IN PLANT TRAINING FROM ALWAR DAIRY
PRESENTED BY: SUBMITTED TO:
Ajeet singh jadaun Mr.RAHUL AGWRWAL
Mr.VIKASH BANSAL
INDEX
Introduction
Quality Control
Processing Section
F.M.P(Fermented Milk Product)
Alwar dairy was taken in march 1972 at alwar zila dugdh utpadak
sahakari sangh Ltd.Alwar was registered under cooperative act 1965
to work. Initially the union did not have processing facilities. It was
started with modest beginning of procuring 500litre of milk per day.
The initial handling capacity of the dairy plant was 1litre per day
with a powder plant 10mt per day capacity, which was commissioned
in the year 1979 under operation through flood program one by
national dairy development board of service of thousands ruler
farmers families of alwar.saras there of under brand name of saras
the plant is managed and operated by well qualified, competent an
experience managerial cadre and highly motivated work force
provide highest quality of product and best of the service to the our
esteemed customer.
Alwar dairy has earlier opted the quality management system
certification as per ISO 9001:2008 in combination with
IS:15000(HACCP) in the year 2000 for the further improve the
efficiency effectiveness of the plant performance.
COMPOSITION OF MILK
TOTAL WATER85
SOLID15% %
FAT3.4% SNF
VITAMIN PROTEIN MINERAL VITAMIN GAS
ASSOCIATED
TRUE FAT LACTOSE4.9% 0.7%
FAT A,D,E,K 3.3% B O2&Co2
Ca,K,Na,P, COMPLEX
Cu &
C
CASSEN WHEY
2.Quaility control
Dock testing
Chemical testing
Processing testing
Microbial testing
Dock testing
a. Sensory testing
Taste, smell, visual observation and temperature-These tests are also called
’organoleptic tests‘. It is also reliable if the person carrying out the tests is
experienced. The tester smells the milk, observes the appearance, tastes if
necessary, checks the can for cleanliness, looks for sediment, and filters the milk to
check its cleanliness. If doubts arise after the examination about the quality of the
milk, other tests can be done to determine the quality.
b. Alcohol Test
Take 5ml of milk sample in the test tube.
Add 5ml of ethyl alcohol(50-60%) for raw milk(in summer, winter) slowly
by mixing the contents of the test tube.
Observe for any flakes formation, if yes, alcohol test is positive otherwise
negative.
Chemical Testing
a. Adulterants and Preservative
Salt
1ml N/10 AgNO3 + 2-3 Drops of Potassium Chromate (5%) + add milk quantitatively
Yellow color indicate positive & brown color indicate negative.
Neutraliser
5ml milk + 5ml ethanol + few drops of Rosalic acid ( 1% in Alcohol)
Rose red / pink color indicate positive else negative.
Urea
1ml milk + 1ml Di Methyl Amino Benzaldehyde
Dark yellow positive or light yellow negative.
Starch
1ml milk boil it + 1ml (1%) iodine solution
Purple color positive else negative.
Sugar
10ml milk + 1ml conc. HCl + pinch of Resorcinol. Mix the contents.
Kept in water bath for 5 mins. Look for color change.
Red color indicate positive otherwise negative.
Detergent
1ml milk + 1ml Ortho Bromo Cresol (0.5%)
Purple color positive else negative.
Sulphate
20ml milk + coagulate the milk with 1% lactic acid. Filter it. Collect the filterate. Add 1ml 5% BaCl2 to 5ml
filterate.
Presence of turbidity indicate positive else negative.
Ammonia compounds(pond water)
. Take 5ml milk in a test tube.
. Add 1ml of nesseler’s reagent from the side of the tube.
. Yellow or brown colouration at the bottom indicates the presence of ammonia radicals(NH4).
. The intensity of colour depends upon the concentration of the ammonia compound.
Hydrogen peroxide
Take 5ml milk in a test tube.
Add 2-3 drops P-Phenylene diamine dihydrochloride (1%) .
Formation of blue colour indicates hydrogen peroxide(H2O2) test positive.
Formalin Test
To 5ml milk in a test tube add 0.5ml of 1% FeCl3 solution.
Mix well and add concentrate sulpheric acid slowly along the side of the test tube.
Formation of violet ring at the junction of two liquids, confirm presence of formalin.
Processing Testing
Acidity Test
To 10ml throughly mixed sample in a flask or beaker, add 10ml distilled water and 1ml of
phenolphthalein indicator.
Mix and titrate against N/10 sodium hydroxide till the end point, faint pink colour just appears.
The volume of N/10 NaOH used, multiplied with 0.09, give the percentage of titrateable acidity
in the milk samples.
C.O.B Test (clot on boiling)
Take 5ml of milk sample in a test tube.
Heat it on a flame and observe for any cloting.
If no clot, C.O.B is nagative, if clot is formation is there C.O.B is positive.
Testing of Moisture percentage
Weight a dried and cooled dish(A).
Weight 10gms of sample into dish(B).
Keeping the dish in the oven maintain 100(+-2degree) celius for two
hours.
Transfer the dish to dessicator for cooling.
Weight the dish(C).
Moisture% = (B-C)/(B-A)*100.
Fat test (Gerber method)
. Take 10ml of Gerber sulphuric acid (90-91% by mass) in butyrometer.
Transfer 10.75 ml of milk.
Then add 1ml of iso amyl alcohol.
Adjust the level by addition of distilled water.
Close the neck of butyrometer by rubber lock stopper.
Shake the butyrometer to mix the contents and then invert the
butyrometer few times to mix the contents thoroughly.
Transfer the butyrometer in centrifuge.
Centrifuge at maximum speed for at least 5 minutes.
Keep the butyrometer in 65OC water bath.
SNF test
Transfer the milk in lactometer jar at 15.50C or 290C according to
. lactometer used.
Left for sometime so foam which are present come up
Remove the foams.
Dip the lactometer in lactometer jar.
Immediately read the lactometer reading at 15.50C.
Apply the correction factor if any.
Calculate the SNF as
%SNF = CLR/4 + 0.2 Fat% + 0.14 (for raw milk)
%SNF = CLR/4 + 0.2 Fat% +0.4 (for pasteurised milk)
Correction factor is +0.2 for 1oC rise & -0.2 for 1oC fall.
Microbial Test
MBRT (Methylene Blue Reduction Time) Test for milk
Take 10ml milk in sterilised test tube.
Add 1ml of Methylene blue solution in test tube.
Place the tube in water bath at 37 ± 1oC.
Record the initial time & look for the color change.
Record the MBR time.
Processing Section
Skim milk Double Toned Milk Standardized FCM Milk
toned milk Milk
Fat% 0.50max 1.60 3.10 4.6 6.10
SNF% 8.80 9.10 8.60 8.60 9.10
Acidity% 0.10-0.14 0.10-0.14 0.10-0.14 0.10-0.14 0.10-0.14
MBRT 5hrs 5hrs 5hrs 5hrs 5hrs
Processing of milk
DOCK PASTEURATION SEPRATOR
CHILING
RAW MILK BALANCE TANK MACHINE
3-4DEGREE
WEIGHING& RAW MILK
SAMPLING
SILO TANK
TANK
PUMP TO THE CHILING
PROCESSING MACHINE PACKAGING STORAGE
SECTION 8-12DEGREE
pasteurization
Regeneration 1(45-60)
Separator(1475rpm)
HOT (78-80)
HOLDING TUBE(17sec)
Regeneration2(45-60)
COLD(3-4)
SILO TANK
C.I.P
HOT WATER(55-65)
LYE(70)
ACID(80)
LYE(70)
HOT WATER(55-65)
PROCESS MILK
Ghee ProcessCREAM BY SEPRATION OF MILK
BUTTER CHAIN
MILK PROCESS MELTIVATOR(90)
CATTLE TRANSFER(95-105)
RAW GHEE BUTTER IMPURITIES
GST HOPER
CLEANIFIER MELTIVATOR
GHEE TANK RESIDUCE
PACKAGING DRAIN
STORAGE
PROCESS MILK
CURD PROCESS PRE HEATER(40)
BALANCE TANK
ADD CULTURE(.1%-.2% BY VOL. )
FILLING OF CUP
INCUBATION(3-4HRS)
IMMEDIATELY COOLING BELOW 5
STORAGE
PLAIN CHACH PROCESS MILK
PRE HEATER(40-42)
BALANCE TANK
ADD CULTURE(.1%-.2% BY VOL. )
CUTTING DILUTION THROUGH CHILLER
PACKAGING
PROCESS MILK
LASSI PRE HEATER(40-42)
BALANCE TANK
ADD CULTURE(.1%-.2% BY VOL. )
CUTTING DILUTION THROUGH CHILLER
ADD SUGAR(10-12%)
PACKAGING
STORAGE
PROCESS MILK
NAMKEEN CHACH PRE HEATER(40-42)
BALANCE TANK
ADD CULTURE(.1%-.2% BY VOL. )
CUTTING DILUTION THROUGH CHILLER
ADD JEERA& SALT(0.1%&0.25%)
PACKAGING
STORAGE
CURD
SHREEKHAND
MUSLIN CLOTH(24 HR)
ADD SUGAR 70%
ADD SAFFRON 0.013%
PACKAGING
STORAGE
PROCESS MILK
PANEER PROCESS PRE HEATER(60)
Paneer vet (double wall jacket)80
ADD Citric acid(.2% BY VOL. )
Casein separate
pressing
chilling
packaging
STORAGE
