Report On Industrial Training at Amul Dairy, Anand Kaira District Co-operative Milk Producers Union Ltd. Submitted to: Er.Atul Anand Mishra Submitted by: Arpita Banerjee (15BTFT075) Priya Rai (15BTFT101) Anushree (15BTFT065) Shivam Singh (15BTFT060) Abhinav Anand (15BTFT046) Department of Food Process Engineering Vaugh Institute of Agricultural Engineering and Technology (VIAET) Sam Higginbottom University of Agricultural Technology and Sciences (SHUATS), Allahabad-211007 (U.P State Act No.35 of 2016, As Passed by U.P Legislature)
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Report
On
Industrial Training at
Amul Dairy, Anand
Kaira District Co-operative Milk Producers Union Ltd.
Submitted to: Er.Atul Anand Mishra
Submitted by: Arpita Banerjee (15BTFT075)
Priya Rai (15BTFT101)
Anushree (15BTFT065)
Shivam Singh (15BTFT060)
Abhinav Anand (15BTFT046)
Department of Food Process Engineering
Vaugh Institute of Agricultural Engineering and Technology (VIAET)
Sam Higginbottom University of Agricultural Technology and Sciences
(SHUATS),
Allahabad-211007
(U.P State Act No.35 of 2016, As Passed by U.P Legislature)
ACKNOWLEDGEMENT
We sincerely express our deepest sense of hearty gratitude to the following people for supporting and
guiding us ahead in the journey of making the project report of Industrial In-Plant training.
We express our profound gratitude and indebtedness to The Father of “The white Revolution, Dr.
Varghese Kurien” for envisioning this dairy and helping it becomes the stage of learning.
We would like to express our thanks to Dr. D. C. Joshi (Principal of college of food Processing
Technology& Bio-Energy, Anand) for permitting us to do our In-plant training in Amul Dairy, Anand.
We would also like to thank All the professors of our college for supporting & guiding us throughout
our graduation.
We are thankful Dr. K. Ratnam, Managing Director, Kaira District Co-operative Milk Producers
Union Limited for giving us such prestigious opportunity to undergo In-Plant training in this organization.
We are also thankful to Mr. D. R Sharma (Production Manager), Mr. Mrunal Desai (H.R
Department) without whose guidelines and help we would not have been able to complete our In-Plant
training. Our heartiest thanks to Mr. V. R Joshi (Production manager in Kheda satellite dairy) and Mr.
Subhankar Mitra (Production manager in food complex Mogar.
We are also thankful to all section In-charges and operators who gave us positive response and
guidance during our training period.
Last but not the least, we express our deep feelings of love and affection to our beloved parents for
providing us valuable opportunities which helped us to stand out on our own feet this stage.
Thank You
Arpita Banerjee (15BTFT075)
Priya Rai (15BTFT101)
Anushree (15BTFT065)
Shivam Singh (15BTFT060)
Abhinav Anand (15BTFT046)
Place: Amul dairy, Anand
Date: 30/06/2017
INDEX
Sr.
No.
Content
1 List of Tables
2 Introduction of company
3 Product range
4 Amul-3 processing plant
5 Amul-2 processing plant
6 Milk pouch packaging section
7 Buttermilk section
8 Dahi section
9 L & T Powder plant
10 Butter section
11 Ghee section
12 Flavoured Milk
13 QA Laboratory
14 Conclusion
List of Tables
Table No. Title I Company profile
Ii Product Range
1.1 Amul-3 equipment list
1.2 Amul-3 CIP
1.3 CIP of RMRD
2.1 Amul-2 Can washing
2.2 Amul-2 equipment list
2.3 Amul-2 CIP
3.1 FFS pouch packaging machine
3.2 Milk pouch standards
4.1 Specification of buttermilk
5.1 Specification of Dahi
6.1 Specification of powder
6.2 Equipment list (L & T powder plant)
6.3 Powder packaging
7.1 Specification of butter
7.2 Butter section equipment list
8.1 Chemical composition of ghee
8.2 Ghee section equipment list
8.3 Standards of weight
9.1 Product list of Flavoured milk
9.2 Specification of Flavoured milk
9.3 Equipment list
9.4 Standards of weight
9.5 CIP of storage vats
9.6 CIP of filling machine
10.1 Tests done at RMRD lab
10.3.1 Powder analysis
10.3.2 Ghee analysis
10.3.3 Butter analysis
10.3.4 Flavoured milk analysis
10.3.5 Tests for Buttermilk & Dahi
10.3.6 Water analysis
10.3.7 Strength of acid & soda
10.3.8 Packaging material testing
10.3.9 Equipments of Central laboratory
10.4.1 Different microorganisms
10.4.2 Sampling plan for analysis of product
INTRODUCTION
AMUL is based in Anand town of Gujarat and has been a sterling example of a Co-operative organization‟s
success in the long term. It is one of the best examples of Co-operative achievement in the developing world.
“Anyone who has seen… the Dairy Co-operatives in the state of Gujarat, especially the highly successful one
known as AMUL, will naturally wonder what combination of influences and incentives is needed to multiply
such a model a thousand times over in developing regions everywhere.” The Amul Pattern has established
itself as a uniquely appropriate model for rural development. Amul has spurred the White Revolution of
India, which has made India the largest producer of milk and milk products in the world. It is also the
world‟s biggest vegetarian cheese brand.
AMUL means „priceless‟ in Sanskrit. The brand name “Amul,” from the Sanskrit word “Amulya” was
suggested by a quality control expert . Amul products have been in use in millions of homes since 1946 and
made Amul a leading food brand in India.
Today Amul is a symbol of many things.
High-quality products sold at reasonable prices.
Proven model for dairy development.
Genesis of a vast co-operative network.
Today,there are twelve dairies producing procucts under the brand name of AMUL. AMUL is now Asia‟s
largest dairy brand and it is the world‟s second largest firm producing dairy products.
80% of profit is divided to farmers according to ratio of milk procured.
Company profile:
Name of plant
Kaira district co-operative milk producer‟s
union ltd.
Date of registration 14th
December 1946,under cooperative act
Registration no. p.330/1946
Brand Name Amul
Societies
1176 villages co-operative societies with
6,69,566 members
Premises
49.55 acres
Milk procurements 40 lakh liter per day
Plants Dairy plant – Anand
Kaira Satellite Dairy – Khatraj
Food complex – Mogar
Kanjari Plant – Nadiad
Amul research & development
association.
(table no: i)
History & development of AMUL:
Amul-cooperative registered on 14th December 1946 as a response to the exploitation of marginal milk
producers by traders or agents of the only existing dairy, the Polson dairy, in the small city distances to
deliver milk, which often went sour in summer, to Polson. The prices of milk were arbitrarily determined.
Moreover, the government had given monopoly rights to Polson to collect milk from Kaira and supply it to
Bombay city.
Angered by the unfair trade practices, the farmers of Kaira approached Sardar Vallabhbhai Patel under the
leadership of local farmer leader Tribhuvandas K. Patel. He advised them to form a cooperative and supply
milk directly to the Bombay Milk Scheme instead of Polson (who did the same but gave them low
prices). He sent Morarji Desai to organise the farmers. In 1946, the milk farmers of the area went on a strike
which led to the setting up of the cooperative to collect and process milk. Milk collection was decentralized,
as most producers were marginal farmers who could deliver, at most, 1–2 litres of milk per day. Cooperatives
were formed for each village, too.
The cooperative was further developed and managed by Dr.Verghese Kurien with H.M. Dalaya. Dalaya's
innovation of making skim milk powder from buffalo milk (for the first time in the world) and a little later,
with Kurien's help, making it on a commercial scale, led to the first modern dairy of the cooperative at
Anand, which would compete against established players in the market. Kurien's brother-in-law K.M. Philip
sensitized Kurien to the needs of attending to the finer points of marketing, including the creation and
popularization of a brand. This led to the search for an attractive brand name. In a brainstorming session, a
chemist who worked in the dairy laboratory suggested Amul, which came from the Sanskrit word "amulya",
which means "priceless" and "denoted and symbolised the pride of swadeshi production."
The trio's (T. K. Patel, Kurien and Dalaya's) success at the cooperative's dairy soon spread to Anand's
neighbourhood in Gujarat. Within a short span, five unions in other districts – Mehsana, Banaskantha,
Baroda, Sabarkantha and Surat – were set up. To combine forces and expand the market while saving on
advertising and avoid competing against each other, the GCMMF, an apex marketing body of these district
cooperatives, was set up in 1973. The Kaira Union, which had the brand name Amul with it since 1955,
transferred it to GCMMF.
Three tier Model of AMUL:
The Amul model of dairy development is a three tiered structure.
1. Dairy Co-operative societies(DCS) at village level. – The role of DCS is to procure & collect milk
from milk producers and transport it to the milk union at district level.
2. Milk union at district level. – The role of MU is processing & value addition in milk and to form
various processed products of milk.
3. State federation(GCMMF) – Selling & marketing of processed products is done only by state
Shelf life: Best before 12 months from packaging when stored refrigerated at 4 oC or below
Storage condition: At 4oC or below
Equipments:
EQUIPMNTS
NAME
CAPACITY NO. SPECIAL INFORMATION
Cream balance tank 350l 2
Cream chiller - 2 Temp- 8-10ºc
Plate length- 207-273
Continuous butter
making machine
2000kg/hr
5000 kg/hr
800kg/hr
3 Made- Contimab
Churning speed-500-1200rmp
Butter blender 1 Vacuum pressure 400-500mm hg
Butter silo 3.5 tones 1
Pasteurized water
tank
5000 lit 1
butter milk buffer
tank
450 lit 1 Temp- 1-2ºc
Wash water tank 500 lit 1 -
Fat recovery tank 450 lit 2 -
Salt dosing unit - 1 Agitator rmp-1380/min
(table: 7.2)
Packaging machine: 1) SIG machine
500 g packing – Capacity – 60-62 pack /min
2) BENHIL case packer machine
100 g packing – Capacity – 150 pack /min
3) HASSIA butter Tub filling machine (Blister pack)
10 g packing - Capacity – 525 packs /min
4) Tin packing machine
400 g Tin - Capacity – 36 packs /min
Packaging machine used: o Parchment paper – used directly for wrapping
o Carton – used for secondary packing,
a. Single laminated foil is used for INDIAN local market.
b. Double laminated is used for EXPORT.
o Tin – used for 400g, Army pack
o Card Board Box – used for tertiary packing.
o Plastic Box – used for school pack
CIP of Butter section:
CIP is done after every 24 hrs. (usually in third shift).
Melting of residual butter is done with hot water for 25 min and molten butter is drained into recovery tank.
Degreasing is done for 10 min.
8. Ghee Section
Introduction:
Ghee, also known as clarified butter or anhydrous milk fat, is prepared by heating butter or cream to just
over 100°C to remove water content by boiling and evaporation, then filtering out the precipitated milk
solids. Ghee is known as ghrta (commonly spelled ghrita) in Sanskrit. Ayurveda has traditionally considered
ghee to be the healthiest source of edible fat, with many beneficial properties. According to Ayurveda, ghee
promotes longevity and protects the body from various diseases.
Amul has a well laid out Ghee section just behind processing section of Amul – 2. It has got all
facilities of white butter melting, sour cream or curd churning, Ghee processing & storage. Ghee is
manufactures mainly by Pre-stratification method from white butter manufactured in butter section. When
Curd is received in dairy or fat is separated from sour milk or sour cream, it is churned to make butter. This
butter is heat clarified to make Ghee for local market. The Ghee manufactures is also export to gulf countries
USA. In this section AGMARK Special Grade Ghee is prepared. The production Capacity of Ghee section is
22-24 TPD.
Definition:
According to FSSR-2011, ghee means the pure heat clarified fat derived solely from milk or curd or from
desi (cooking) butter or from cream to which no colouring matter or preservative has been added.
Product Description and Chemical Composition of Ghee: Ghee could be in liquid, semisolid and some time in solid state based on the storage temperature. Ghee made
from buffalo milk is whitish with greenish tinge and that of cow milk is golden yellow colour. It is usually
prepared form cow milk, buffalo milk or mixed milk.
Composition: Ghee is a complex lipid of glycerides (majorly triglycerides), free fatty acids, phospholipids,
sterols, sterol esters, fat soluble vitamins, carbonyls, hydrocarbons, carotenoids, (only in ghee derived from
cow milk). Its detailed chemical composition is given below.
Constituents Cow milk ghee Buffalo milk ghee
Fat (%) 99 – 99.5 99 – 99.5
Moisture (%) <0.5 <0.5
Carotene(mg/g) 3.2-7.4 -
Vitamin A(IU/g) 19-34 17-38
Cholesterol (mg/100g) 302 – 362 209 – 312
Tocopherol(mg/g) 26 – 48 18 – 31
Free fatty acid (%) 2.8 2.8
(table: 8.1)
Milk fat contains at least 500 fatty acids and fatty acid derivatives with 4 – 20 or more carbon atoms in their
chain. The fatty acid may saturated or unsaturated and usually contains an even number of carbon atoms.
Composition of fatty acid also varies between buffalo milk fat and cow milk fat.
Methods for manufacturing Ghee:
Different methods are used for the preparation of ghee. The adoption of a particular method is mainly
dependent on the scale of production. The classification and description of these methods is given as below:
1. Indigenous (Desi) method
2. Direct cream method
3. Creamery butter method
4. Pre-stratification method
5. Continuous method
From these methods Pre-stratification is used in Amul - 2 Ghee section.
PRE-STRATIFICATION METHOD: To produce ghee in Amul-2 sour cream, sour milk, serum, curd, whey fat, & white butter is used. When
sour cream, sour milk, serum, curd, whey fat is used, first it is churned in butter and then it is melted at 95oC.
While white butter received from butter section is melted at 95oC in an open melting vat having steam coil in
its bottom. It is left for 1 hour in the vat to separate layer of fat. During this period, butter stratifies into three
parts. The top layer consists of clotting, denatured protein & impurities; the middle layer fat; and the bottom
layer consist of butter milk serum.
The melted butter is pumped to pre-stratification tank. The division helps in removal of butter & buttermilk
serum. It contains about 80% of moisture & 70% SNF content. Fat layer is settled down in settling tank for 2
hours. The melted fat is then pumped to ghee melting pot where it is heated to 110 - 115oC for about 45
mins. For brown ghee, temp. is 143 – 145oC for same time. Ghee is allowed to settle for 1 - 2 hours in ghee
tub and then it is transferred to filter & then to clarifier. After clarification, ghee is stored in storage tank.
Then, it is pumped in overhead tank of packaging machine. Ghee is packed at 45oC in pouch, Tin, & in jar.
Flow chart for Ghee: White butter Sour cream/sour milk/serum/curd/whey fat
Butter churner (45 min, cap – 2000 to 3000 L) buttermilk
Equipment Capacity No. of Equipment Milk tank 10,000 L 3
Process vat(Provat) (1)2500 L
(2)5000 L
2
Slurry tank 15000 L 1
Pasteurizer 10,000 L 1
Homogenizer 5000 L 1
Chiller 10,000 L 1
Bulk Milk Cooler (1)5000 L
(2)2500 L
(3)2500 L
3
Metal Can filling
Machine
100 cans/min 1
Glass bottles Filling
Machine
80 cans/min 1
(table:9.3)
Standards of weight:
Product name Specific Gravity Wt. of packaging
material (g)
Net wt.
(g)
Gross
wt. (g)
Approx.
wt. (g)
Empty
can
/Bottle
Bottom
/ Crown
Koko Can 1.069 32 5.4 214 251 251 - 253
Coffee Can 1.058 32 5.4 212 250 250 - 252
Milk shakes/badam
Can
1.066 32 5.4 213 250 250 - 252
Koko bottle 1.069 150 2.2 214 366 366 - 368
Coffee bottle 1.058 150 2.2 212 364 364 - 366
(table: 9.4)
CIP (Cleaning In Process)
CIP for process vats, storage vats, PHE, bulk chiller, Homogenizer and pipelines:
CIP steps Time (min) Temperature (oC)
Rinsing with water 20 60
Lye circulation (0.8 %) 40 80
Fresh water circulation 20 60
Acid circulation 30 70
Fresh water circulation 20 60
(table: 9.5)
CIP for can filling machine, overhead tank/bottle filling machine:
CIP steps Time (min) Temperature (oC)
Rinsing with water 5-10 50-55
Lye circulation (0.5-0.8%) 20-30 75-80
Hot water circulation 15 50-55
Acid circulation (0.4-0.6%) 15-20 72-75
Hot water circulation 15 50-55
Lye circulation 5-10 75-80
Hot water flushing 20 50-55
(table: 9.6)
Cleaning of Sterilizer:
All sterilizers are cleaned manually from inside daily.
10. Q A LABORATORY
Introduction:
Quality Assurance (QA) is a way of preventing mistakes or defects in manufactured products and avoiding
problems when delivering solutions or services to customers, which ISO 9000 defines as “part of quality
management focused on providing confidence that quality requirements will be fulfilled”.
This Department in the dairy plant has to perform multifarious activities and keep track of different aspects
while maintaining a strict vigil on the quality of every packet of every product originating from the dairy. In
laboratories all the raw material, ingredients, products in progress, finished products as well as packaging
materials are tested for their physical, chemical and microbiological quality to maintain hygienic condition in
the production area.
There are FOUR main quality control /assurances laboratory at Amul dairy as follows:
1. Milk reception Laboratory at Amul-3
2. Milk reception Laboratory at Amul-2
3. Central laboratory
4. Microbiology laboratory
The tests done in the Reception lab of Amul – 3 include the analysis of raw milk as well as Pasteurized milk.
In the Reception lab of Amul – 2, mainly the quality of raw milk, flavored milk and dried milks are tested.
In Microbiology lab the microbial analysis of product is done.
The Central Laboratory is the main lab where all the in process checks, finished product analysis, packaging
tests, water analysis are done.
1. Milk reception laboratory at Amul-3 Amul-3 testing lab is a reception laboratory; therefore platform tests are performed here to for acceptance or
rejection of the raw milk. In addition with that the adequacy of pasteurization of pasteurized milk is also
checked here.
After arrival of milk tanker first of sampling is done & following parameters are checked for acceptance or
rejection:
Temperature: using digital thermometer it should be below 10oC.
Smell: should be free from taints or abnormal smell.
Visual inspection: should be absence of abnormality
Taste: pleasant.
Then sample is taken to reception lab for following tests:
Sr.
No.
Test Procedure Interpretation
1 Acidity 10 ml milk + 5 drops of phenolphthalein
indicator. & Titrate against N/9 NaOH till
faint pink colour appears.
Acidity = Titre value×0.1 % as lactic acid
It should not exceed 0.14% for
cow milk & 0.17% for Buffalo
milk.
2 MBRT test Take 10 ml milk + 1 ml methylene blue
dye in a test tube. Close it with rubber cock
This test is used to check the
bacterial load in the milk. If milk
& put it into water bath at 37oC. Check at
15 min intervals & note down the time
taken to reduce the dye.
is having high bacterial count the
dye will be reduced in lesser time
& vice versa.
3 Phosphatase test Take 1 ml milk + 5 ml test solution in a
test tube; put it in water bath at 370C for
30min.
If yellow colour appears this test is +ve &
white colour remains means test is –ve.
This test is used to check the
adequacy of pasteurization in
milk.
4 COB Approx. 5 ml milk sample taken in test
tube & boiled for 2 min in a water bath.
Then it is observer for any precipitated
particles.
It is a quick test to determine
developed acidity and suitability
of milk for processing. Milk
should not curdle upon heating.
5 Alcohol test Take 2 ml milk + 2ml alcohol (68% conc.).
Mix vigorously & check the curdling on
the test tube.
If there is no flakes of curd the
test is –ve. The milk that is used
to make flavour milk should be
alcohol –ve.
6 Fat(Gerber
method)
Take a butyrometer add 10 ml H2SO4 (92%
conc.) + Few drops of water + 10.75 ml
milk + 1ml amyl alcohol.
Stoppered & centrifuge at 1100 rpm for
5min.
It should be around 4% for cow
mil & 6% for buffalo milk.
This method is also used to
standardize the Milkoscan.
7 SNF It is measured by gravimetric method.
SNF% = TS% – Fat%
It is around 9%.
(table: 10.1.1)
The constituents of milk can directly know by using Milcoscan like fat, SNF, Lactose, sucrose, FPD, etc.
There is a Bactoscan also. Bactoscane is used to determine the total bacterial load in the raw milk sample. It
employs the use of ethylene bromide red dye (fluorescent dye) to stain or highlight the bacteria the filler used
top allows the bacterial cell (0.2-10 micron size) to pass through and all other cells are filtered. The
highlighted bacterial cells are thus obtained in the filtrate and the amount of light (blue) scattered from their
cell gives the bacterial load. The count is obtained as individual bacterial count (IBC) can be considered as
colony forming unit.
2. Milk reception Laboratory at Amul-2 This lab is mainly used for the pricing of milk. Every village society sent a sample of their milk with the milk
tanker. These samples are tested here for fat & SNF using milkoscan & on that basis pricing is done. A SMS
showing % fat & SNF & amount of their milk is sent to that village society immediately after testing. If they
have any doubt regarding to their sample they can report within 24 hrs. After 24 hrs. samples will be
discarded.
Other activities: In this lab they also keep the records of average weight of milk pouches & flavor milk cans.
PH of flavour milk is checked using the pH meter.
Acidity & alcohol test is done of milk sample from the batch taken for preparation of flavor milk.
Moisture of powder checked using Moisture analyzer.
Clarity of ghee is observed after melting on hot plate. If there is any ghee residue that batch will be
reprocessed.
3. Central laboratory: In the central lab all the finished products are tested for their parameters using different methods. In addition
to that water analysis, strength of soda & acid, packaging material tests are also done.
Tests done for Powder:
Sr.
No
Tests Procedure Observation &
Interpretation
1 Grading For reconstituting any powder 200 ml water
is used. Into it SMP- 20gm, Amul spray -
28g,Amulya – 28g,WMP – 26g are added
and dissolved with the help of a flat blade
disc blender for 90 sec with 4000rpm.After
the reconstitution grading is done by looking
at the top and bottom of the beaker. The
grade is given according to number of
scorched black particles.
The black particles denote
burnt particles. After
filtration if wt. of burnt
particles are
0-7mg - A grade.
7-15mg – B grade
Above 15mg – C grade
C grade should be
reprocessed.
2 Insolubility index
It is volume in milliliter
of sediment obtained
when a dried milk or
dried milk product is
reconstituted.
50 ml of reconstituted milk is taken in an
Insolubility index tube up to 50 ml mark and
centrifuged at 1100 rpm for 5min.
After centrifuging, the
insoluble powder settles
down. The volume of this
powder should be less
than 1.5 ml, else the CIP
of system is required as
drying may be
incomplete.
3 Moisture 2-2.5 gm of powder is taken in the
Automatic Moisture Analyzer. The meter
gives reading in 5 min.
The moisture content
should be between 2.6 –
3.3%. If it is more, the
batch is rejected and test
is done for condensed
milk and the flow rate of
milk to the dryer is
reduced.
4 Fat content Take 10ml conc.H2SO4 (92%) + 2.5g
powder + 1ml Isoamyl Alcohol + 1ml
distilled water into 36%butyrometer. Rubber
stopper it & centrifuge it at 1100rpm for
5min.
SMP – 0.5 to 1%
WMP – 26 %
Amul spray – min 18%
Amulya – min 20%
5 Coffee Test
To check heat stability
150ml distilled water is heated to 90oC &
1.5g of coffee powder is dissolved. When
it‟s temp. reaches 80oC, 5g of powder is
added and stirred with a spoon for 15 sec in
clockwise & anticlockwise direction.
Observe bottom & Upper
layer, if there is any clots
coffee test is negative.
Take 50ml solution, put it
in centrifuge & observe
sediment layer.
6 Acidity The No. of ml of 0.1N NaOH solution
required to neutralize a quantity of
reconstituted milk. Until pink colour
obtained in the presence of phenolphthalein
indicator.
Acidity should be up to
1.5%.
7 Wettability test
Wettability is the ability,
Take 13g powder sample, and then add this
powder in 100ml water at 45oC. Temp of
For Agglo powder 19 to
20 sec
expressed as the time in
seconds, necessary for a
given amount of powder
to penetrate the quiet
surface of the water
powder is 35oC. Then note down time.
For non-Agglo powder
max 40sec
8 Bulk density
Bulk density depends on
water content & particle
size in measuring
cylinder.
Take 10 gm. of powder & tape 100 times in
Stampf-volumeter & note down volume.
BD = Mass/ Volume
Up to 0.6
9 % Agglomerate
Powder
This test is done for Amulya & Amul spray.
50g powder is sieved manually on sieve
(250µ) mesh for 5min.
The mass of powder
retained on sieve
multiplied by 2, gives %
agglomerate. It should be
around 36-38%.
10 Total solids of Milk
concentrate
Take 2g of milk concentrate in a disc. Put it
on a boiling water to evaporate moisture.
Then Place it in Oven maintained at 98-
100oC, 3hrs. Weigh the dish at hourly
interval until constant weight attain.
TS% = (wt. of residue/sample wt.)*100
45 to 50%
11 Ash Take 3g of powder in crucible & put it in a
muffle furnace at 550oC for 5-6 hrs.
Ash = (wt. of sample after drying/before
drying)*100
Max 8.5%
12 Presence of vitamin 50 ml reconstituted milk+2-3 drops of
indophenols blue
Blue colour appears
vitamins are present
13 Presence of Iron 10 ml reconstituted milk + Ammonium
thiocyanate + conc.HCl
Formation of red
precipitate shows
presence of iron
(table: 10.3.1)
Ghee Analysis:
Sr.
No
Tests Procedure Interpretation
1 Baudine test Take 5ml ghee in test tube. Add equal
quantity of concentrated HCl. Add furfural
solution, Mix it well. Observe.
This test should be –ve.
2 FFA Take 9.4 ml ghee in conical flask.
Add 50 ml neutralized spirit & plug it by
cotton. Put on hot place / boiling.
Cool at room temperature.
Titration against 0.1 N NaOH & Observe
light pink colour and note the reading.
FFA % = Titrate value × 0.3
Special grade: 1.4%
FFA(max)
General Grade: 2.5%
FFA(max)
Standard Grade : 3.0%
FFA(max)
3 RM value Take 5gm sample in Polenske flask. Add
20ml glycerin + 2ml 50% NaOH solution.
Heat the flask over a flame until mixture
become perfectly clear. Cover the flask with
watch glass & cool. Add 93ml boiling
Should be 28 min.
distilled water slowly drop by drop + 50 ml
dil.H2SO4 (2.5 N). Connect the flask with
distilled unit. Heat the flask until insoluble
acids are completely melted (without
boiling). Collect the distillate at 19-21 min
(100-110ml). At 110ml remove the flame,
cool it. Immerse in water at 15oC. Take 100
ml filtrate, add 1ml phenolphthalein
indicator. Titrate it with 0.1N NaOH
solution, Light pink colour appear.
RM Value = (Burette reading – Blank
reading) * 1.1
4 Polenske value Wash the condenser with the 45ml portions
of cold distilled water passing each washing
separately through the 25ml, cylinder the
110ml flask. Dissolve the insoluble acids by
three similar washings of the condenser with
45ml of neutralized Alcohol & titrate it.
Filter it. In filtrate add 1ml phenolphthalein
indicator & titrate with 0.1 N NaOH solution.
Polenske Value = (Burette reading – Blank
reading)
1.0 to 2.0
5 Peroxide value Take 10gm of sample in 250ml conical flask;
add 30ml Acetic acid-chloroform solution.
Swirl the flask until sample is dissolved
+0.5ml of saturated KI solution, allow the
solution
to stand for 1min. 30ml distilled
water, shake well. Add starch as indicator.
Titrate with 0.01N sodium thiosulphate
solution till yellow colour disappears.
PV = (vol.of sodium thiosulphate * No. of
sodium thiosulphate*1000) / wt. of sample
0.55
(table: 10.3.2)
Butter Analysis:
Sr.
No.
Tests Procedure Interpretation
1 Moisture Take 10g of butter in aluminum dish. Heat
the dish on electric hot plate with constant
stirring. Curd at the bottom has attained the
characteristics slightly brown colour. Allow
the cup to cool in desiccator. When cooled
place the cup on the balance
Moisture content = (wt. before heating – wt.
after heating) / (wt. before heating)
16%(max)
2 Salt Take 10 g of sample in a beaker.100 ml
distilled water, heat it. Add into sample &
mix it well. Take 10ml sample & titrate with
3%(max)
0.1N AgNO3 with K2CrO4 indicator.
Salt = (titre value*mol. wt. of AgNO3)*100/
(wt. of butter)
3 Curd Take 10gm sample. Melt it. Give 3 wash of
petroleum ether. Dry it in oven 1 hr. &
weigh.
1.5%(max)
4 Fat Fat =100 – Moisture – Salt – Curd 80%(min)
(table: 10.3.3)
Flavoured milk analysis:
Sr.
No
Tests Procedure Interpretation
1 Alcohol test
For Raw milk
Take 2 ml milk + 2ml alcohol (68% conc.).
Mix vigorously & check the curdling on the
test tube.
The raw milk used for
flavoured milk should be
alcohol –ve.
2 pH Using pH meter. 6.3 to 6.5
3 Fat
Gerber method
Take 10ml conc.H2SO4 (92%) + 2.5g
powder + 1ml Iso Amyl Alcohol + 1ml
distilled water into 10%butyrometer. Rubber
stopper it & centrifuge it at 1100rpm for
5min.
Koko- 2.4 to 2.5
Kafe- 4.85 to 4.90
Shakers- 3.4 to 3.5
4 SNF SNF% = TS% – Fat% 8.6 to 8.8
5 Cream Index(CI)
Used to check the
efficiency of
homogenization
Cool the milk sample at 20oC & take 50 ml
in each of the 2 centrifuge tubes. Centrifuge
the tubes at 1000 rpm for 15 min. Using fine
pointed pipette take 5ml upper part of the
layer & collect in a beaker. Then collect the
remaining milk in another beaker.
Determine fat content of A & B.
CI = (A-B)/B*100%
It should be <10%
(table: 10.3.4)
Tests for Buttermilk & Dahi:
Sr.
No
Tests Procedure Interpretation
1 TS Take 10 gm. of Buttermilk in a plate & place
it in a Hot air oven at 100oC until constant
wait attains.
Buttermilk – 6 to7%
2 Acidity 10 ml Buttermilk/Dahi + 5 drops of
phenolphthalein indicator. & Titrate against
N/9 NaOH till faint pink colour appears.
Acidity = Titre value×0.1 % as lactic acid
Buttermilk- 0.39 to 0.43%
Dahi - 0.55%
3 Fat Gerber Method Butter milk- 0.5%
Dahi- 3.1-3.3%
4 SNF SNF% = TS%-Fat% Butter milk – 4.5 to 5%
Dahi – 11.27%
(table: 10.3.5)
Water analysis:
Sr.
No.
Tests Procedure Calculation
1 Hardness
Pipette 100ml water into a conical flask.
Add 2 drops ammonia buffer solution (pH
10) followed b) 3 drops of Eriochrome
Black T indicator solution.
Titrate with 0.02 M EDTA until the
solution turns from wine red to sky blue
with no hint of red.
Total Hardness (as mg/lit of
CaCO3) = Reading X 10 ppm
2 Chloride Pipette 10ml water into a conical flask.
Add 2 drops of 5% K2CrO4 solution as
indicator.
Titrate with 0.1 N AgNO3 until the
solution turns from yellow to brie red
colour.
Chloride = (Reading X N X
35.45 X 1000)/V = Cl ppm
3 Alkalinity Take 20.0ml water sample and add 2-3
drops phenolphthalein indicator and titrate
with 0.1 N H2SO4. Note down the reading
as a reading (A). (Pink to colourless is end
point). Then add 2-3 drops mix indicator
and titrate with 0.IN H2SO4.
Light green to pink Colour is end point.
Note down reading as (B).
1) Phenolphthalein
Alkalinity (AS mg/lit
of CaCO3) = A*N *
50000 / V
2) Total Alkalinity (AS
mg/lit of CaCO3) =
((A+B)* N * 50000) /
V
Where, N= Normality of
H2SO4
A = Reading of
Phenolphthalein indicator
titration (1st Titration)
B = Reading of Mix indicator
titration (2nd
Titration)
V = Volume of water = 0.108
3) Alkalinity (As mg/lit
of NA2CO3) = (1.06 X
Total Alkalinity) -
Total hardness
(table: 10.3.6)
Strength of Acid & soda:
Sr.
No.
Tests Procedure Calculation
1 Caustic Soda Take 10ml dist. Water in 250ml conical flask Strength of Caustic soda
% = (Reading*N x 40) /
and weight 0.5g caustic soda in 250ml
conical flask. Add 2-3 drops phenolphthalein
indicator and titrate with 0.5N HCl. Pink to
colourless is end point.
(Weight of caustic soda*
10)
2 Nitric Acid
Take 10ml dist. Water in 250ml conical flask
and weight 0.5g Nitric Acid in 250ml conical
flask. Add 2-3 drops phenolphthalein
indicator and titrate with 0.5N NaOH.
Colourless to pink is end point.
Strength of Nitric Acid %
= (Reading X N x 63) /
(Weight of Nitric Acid X
10)
Where, N = Normality of
HCI or NaOH
(table: 10.3.7)
Packaging material tests:
Sr.
No
Packaging material
& its characteristics
Tests Procedure Interpretation/
Calculation
1 Card board Box
(CBX)
5 ply
(12×1kg Box)
Weight test weigh the entire package in box form
without cutting any part of it on a
sensitive balance.
-
Dimensions Measure the inner dimensions of the
folded box with an accurate cm scale
L*b*h
Bursting
Strength
Using digital bursting strength
apparatus.
The bursting
strength should be
12 kg/ Cm2 .
Grammage
(GSM)
A 10×10 cm specimen is cut from the
CBX and then put it on boiling water
for 10min so that starch based adhesive
melts and the ply layers get separated.
The individual layers allowed to dry at
room temp for 30 min & the oven dried
for 10 min. then each layer weigh
separately.
The resultant
weight is multiplied
by 10 to give GSM.
Outer printing
of CBX
The card board random sample is
chosen & viewed for its outer printings.
Correct details
regarding title of
manufacturer,
weight of product,
stackability, etc.
2 Milk pouch & Ghee
Pouch
(LDPE+LLDPE)
Grammage A 10×10 cm square is cut and weighed. It represents Grams
per square meter.
Thickness Using micrometer Milk pouch-55
micron
Ghee pouch- 100
micron
Outer printing A random sample is picked up and all
printed features such as Principle
display panel, Manufacturer detail,
Product detail, Nutritional facts,
Address of Company, etc.
All the details
should be correct.
3 Tin containers Lacquering
(table: 10.3.8)
Equipments present at central lab:
Sr.
No.
Equipments / Instruments Purpose
1. Milkoscan Fat, SNF, Protein, Lactose
Determination
2. Food scan Fat, moisture, Protein, Lactose
of butter, cheese
3. Auto Titrators Acidity Determination
4. Conductivity Meters Conductivity of CIP Chemicals
5. Microwave Moisture Analyzer Moisture Detection
6. IR Moisture Analyzer Moisture Detection
7. Stamp Volumeter Density of Powder
8. Bursting Strength Analyzer For Packaging Material
9. pH Meter pH Measurement
10. Solubility Index Mixer Solubility Index of Powder
11. Electronic Weighing Balance For Weighing Purpose
12. Gerber Centrifuge For Determination of Fat
13. Muffle Furnaces For Ash
14. Spectronic 20 For colour determination
15. Oxygen Analyzer For determination of Oxygen
content in packages
16. Bulk Density Apparatus For determining Bulk density
17. Electric Hot Plate For heating purpose
18. Remi centrifuge For determination of
insolubility index
19. Refractometer For determination of
Refractive Index
20 Food Scan For chemical analysis of butter
& powder
(table: 10.3.9)
4. Microbiology laboratory:
Since milk and milk products are extremely susceptible to microbial contamination during their
production and processing, it becomes a necessity to assess the microbiological quality of these products in a
quality control lab. As bacterial load is the function of the species of bacteria as well as their number, a
program for controlling the total bacterial load of milk and dairy products must include metabolic activity
test (indirect test) as well as test involving the enumeration of bacteria or test for the presence and absence of
specific pathogenic organism(direct test). The routinely used method in quality control laboratories are:
One random sample of every product is analyzed daily for SPC, Coliforms and Yeast & mold using
readymade dehydrated petrifilms. Pathogen tests are done weekly or once in two weeks.
Different microorganisms:
Type of
Microorganism
Media pH of the Medium Appearance of the Colony
Total viable count Plate count agar 7.0 +/-0.2 -------
Coliforms Violet red bile agar 7.4+/-0.2 Red/ Purple colony
Yeast & mold count Potato dextrose agar 5.6+/-0.2 White/grey/yellow/ black
colony formed
E.Coli Eosin methylene blue
agar
6.8+/-0.2 Green metallic sheen, black
centered colony
Salmonella Bismuth sulphite agar 7.6+/-0.2 Black metallic sheen
Shigella Brilliant green agar 6.9+/-0.2 Pink coloration
S. aureus Baird parker agar 6.8+/-0.2 Black colony surrounded by
clear zone
B. cereus Bacillus cereus agar 7.2+/-0.2 Pink/ white colony
Listeria
Monocytogenes
Listeria agar 7.2+/-0.2 Black colony
Fecal Streptococci Mac Conkey‟s agar 7.4+/-0.2 Pink colony
Vibrio Cholera Thiosulphate citrate bile
salt sucrose agar
8.2+/-0.2 Yellow colony
Anaerobic Spores Liver meat infusion agar 6.9+/-0.2 ----------
(table: 10.4.1)
Sampling plans for analysis of products:
PRODUCT PARAMETERS FREQUENCY REJECTION CRITERIA
Raw milk Plate Count 2 Tankers/ day >5000000 cfu/ml
Pasteurized Milk
from running
Pasteurizer
Plate Count, Coliform
Count
1 sample /day >30,000 cfu/ml
Present in 0.01ml
Pathogen Test 5 samples /month Present
Railway tanker
milk
Plate Count, Coliform
Count
Every tanker >30,000 cfu/ml
Present in 0.01ml
Sterilized
Flavoured milk
Plate Count, Coliform
Count
1 sample / shift
> 5 / ml
Spore Count
Various milk
powders
Plate Count Composite sample of
two / shift
> 40000 / g
Coliform Count Present in 0.1 g
Pathogen Present
Butter Plate Count 2 samples / line / shift
>5000 / g
Coliform Count > 5 / g
Yeast & Mold Count > 5 / g
Pathogen Weekly- 7 days
composite
Present
Export Butter
Plate Count 100 g – every 50th
case of each
consignment.
500 g – every 100th
case. Composite
sample for each
consignment.
>5000 / g
Coliform Count > 5 / g
Yeast & Mold Count > 5 / g
Pathogen Present
Raw materials-
Maltodextrin ,
Salt, Annatto,
Coliform Count Each consignment or
Twice in a month
Present in 1 g
Yeast & Mold Count Present in 1 g
Vitamins , Corn
oils, Colour
Pathogen Present
Raw materials –
Sugar , TSP
Coliform Count Twice in a month Present in 1 g
Yeast & Mold Count
(Table: 10.4.2)
CONCLUSION
Amul spurred India‟s White Revolution, which made the country the world‟s largest producer of milk
& milk products. In the process Amul become the largest food brand in India and has ventured in to
markets overseas.
Amul committed produce safe and wholesome food to continually remain as the market leader by the
providing the food product delight customer expectation & best of safety.
Here in Amul learned about the practical working at the Industrial level. The various problems that
can occur & the different ways to shoot them.
The important of working environment and how to generate highly professional work environment.
We also learnt about how to manage the available resources to extract maximum production and the
handling of manpower to get the professional work experience.
Working in any industry is difficult without mutual understanding, co-operate nature and team work.
Here in Amul learned about all these things. To learn all the above things the historic unit of Amul is