Submitted by:

Nishant Sachdeva

L-2010-A-03-B.tech FT

Industrial TrainingThe Ludhiana District Co-operative Milk

Producer's Union Ltd.

Introduction First Milk Plant, of the State was setup at Verka near Amritsar.

The brand name of Milk and Milk Products was adopted as

Verka.

The Foundation stone of Milk Plant, Ludhiana was laid by Hon.

S. Parkash Singh Badal, the then Chief Minister of Punjab in

1970.

Commissioning of the Plant was done by Punjab Dairy

Development Corporation in 1974.

Inauguration was done by Late Smt. Indira Gandhi the Prime

Minister of India.

The capacity of the plant was 1.00 lac. Litre per day, and now

the milk handling capacity is 4.00 Lac Liter per day.

• Amritsar

• Bathinda

• Chandigarh

• Faridkot

• Ferozpur

• Gurdaspur

• Horshiarpur

• Jalandhar

• Ludhiana

• Patiala

• Ropar(Mohali)

• Sangrur

MILKFED has its milk unions in almost all the districts of Punjab. These

district units are:-

These plants in all these unions are being run under the brand name VERKA.

Present Status

No. of societies increased from 94 to 802 and its membership

from 5400 to 78500.

Milk Procurement has increased from 10200 LPD to 2,50,000 LPD.

Highest milk price is being paid to the milk producers as compare

to other plants in the states

Products being manufactured by Ludhiana Plant are sold at

premium rates through out of the country and in the

International Market.

City supply has increase from 66000 LPD to 1,98,000 LPD.

Turnover the plant touched to 283 crores Profit of the union has

increased manifold.

Capacity utilization of the plant is more than 85%.

Full name : The Ludhiana District Cooperative Milk Producers Union Ltd.

Foundation : Laid by Hon. Sh. Prakash Singh Badal in 1970

Capacity : Then 1 lakh L/day, Now 6 lakh L/day

Head office : Punjab State Co-operative Milk Producers Federation Ltd. S.C.O.153-155, Sec. 34-A, Chd.

Inauguration date : 31stOctober, 1974

Chairman : Sh. Ajmer Singh

No. of societies : 816

No. of Chilling centers : 4

Brand name : VERKA

Products marketed by : The Punjab State Co-operative Milk Producers Federation. Ltd.

Quality certificates : International Quality Certificate ISO-9002 & IS-15000 (HACCP)

• Verka milk plant (VMP), Ludhiana is known as The Ludhiana Dist.-Co-

operative Milk Producer’s Union Limited, Ludhiana . It is situated on

Ferozpur Road, about 5 km. away from both railway station and main bus

stand.

• The plant has bagged first position in Northern Zone

• It is fully equipped with modern fluid milk plant facilities. The latest state

of art technology in milk drying is available in this plant.

• The products manufactured by this Plant at present are STM, DTM, FCM,

SMP, WMP, Ghee, Butter, Paneer, Milk-Cake, Dahi, Kheer, Lassi .

Contd…

Some objectives of the Milk Plant are:-

• To uplift social and economic status of milk producers.

• To develop dairy as industry allied to agriculture.

• To provide better and remunerative prices for milk.

• To provide veterinary aids to animals of milk producers at their doorstep.

• To provide better quality cattle feed at reasonable rates.

• To educate the milk producers about lowering down the cost of milkwithout compromising quality.

• To create employment opportunities for rural youth by milk productionactivities.

• To provide awareness among milk producers for socio-economic changethrough co-operative set-up.

Product brand name : VERKA

Milk handling capacity : 6 lakh litres per day

Production of market milk : 2.5 lakh litres per day

Production of butter : 13000 Kg per day

Production of ghee : 14 MT per day

Production of powder : 30 MT per day

Production of paneer : 400-450 Kg per day

Production of kheer : 200 Kg per day

Production of milk cake : 30-40 Kg per day

Production of dahi : 1400 Kg per day

Production of lassi : 3000 Kg per day

POWDER SECTION

• There are definite indication of greater future productions of dried milk & milk products due to their better keeping quality, they require less storage space & lower transportation costs. All these are economically attractive.

• Dried milk provides a means of handling the excess milk supply in a dairy factory during flush season, while in lean season that meant for the production of dry milk can be diverted to market milk. Thus, dried milk is called the balance wheel of dairy industry.

• VERKA MILK PLANT, LUDHIANA has two separate drying plants.

The Dairy has two separate drying plants, viz:

• Powder section with MVR unit & TVR unit (30TPD)

• Powder section with TVR unit only (6.5TPD)

Compositional & other Standards maintained :-

Parameters SMP Standard grade SMP Extra grade WMP

Moisture (%) 3.2-3.6 3.0-3.4 Max. 3

FAT (%) Max. 1.3 Max. 1.2 26.5-27.5

Acidity (%LA) 1.0-1.25 1.0-1.2.5 Max. 1

B.D. Agglomerated (gm/ml) 0.45-0.55 0.5-0.6 0.5-0.6

Insolubility Index (50ml) Max. 0.15 Max. 0.15 Max. 0.5

Ash content (%) Max. 8.2 Max. 8.2 Max. 0.5

Coliform Nil Nil Nil

PROCESS CONTROL

Lumpiness in Powder

1. Ensure proper cooling of powder

2. Dehumidifier should be properly operating

Low moisture in Final Product 1. Increase flow rate

2. Adjust outlet temp

Burnt Powder Particles 1. Adjust inlet temp

2. Check the function of feed flow controller & feed pump

3. Nozzle of jets are whether chocked partially

Sooty Powder 1. Clean or change the filter.

2. Check up air heater

Very Fine Powder A Particles 1. Increase in degree of concentration

2. Control the feed temp.

Solubility Index Increased 1. Check the outlet temp.

2. Control feed rate

OPERATING PARAMETERS FOR EVAPORATING PLANT

PARAMETER STANDARD & EXTRA GRADE W.M.P CONCENTRATED MILK

Milk feed rate (lts/hr) 16000-17000 3500-14500 16000-17000

Steam pressure (kg/sq.cm) 5-6.5 5-6 5-6.5

Thermal vapor recompression

(kg/sq.cm.)

2-2.5 2-2.5 1-1.5

High heater (temp oC) 90+/-2 95-100 90+/-2

Holding heater temp (oC) -Do- -Do-` -Do-

Flush vessel temp (oC) 73-85 73-85 73-85

Jacket temp (oC) 69+/-1 69+/-1 69+/-1

Vapor Separator I (oC) 66+/-2 66+/-1 66+/-1

Vapor Separator II (oC) 58+/-2 58+/-1 58+/-1

Vapor Separator III (oC) 50+/-2 50+/-1 50+/-1

Vacuum in condenser 0.9m bar 0.9m bar 0.9m bar

T.S. % of condenser 20+/-3 20+/-3 20+/-3

OPERATING PARAMETERS FOR DRYING PLANT

PARAMETERS SMP WMP

Chamber inlet air temperature (oC) 170+/-10

180+/-10

165+/-5

170+/-5

Vibro fluidier air inlet temperature (oC) 90+/-5 65+/-10

Chamber outlet temperature (oC) 80-90 80-90

Vibro fluidier outlet temperature (oC) 64+/-2 65+/-2

Chamber vacuum (mm.w.c) 5+/-2 15+/-2

Atomizer load (amp) 55+/-5 55+/-5

Load on exhaust fan (amp) 95+/-5 95+/-5

Powder output (kg/hr) Min. 1375 Min. 1500

Powder Plant

Drying Chamber

Cyclone

Control Panel

Processing Operations

• Chilling: Milk is chilled below 4 ºC. The raw chilled milk is utilized for the various products processing operations. The chilled milk is stored in tank called as Silo. The chiller is plate heat exchanger type.

• Pasteurizing: Milk is heated at 63 ºC for 30 minutes or 75-80 ºC for 15 sec and then cooled immediately below 14 ºC.

Type of milk received :-

Cow Milk :- Fat Min. 3%, SNF Min. 7.9%

Buffalo Milk :- Fat Min. 6%, SNF Min. 8.6%

Mixed Milk :- Fat Min. 5.4-5.5%, SNF Min. 8-8.5%

Make : Cast iron grid tiles, edges are of cast iron

planting

Width : To overcome heavy stresses

Types : 1.5mm

Slope : Open

Cans : 40 Liters capacity, weighing 6-6.5 kg

Material : Aluminum

• Starting the RMRD

• Unloading and Conveying

• Opening the lids

• Grading

• Weighing and Sampling

• Cleaning & Washing of cans

• Recording of cans

• Loading

• Closing down RMRD

Composition of Milk

Characteristic Cow milk Buffalo milk

Fat 4.0-4.5 % 6.5-7.0%

Carbohydrates 4.5 % 4.7 %

SNF 8-8.5 % 8.5- 9.0%

Proteins 3.3 % 3.6 %

Minerals 0.6 % 0.7 %

Water 87-88 % 84-85 %

Milk

Fluid Milk

Packing Given

Prefernce

Lassi

Milk-cake

Kheer

Dahi

Surplus Fat

Table Butter

White Butter

Ghee

Skim Milk

Skim Milk Powder

City Supply Section

Compositional & other Standards maintained :-

Equipments used are- Steam Jacketed Vat, Trolleys, Sealing Machine, Hoops,

Automatic Machine For Processing.

• Cleaning of vats, hoops & muslin cloths is done manually, then they are

sanitized with 0.5% teepol & hot water at 55-60oC

Fat Not < 50% of dry

mater basis

Moisture Not > 70%

Texture Soft & spongy

Taste & flavor Pleasant

Whole milk

Heating (90oC) for 15 min

Filtration (with clean muslin

cloth)

Coagulation (1-2% citric acid)

Separation of whey

Hoping

Pressing

Cutting into blocks

Dipped in pasteurized &

chlorinated chilled water (4-10oC/45-60 min)

Cut into pieces & weighing

(200gm manually)

Packing in polythene

sachets

Storage at butter cold store Dispatching

Flow diagram for Paneer

manufacture

This dairy plant follows the ISI standard of dahi. Mostly it is manufactured

every two alternate days in flush seasons.

Compositional & other Standards maintained :-

Equipments used are- Steam Jacketed Vat, Weighing Balance, Cans, Incubation

Chamber, Dahi Packaging Machine.

Fat 4-5%

Protein 3.2 -3.4%

Acidity 0.8-1.0%

Taste Cream-sour

Flavor Acid

Milk is taken in Vat For DahiPreparation

Standardization &

Homogenization

Pasteurization (80-90oc/15-30

Min)

Cooling (37°C)

Inoculation with Lactic Culture (from previous

day Dahi)

Filling by pipe filler in

polystyrene cups

Sealing the Cups

Putting 12 Cups in each Card Board Box

Incubation (37oc/1.5-2hr)

Dahi Prepared

Cooling & Storage (5oc)

Dispatch

Flow diagram for Dahi manufacture

Ludhiana milk Plant is engaged in making two types of butter viz

Table Butter

White Butter (White Butter is made and stored as stock and is used

in lean season for recombination and is also used as base material

for ghee & often supplied for bulk demand).

The dairy produces butter by batch churn method. There is also a

provision for continuous butter making machine.

The packed butter is stored at -17 to -29oC till dispatch.

Loading of churn 1/3rd volume of drum capacity

Loading temp (oC) < 10-12 oC

Churning temp (oC) < 10-12 oC

Color addition 1ml/kg fat

Spray water temp (oC) Max 5

Speed of churning

28-30 rpm (1st gear)

14-18 rpm (2nd gear)

7-8 rpm (3rd gear)

Salt addition (dissolved in pasteurized warm

water)22mg/kg of butter yield

Vacuum during operation 300-350mm

FAT % in cream 40-42

Cream from separator

Cram pasteurization

Storage in cream tank for

ageing

Feeding to butter churn

(In case of table butter color is

added @ 1ml/kg/fat)

Churning at 1st

gear up to breaking point

(30-35min)

Churning at 2nd

gear (30-45 min)

Churning at 4th

gear of white butter

Removal of buttermilk

Washing at 2nd

gear (6-8oC/15 min after

adding water)

Equal in volume of buttermilk removed)

Draining of water

2nd washing

Salt @ 2.2% is added (for table

butter)

Working & controlling of moisture at 2nd

gear

(25-30 min. 300-350mm)

Unloading (before it rotate at 2nd gear for 5

min)

Packaging (500, 100, 10 gm)

Storage (-17 to -29oC)

Package in card board boxes

Flow diagram for Table Butter manufacture

Compositional & other Standards maintained :-

• Equipments used are- Butter Melting Vat, Pre-stratification Tank, Ghee

Boiler, Settling Tank, Filling/Storage Tank, Ghee Clarifier, Electronic

Weighing Balance, Closure Punching Machine, Pouch Filling Machine.

Flavor & color Pleasant & white or yellow

Moisture Max. 0.25%

F.F.A (% Oleic Acid) Max. 0.03%

B.R. reading at 40oC 40-43

Peroxide value Max. 1

Sediment Absent

Pre-melting temp (oC) 75-80

Cooking temp (oC) 105-112

Batch time (hr) Max. 4

Steam pressure in kettle (kg/sq.cm.) 2

Filtration Falalin cloth

Clarification temp (oC) 95+/-5

Setting time (hr) Min. 6

Ghee filling tank temp (oC) 43+/-5

Ghee filling temp (oC) 42+/-5 °C

After packaging the packed corrugated boxes are kept in

granulation room for 24 hrs. Then the boxes are transferred into

storage room till dispatch.

LASSI : Lassi is a drink made of standardized milk with 50:50

dilutions with water.

Receiving milk

↓

Standardization(4.5%fat and 8.5%snf)

Heating of milk85°c /5min

Cooling down to 40°c

Inoculation with culture at 1% at 40 °cInoculation at 40 °c(till acidity reach 0.67%)

Addition of pasteurizedchilled water 2%

Breaking of coagulum( acidity o.54%)

Packaging

Cold storage less than 5°c

Kheer is concentrated heat desiccated indigenous dairy product.

Taking milk in double jacketed vat

Heating milk to desirable reached with consistency with

continuous stirring

Addition of basmati rice in boiling milk and stirring

Heating it till desired consistency reached with

stirring

Addition of sugar

Addition of mixture of sodium benzoate and Elaichi powder

Stirring for some time and filling in cups(200 g)

Storing in cold room(below 8˚C)

Any question ?