A STUDY ON PRODUCTION MANAGEMENT

SKILLS GAINED IN THE ORGANISATION

PRODUCTION DEPARTMENT (TOPIC CHOOSEN)

 The production department of the Kolar dairy performs the function of developing

 Procedures to transform a set of input elements like raw material like milk,
money, machine into
 Specified output like curds, butter, ghee, Peda, masala butter milk etc. in assigned
quality and Best in order to achieve the organizational goals successfully. Production
department is the most Important and the largest department in the organization.
 Komul has a well-organized and totally computerized system of production. The
scope of the Department is to plan, execute and control all production activities with
the available resources Inputs and equipment in co-ordination with the other
department.
 The Production manager heads the production department. The production
manager monitors the Activities of this department with the support of Deputy
Manager, Asst. manager and technical Officers.
 The production department works 24 hours every day. As much as 100 thousand Kegs
 Packets of milk made every day and all are sold every day. The milk from the dairy is
Transported through trucks to the dealers. Out of 4.56 lakh liters of milk procured
100008 liters Are sold as liquid milk („Nandini‟ Milk) and the rest is converted into
milk products like Butter, Curds, Ghee, Peda etc.,

MILK STORAGE SILO’S

Three raw milk silos of capacity 1 lakh litres each are provided. The raw milk storage
tank contains side mounted agitator to ensure uniform temperature and fat distribustion
without any adverse effect on the contents. The silos are insulated with puf (poly urethane
foam) to ensure that the temperature rise does not exceed 1ºC in 24hrs. apart form fresh
milk Received in raw milk tankers, various stream entering the rawmilk silosare:

 Rinse milk recovery

 Inter silo transfer

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 A STUDY ON PRODUCTION MANAGEMENT

MILK PROCESSING (PROCESS)

Milk contains all the nutrients required by the neonate and has thus been recognized as
perhaps nature’s ultimate food; furthermore, it is also ‘a rich source of protective agents,
enzymes and growth factors. Milk constituents are divided mainly into three groups namely Fat
soluble, water soluble, solid-not-fat (SNF). The constituents other than water are called total
solids (TS). Total solids minus butterfat are known as solid not fat. All the constituents except fat
are known as milk serum.The relative ease with which milk can be converted into a wide variety
of products makes it extremely useful base material. In some cases, milk undergoes relatively
limited processing, consisting of heat treatment to increase the bacterial shelf life of the product
and homogenisation to increase the physical shelf life through fat separation. Milk has a high
nutritional value but it is an excellent medium for microbial growth. Milk is heated for a variety
of reasons. The main reasons are: to remove, the pathogenic organisms-, to increase shelf-life up
to a period of six months; to help subsequent Processing.

Steps involved in milk processing

1) MilkReception

2)Testing:
 Fat percentage: Gerber method/ Electronic milk tester method/ Fatomatic method

 SNF: Lactometer reading at 27 °C is noted

3) Chilling:

It is the process of cooling the milk below 4ºC to supress the bacterial activity, so that the
shelf life is extended upto12-18 hrs and facilitates further processing of the milk. Milk is
chilled by passing through the plate chiller(plate and frame heaiex changers-milk and cold
water is passed in counter current manner resulting in the cooling of milk and stored in silos.

4) Storage of raw milk:

The milk is pumped through a filter storage tank and stored till standardization.

5)Standardization of milk:
It is the process of adjusting the, fat content in varieties of milk to meet the statuary
requirement. The process facilitates raising or lowering of fat content of the milk. It is carried
out by skimmed milk/cream/skim/milk powder depending on the initial fat/SNF content of

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 A STUDY ON PRODUCTION MANAGEMENT

milk in the storage tank. Standardization is done on raw milk. DKMU Ltd markets four types
of milk.

Toned milk

3% fat .and 8.5% SNF

Homogenized milk
3.5% fat and 8.5% SNF
Shubham
4.5% fat and 8.5% SNF

Samridhi

6.0% fat and 9.0% SNF

Trupti

3.5% fat and 8.5%SNF

Healtylife

1.5%fat and 9%SNF

6)Pasteurization

It is the process of heating the milk to 71.5 °C/15 sec holding and immediately cooling to 5
°C or below. The purpose is to render the milk safe for human consumption by destructing
some of the pathogenic microorganisms.

7) Cream separation

process where cream and skimmed milk are separated using a cream separation machine
8)Homogenization:
Homogenization is the process in which size of the fat globules in the milk are down
broken into smaller and uniform size of fat particles of 1-2 . This prevents the cream
Formation. It also ensures that the milk fat is evenly distributed. Chilled milk cannot be sent
to the homogenizer since the fat will be in solid state and difficult to homogenize hence the
milk sent to it should have a temperature of around 60 °C. Partially heated milk from the

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 A STUDY ON PRODUCTION MANAGEMENT

pasteurizer is forced towards a small passage with high pressure in an adjustable valve by
multiple cylinder pistons pumps; the shearing effect causes the fat globules to break down.
Then it is sent back to refrigeration. It is a two stage homogenizer of 500psi and 2500psi.

9) Packing and cold storage

After the pasteurization, pasteurized milk is packed with the help of packing machine. Packed
milk packets are stored at 4 °C till its delivery to milk delivery trucks. These milk packets are
stored in a separate cold room.
10)Dispatch

Packet milk is stored in a separate crate and distributed to the dealers Through organized
tendered contract vehicle.
11) Cleaning in place(CIP)

CIP is an automated process which is done for cleaning and sterilizing of the pasteurizing and
homogenizer equipment. Chemicals used are caustic soda (NaOH) and nitric acid (HNO3 )
12) Curd processing

 Microbial culture: Mixed strain (containing lacto baccilus Lactis)

 Pure Culture was obtained from NDRI-Delhi
 Curd

characteristics

Fat 3.1%

Acidity 0.8-1.0% (sweet curd-0.7%, sour curd-

1%) Protein 3.4g Vitamin A 0.03nig

Storage

 Dry condition at room temperature

 Shell life: 3 days from packaging
 Quality control test: chemical and microbiological test

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