clearance. The
freezer after attaining -2ᵒC, starts delivering ice cream for production.
• After cooling at -2ᵒC with specific over run, ice cream is dosed in ice cream filler. Ice
cream is filled in mold pockets through volumetric filler.
• Ice cream is cooled by brine solution (CaCl2 + H2O) at -39ᵒC.
• Ammonia -40ᵒC is used as a refrigerant in PHE and it cooled brine which is used as a
coolant for the products.
• Sticks are inserted into mould pockets when ice cream become semi-solid and ice cream
filled pockets reaches stick insertion point Warm Brine at (15-20ᵒC) is pumped for
defrosting and to facilitate extraction.
• Product is then transferred further for wrapping.
• After wrapping, packed in master carton which is then transferred to palletizing after
proper taping and coding on it.
• Then transferred to cold store where it is kept for 3 days for the final micro results after
which it is available for sale.

SL-800 Process:
• Mix is delivered to freezers, that start cooling the Mix after attaining -5ᵒC.
• Inclusions plus ice cream are fed into the feed pump and passed through the mixer &
transfer to distribution head.
• The ice cream flow toward distribution head & through hose pipes comes in to the
extruder fixed on machine. Sticks are loaded in stick magazine. Sticks are inserted
through a space in extruder into the extruded product.
• The product is than placed on stainless steel plates which then enter into the hardening
tunnel. Tunnel temperature is kept at -40ᵒC and high speed air is blast in to the tunnel
on products, this air is cooled by ammonia evaporators which hardens the product.
• After 30 minutes product on it exit from the tunnel, where it further transfer for
wrapping.
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• After that, the product is packed in carton which then transferred to palletizing after
proper carton taping and coding.
• Then transfer to the cold store, where it kept for 3 days for the final micro results after
which it is available for sale.

Big Drum Process:

• Mix from aging tank transferred to the freezer. The freezer after attaining -3ᵒC starts to
foam ice cream product.
• After freezing at -4ᵒC to -5ᵒC ice cream is fed to distribution head through SS pipes.
• Cone sleeves with wafer are loaded manually in cone dispenser. Cones are dispensed
automatically in lamellas. Chocolate is sprayed in cone wafers to prevent moisture
absorption.
• Lamellas with chocolate sprayed cones when reach filling point ice cream is filled cones.
• After that, cones reach on ejection point and ejector uplift the cones to the height of
conveyor 2.
• Cones are transferred on baskets.
• Basket transfer-conveyor, transfer the cones to the tunnel, where temperature is -38ᵒC
for further hardening the product.
• The product is then transferred to palletizing room where these cartons are stacked on
plastic pallets.
• The product is then transferred to the cold store, where it is kept for 3 days for the final
micro results after which it is available for sale.

Cold Store Department:

• Used for the storage of final products.
• Storage temperature ranges from -25ᵒC to -28ᵒC.
• 3 cold stores are present; each cold store capacity is 900 pallets.

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Random activities:
1. Visit of cold storage
2. Safety audits
3. Media preparation + washing
4. Milk processing training
5. Work on Lactoscan

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