ICAR- NATIONAL DAIRY RESEARCH INSTITUTE, KARNAL

IN- PLANT TRAINING REPORT

VERKA PLANT, MOHALI
 IN- PLANT TRAINING REPORT, VERKA MOHALI DAIRY,
S.A.S. NAGAR, PUNJAB

(AN IS/ ISO 9001:2008 & IS 15000:1998 CERTIFIED UNIT)

SUBMITTED BY- SIMRAN

REG. NO. - 17-B-DT-33

B.Tech 4th year (DAIRY TECHNOLOGY)

NATIONAL DAIRY RESEARCH INSTITUTE

KARNAL-132001, HARYANA, INDIA

ACKNOWLEDGEMENT
The internship opportunity I had with Verka, Mohali was a great chance
for learning and professional development. Therefore, I consider myself
as a very lucky individual as I was provided with an opportunity to be a
part of it. I am also grateful for having a chance to meet so many
wonderful people and professionals who led me though this training
period.
I am highly thankful to Dr. Latha Sabikhi (Head Dairy Technology and
Placement cell, NDRI Karnal) , Dr. Yogesh Khetra (Scientist) and Mr.
Gaurav Deshwal (Scientist) who gave this wonderful opportunity, their
due attention, guidance and provided the necessary facilities during in
plant training.
It is my radiant sentiments to place on record my best regards and
deepest sense of gratitude to Mr. Rupinder Singh Sekhon, General
Manager (Verka, Mohali Dairy).
I all feel thankful to Mr. Raman Kant Sharma (Mgr. Q.A.), Mr. Shubham
Gote (Asst. Mgr. Q.A.), Mr. Ravi Shukla (Dy. Mgr. Q.A.) , Ms Neha (Dy.
Mgr. Prod.), Ms Dalbeer Kaul(Ass. Mgr. Prod.), Mr. Gourav Gholia
(Ass. Mgr. Prod.), Ms. Aditi Baryah(Ass. Mgr.Prod.), Mr. A.K.
Mishra( Mgr. Procurement), Mr. Manpreet Singh(Procurement),Mr.
Preetpal Singh( Ass. Mgr. Engg.) for their guidance which was extremely
valuable for my training. I am also thankful to all the staff who really
showed cooperation and support.
I tender my unconditional apology to the persons whose names cannot be
mentioned due to limitation of space. I express my gratitude to them for
their continuous encouragement.
 CONTENTS

 Introduction to organization
 Present status of plant
 Procurement section
 RMR in plant
 Sampling
 Q.A. Section
 Test performed in lab
 Microbial testing of milk and milk products
 Production section
 Liquid milk plant
 Old plant
 Fermented dairy plant
 Engineering section
 Marketing section
 Conclusion

INTRODUCTION TO ORGANIZATION
The Punjab State Cooperative Milk Producers’ Federation Limited
(MILKFED) came into life in the year 1973 to improve dairy farming in
the state of Punjab. The primary aim was to provide a good market to
the state milk producers by value addition and marketing of produce.
Another objective was to provide technical inputs for the enhancement
of milk production.

Though the federation was registered quite earlier, it came into its real
form in the year 1983 when the milk plants of the former Punjab Dairy
Development Corporation Limited were granted to the Cooperative
Sector under Operation Flood. The move was carried out in the state to
provide better deal to the farmers and better products to the
customers.

MILKFED is set-up as a three tier system with Federation as the apex

body at the State Level, Milk Unions at the District Level and
Cooperative Societies at the village level. The organization has
continuously advanced towards its objectives.

Objectives
1. To ensure quality milk procurement at remunerative price
coupled with improved animal productivity for reducing cost of
milk production for sustainable growth of the milk producers
2. To provide quality extension services at the door steps of milk
producers
3. To ensure Quality Assurance in procurement, processing &
marketing and enhancing efficiency in the entire value chain
4. To ensure acquisition, development and retention of competent
manpower
5. To improve fiscal management by optimizing the returns on
capital
 6. To ensure continual modernization in the entire value chain
through effective leveraging of technology
7. To embrace innovation in the entire value chain for consumer
delight
8. To ensure continual expansion of distribution
9. To enhance brand equity

THE ROPAR DISTRICT COOPERATIVE MILK PRODUCERS UNION LTD.

VERKA MOHALI DAIRY, S.A.S. NAGAR, PUNJAB

Milk Union Mohali registered during 1978 and started functioning on an

and Pattern from Sept.’1979. It purchases fresh Milk twice a day
directly from Milk Producers by organizing Milk Producers’ Co-
operative Societies (MPCS) at village level  in entire Ropar  & Mohali
District  and part of Fatehgarh Sahib and Patiala Districts. Presently, The
Ropar District Cooperative Milk Producer’s Union Limited, Milk Plant
Mohali is a front-line Milk Plant in Co-operative Sector having installed
handling capacity of around 9,00,000 litres of Milk per day.

1295 functional milk producer co-operative societies formed at village

level are supplying about average of 5-6 lakh litres of Milk per day. This
milk procurement goes to about around 7.5 lakh litres in a day during
peak flush season. Fresh milk is procured directly from milk producers
through village level societies twice a day. The main function of this
plant is to provide best quality of Pasteurized Liquid Milk to the
consumers in Chandigarh and its satellite cities.

Apart from Liquid Milk supply (Full Cream Milk, Std. Milk, Toned Milk,
Double Toned Milk & Skimmed Milk), this Plant also manufacture
Butter, Ghee, Paneer, Kheer, Curd, Plain Lassi, Namkeen Lassi, Sweet
Lassi, Shahi Dahi. All the products are manufactured under the brand
name of VERKA.
 PRESENT STATUS OF VERKA PLANT,MOHALI

State Punjab
District Mohali
Address Verka Mohali Dairy,
S.A.S. Nagar,Mohali-160055
Product Profile Full Cream Milk, Standardized Milk,
Toned Milk, Cow Milk, Double
Toned Milk, Butter, Ghee, Paneer,
Dahi, Lassi-(Plain, Sweet, Spiced),
Chhach, Kheer.
Product Brand Name Verka
Marketed By The Ropar District Milk Producers
Union Ltd., Verka ,Mohali Dairy,
S.A.S. Nagar (Mohali)-
160055(Punjab)

Milk Handling Capacity 5.5 Lakh L per Day(Liquid Milk),

1.7 Lakh L per Day(Fermented Unit)

Number of Societies under Milk 1295

union
Number of Chilling Centers 3

PROCUREMENT SECTION
Processing of milk can only be done if milk has been collected in
adequate quantities so the procurement section authorities collect milk
from villages and bring to the milk plant for processing.

COLLECTION OF RAW MILK

Farmers Farms

Societies

BMC (1-4 KL/DAY) MCC (30-40 KL/DAY)

To Plant through tankers

 FLOW CHART OF MILK FLOW IN CHILLING CENTRES

Milk from societies

RMRD of chilling centres

Grading

Good Milk Sour Milk

Weighing Churning

Sampling Sour cream Buttermilk

Dumping

Chilling (5oc) Transferred to central Draining

Dairy in cans

Raw milk storage tank

TESTS PERFORMED IN BMC AND MCC

1. Organoleptic tests
2. Temperature
3. Fat % (For individual producers of village by Milkoscreen; for
societies by Gerber method)
4. SNF % (For individual producers of village by Milkoscreen ; for
societies by Lactometer reading)
5. Tests for adulterants using Milkoscreen in Milk Chilling Centres.

General Information

SOCIETIES 1295

BMC 305

MCC 3

FARMS 450

MILK PROCUREMENT/ DAY 7-8 LAKHS LITRES

 Reception of milk

As the reception of raw milk is the most vital unit operation to many
dairy plants, hence the reception should be efficient and prompt with
all possible hygienic control to ensure best quality raw milk to produce
equally good quality products.

SOURCE MODE OF RECEPTION

Cooperative societies stainless steel cans

Chilling centers Insulated milk tankers and SS cans

Return milk from city supply

Type of milk received -

1. Cow Milk

2. Buffalo Milk

3. Mixed Milk

Time of milk reception-

1. Flush season: Morning 8:00am – 10:00am

Evening: 6:30pm – 8:00pm

2. Lean Season: Morning 6:00am – 8:00am

Evening: 6:00pm – 8:00pm

ACTIVITIES CARRIED OUT BY MILK PROCUREMENT SECTION
 Milk Procurement
- To encourage the milk producers to join dairy co-operative
society.
- To guide working aspect of dairy co-operative society.
- To supervise the activity of milk collection from starting to
dispatch.
 Feed and Fodder
 Animal Health care and input breeding
 Training and Extension
- To enhance milk procurement.
- To impart training to D.C.S. secretaries
- Village level extension
- To bring socio-economic upliftment of milk producers

FACILITIES PROVIDED TO MILK PRODUCERS:

 Subsidy on milking machine
 Subsidy on milkoscreen.
 Subsidy on B.M.C.
 Subsidy on seeds
 Subsidy on chaff cutter
 Free veterinary services
 Artificial insemination provided at lower rates for improvement in
breeds
 Subsidized milk products.
 Machinery provided for silage making at low price
 RAW MILK RECEPTION IN PLANT

Tanker (Gate entry-seal check)

Weigh Bridge Gross wt.

Tare wt.
Net wt.

Sampling (4 samples from each tanker/portion

of tanker )

Sample approved Sample not approved

Unloading

Manual Automatic
Pumped to Deaeration Vessel
Storage Tank

Duplex Filters

Raw Milk Chiller (Milk Chilled to 3°C)

Pumped to RMST (Raw Milk Storage Tanks)

 SAMPLING
SAMPLING OF RAW MILK:
a) Sampling of raw milk at R.M.R.D. of B.M.C.: Sample of different
societies is taken into sample bottles. If any can having less CLR
the separate sample is taken in cans
b) Sampling of raw milk from tankers: Sampling is done after
thorough plungering by opening the upper lids of the tankers in a
pan & sample is collected in 200 ml sampling bottle. Four Samples
are taken for Single Portion tankers and 8 Samples (4 for Front
Portion + 4 for Rear Portion) for Double portion tankers.
c) Out of four samples collected from each portion, one sample is
control sample, two samples are for raw milk testing, and the
remaining one goes security for random checking.
d) In case of double portion tankers green and blue sample bottles
are used for front and rear portion respectively and in case of
single portion tankers white sample bottles are used.
e) Sampling of processed milk dispatched to other milk unions:
Sampling is done after thorough plungering by opening lids of
tankers in pan & sample is collected in 200 ml sampling bottle.

SAMPLING FROM STORAGE TANK

a) Check whether the agitators of storage tank are running or not
b) Place a crate or bucket under the outlet of storage tank
c) Open the screw adjusts to main outlet of storage tanks
d) Check temperature of milk by thermometer
e) Rinse the bottle under the flow of milk and then collect the
sample.
SPECIFICATION TO GUIDE THE RMRD

Alcohol test : Negative

Acidity : 0.11 to 0.14%
Adulteration : Negative
R.M. Value : 28-32
COB : Negative
Sodium content : less than 450 ppm
B.R. reading : 40-43
P.V. Value : 1-2

TESTS PERFORMED IN LABORATORY ON RAW MILK

RECEPTION:

1) FAT test
2) SNF test
3) Adulteration test (negative)
4) BR reading of milk (40-43 at 40ºC)
5) Sodium test of milk (upto 450 ppm)
6) RM value of milk (28-32)
7) Quantity: To be checked
8) Acidity
9) MBRT: for good quality raw milk is 2 hrs.
 QUALITY ASSURANCE SECTION
Quality Assurance

Dock Lab at Ground Floor Quality lab

Chemical Microbiological AGMARK

TESTS FOR RAW MILK

1. Organoleptic test
2. In Dock Lab
 Fat% by Gerber or Milkoscan
 SNF% by lactometer or Milkoscan
 Acidity%
 Adulteration by Milkoscan or Adulteration strips
 Alcohol test
 COB (Clot on Boiling)
 Sediments
 MBRT
 Heat stability
 Sodium ion content
 Butyro refractometer (BR) reading
 Reichert- Meissel (RM) value
 Polenske Value
PRODUCT ANALYSIS

TESTS FOR MILK AND POUCHES OF PACKED PASTEURISED MILK

1. Weight
2. Leakage
3. Drop test
4. Length
5. Bursting strength
6. For milk:
 Temperature
 Acidity
 Fat %
 SNF%
 Total Solids by gravimetric method
 Alkaline Phosphatase
 MBRT

TESTS FOR GHEE

1. Colour
2. Flavour
3. FFA (Free Fatty Acid) as % Oleic Acid
4. RM Value
5. Polenske Value
6. BR reading
7. % Moisture
8. Adulterant – Baudouin test
 TESTS FOR BUTTER

1. Fat %
2. Moisture%
3. Curd%
4. Acidity%

TESTS FOR PANEER

1. Organoleptic
2. Fat%
3. Moisture% By FoodScan or Manual
Testing
4. Total Solids%
5. Acidity%

TESTS FOR DAHI

1. Acidity
2. Fat%
3. Total Solids
4. Protein%
By Milkoscan or Manual Testing
TESTS FOR LASSI
1. Acidity
2. Fat%
3. Total Solids
TESTS FOR KHEER
1. Organoleptic
2. Fat%
3. Total solids

TESTS FOR ACID AND LYE

1. Strength checking

TESTS FOR MILK POWDER

1. Taste and Flavor
2. Color
3. Moisture%
4. Fat%
5. Bulk Density
6. Solubility Index
7. Sediment
8. Acidity
9. Neutralizer
10. Adulteration
11. Protein%

TESTS FOR TREATED AND UNTREATED WATER SAMPLES

1. Hardness
2. B.O.D
3. C.O.D
4. pH
 TESTS PERFORMED IN LAB

ACIDITY TEST
Bacteria that normally develop in raw milk produce more or less of
lactic acid. In the acidity test the acid is neutralised with Sodium
hydroxide and the amount of alkaline is measured. From this, the
percentage of lactic acid can be calculated.
Procedure
• Take 10 ml of sample(can be milk, lassi, cream, dahi etc.) in 10 ml
conical flask.

• Hold the flask against white surface.

• Add 1 mL of phenolphthalein to the sample and stir gently

• Titrate against N/9 NaOH solution

• Continue until the appearance of a light pink colouring which

persists for 10-20 seconds and down the volume of NaOH used.

So, %Acidity = volume of NaOH used (in ml)/10

Procedure for acidity of butter sample:

• Take 20 g of butter sample in volumetric flask

• Add 90 ml of boiling distilled water to butter sample in volumetric

flask.

• Hold the flask against white surface.

• Add 1 mL of phenolphthalein to the sample and stir gently

 • Titrate against N/50 NaOH solution

• Continue until the appearance of a light pink colouring which

persists for 10-20 seconds and note down the volume of NaOH
used.

So, %Acidity = 9×Normality of NaOH used× Titration

Value/weight of sample

Procedure for acidity of Paneer Sample:

• Take 10 g of paneer sample (after crushing) in volumetric flask

• Add 10 ml of boiling distilled water to paneer sample in

volumetric flask.

• Hold the flask against white surface.

• Add 1 mL of phenolphthalein to the sample and stir gently

• Titrate against N/10 NaOH solution

• Continue until the appearance of a light pink colouring which

persists for 10-20 seconds and note down the volume of NaOH
used.

So,
%Acidity = 9×Normality of NaOH used× Titration Value/wt. of
sample
Procedure for acidity of Powder Sample:
• Take 1g of powder sample in volumetric flask

• Add 10 ml of distilled water to powder sample in volumetric flask.

• Hold the flask against white surface.

• Add 1 mL of phenolphthalein to the sample and stir gently

• Titrate against N/10 NaOH solution

• Continue until the appearance of a light pink colouring which

persists for 10-20 seconds and note down the volume of NaOH
used.

So,
%Acidity = 9×Normality of NaOH used× Titration Value/wt. of
sample
MBR TEST
It is indirect method of estimation of total bacterial content of milk.
Instead of counting bacteria directly, a correlation is made between the
time required to reduce dye to colorless in milk.
Procedure
 To 10 ml of milk in a sterilized test tube add 1 ml of methylene
blue dye. Plug with a sterilized cork, invert the tube to mix the
contents.

 Incubate at 37°C in a water bath.

 Note down the time in which the colour of dye gets disappear and
that will give the MBRT time.

RESULT INTERPRETATION CHART FOR MBRT

 ESTIMATION OF FAT CONTENT
Fat can be determined using Gerber’s method or using a milkoscan
Gerber Method
Principle: When a definite quantity of sulphuric acid and amyl alcohol
are added to a definite volume of milk, the proteins will be dissolved
and the fat will be set free which remains in liquid state due to heat
produced by the acid. The amyl alcohol used facilitates the separation
of a clear fat column. On centrifugation, fat being lighter will be
separated on top of the solution.

Procedure for estimation of fat% of milk and lassi:

Take about 10 ml of H2SO4 in Butyrometer.
Add slowly 10.75 ml sample (can be lassi or milk) in it.
Add 1 ml isoamyl alcohol and adjust level with distilled water.
Cap butyrometer with lock stopper.
Centrifuge for about 3 minutes.
Take reading of the % fat by reading the butyrometer.
Procedure for estimation of fat% of Paneer and Cream:
 Take about 10 ml of H2SO4 (10% diluted) in Butyrometer.
 Add a known amount of sample (note down the weight) in the
butyrometer
 Add 1 ml isoamyl alcohol and adjust level with distilled water.
 Cap butyrometer with lock stopper.
 Centrifuge for about 5 minutes.
 Take reading of the % fat by reading the butyrometer.

%Fat = 11.26×Fat % obtained in Butyrometer/weight of sample taken

Procedure for estimation of fat% of Dahi:
 Take about 10 ml of H2SO4 (in Butyrometer).
 Add slowly 10.75 ml sample of dahi in it.
 Add 1 ml isoamyl alcohol and adjust level with distilled water.
 Cap butyrometer with lock stopper.
 Centrifuge for about 5 minutes.
 Take reading of the % fat by reading the butyrometer.

ESTIMATION OF S.N.F. CONTENT BY LACTOMETER

Principle: The method is based on the Archimedes Principle, which

states that when a solid is immersed in a liquid it is subjected to upward
thrust equal to the weight of liquid displaced by it and acting vertically
upwards. Lactometers are variable immersion type hydrometers and
calibrated beforehand with liquid of known specific gravity.

Procedure:
• Warm milk in lactometer jar at about 40˚C then cool at 15.5˚C.

• Immerse lactometer in jar and take C.L.R.

% SNF = CLR/4+0.2×fat+0.29

Fat% & S.N.F.% can also be estimated by using milkoscan before

which the sample is heated to a temperature of 40ºC
ALCOHOL TEST
The alcohol test is used for rapid assessment of stability of milk to
processing. This test gives an indication of the mineral balance of milk.
The test aids in detecting abnormal milk such as colostrum, milk from
the animal in the late lactation, milk from animal suffering from mastitis
and milk in which mineral balance has been disturbed.
Procedure:
 Take 5.0 ml of milk in a test tube using graduated pipette.
 Add equal amount of 70% ethyl alcohol
 Close the mouth of the test tube with thumb and mix the
contents well by inverting the test tube several times. Formation
of any flakes on the wall of the test tube indicates poor quality
milk.

TESTS FOR DETECTION OF ADULTERANTS

1. Neutralizer
In milk, sodium hydroxide, sodium carbonate and sodium
bicarbonate are added by adulterators to neutralize the
developed acidity in milk.
Take 5 ml milk sample. Add 5 ml alcohol in it. Add few drops (2-3
drops) of alcoholic Rosalic acid solution.
Result: If red rose colour appears, it indicates added neutralizer
while brownish colour indicates pure milk.
2. Sugar
Take 10 ml of milk in test tube. Add 1 ml conc. HCl and shake. Add
0.1 gm resorcinol and shake well. Place it in boiling water bath for
5 min.
Result: Pink to red colour shows sugar +ve.

3. Glucose
Take 1 mL of milk sample in a test tube. Add 1 ml of modified
Barford’s reagent. Heat the mixture for exact 3 minutes in a
boiling water bath. Rapidly cool under tap water. Add 1 ml of
phosphomolybdic acid reagent to the turbid solution. Observe the
colour.
Result: Immediate formation of deep blue colour after adding
phosphomolybdic acid reagent indicates the presence of added
glucose in the milk sample. In case of pure milk, only faint bluish
colour can be observed due to dilution of Barford’s reagent.

4. Salt
Take 5ml of Silver Nitrate solution (0.1341%) in a test tube. Add
two drops of potassium chromate (1.0% solution) and 1ml milk
sample.
Result: Yellow color indicates positive salt test.

5. Urea
Take 2ml urea detecting agent (DMAB-Dimethyl Amino
Benzaldehyde reagent) and add 2ml milk.
Result: Deep yellow color indicates positive urea test.

6. Ammonium compounds
Take 5ml of milk in a test tube. Add 1ml of nessler’s reagent.
Result: Brownish yellow colour indicates ammonium compounds
+ve.
7. Detergent
Transfer 10 ml of milk sample into a stoppered measuring
cylinder. Add 25 ml of 0.005% MB solution followed by 15 ml
chloroform. Stopper the cylinder or funnel & mix gently by 5
inversions. Allow to settle for 5 minutes. Observe the colour of
chloroform layer (bottom layer).
Result:
Dark blue colour of bottom chloroform layer: Positive
Pure milk will show light blue colour chloroform layer: Negative

 In the image milk is having dark blue colour of bottom layer

which indicates detergent +ve.
8. Maltodextrin
Take 20 ml of milk sample into a clean and dry test tube. Add 1 ml
of enzyme solution and 1 ml of Lactic acid. Keep the sample in the
water bath at 65ºC for 5 minutes. Keep the sample in the normal
water bath at room temperature. Add strip for 10 seconds and
see the colour.
Result:
Change in colour from green colour to brown colour indicates
presence of maltodextrin.
 ESTIMATION OF SODIUM CONTENT OF MILK SAMPLE
Milk is being adulterated with sodium to increase S.N.F. So Sodium
content is checked by ISE sodium analyser. Sodium analyser is
calibrated at 100 ppm & 1000 ppm of sodium. Sodium content of milk
should be between 350-450ppm.
Procedure for estimation of sodium content of milk:
Take 45 ml of milk and add 5 ml of ISA & then dip the probe of sodium
analyzer in beaker. ON the stirrer & wait till reading is stable , when
ready is displayed . Note down the reading.

PHOSPHATASE TEST
Alkaline Phosphatase is an enzyme which is naturally present in milk,
but is destroyed at a temperature just near to the pasteurization
temperature. Alkaline Phosphatase test is used to indicate whether
milk has been adequately pasteurised or whether it has been
contaminated with raw milk after pasteurisation..
Principle: Based on the principle that the alkaline phosphatase enzyme
in raw milk liberates phenol from a disodium para-nitro phenyl
phosphate and forms a yellow coloured complex at alkaline pH. The
intensity of yellow colour produced is proportional to the activity of the
enzyme.
Preparation of phosphatase solution: Add sodium carbonate 1.75 gm+
Sodium hydrogen carbonate 0.75 gm+4 Nitrophenyl Phosphate
disodium salt 0.75 gm + 500 ml water.Mix thoroughly.
PROCEDURE:
 Take 1 ml of milk sample.
 Put 5 ml of Phosphatase solution.
 Incubate it in water bath at temperature of about 37˚C.
 Check for colour change after 15 minutes.
 If colour changes then the milk is not pasteurized.

 In the image Test tube on left side with pale yellow colour is
showing raw milk which is having alkaline phosphatase activity
and test tube on right side is showing no colour change in case of
pasteurised milk having no alkaline phosphatase enzyme activity.

BOUDOUIN TEST
This test is used in order to detect the presence of vanaspathi in ghee
Procedure
 Take 5 ml of the oil or melted fat in a 25 ml measuring cylinder (or
test tube) provided with a glass stopper.

 Add 5 ml of conc. hydrochloric acid and 0.4 ml of furfural solution.

 Insert the glass stopper and shake vigorously for two minutes and
let it stand and allow the mixture to separate.

 The development of red or pink colour in the lower acid layer

indicates presence of sesame oil.

 Confirm by adding 5 ml of water and shaking again .If the colour in

acid layer persists, seasame oil is present, if the colour disappears
it is absent.(As furfural gives violet tint with HCl , it is necessary to
use the dilute solution specified.)

ESTIMATION OF BUTTER SAMPLES FOR MOISTURE%, CURD%

AND FAT%,%SALT
 Note the empty weight of dish as W1
 Now take 10 gm of butter samples and note down the weight of
dish with sample as W2
 Now heat the butter sample so as to evaporate moisture. When
brown residues starts forming then note down the weight of dish
as W3 after keeping it in desiccator.
 Now 3 washings has to be done with petroleum ether so as to
extract fat.
 Heat the sample so as to remove the petroleum ether residues.
 Note down the weight of dish as W4 after keeping it in desiccator.
 Now add 10 ml of distilled water in dish and add potassium
chromate indicator and titrate it against N/10 AgNO3 solution.

%Moisture=W2- W3×100/ W2- W1

%Curd=W4- W1×100/ W2- W1
%Fat=100-(%curd+%moisture)
 ESTIMATION OF BR VALUE OF MILK SAMPLE
Vegetable oils, hydrogenated fats, animal body fats and their blends
have been reported as adulterants in milk and milk fat products. The
elevation of butyro-refractometer (BR) reading of milk fat by addition of
different vegetable oils is used to detect adulteration of milk. . It should
be between 40-43 for milk fat with no adulteration.The average BR
reading of groundnut, cottonseed, corn, sesame,sunflower, mustard,
soya and castor oils are 59.81, 62.43, 64.50, 64.88, 65.25,65.64, 66.00
and 73.00, respectively.
Procedure:
Take AI tubes and fill it with sample. Then keep these in centrifuge so
that cream layer is formed on top. Then take the cream with the help of
spatula and heat cream so as to make ghee. Then put drop of ghee in
butyro -refractometer .Note down the value of BR reading.

RM (REICHERT-MEISSAL) VALUE
It is the number of millilitres of 0.1 N sodium hydroxide or alkali
solution required to neutralize the steam volatile, water soluble fatty
acids distilled from 5g fat under precise conditions specified in the
method.
This value is quite significant for milk fat, since it primarily measures the
butyric acid and caproic acid content in given fat. When compared to
other fats this value for milk fat is high. So this helps in identification of
milk fat from other fats.
Value should be 28 to 32.
  Centrifuge the sample for 15 min.
 Separate the cream and heat it to make ghee.
 Take 5g of ghee in flask.
 Add 20 g glycerol, 2ml of 50% NaOH and 6 to 8 glass beads.
 Heat clarify the sample.
 Add 93 ml boiling distilled water followed by 50 ml 1 N H2SO4.
 Fix it with still head to distillation apparatus.
 Mildly heat the flask so as to form the golden ring on top.
 After that heat it properly so that distillation starts and 110 ml
distillate is collected in round bottom flask.
 Distillate is chilled for 10 minutes in cold water.
 Filter by using whatmann filter paper in another flask,pipette out
100 ml in another dried flask.
 Add 0.5 ml phenolphthalein indicator
 Titrate it against N/10 NaOH.
 RM Value = (ml of 0.1 N NaOH used for sample – ml of 0.1 N
NaOH used for blank ) x 1.1

POLENSKE VALUE
It is number of millilitres of 0.1 N sodium hydroxide or alkali solution
required to neutralize the steam volatile water insoluble fatty acids
distilled from 5 g of fat under the precise conditions specified in the
method. The caprylic and capric although steam volatile, are insoluble
in water are indicated mainly by P.V.
Since most of the steam volatile fatty acids in milk are water soluble
this value helps in identifying the presence of coconut oil content which
contains higher proportion of these acids.
Value should be 1 to 2.
  After finishing RM Value experiment, detach still head.
 Wash the condenser with three successive 15 ml portions of cold
distilled water , passing each washing separately through the
cylinder, the 100 ml flask, the filter and the funnel
 Discard the washings
 Dissolve the insoluble acids by three similar washings of the
condenser, the cylinder and the filter, with 15 ml of neutralized
alcohol each time, collecting the solution in the 110 ml flask and
draining the ethanol after each washing in a flask.
 Cork the flask and retain the solution for titration.
 Titrate the alcoholic solution of the insoluble volatile acids after
addition of 0.25 ml of phenolphthalein indicator with 0.1 N
aqueous NaOH until it becomes pink.
 Calculations: Polenske Value = S-B
Where S = Volume in ml of 0.1 N NaOH used for sample of PV
B = Volume in ml of 0.1 N NaOH used for blank of PV

ESTIMATION OF PROTEIN CONTENT OF VARIOUS MILK AND MILK

PRODUCTS BY KJELDHAL METHOD
Principle: The test portion is digested using a block digestion with
mixture of conc. H2SO4, CuSO4, K2SO4 as catalyst to convert organic
nitrogen to ammonium sulphate. During digestion copper sulphate is
added to fasten the digestion process. Potassium sulphate is added to
raise the boiling point of the digestion mixture. Addition of excess
sodium hydroxide to the cooled digest liberates ammonia. The
liberated ammonia is distilled, using automatic steam distillation and
collected into an excess of boric acid solution followed by titration with
dil. Hydrochloric acid solution. The quantity of acid required for
titration is equivalent to the concentration of ammonia in the distillate.
The nitrogen content of the sample is calculated which on
multiplication with suitable factor gives % of protein.
Procedure:
Test portion and pre-treatment:-
To a clean and dry digestion tube, add approx. 2 g of milk or lassi
sample (in case of paneer, dahi, kheer about 1-2 g of sample is taken
and for powder about 0.5 g of sample is taken), 0.8 g of CuSO 4, 7 g of
K2SO4, 12 ml of sulphuric acid and 5 ml of hydrogen peroxide is added.
Use the sulphuric acid to wash down any digestion mixture or test
portion left on the upper walls of the digestion tube. Gently mix the
contents of the tube.
Digestion:
1. Set the digestion block at a low initial temperature so as to
control foaming (approximately at 200 degree Celsius). Transfer
the tubes to the digestion block and place the exhaust manifold
which is further connected to a water jet pump in the top of the
tube. The suction rate of the jet pump should be just sufficient to
remove fumes.
2. Digest the sample until white fumes develop. Then increase the
temp. of digestion block to between 410 degree Celsius to 430
degree Celsius and continue digestion of the sample until the
digest is clear. The total digestion time will be b/w 1.5h to 2.5 h
3. At the end of the digestion, the digest shall be clear and free from
undigested material (indicated by light blue green colour).
Remove the tube from the block with the exhaust manifold in the
place and allowed to cool for atleast for 15 min.
Reaction:
Proteins+ H2SO4+ CuSO4 + K2SO4 (NH4)2SO4
Distillation:
1. Connect the distillation until the 50% NaOH solution, 4% boric
acid solution, indicator(methyl red+ bromocresol green) and
distilled water at proper place.
2. Transfer the digestion tube to the distillation unit and place a
conical flask under the outlet of condenser in such a way that
the delivery tube is in contact with the surface of the flask so
that the delivery tube is below the surface of the excess boric
acid solution after its addition.
3. Adjust the distillation unit to dispense 25ml of boric acid and
50 ml of sodium hydroxide solution and distill off the ammonia
liberated by the addition of sodium hydroxide solution.
Quantity of alkali added is about 4 times the amount of
sulphuric acid used.

Reaction:
(NH4)2SO4 + 2NaOH 2 NH4OH + Na2SO4
NH4OH steam NH3 + H2O
Titration: Titrate the contents of the conical flask with the 0.1 N
hydrochloric acid standard solution using a burette and note down the
amount of titrant used. The end point is reached at the first appearance
of the violet colour in the contents
Reaction:
NH3 + H2O +H3BO3 NH4+ + H2BO3-
NH4+ + H2BO3- + HCl NH4Cl + H3BO3
Blank test: Carry out a blank test following the procedure described
above without taking any test portion.
Calculation:
% Nitrogen content = (T.V.-B.V.)×14.007×0.1×100/weight of sample
% Protein content = % Nitrogen content×6.38
Where,
T.V. =Volume of HCl used for titration of test sample
B.V.= Volume of HCl used for titration of blank sample

MICROBIOLOGICAL TESTING OF MILK AND MILK PRODUCTS

Medium Used for Prepare Incubation Incubati Dilute
Microorgani d by temperatu on time d
sm re used
for
platin
g
Violet Red Bile Coliforms Mixing 35-37ºC After 18- 10-1
Agar(VRBA) 41.53g 24 hours
of agar
in 1000
ml of
distilled
water
Plate Count Standard Mixing 35-37ºC After 48 10-3
Agar (PCA) plate count 23.5 g hours
Agar(SPC) of agar
 in 1000
ml of
distilled
water
Potato Yeast and Mixing 20-25ºC After 5 10-1
Dextrose moulds 39 g of days
Agar(PDA) agar in
1000 ml
of
distilled
water
Chlorampheni Yeast and Mixing 20-25ºC After 5 10-1
col Yeast Moulds 40 g of days
Glucose Agar agar in
1000
mL of
distilled
water
Lee’s Agar Streptococcu Mixing 35-37 ºC After 48
s 51.52g hrs
Thermophilu of agar
s and in 1000
Lactobacillus mL
Bulgaricus
 Normal saline prepared by mixing 8g in 1000 ml

LIST OF MICROBIOLOGICAL TESTS FOR MILK AND MILK PRODUCTS

1. MILK POWDER
 a. SMP: Coliforms, SPC, Yeasts and mould count, E.coli
b. WMP: Coliforms, SPC
 For powder to make dilutions distilled water is used instead of
normal saline
 Dilution prepared by mixing 11 g of powder in 99 ml distilled
water or by mixing 1 g in 9 ml of distilled water
2. BUTTER & GHEE
a. White butter: Coliforms, SPC, Yeasts and mould count
b. Ghee : Coliforms ,Yeasts and mould count
 There is no need to prepare any dilution for butter and ghee
3. MILK: Coliforms, SPC
4. DAHI: Coliforms, Yeasts and mould count
 Dilutions are made for both milk and Dahi.
5. LASSI: Coliforms, Yeasts and mould count
 There is no need to prepare any dilution for Lassi
6. PANEER: Coliforms, SPC, Yeasts and mould count
 Dilution is made for paneer
7. KHEER: Coliforms, SPC, Yeasts and mould count
 For kheer dilution is made by taking 4-5 spatula of kheer instead
of 1 ml
 Preparation of Adulteration testing strips for glucose
, maltodextrin , urea , neutralizer , hydrogen
peroxide , sucrose.
w
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PROCESSING SECTION:-
1) Liquid Milk Plant (LMP)
2) Old Plant
3) Fermented Dairy

GENERAL FLOW DIAGRAM OF MILK PROCESSING

 LIQUID MILK PLANT (LMP)
EQUIPMENT MAKE CAPACITY NO OF
UNITS
RMST IDMC 60KL 2
HMT 60KL 2
PMST IDMC 60KL 2
BANSAL 60KL 2
TECHNOCRATES
Pasteurized IDMC 5KL 2
Water Tank
2KL 1
Cream IDMC 10KL 2
Storage Tank
1KL 1
Cream GEA 20KLPH 2
Separator
Homogenizer GEA 20KLPH 1
PHE IDMC 5KLPH 2
20KLPH 1
Pasteurizatio TetraPak 5KLPH 1
n Unit
IDMC 20KLPH 2
CIP SECTION
Acid Tank IDMC 10KL 1
Lye Tank IDMC 10KL 1
Hot Water IDMC 10KL 1
Recupration IDMC 10KL 1
Tank
Soft Water IDMC 10KL 1

PASTEURIZED MILK
Verka Milk is pouch packed and available in many variants for the
convenience of its consumers thus providing them fresh and healthy
milk every day. It is pasteurized in state-of-the-art processing plants
and meets the FSSAI standards. Pouch Milk is available in an array of
variants; Full Cream, Standard Milk, Toned, Double Toned, Skimmed,
Cow Milk.

EQUIPMENTS AND UTILITIES REQUIRED FOR MANUFACTURING

 PASTEURIZED MILK

1. Storage Tank or Silo

2. Milk Pasteurizer

3. In-line Duplex filter

4. Cream Separator

5. Cream Pasteurizer

6. Homogenizer

7. Pumps, Valves and pipe lines

8. C.I.P. system

9. Chilled water (0-1OC)

10. Electricity

11. Soft water (hardness <10 ppm)

12. Steam (2.5-3 kg/cm2)

13. Compressed air (6 Kg/cm2)

FLOW CHART FOR PASTEURIZED & STANDARDIZED MILK

 RMST

Balance Tank

Duplex filter Regeneration I

Cream separator Regeneration II Homogenizer

Cream Regeneration III

Cream Pasteurizer Heating (76 ℃ ± 2℃)

Cream Storage Tank Holding

(76 ℃ ± 2℃ /15 sec)

FDV

Temp~74℃ Temp<74℃

Regeneration I

Regeneration II

Regeneration III

Chilling

PMST

HMST

Packaging Machine
 Cold Store

Dispatch

Sr Milk Variant Colour Fat% SNF% Quantity

No Variant
1 Double Toned Yellow 1.5 9.0 200mL
Milk 500ml
(SLIMMER’s) 6L
2 Toned Milk Blue 3.0 8.5 500mL
(TAAZA) 1L
6L
3 Standardized Green 4.5 8.5 500mL
Milk (SHAKTI) 1L
1.5L
6L
4 Full Cream Milk Red 6.0 9.0 500mL
(GOLD) 1L
1.5L
6L
5 Cow Milk Pink 4.0 8.4 500mL
3.5 8.4 1.5L

Composition of Various Variants Of Pasteurized And

Standardized Milk Manufactured By Verka:

Nutritional Standardized Full Toned Double Cow

Information Milk Cream Milk Toned Milk
per 100 ml Milk Milk

Energy value 72.0 87.0 58.0 46.0 67.0

(kcal)

Total Fat (g) 4.5 6.0 3.0 1.5 4.0

Saturated fat 2.9 3.8 1.9 0.96 2.5

(g)

Trans fat (g) 0.0 0.0 0.0 0.0 0.0

Cholesterol 10.8 14.4 7.2 3.6 9.6

(mg)

Total 4.8 5.1 4.8 5.1 4.6

Carbohydrate
s (g)

Proteins (g) 3.0 3.15 3.0 3.15 3.1

Minerals (g) 0.7 0.75 0.7 0.75 0.8

Added - - 77 77 -
Vitamin A (IU)

Added - - 55 55 -
Vitamin D (IU)
POUCH FILLING SECTION

Sr MAKE NO OF HEADS NO OF UNITS

No
1 SAMARPAN 2 6
2 RMC PACKAGING 2 1
3 VIJAIPAC 2 1
4 STARPAC 2 1
5 SETPAC 2 1
6 NEOTECH 2 1
7 SAMARPAN 1 1
8 FILLPAC SERVO 1 1
9 RMC 1 2

 Total Heads of Film Forming Machines=27

 InkJet Printer are used for printing date, time , batch no , shift on
pouches.

 Polyfilms providing companies= IDMC, Metro, Vardhman,

Rainbow, Osho

 Weight range for pouches:

500mL= 514-518 g
1L = 1027-1032 g
6L = 6.160-6.180 g

 Speed of packaging machines:

 500mL= 70-75/min
1L= 40-50/min
1.5L = 21-23/min
6L = 7-8/min

 POUCH FILM YIELD:-

Yield= No of pouches/Net wt of roll
 200mL - 620-630 pouches/Kg film
 500mL - 400-405 pouches/Kg film
 1L - 242-246 pouches/Kg film
 1.5L - 120-125 pouches/Kg film
 6L - 40-42 pouches/Kg film

 Crate Washer:
Number= 3 adjoining 3 milk filling lines
Manufactured By- SWASTIK Enterprises Ltd.
Year of Manufacture - 2013 – 2014
Detergent Strength –1.2 %
Capacity – 1200 crates per hour

SHELF LIFE OF PASTEURIZED MILK : 2 days from the date of

manufacturing when stored refrigerated below 5°C.

OLD PLANT:-
1) Processing Section (GOMA) 5) Kheer Section
2) Reconstitution Section 6) Butter Section
3) Paneer Section 7) Sweets Section
4) Ghee Section

PROCESSING SECTION
 PANEER SECTION

Chhana or Paneer means the product obtained from the cow or buffalo
milk or a combination thereof by precipitation with sour milk, lactic acid
or citric acid. It shall not contain more than 70.0 per cent moisture and
the milk fat content shall not be less than 50.0 per cent of the dry
matter. Milk solids may also be used in preparation of this product.
Traditionally Paneer is a form of pressed chhana, used for preparing
cooked vegetable dishes.

Ingredients:

 Pasteurized Standardized milk

 a. Fat 5.00±0.05%, S.N.F. 8.60±0.05%
b. MBRT: 6.00 hours min.
c. Phosphatase test: Negative
d. Acidity (L.A.) 0.13 ± 0.01%
 Citric acid and GDL

EQUIPMENTS & UTILITIES OF PANEER SECTION

1. Milk storage tank (Capacity of 10,000 L each)

2. PHE for milk with holding at 90ºC for 5 minutes and milk outlet
temperature at 74±2 ºC

3. Paneer hoops
4. Paneer press
Number: 8
Pressure: 2.6-3.6 kg/cm2

5. Paneer cooling vat-2

6. Paneer cutting machine

7. Paneer shredding machine

Number: 1
Manufactured By: Kalsi

8. Paneer packing machine:

Manufactured By: Multivac
Speed: 36 packets/min
Sealing Temperature: 150°C
Vacuum pressure: 967 millibar

10. Cold store: less than 4°C

11. Steam Pressure: 2-3 kg/cm2

12. Chilled water: less than 4°C

FLOW DIAGRAM FOR PANEER MANUFACTURING
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Capacity of the Machine: 36 packets/min
Thickness of packaging material: Top - 68-70 μm
Bottom - 140-145 μm

Steps of packing of Paneer pouch in Multivac machine:

A. Feeding the lower web

B. Forming film
C. Feeding in the product
D. Feeding the upper web
E. Evacuation
F. Gas flushing with inert gas
G. Sealing
H. Cutting
I. Discharging packs

COMPOSITION

Fat 22.5%
Protein 18.5%
Carbohydrates 3%
Minerals 0.9%
Energy Value 289 kcal

Shelf Life of Paneer:

10 days from the date of manufacturing when stored in refrigeration

temperature below 5°C

GHEE SECTION
Ghee means the pure clarified fat derived solely from milk or curd or
from desi (cooking) butter or from cream to which no coloring matter
or preservative has been added.
The standards of quality of ghee produced in Punjab as per FSSAI:

1. Butyro Refractometer reading at 40°C: 40.0 to 43.0

2. Min. R.M. Value: 28
3. FFA as % oleic acid in fresh ghee: <0.3%
4. Moisture (max.): 0.3%

Produced in utmost hygienic conditions, Verka ghee is a rich source of

vitamins and antioxidants that stimulate bone metabolism and body
growth. The ghee is made from fresh cream and has a natural flavor
and mouthwatering aroma.

EQUIPMENTS AND UTILITIES REQUIRED

1. Butter churn/CBM (Continuous Butter Making Machine)

2. Butter melting vat
3. Pre-stratification Vat
4. Ghee Boiler/ Ghee cooking vat
5. Ghee settling Vat
6. Ghee clarifier
7. Ghee filling vat/tank (buffer vat/tank)
8. Ghee pouch/ Container filling/sealing machine
9. Ghee tin filling and seaming machine
10. Ghee granulation room
11. Store room which should be maintained below 30°C
12. Steam (2 to 3kg/sq cm)
13. C.I.P. System
FLOW DIAGRAM FOR GHEE PROCESSING
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SPECIFICATIONS FOR GHEE
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Physical properties
Parameters Standards
Color Yellowish White
Body & Texture Uniformly granular without any
greasiness
Flavor & Taste Clean , fresh and pleasant
Residue Nil

Chemical properties
Parameters Standards
Moisture(%max) 0.3
FFA (as % oleic acid)max 0.3
B.R. Reading (40°C) 40-43
R.M. Value (min) 28
Polenske Value 1-2
Baudouin Test Negative
Total Fat (min%) 99.7

Microbiological Specifications
Parameters Standards
SPC/g(max.) Nil
Coli form/g(max.) Nil
Yeast & Mold/g Nil

SHELF LIFE
12 months of tin packing and 9 months of ceka containers /
monocartons / pouches when stored in cool and dry place
NUTRITIONAL INFORMATION OF GHEE

Nutritional Information Per 100g

Energy Value(kcal) 897
Total Fat(g) 99.7
Saturated Fat(g) 64
Trans Fat(g) 0
Cholesterol (mg) 240
Total Carbohydrates(g) 0
Added Sugar(g) 0
Protein(g) 0
Minerals(g) 0
Vitamin A (mcg) 450
PRODUCT PACKING
1. Ceka container (900 g)- 1L
2. Tin (1 L) = 900 g ghee at 45°C (Weight of container is 98 g)
3. Tin 15 kg = 16.65 L at 45°C

GHEE FILLING AND PACKAGING MACHINE- CEKACONTAINER

• Manufactured By: Shubham flexible packaging

• Speed: 16 packets /min
• Weight of ceka container: 943 to 944 g
• Steps of filling and packaging:
1. Opening of carton
2. Opening of inner foil
3. Bottom sealing of inner foil
4. Folding of bottom sides of carton
5. Application of glue
6. Bottom folding of carton
7. Filling of ghee
8. Top sealing of inner foil
9. Folding of top sides of carton
10. Application of glue
11. Top folding of carton
12. Conveyor
 BUTTER SECTION
Pasteurized white butter

Surplus milk is converted into butter during scarcity the milk intended
for butter making is used for more essential products. White butter is
made & stored as stock & is used in lean season for recombination&
also use as base material for ghee & often supplied for bulk demand. In
Verka Mohali Dairy butter is made by the use of butter churn as well as
by using continuous butter making (CBM) machine

COMPOSITION OF WHITE BUTTER

PARAMETERS WHITE BUTTER

Fat(%) Min. 80
Moisture(%) Max. 16
Curd(%) Max. 1.5
Coli form Nil
Yeast & Molds(cfu/g) Max. 20
Fat in buttermilk(%) Max. 1
Salt -

WASH WATER FOR RECOMBINATION

Treatment Pasteurized chilled

chlorinated water with 10-
24ppm
Washing Temperature(1st and 6-8°C
2nd wash)
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FLOW DIAGRAM FOR BUTTER MANUFACTURING
Cream
BUTTER MANUFACTURING PROCEDURE

• Pasteurized cream of 42-43% fat at a temperature of about 10ºC is

fed to the balance tank of CBM.

• Then this cream is converted to butter with the machine by churning

the cream at a high speed.

• Butter milk is collected separately and is passed through chiller to

cool it at a temperature of less than 4oC.It can be used again in the
standardization of milk.

• Butter is packed in 15 kg cartons and sent to cold store.

CONTINUOUS BUTTER MAKING MACHINE

Make: HMT

Steps of operation:
 Cream is fed to the churning cylinder

 A rotating beater with variable speed control intensively beats

the cream to form butter grains. Mixture of butter grains and
buttermilk drops into returning cylinder where the grains are
formed into lumps in the separating drum.

 Buttermilk is separated from the solid butter ,collects in a vessel

and is pumped out by centrifugal pump

 Wash water enters the washing tube and further reduces the curd
content of the butter.
  Washed butter is kneaded by two screw conveyors rotating in
opposite directions and also by screen discs in the kneading
cylinder.

 Finished butter is extruded from the mouthpiece of the kneader.

UNLOADING OF BUTTER FROM BUTTER CHURN:

After moisture control, churn is rotated at 2nd gear for 5 min. Then
gravity forces are used for unloading butter in washed & sanitized
trolleys. A white clean sterilized muslin cloth is covered on the trolley &
shifted to cold storage for hardening & preventing moisture loss & kept
until its packaging.

PACKAGING OF BUTTER:

Butter is packed in polythene bags of 15kg and then into cartons before
washing with chlorinated water of concentration 10-24 ppm.
White butter is generally converted into Ghee. It is stored as stock of fat
to be used for recombination or for Ghee preparation during lean
season.

KHEER SECTION
Kheer is also known as Basundi, is an Indian Dessert prepared by the
partial dehydration of whole milk in a karahi over fire together with
sugar and usually rice or occasionally semolina. It is very popular in
Punjab and whole northern region.
Verka Kheer is a perfect combination of taste and health. Made with
finest ingredients, Verka kheer is immensely liked and is gaining new
heights of popularity. It provides calcium for strong bones & teeth and
provides protein for active life and growth. Available in affordable and
convenient cups, it is a perfect on the go dessert.

INGREDIENTS

1. Pasteurized Standardized Milk which shall meet following

specifications:

a) Fat 3.0% +/- 0.05%

b) SNF 10.0% +/- 0.05%
c) MBRT: min. 6.00 hrs
d) Phosphatase test: Negative
e) Acidity% (L.A.) max. 0.145

2. Rice – Basmati half piece of reputed brand (6 months to 12 months).

It should be free from extraneous matter.
3. Sugar – as per IS 1151:2003
4. Green cardamom – as per IS 1877:1985
5. Sodium Benzoate – (IP grade/ IS 4447:1994)

FOR PREPARATION OF ONE LOT OF KHEER:

Quantity of milk 160 kg

Steam Pressure 1.5 kg/cm2
Rice 10 kg
Sugar 12.8 kg
Elaichi 100 g
Sodium benzoate 15 g

EQUIPMENTS AND UTILITIES REQUIRED

1. Milk storage tank

2. Kettle with surface scrapper
3. Double jacket hopper with facility of cooling and stirring
4. Kheer filling and sealing machine
5. Cold store

Kheer filling and Sealing Machine

• Make: TOOL Masters

• Model – Pro pak
• Speed: 26 cups/min.
• Parts of machine
1. Cup Destacker
2. Filling station
3. Lid applier
4. Sealing station
5. Cup ejector
  Packaging Material- Cup- Polystyrene with Aluminium laminate
Bucket and lid - Polypropylene

SHELF LIFE
Shelf Life of Kheer is 10 days when stored refrigerated below 5ºC.

COMPOSITION OF KHEER

Nutritional Information Per 100g

Energy Value(kcal) 114
Total Fat(g) 3.4
Saturated Fat(g) 2.17
Trans Fat(g) 0
Cholesterol(mg) 8.16
Total carbohydrate(g) 17
Added Sugar(g) 9
Protein(g) 4
Minerals(g) 0.96
Calcium(mg) 160

Physical properties of kheer:

Color- Light Brown
Body and Texture- Thick and Viscous with uniform rice distribution
Flavor and Taste- Clean, fresh and sweet with pleasant aroma

FLOW DIAGRAM FOR KHEER MANUFACTURING

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FERMENTED SECTION
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DAHI SECTION
According to FSSAI, Dahi or curd means the product obtained from
pasteurized or boiled milk by souring, natural or otherwise, by a
harmless lactic acid culture or other harmless bacterial culture may also
be used in conjunction with lactic acid bacteria cultures for souring.
Dahi may contain added cane sugar. Dahi shall have the same minimum
percentage of milk fat and milk solids-not-fat as the milk from which it
is prepared.
Verka Dahi is made from pasteurized milk and packed in advance Dahi
packing facilities. Made from pasteurized toned milk with 10.5% SNF,
Verka Dahi meets the requisite FSSAI standards. It is ideal for daily
consumption as it provides calcium for strong bones and teeth. It
provides protein for active life and growth and helps in improving
digestion.

INGREDIENTS

1. Milk: Fat 3% min; SNF 10.5% min

2. Culture : Freeze dried cultures
Companies providing cultures are CSL (Italy), CHR Hansen (Denmark),
and Danisco (France)
SPECIFICATIONS OF MILK FOR DAHI:
 PARAMETERS STANDARDS
Color White
Flavor & Texture Clean and Fresh

CHEMICAL SPECIFICATIONS OF MILK FOR DAHI:

PARAMETERS DAHI SHAHI DAHI SLIMMERS

DAHI
Fat(% min) 3±0.05 4.5±0.05 1.5±0.05
SNF (%min) 10.5±0.5 10.5±0.5 10.5±0.5
Acidity %L.A 0.155 0.155 0.155
max
MBRT (hr )min. 6 6 6
Phosphatase Negative Negative Negative
Test
Creaming Index <10 <10 <10

DAHI PACKAGING MACHINES

1. Oystar Gasti Dogatherm

Made in: Germany
Use: Filling and packaging -200g and 400g
Dahi Maximum Speed: 150 cups/min
Minimum speed: 75 cups/min
Motor running: 1
Total pressure (working): 6.5 kg/cm sq
Automatically cleans the cup using air pressure

 Parts of Gasti Packaging Machine

i. Milk hopper (100 L)
 ii. Cup Destacker
iii. Cup controller and dust remover
iv. Filling station
v. Lid applier
vi. Sealing station (Heat Sealing at 280 to 290°C)
vii. Coding
viii. Cup ejector
 Details about pressure of machine for doing different jobs:
i. Sealer – 05 Bar / 70 psi
ii. Lid applier – 5.5 Bar / 80 psi
iii. Membrane nozzle – 0.9 Bar / 14 psi

2. ISF Dahi Cup Filling Machine 6000 LC

i. Made in: India
ii. Use: Filling and Packaging 100g, 200g and 400g Dahi
iii. Speed: 6000 cups/ hr (100g cups)
iv. Pressure of heaters; Around 315

 Parts of Machine
i. Cup De-stacker vi. Lid Applier
ii. Cup press vii. Heat Sealing
iii. Vacuum cleaner viii. Cup ejector
iv. UV Light
v. Filling
Details about pressure of machine for doing different jobs:
 Stokes per min. – 18
 Product count – 05
 Pressure of heaters – 315 ( average )
 Temperature of sealing - 290°C
FLOW DIAGRAM OF DAHI
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MILK PROCESSING FOR DAHI
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 Storage Tank (milk at 4-5°C)

Balance Tank

Filter

Regeneration

Homogenizer

Heating & Holding (90°C/5 min)

Milk Outlet (44-45°C)

Inoculation Vat

Mixing of culture (43°C)

Packaging Machines

Filling in cups

Specifications of dahi:
 PARAMETERS STANDARDS
Color White
Body & Texture Firm and smooth without
any whey separation
Flavor Fresh, Clean & mild acidic

Maximum acidity (% LA) during transfer from incubation room to cold

store is 0.62% and during dispatch it should be 0.85±0.05 % LA.

COMPOSITION OF DAHI

Nutritional Information Per 100ml

Energy Value(kcal) 67
Total Fat(g) 3
Saturated Fat(g) 1.9
Trans Fat(g) 0
Cholesterol(mg) 7.2
Total carbohydrate(g) 5.9
Added Sugar(g) 0
Protein(g) 3.7
Minerals(g) 0.9
Calcium(mg) 150

SHELF LIFE
7 days from the date of manufacturing when stored in refrigerated
condition below 5ºC

LASSI SECTION
Lassi is a cool refreshing milk based drink. It is a 'perfect thirst quencher
and best alternative for aerated drinks. In addition, Lassi contains
probiotic organisms that help boost digestion and immunity.

PLAIN LASSI:
Verka Plain Lassi is a refreshing drink that can be savored anytime.
Made from Fresh Verka Milk, Plain Lassi also makes for a great
accompaniment to your food.

SPICED LASSI:
Verka Spiced Lassi contains jeera, chilli & ginger which makes for a
great drink that is both tasty and energizing. The lassi that best suits the
palate of North Indians is a loved drink during summers.

SWEET LASSI:
Verka Sweet Lassi is renowned for its taste and is a best substitute for
cold drinks during summers. The lassi is processed using fresh curd and
makes for the best of refreshments.

Ingredients Required:
• Dahi made from StD. milk
• DVS Culture
• Pasteurized Soft water
• Sugar
• Spiced powder
• Edible common salt

Specifications of milk for Lassi:

PARAMETERS STANDARDS
Plain Low
Fat/Spiced/Sweet
Lassi
Fat % 4.5±0.05 3±0.05
S.N.F. % 8.5±0.05 7.8±0.05
Acidity (%L.A.) 0.13
MBRT (hr) min. 6
Phosphatase Negative
Test

EQUIPMENTS & UTILITIES REQUIRED:

1. Storage tank or silo
2. Multi-purpose vat/storage tank
3. PHE with holding time of 10 minutes at 90ºC
4. Milk chiller
5. Pouch packing machine
6. Lassi Thermizer (pasteurizer)
7. Shear pump
8. Cold storage to maintain less than 4ºC
9. Pumps, valves and pipe lines
10. Chilled water (0-1ºC)
11. Soft water (hardness <10 ppm)
12. Steam (2-3 kg/cm2)
13. Compressed air (6 Kg/cm2)
14. C.I.P. system

SPECIFICATIONS FOR LASSI:-

PARAMETERS STANDARDS
Color White
Body & Texture Smooth without any grittiness
Flavor & Texture Plain Lassi Low Fat Spiced Lassi Sweet Lassi
Fresh, Fresh, Fresh, clean, Fresh, clean,
clean mild clean, mild mild acidic mild acidic and
acidic and acidic with spicy sweet
heavy taste
mouth
feel

FLOW DIAGRAM OF LASSI MANUFACTURING

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For spiced lassi – spice powder and salt @ 0.5- 0.7 % and 0.45 %
respectively.
For sweet lassi – Sugar @ 10% of lassi

NUTRITIONAL INFORMATION OF LASSI OF VERKA

Nutritional Plain Lassi Sweet Lassi Spiced Lassi

Information
(per100mL)
Energy Value(kcal) 36 60 20
Total Fat(g) 2.4 11.6 1.6
Saturated Fat(g) 0 10 0
Trans Fat(g) 2.25 1.1 1.1
Cholesterol(mg) 1.45 0.7 0.7
Total 0 0 0
carbohydrate(g)
Added Sugar(g) 5.4 2.6 2.6
Protein(g) 1.5 1 1
Minerals(g) 0.35 0.24 0.24
Calcium(mg) 58 40 40

Chemical Parameters of Lassi:

Parameters Plain Low Fat Spiced Sweet

Fat% 2.25±0.05 1.1±0.05 1.1±0.05 1.1±0.05
MSNF % 4.25±0.05 2.84±0.05 2.84±0.05 2.84±0.05
Acidity %max at 0.45 0.35 0.35 0.35
dispatch
Total 2.4 1.6 1.6 11.6
Carbohydrate
Added Sugar% - - - 10
Added Salt% 0.45
Protein% 1.5 1 1 1
Microbiological Specifications of Lassi:

Yeast & Mold/g Nil

Coli form/g Nil
E.coli/g Absent
Salmonella/25g Absent
Staphylococcus aureus/g Absent
Listeria monocytogenes/g Absent

Shelf life of Lassi:

6 days from date of manufacturing when stored refrigerated below 5ºC
 ENGINEERING SECTION

Service section is very important section of a dairy plant. The various

sections under this are:
 REFRIGERATION
 BOILER
 SOFTWATER PLANT
 ELECTRICAL
 TRANSPORTATION
 WORKSHOP
 INSTRUMENTATION
 CARPENTARY AND PLUMBING SECTION
 ETP

REFRIGERATION UNIT
Refrigeration is also essential for providing a very important utility i.e.
chilled water which is important for many processes such as
pasteurization. It is also playing an important role in maintaining the
temperature of cold stores and ghee granulation room. In this plant
there is a well - equipped & large refrigeration section, which meets the
entire refrigeration load of the plant.
 1. Compressor Motor
2. Compressor
3. Discharge Line
4. Oil Separator
5. Check Valve
6. Condenser
7. Receiver
8. Safety Valve
9. Liquid Line
10. Expansion Valve
11. Chilled Water Tank
12. Agitator Fan
13. Evaporator
14. Chilled Water
15. Suction Line

Sr EQUIPMENT MAKE UNITS

No
1 Compressor (Screw FrickMicrotech 5
Compressor)
2 Receiver (High Pressure) Frick 2
3 Receiver (Low Pressure) - 2
4 Condenser Evapco 4
5 Water Storage Tank IDMC 2

BOILER SECTION
Steam boiler or simply a boiler is basically a closed vessel into which
water is heated until the water is converted into steam at required
pressure. There are three working boilers in this dairy plant. Majorly all
the heat treatments, heating, cleaning etc are done with the help of
steam in the dairy plant.

MOUNTINGS

 SAFETY VALVE: - A spring type safety valve is provided with the

boiler. If steam pressure too high than that of design pressure, the
valve reduces the pressure by moving upwards and therefore
prevents bursting of the boiler.
 BLOW DOWN VALVE: - The blow down valve helps to remove the
dissolved solids with water from the boiler.
 NON-RETURN VALVE AND MAIN STEAM VALVE: - There is also a
non-return valve and main steam valve.
 BYE-PASS LINE: - The condensed steam is removed through the
bye-pass line.
 TEMPERATURE VALVE: - To regulate the temperature of the boiler
there is a temperature valve. The oil used as a fuel in the boiler is
heated at 1000C. The temperature of the fuel gases leaving the
boiler through the chimney is maintain between 180 0C to 2000C
to preventing the sulphur present in the furnace oil to stick to the
metal surface of the chimney which is responsible for corrosion.
 WATER: - The water used for making steam is the soft water
(8ppm).
 WATER LEVEL INDICATOR: - For indicating the water level inside
the boiler the water level indicator is fitted with the boiler. When
the water level falls down the desired level, the feed water pump
is automatically started and more water is fed to the boiler.
 Fuel oil is sent to heavy oil tank from where the fuel oil is fed to
boiler by pump.
 Then the oil is filtered with the filter and passed through the oil
heater.
 For pre-heating the oil is first heated by an electric heater and
then by steam at 1000C. The return oil from the boiler goes back
to the oil receiving tank.
 Then firing is done automatically and the oil burner is modulating
the pressure jet type with gas electric ignition. There are two
electrodes which gives spark while pushing the switch and then
the oil gets fired thus ignition is done.
  The heat generated by ignition converted the water in to steam.

No of Boilers 3
Type of Boilers Fire Tube

Sr MAKE CAPACITY PRESSURE

No
1 ShellMax (PI4604) 4 ton 10Kg/cm2
2 ShellMax (PI4492) 3 ton 10Kg/cm2
3 Energy Process (5305) 6 ton 8Kg/cm2

Fuel Used Fuel Oil/LPG

Hardness of Treated Water 0-4 ppm
pH of Water 9.5-12
TDS 2500-3500 ppm
Chemicals Used Thermosol S
Thermosol F
SOFT WATER PLANT
Water softening, the process of removing the dissolved calcium and
magnesium salts that cause hardness in water. Unlike
hard water, softened water will not form insoluble scale or precipitates
in pipes and tanks or interfere with cleaners such as soap. The Water
Softeners are charged with a high capacity polystyrene bead cation
exchange resin in sodium form. When hard water passes through this
resin column, the hardness forming calcium and magnesium salts are
replaced with sodium salts which do not posses any hardness
properties. This softening process is continuous until the material is
exhausted of sodium salts when it is regenerated with a solution of
common salt.

The Water Softener unit is designed on the advanced Co

current/counter-current principle that ensures consistent good quality
treated water.
This water softening Plant consists of Water Softener Vessel with
Resin, Brine Tank, accessories and Storage Tanks.

FLOW DIAGRAM:-

SPECIFICATIONS:-

No of Tanks 3
Capacity 20KL, 30KL, 50KL
Disinfectant Used Sanosil (W10)
pH of Soft Water 7.5
 ELECTRICAL SECTION
Electric supply system is one of the most important systems for a dairy
plant. In the dairy plant electric energy is utilized for lightening and
power control of movable equipments and also for heating. Proper
utilization of electrical energy not only reduce the electric bill but also
improve the economic health of dairy plant. In this plant electricity is
received at high 11kv from P.S.E.B. through high tension lines. From
this, electricity goes to the four step down transformer where 11kv
supply is converted into 440volts.All the supply lines are connected to
Bus Chamber. Then electricity is supplied to the various sections
through the LT panel where a number of capacitors are provided for
raising the power factor to 0.85-0.90. For each section, there is a
separate control board and main switch for controlling the electricity
supply.
POWER FACTOR: - Power factor is very important because if it is low,
an excessive amount of current must be carried through the motors
and conductors cause overheating of moors and excessive voltage
drops in the lines.
SECTION OVERVIEW:-
EQUIPMENT UNITS MAKE CAPACITY
TRANSFORMERS 1 The Indian 750KVA
Transformer Limited
1 On Load Gears 630KVA
1 Prolec 1600KVA
1 Kirloskar 1000KVA

Generator 4 500KVA (3),

1600KVA(1)
 MAINTAINANCE OF ELECTRICAL EQUIPMENT:-
 Clean all the electrical equipment properly and should be
free from any dust.
 Check the DG set in all aspects. It should be ready to use in
case of any emergency during breakdown/shutdown in
power supply.
 Proper attention should be given towards the transformers
oil level and temperature under load should be checked
frequently.
 Check all the protection control system in H.T. panel.
 Clean all L.T. panels and ensure that the contacts are
proper.
 All fuses used in the system should be of proper rating.
 Check the contact of main switches and ACB’S and ensure
that they are functioning well.
 Check all the connections frequently and ensure that there
should be no loose connections.
 Check and clean all distribution board.
 All the electrical installations should be properly earthed.

ETP SECTION
Effluent treatment is the process of treating effluent released from the
plant. It includes physical, chemical, and biological processes to
remove physical, chemical and biological contaminants. Its objective is
to produce an environmentally safe treated effluent and a solid waste
or treated sludge suitable for disposal or reuse. According to
government regulations waste water should be treated to certain
standards before they are disposed off. After treatment this water can
be used for irrigation purpose.
The effluent treatment facility consists of the following units
• Effluent collection sump
• Sludge removal chamber
• Chemical solution dosing systems
• Aeration Tanks
• Secondary clarifier
• Sludge drying beds
PROCESS FLOW:-
Capacity of ETP:-7.5 lakh litre/day

MARKETING SECTION
Reputation of any organization and selling of products is sustained
primarily by its product quality, pricing policy and schedule of
advertisement. Profitability of any organization depends on overall
sales; pricing policy is another important factor which also affects the
overall sales well as profit. Main intention of this organization is to set
optimum profit and consumers’ satisfaction. When quality control
section pass the product quality as ‘satisfactory' then it is ready for
marketing. All types of fluid milk and milk products are marketed under
the brand name 'Verka'.

MARKETING OF FLUID MILK: - Milk Plant, Mohali, supplies different

types of fluid milk to local market of Mohali , Chandigarh, Some parts
of Haryana and Himachal Pradesh and Delhi through different routes in
day and night. Milk is also supplied to different milk bars.
MARKETING OF MILK PRODUCTS: - Collection of demands for
various milk products and supply to the same within Mohali district and
nearby places is done by milk plant itself. For other places outside
Mohali district and for other states demands are collected by Head
office, Chandigarh and supply order is sent to Milk plant, Mohali.

Milk products are advertised by 'The Punjab State Co-operative Milk

Producers Federation Ltd., Milkfed, Punjab.-Some of modes of
advertisement are through Newspaper, Stickers, Danglers, Scooter
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Stepheny Covers, Glow shines, Hoarding, Sun caps, Leaflets, Wall
painting, Booth-painting etc.

AREAS COVERED BY MOHALI PLANT:-

Punjab- Mohali ,Ropar, Zirakpur, Nangal, Kharar
Chandigarh
Haryana- Panchkula, Kalra, Pinjore
Himachal Pradesh- Mandi, Bilaspur, Solan, Shimla, Nalagarh
Delhi

No of Routes- 95

Milk booths- 40 (Mohali), 120 (Chandigarh)

Milk Bars- 7

AVERAGE DAILY DEMAND:-

Liquid milk

Paneer

Lassi

Dahi
Around 4.5 lakh Litre

Around 5500 Kg

Around 1-1.5 lakh Litres

Around 60000 Kg
 CONCLUSION
As dairying and its related activities are predominately carried out by
small and marginal land holders in villages, it constitutes a large portion
of their total income. Any further development of this sector by
providing them facilities of better marketing of their produce would
surely go a long way not only to improve their income but also to
redefine the state of rural economy. So dairy is very important sector
and in Punjab Milkfed is playing very important role for promotion of
dairy and bringing prosperity among milk producers of the state. I have
undergone training at verka plant, mohali from 15-02-2021 to 30-06-
2021 in all departments of the plant and I have learnt various aspects of
dairy technology. My training was interesting and full of knowledge.
No plant can be fully perfect and mohali plant is no different. There are
some shortcomings in this plant. Verka needs to improve their image in
people by advertising more and making the plant work in a more clean
and tidy manner as people usually think that verka products are not
made in hygienic conditions. More advertising should be done to make
people aware about Verka.