Presentation of

Student READY – Internship / In – Plant Training

(FPO 4206)

KAIRA DISTRICT CO-OPERATIVE MILK PRODUCER’S UNION LTD, ANAND

Submitted
To I/c
Principal
College of Food Technology

Submitted By
KRUTIKA VAGHELA
15-00076-2019

COLLEGE OF FOOD
TECHNOLOGY
SARDARKRUSHINAGAR DANTIWADA AGRICULTURAL UNIVERSITY
SARDARKRUSHINAGAR - 385506
Outline :
• Introduction
• Plant and Their Sections
• QA
Introduction :
AMUL first formed in 1946 with the name of KAIRA DISTRICT CO-
OPERATIOVE MILK PRODUCERS UNION. It handling 250 liter milk per
day in the starting period.
 The official registration date is 14 December, 1946
A brand name AMUL is managed by GCMMF (Gujarat Co-operative Milk Marketing
Federation Ltd.)
 AMUL means “AMULYA” which means “Priceless”.
 Today Amul Dairy is number one in Asia and number 16 in world according to 2020.
AMUL follows “AMUL Model” or “ANAND Pattern” which is replaced with all
over country under operation flood programmed.
 The Trio of Tribhuvandas, Kurien and Dalaya is the reason of AMUL success.
Company Profile :
Name of Plant Kaira District Co-Operative Milk Producer’s Union
Ltd.
Date of Registration 14th December 1946, Under Co-operative Act
Registration No. p.330/1946
Brand Name AMUL
Societies 1176 Village Co-operative societies with 6,069,566
Premises 49.55 acres
Plants Dairy Plant – Anand
Kaira Satellite Dairy –
Khatraj Food Complex –
Mogar Kanjar Plant –
Nadiad
Amul Research and
Development Association
AMUL
Logo
•The logo of AMUL is a ring consisting of four hands, encircled by the words “KAIRA DISTRICT CO-OPERATIVE
MILK PRODUCER UNION LIMITED”. The ensure of this logo us coordinate efforts of four groups of people.

a. First Hand is for farmers or producers, without whom the organization would not be existed.

b. Second Hand is for the representative of processors by whom the raw milk processes in to different finished
products.

c. Third Hand is for marketers without whom the products would have not been able to reach the consumers.

d.Fourth Hand is for customers without whom the organization could not carry on because they are the people who
consume the products.
Training Plant and Their Sections :
AMUL DAIRY

KHEDA AMUL MAIN AMUL

SATELLITE DAIRY,ANAN CHOCOLATE
DAIRY,KHTRAJ D PLANT,MOGAR
 2) Food Complex, Mogar
 Old Chocolate
1) AMUL Main Plant – Anand :  Malt Milk Food
 AMUL – 3 Processing Plant  Bread Spread Plant
AMUL – 2 Processing Plant
 Ghee Section
3) Kheda Satellite Dairy, Khatraj
 Sterilized Flavored Milk  Milk Processing
Milk Pouch, Butter Milk and Dahi Cheddar Cheese
Milk Powder Plant Process Cheese Pkg.
Butter Section Mozzarella Plant
Paneer Plant
Whey Powder Plant
 Old Chocolate Unit :
 Inthe AMUL their are basically Chocolate plant which
separated in two parts : old chocolate plant and new
chocolate plant.
 The New Chocolate plant is fully automatic and no need
of the workers in that section.
 Inold chocolate the equipment are the semi
automatic
and need around 150 worker in one shift.
 Old Chocolate is the oldest plant of the
Tribhuvandas Food Complex Mogar.
 Theproduction Capacity of the New Chocolate plant is
30 MT and Old Chocolate plant is 20 MT.
 AlsoIn Old Chocolate plant they produces 38 types of
Chocolate.
Types of Chocolate :
Raw Material :
 The raw material used as per chocolate
type.
 The list of raw material is :
1) Cocoa Powder
2) Cocoa Butter
3) SMP
4) Vegetable Oil
5) Sugar
6) Flavour
7) Soya Lecithin
8) Preservatives
Processing Of Different Chocolates :
1) Chocolate Slab :
2) Chocozoo :
3) Wafer Chocolate :
4) Filled Bar :
5) Chocolate Syrup :
Nutritional Value of Different Chocolate :
Dark bindazz Dark Milk Almond Fruit n nut
chocolate passion chocolate bar
Energy 544 513 522 544 450 499
(kcal)
Total fat(g) 33.4 26.9 28.9 34 18.4 32.6
Carbohydr 58 62.6 61 53.7 64.9 48.8
ates(g)
Protein (g) 5.2 5.5 5.6 9.7 6.4 7.3
Sodium 5 45 17 113 112 33
(mg)
Total Line In Old Chocolate Plant :
 Total Processing Line :
1) Line 1, 2 and 3 : Chocolate Slab,
Chocozoo
2) Line 4 : Filled Bar Chocolate
3) Line 5 : Wafer Chocolate
4) Line 6 : Chocolate Syrup
 Total Packaging Line :
1) Line 1, 3, 5 and 7 : Chocozoo
2) Line 2 : Filled Bar Chocolate
3) Line 4 and 5 : Chocolate Slab
4) Line 8 : Chocolate Syrup
5) Line 9 : Wafer Chocolate
Malted Milk Food (MMF)
 Thefirst malted milk powder manufacturing techniques was developed by William
Horlick of the U.S.A. in 1883.
 InAmul they have the section where the malted milk powder is processed and
made the different types of malted milk powder such as AMUL Pro, AMUL Pro
Plus, Coffee Instant Mix and AMUL Pro Instant Mix.
 This plant capacity is 9 ton.
 It produces in batch of 1465 L and they produces three batch in one shift.
 In
the packaging of the product they pack 25 gm , 50 gm, 200 gm and 500 gm
pouches, 500 gm cube jar and 500 gm refill pack.
Ingredient :
1) Mal dextrin powder
2) Milk Powder (SMP / WMP)
3) Salt and Lecithin
4) FinaAMUL – 2705
5) Sodium bicarbonate
6) Vitamin Premix
7) Cocoa Flavour
8) Milk Caramel Flavour
9) DHA
10) Alkalized Cocoa Powder Fat
Processing Flowchart of MMF :
Product Specification :
Parameter Specification
Moisture % Max 4.0
Protein % Min 11.5
Fat % Min 8.0
Total Ash % Max 5.0
Acid Insoluble Ash % Max 0.1
Solubility % Min 90.0
Cocoa Powder % Min 5.0
Total Bacterial Count, cfu/g Max 50,000
Coliform Count in 1g Product Max 10
CIP
Schedule :
 CIP done after every 25 batch.
 Trays are washing every Sunday.
Hot Water 90 to 100 oC 1 hr

Caustic Soda Conc. 0.05 1 hr

Hot Water 90 to 100 oC 1 hr

 Self Life : 12 month when stored at cool, dry and hygienic

place.
 Price : 20 Rs / 50 gm
Bread Spread Processing Plant (BSP) :
 With the help of NDDB, the Union established a Bread Spread Plant in Mogar in 1994.
 The plant has a 25 TPD installed capacity.
 The product range is : High fat bread spread called Delicious, Medium fat bread spread called
Amul lite, and low fat bread spread called Amul lite thin n trim.
1)Amul Delicious: It is a product created from a water and vegetable oil or fat emulsion. It contains
the same percentage of fat as butter.
2)Amul lite: It also falls under the category of tasty or spreadable fat with milk fat. Amul light is a
low-fat, low-calorie, low-cholesterol bread spread with a high PUFA and omega 3 fat content,
making it a healthier alternative to butter and Delicious.
 High Fat Bread Spread : Delicious 75 % Fat, 20-22 % moisture
 Medium Fat Bread Spread : Amul Lite 65-70 % Fat, 25-28 % moisture
 Low Fat Bread Spread : Amul Lite Slim n Trim <60% Fat, 37% moisture
- Amul lite : milk fat bread spread ( made from white butter
- ) Delicious :Vegetable fat spread ( made from palm oil )
Processing Flowchart of
BSP :
CIP
Schedule :
 CIP is done after every 15 days, 24 hr all line all
tank.
AMUL 3 Processing
Unit :
 Receptionany dairy's dock is where milk is first emptied and sent to the storage. Only road
milk trucks carrying raw milk from village cooling units and chilling centres arrive at
Amul-
3. For unloading milk trucks, there are four receiving areas. It offers computerised greeting
services.
 Total Storage Capacity – 30 lakh lit. / day
 Recent handling capacity – 22.5 lakh lit. / day (Lean Season)
 Tanker – 190 to 200 per day (22,000 to 25,000 lit. Per tanker)
 MilkUtilization : Amul – 2 and F – 60 : 55%, Amul – 3 Powder Plat (L & T) : 30%, Market
Milk : 1%, Tea Special : 2%, Amul Tazza : 2%, Amul Gold : 3%, Amul Flavoured Milk :
1%, Cream : 6%
Process Flowchart of AMUL – 3
Unit : is divided into two parts:
 The process

1) Raw Milk Tanker to Raw Milk Silo:

2) Raw Milk Silo to Pasteurized Milk Silo :
Understanding of Pasteurization :
 The Pasteurization process flowchart is shown below:
CIP
Step :
CIP Step Pasteurizer Silo / Tanks Transfer Lines
Time (Min.) Temp. (oC) Time (Min.) Temp. (oC) Time (Min.) Temp. (oC)
Rinsing with 10 Ambient 5 Ambient 5 Ambient
water
Lye Solution 30 80 20 80 5 80
(1.4 to 8%)
Fresh water 5 Ambient 7 Ambient 5 Ambient
Acid 20 60 15 60 5 60
Circulation
(0.8 to 1.2 %)
Fresh water 10 Ambient 7 Ambient 5 Ambient
AMUL – 2 Milk Processing Unit :
 The first AMUL RMRD (Raw Milk Reception Dock), where milk was directly
received in cans, was AMUL 2. Over time, AMUL's capacity has grown, and it now
accepts milk tankers, which are mostly received at AMUL 3.
 Types of Reception done are –
 Milk can Reception
 Milk Tanker Reception
 Reception of Sour Cream from Khatraj.
 Raw Milk at Amul – 2 is received mainly through cans. There are two reception
lines for unloading milk cans in Amul – 2.
 Raw milk is received in morning and evening different two shift.
 Butter Milk is also produces in this section.
Process Flowchart of AMUL – 2
Unit : is divided into two parts :
 The process

1) Cans to Raw Milk Collection Tank :

2) Raw Milk Tank to Market Milk Packing tank :
 Butter Milk Process :
 ButterMilk is prepared in AMUL – 2. It is standardized and paced in pouch. It has
a fat of minimum 0.5%, Total solids 6 to 7% and acidity 0.39 to 0.41%.
 Process Flowchart is shown below :

Sr. No. Parameters Specification

1. Temp. Of dispatch Not more than 8 oC

2. Acidity (%) LA 0.35 – 0.45

3. Fat (%) Min. 1.00

4. Total Solids Min. 6.5

5. Organoleptic Test (OT) Fresh, Free from any off flavour

Ghee Section :
 Ghee may be made in five different ways: the Desi or Indigenous technique, the Direct
cream method, the Creamery Butter method, the Pre-stratification method, and the
Continuous method. However, Amul manufactures primarily using the Pre-Stratification
Method using white butter produced in the butter department. White butter is made by
churning curd that has been received in a dairy or fat that has been removed from sour milk
or sour cream. To prepare ghee for the local market, this white butter is heatedly clarified.
 In Amul 2 they used the Pre Stratification Method in production of Ghee.
 White butter-based ghee is exclusively preferred for export purposes. AGMARK
exceptional quality (Red Label) ghee is made in this part. The ghee segment has a
production capability of 16 to 18 TPD. (Avg. Production).
 Pouch packing – 9 months, Tin packing – 12 months
 Jar packing – 6 months, Bulk packing – 12 months
Process Flowchart of Ghee :
Flowchart of Brown Ghee :
CIP
Schedule :
 After use of every melting system hot water of 70 to 75 °C is filled up and flushed.
 Thenit is cleaned with 0.2 to 1 % of lye solution at temperature of 70 °C
and Circulation and drained.
 After this the cleaning procedure is carried out with hot water of 70 to 75
°C without lye. The system washed third time with water for 25 to 30 min.
 Finally rinsing is done.

 Clarifier
: Detergent solution, had brash cleaning with hot water having
temperature 40 to 42 °C is used for cleaning after every use.
Sterilized Flavour Milk :
 Amul Flavored Milk is Sterilized Homogenized Dairy Based Drink. Amul
Flavour Milk is the balanced blend of best quality fruit solids and goodness of
milk.
 Flavour Milk must be homogenized, boiled, pasteurized or sterilized. It
has a longer shelf life than milk because of this treatment.
 It is one of the lucrative product of the AMUL.
 The flavour milk section is located in the AMUL 2.
 The products are – AMUL Kool : Café, Koko, Kesar, Badam, Elachi etc., Amul
Pinacolada, Irish Drink etc.
Process Flowchart :

Milk Standard Should be : 3.5 % Fat and 8.5 %

SNF
CIP
Steps : different equipment are shown below :
 CIP of the

1) Process Vat, Storage Tank, PHE, Bulk Chiller, Homogenizer, Pipelines

Process Step Time (Min.) Temperature (oC)

Rinsing with water 20 60

Lye circulation (Con. 0.5 – 0.8%) 40 80

Fresh water circulation 20 60

Acid circulation (Con. 0.64 %) 30 70

Fresh water circulation 20 60

2) Sterilizer : It clean manually from inside daily.

3) Sterilizer Creates and Trolleys : It manually clean once in moth by brushing with Teepol
solution and rinsing with water.
4) Can Filling Machine, Overhead tank, Bottle Filling
Machine

Process Step Time (Min.) Temperature (oC)

Rinsing with water 5 – 10 50 – 55

Lye circulation (Con. 0.5 – 0.8%) 20 – 30 75 – 80

Hot water circulation 15 50 – 55

Acid circulation (Con. 0.64 %) 15 – 20 72 – 75

Hot water circulation 15 50 – 55

Lye circulation 5 – 10 75 – 80
Hot water flushing 20 50 – 55
Milk Pouch, Butter Milk and Dahi Pkg. :
 The Amul 2 facility’s pouch packaging division is responsible for putting various
varieties of milk, buttermilk and Dahi into pouches.
 The LDPE packs used to package.
 The processing and packaging of Dahi, Buttermilk and Jeera Butter milk make up
the majority of the Dahi segment.
 In this section they pack 180, 200, 250, 300, 500 and 1000 ml of milk pouch.
 The pouches are – Amul Gold, Shakti, Tazza, Tea Special Milk, A2 Buffalo Milk.
Sr. No. Milk Fat % SNF % Specific Gr.
1 Amul Shakti 4.55 – 4.60 8.60 – 8.70 1.030

2 Amul Gold 6.05 – 6.10 9.10 – 9.15 1.030

3 Amul Taaza 3.5 – 3.55 8.60 – 8.65 1.031

4 Tea Special 4.55 – 4.60 8.60 – 8.70 1.030

5 A2 Buffalo Milk 6 9 1.032

Process Flowchart of Milk Pouch Packing Machine :
Dahi Processing :
 Dahi is the fermented milk product produced by bacterial fermentation of milk.
 In the Dahi Section they produces two types of Dahi – Masti Dahi, Amul Lite Dahi.
 In
the Masti Dahi they used the 3.2 to 3.3 % Fat and 11.1 to 11.2 % SNF standard
Milk.
 Also the Cultured used are RST 774 and CHN 11.
 In case of Amul Lite Dahi the milk fat is upto 0.5%.
Sr. No. Parameters Specification
Amul Masti Dahi Amul Lite Dahi
1 Fat % 3.5 0.5
2 SNF % 11.5 12.0
3 Acidity % Lactic acid Max. 0.128 0.125
4 Acidity % LA as Transfer to Cold Store Min. 0.500 0.500
5 Acidity % as LA at dispatch Max. 1.00 1.00
Flowchart of Dahi Processing :
Milk Powder Plant :

In the Amul Main plant there are the two plant for the production of the milk
powder.
1) F – 60 Powder Plant : Mainly Produces SMP (Skimmed Milk Powder)
2) L & T Powder Plant : It produces SMP, WMP (Whole Milk Powder also
known as Dairy Whitener), Infant milk Food also known as Amul spray.
F- 60 Powder Plant :

 It is the oldest plant which is located in Amul 2.

As the name F -60 means the F is stand for the Ferrum Packing Machine and
60 is denoted the capacity of the plant is 60 MT.
Also the F- 60 plant contain the Condensing plant that has five
effect evaporator and can evaporate 14,000 lit of water per hours.
Process in F – 60 plant :
 It divided into two parts :
L & T Powder
Plant : is located in the Amul 3.
 This plant

 The Larsen and Toubro plant is a fully automated tall fluidized bad dryer plant
where the normal milk is dried in two stages using spray dryer and vibro fluidized
bad dryers.
 This plant capacity is more than 60 MT. it produces powder in the flush season
approx 85 MT and in lean season is 70 to 75 MT.
 The whole plant is divided into 5 major section :
1) Feed Preparation Section
2) Evaporation Section
3) Drying Section
4) Powder Conveying and Storage Section
5) Packaging Section
Process in L & T Powder Plant
CIP
Steps :
Normal CIP – after every 24 hours of continuous operation.
 Soft water flushing is done at ambient temperature for 30 -35 min.
 Chemical cleaning with Lye (1.5%) at 60 oC for 70 min,
 Hot water flushing at 60 oC for 35 – 40 min,
 Extended CIP after maximum four normal CIP cycles, chemical cleaning with Acid
(1.5%) at 60 oC for 40 min. Followed by hot water flushing at 60 oC for 35 – 40
min. in addition to above 3 steps.
Butter Section :
 The Amul butter is one of the dairy company’s most well known products.
 The Amul 3 building has the butter division, which produces table butter and white
butter.
 The sector is fully computerized and furnished with the most recent
imported machinery.
 Exports of Amul white and table butter go to the US and Gulf nations. Amul Table
Butter upholds AGMARK (E-7) Criteria.
 Amulis produces butter since 1945 with first wooden butter churn and evaluated to
Automatic Continuous Butter Making Machine.
Process Flowchart for Butter :

Preparation of Colour and Salt

Solution
CBMM (Continuous Butter Making
Machine) :
 The CBM machine use the “Fritz” method of continuous butter production. During the
accelerated churning process, high speed beaters separate the fat from the cream, which
then done after draining the buttermilk.
 Cream is put through a high speed beater in the churning section, which simultaneously
guides cream the cylinder walls, causing foam to form along with fat globules to form in
the cylinder during the churning process and pin head sixed bitter granules to form.
 The mixture of butter granules and butter milk then falls into the screw conveyer and then
into the rotating drum, where the butter milk is separated.
 The butter granules are worked on down between a series of revolving augers, where they
are eventually extruded into ribbons and placed right into butter trolleys.
Machine Description :

1) Double Cooled Churning Cylinder

2) First Working Section
3) Squeeze Drying Section
4) Second Working Section
5) Injection Chamber
6) Vacuum working Section
7) Final Working Stage
8) Transmitters
Packaging Machine and CIP of
Section :
 List of Packaging Machine in butter section :
1) SIG machine – 500 g packing
2) BENHIL case packer machine – 100 g packing
3) HASSIA butter tub filling machine – 10 g packing
4) Tin packing machine – 400 g Tin
 CIP is done after every 24 hr. melting of residual butter done with hot water for
25 min and molten butter is drained into recovery tank. Degreasing is done for 10
min.
QA (Quality
Assurance) :
 Any manufacturing or production process must include both quality assurance and
quality control.
 The basic difference between QA and QC is the QA is make sure the process of
system is adhere to strict quality standard and QC is to evaluating, examining
and watching over process to make sure they match required standard.
 The AMUL take the different policy are :
1) Quality Policy
2) Food Safety Policy
3) Halal Policy
4) Environment, Health and Safety Policy
5) Jewelry Policy
6) Glass Policy
Activity of QA
Lab : product checking and releasing including updating of records timely.
 Finished

 Plant or surrounding hygiene audit and recording of CCP and CP.

 Validation and verification of plan process and documents.
 Monitoring and recording of CIP, Fumigation and Sanitization.
 Monitoring of Activities in plant.
 Audit Preparation.
 MIS (Management Information System) Preparation.
 All raw material and packaging sampling analysis and releasing GR (Goods
Receipt) in SAP (System Analysis Program).
 In process and Finished products sampling and analysis and SAP entry.
Product Analysis :
 The List of different test are :
1) Raw Milk / Platform test
2) Flavored Milk Test
3) Butter / BSP Test
4) Milk Powder and Whey Powder Test
5) Cheese and Paneer Test
6) Chocolate Test
7) Malted Milk Food Test
1) Raw Milk or Platform Test :
Sr. No. Test Name Procedure Observation and Limits
1 Temperature Direct Measured by Glass Thermometer Less than 10 oC
2 Acidity Take 10 ml sample in flask, Titre reading is multiplied by 01 to
add
give % LA acidity. It less
Phenolphthalein indicator. Titrate against N/9
than 0.142%.
NaOH till the light pink colour appears.

3 MBRT Take 10 ml of milk in a sterilised MBR Tube. Tube Decolouration first after 10 min.
Add 1 ml of MBR dye. Plug with a sterilized and for pasteurized milk time should
cork. Invert the tube to mix the contents and be 5 hrs or at least 4 hr. where the raw
incubate at 37 oC in a water bath. milk time is 30 min.

4 Fat Gerber Method It should be 4 % for Cow Milk, 6 %

for Buffalo Milk.
5 Alkaline Phosphate Take 1 ml milk + 5 ml test solution in a test This test is used to check the adequacy
tube; put it in water bath at 370C for 30min. If of pasteurization in milk.
Test
yellow colour appears this test is +ve & white
colour remains means test is –ve.
2) Flavored Milk :
Sr. No. Test Name
1 Ph
2 Acidity
3 Alcohol
4 Creaming Index
5 TS
Procedure Observation and Limits
Direct Measured by PH Meter Should be between 6.3 to 6.5
Take 10 ml sample in flask, Titre reading is multiplied by 01
add
to give % LA acidity. It less than
Phenolphthalein indicator. Titrate against
0.142%.
N/9 NaOH till the light pink
colour appears.
Take 10 ml milk sample in test tube and The presence of clot or flakes
add equal amount of ethyl alcohol. Mix it denotes positive test.
and note for any flakes or clot.
Take milk; heat up to 21 o C % Cream present in the sample
and
that is % Creaming Index = (A-B
centrifuge 1100 rpm for 15 min. The fat
/ B)* 100
cream layer and non fat portion separate
It should be less than 10.
out.
TS % = Fat % + SNF % It should be less than 19.50 %
3) Butter and BSP
Test :
1
Sr. No. Test Name
Moisture %
Procedure
Weight clean and dried flat bottomed dish, which is pre weighed.
Observation and Limits
It should be max 16% and usually in the range
Transfer of 10 ml sample into the dish and note the weight. of 15 to 16%.
Heat butter on hot plate, rotate the dish while heating so as to aid the
moisture to escape. Heat till light dark brown colour appears. Cool to
room temperature and weighted the dish.

2 Salt % Firstly perform the moisture test. Add 100 ml of distilled water to the Salt % =
dish with residue. Shake the content s thoroughly, so as to distribute the It should be between 1.9 to 2.3%.

salt evenly out the solution. Pour the solution into the separating funnel.
Take 10 ml of solution add 4 to 5 drops of 5 % potassium chromate
solution and titrate with N/10 silver nitrate solution till the brown colour.

3 Fat %
4 Curd %
Firstly perform the moisture test. Add 10 to 20 ml of petroleum ether to Is should be min 80% and usually between 80
the residue. Slowly heat until the sediment gets dried. Cool and to 82 %.
weight Or
the difference in the weight gives the fat content. Fat = 100 – moisture – Salt – Curd
Firstly perform the moisture test. Add 10 to 20 ml of petroleum ether to Curd + Salt % = (wt of residue / wt of
the residue. Slowly heat until the sediment gets dried. Cool and butter)*100
weigh. Table butter content % = 0.8 to 0.9
Add 100 ml of water at 60 to the sediment and run the salt test. White butter Content % = 1.1 to 1.3
4) Milk Powder and Whey Powder Test :
Sr. No. Test Name Procedure Observation
1 Grading of For reconstituting any powder solvent used is The grading is given according
Reconstituted Milk 200 ml water. To it Amul Spray – 28 g, Amulya to
– 28 g, WMP – 26 g, Cheese Whey Powder – scorched particles.
20 g are added and dissolved with the help of A – no scorched Particles
flat blade disc blender for 90 second with 4000 AB – 1 to 7 Particles
rpm. After the process observed by looking at BC – 8 to 15
scorched particles by bottom of the beaker. Particles C – >15
Particles
2 Insolubility Take 50 ml of the reconstituted milk after After centrifuging the insoluble powder
Index removal of the form is taken in an insolubility settles down the volume of this
of the Milk index tube up to 50 ml mark and centrifuged at powder should be less than 0.5 ml.
1100 rpm for 5 min.
3 Moisture of the This is done by taking 2 to 2.5 g of powder in The moisture content should be between
Powder the automatic moisture analyzer. The meter 2.6 to 3.3 %.
gives the reading in 5 min.
4 Fat content Take 10.75 ml of reconstituted milk (3 g SMP – 0.5 to 1 % Fat
by powder) and add 10 ml of H2SO4 and 1 ml of Amul Spray – in 18
Gerber Method Amyl Alcohol. Now Centrifuged in Gerber % Amulya 0 min 20
Machine at 1100 rpm for 5 min. %
5 Coffee Test
6 Agglomerate Powder
Sieve Test
7 Bulk Density
Heat 150 ml of water to 90 oC and add 1.5 g coffee powder and If powder clots or settles then the coffee test is
dissolved and when its temperature reaches to 80 oC add 5 g of negative that is coffee is in dispersible in reconstituted
test powder and stirred with spoon for 15 second. milk. This test is important for check protein
denaturation.
This test is done for Amul Spray and Amulya. The mass of the powder retained on the top of the
Take 50 g of powder is sieved manually on a vibro sieve mesh sieve multiplied by 2 gives % Agglomerate. It should
for 5. be around 36 to 38 %.
Take 50 g powder is taken in a 200 ml measuring cylinder and it The volume of the powder is noted and from the chart
is introduced in a 100 counter machine which vibrates and bulk density is noted.
switched off after 50 vibration counts. It should be above 60.

8 Head Space Analysis This finished packed product is tested in Oxygen to get % O2 in % N2 = 100 – O2
head space. It is used to estimate the N2 Flushed in the packet. It should above 90 %.

9 Presence of Vitamin Take 50 ml reconstituted milk and add 2 to 3 drops indophenols Reduction of indophenols blue to colorless form
and Iron blue and ammonium cyanate and add conc. HCL shows the presence of Iron and formation of red
precipitate shows the presence of vitamins

10 Titratable Acidity Take 1gm of sample and add 10 ml of water and add 1 ml TA % = Reading * 0.9
phenolphthalein indicator and titrate against N/10 NaOH till a
faint pink colour persists.
11 Total Ash Content Take 3 gm of powder in a dried silica crucible and heat on a Ash % = (M2 – M / M1 – M)*100
heater till no smoke comes out of powder. Then keep it in muffle M2 – weight of crucible with ash
furnace maintained at 550 for 3 hr till grey ash formation. Then M – weight of empty crucible
cool in desiccators and weight. M1 – weight of crucible with powder

12 Total Carbohydrates Determined by the Sum of Moisture, Protein, Fat and Ash. And Total Carbohydrate = 100 – (A+B+C+D)
subtract from 100. A= moisture, B= Protein, C= Fat, D=
Ash.
13 PH It analyzed by the PH meter It generally 6.6 t 6.8.
5) Chocolate Test :
 Firstly they analysis on the raw product of chocolate.
1) Cocoa Powder: Moisture, Fat, Sieve Test, Total Ash
2) Cocoa Butter: FFA and Slip melting point
3) Lecithin; Acid Value, Moisture.
4) Milk Powder: Physical Appearance, Moisture and Fat
5) Liquid Glucose: PH and TS
6) Flavour: Test Certificate
 Then Final Product Analysis: Weight, Heat Sealing integrity, OT, Moisture, Fat, Protein, Slat. Complete
analysis of chocolate is done once in a month of any code no.
1) Moisture : by Hot Air Oven Method
2) Fat : By Soxhlet Apparatus
3) Protein : By Kjeltec Machine
4) Lactose in Milk Chocolate : Lane and Eynoe’s Method
6) Malted Milk Food Test :
 Raw Material Analysis are:
1) Malt extract: OT, Sediments, Acidity, Protein, TS
2) Cocoa Powder: Moisture, Fat and Total Ash
3) Cocoa Butter: Physical Appearance, Moisture and Fat
4) Lecithin; Acid Value, Moisture, Acid Insoluble matter
 Then Final Product Analysis: Weight, Coding and other parameter are
determined by the FT-NIR machine.
 Equipment Photo used in Lab :

MilkoScan FT 120 MilkoScan FT 2 MilkoScan FT 3 Moisture

Analyzer

FT NIR PH Meter
Food InfraXact 7500
Scan