INDUSTRIAL TRAINING

AT
VERKA MILK PLANT, MOHALI

REPORT ON
QUALITY CONTROL AND PRODUCTION MANAGEMENT

NAME:GAGANDEEP KAUR

ROLL NO: 219301

 DECLARATION

I hereby declare that industrial training in Verka Mohali Dairy, Mohali is an authentic record
of my own work as requirement of training during the period from 03.01. 2022 to
03.02.2022 for the award of degree of M.Sc. chemistry.

PLACE:MOHALI
NAME:GAGANDEEP KAUR
DATE:
 CONTENTS

• INTRODUCTION TOCOMPANY
• COMPANY OBJECTIVES
• COMPANY DETAILS
• RMRD (RAW MILK RECEPTION DOCK)
• DIFFERENT SECTIONS IN VERKAPLANT
• THREE MAIN LABS OF PLANT
• TESTS PERFORMED IN DIFFERENTLABS
• MILK PROCESSING AND PACKAGINGSECTION
• FERMENTED DAIRY PROCESSING AND PACKAGINGSECTION
• KHEER PROCESSING AND PACKAGINGSECTION
• PANNER PROCESSING AND PACKAGINGSECTION
• BUTTER PROCESSING AND PACKAGINGSECTION
• GHEE PROCESSING AND PACKAGINGSECTION
• ENGINEERING SECTION
• CONCLUSION
 INTRODUCTION TO COMPANY

The Punjab State Cooperative Milk Producers' Federation Limited (MILKFED) came into
existence in the year 1973 to improve dairy farming in the province of Punjab. The
essential point was to give a worthwhile milk market to the state milk makers by esteem
expansion and showcasing of produce Another of its goal was to give specialized
contributions to the improvement of milk creation. In spite of the fact that the alliance was
enlisted very before, it came into its genuine structure in the year 1983 when the milk
plants of the previous Punjab Dairy Development Corporation Limited were allowed to the
Cooperative Sector under Operation Flood. The move was completed in the state to give
more ideal arrangement to the ranchers and better items to the clients MILKFED is set-up
as a three- level framework with Federation as the summit body at the State Level, Milk
Unions at the District Level and Cooperative Societies at the town level The association
has ceaselessly progressed towards its pined for destinations clear cut in its by-laws.

OBJECTIVES OF A COMPANY:
a. To guarantee quality milk acquirement at gainful cost combined with improved creature
usefulness for decreasing expense of milk creation for economic development of the milk
makers.

b. To give quality expansion administrations at the entryway steps of milk makers.

c. To guarantee Quality Assurance in obtainment, preparing and advertising and improving

effectiveness in the whole worth chain.

d. To guarantee procurement, improvement and maintenance of capable labour.

e. To improve financial administration by enhancing the profits on capital.

f. To guarantee ceaseless modernization in the whole worth chain through successful

utilizing of innovation.

g. To accept development in the whole worth chain for purchaseramuse.

h. To guarantee constant extension of conveyance.

J. To improve brand value.

THE ROPAR DISTRICT COOPERATIVE MILK PRODUCER'S
UNIONLIMITED

VERKA MOHALL DAIRY, S.A.S. NAGAR. PUNJAB

Milk Union Mohali enrolled during 1978 and began working on Anand Pattern from Sept.
1979 It buys new Milk double a day straightforwardly from Milk Producers by getting
sorted out Milk Makers' Co usable Societies (MPCS) at town level in whole Ropar and
Mohali Distt. furthermore, part of Fatehgarh Sahib and Patiala Districts. By and by. The
Ropar District Cooperative Milk Maker's Union Limited, Verka Mohali Dairy is a front-line
Milk Plant in Co-employable Sector having introduced taking care of limit of 5,00.000 liters
of Milk for every day 1210 utilitarian milk maker co-usable social orders shaped at town
level are providing about average of 3,62,000 liters of Milk each day This milk acquisition
goes to around 5,20,000 liters in a day during top flush season New milk is acquired
straightforwardly from milk makers through village level social orders double a day The
principal capacity of this plant is to give best nature of Pasteurized Liquid Milk to the
buyers in Chandigarh and its satellite cities. A part from Liquid Milk supply (Full Cream
Milk, Std. Milk, Toned Milk, Double Toned Milk &Skimmed Milk), this Plant likewise produce
Ghee, Pancer, Curd, Plain Lassi, Kheer. Spiced Lassi, Sweet Lassi, Raita. To safe
gatekeeper the interest of regarded buyers and our milk makers, assembling of Verka
desserts with unadulterated Desi Ghee and Khoa in plant grounds has been dispatched.
Every one of the items are produced under the brand name of VERKA Being a practical unit
with strong monetary wellbeing, this plant delivers profit to all part social orders out of its
procuring each year.
 MILK RECEPTION FLOW CHART

Tanker

Weigh bridge

Sampling

Sample Approved Sample Not Approved

Unloading

Manually Automatically

Pumped toStoragetank Deaeration Vessel

Duplex Filter

Raw Milk Chiller (Milk Chilled to 3degree Celsius)

Pumped to RMST (Raw Milk Storage Tank)

TESTS PERFORMED IN LABORATORY ON RAW

MILKRECEPTION:

1) FAT test (By Gerbermethod)

2) SNF test (by lactometer) SNF CLR/4+0.22F+0.29CLR= corrected lactometer reading at

27° CF= fat of milk by Gerbermethod.

3) Adulteration test(negative)

4) BR reading of milk (40-43 at40°C)

5) Sodium test of milk (up to 450ppm)

6) RM value of milk(28-32)

7) Quantity To be checked

8) Acidity

9) MBRT for good quality raw milk is 2hours

.
DIFFERENT SECTIONS IN VERKA PLANT

►Quality controlsection

1. Mainlab

2. Dock lab

►Milk processingsection

ProcessingSection

►Filling Section

►Curd Manufacturing and Packingsection

►Kheer Manufacturing and Packingsection

► Lassi Manufacturing and Packingsection

► Panner Manufacturing and Packingsection

►Butter Manufacturing and Packingsection

➤Ghee Manufacturing and Packingsection

RAW MILK RECEPTION DOCK.-:

1 Verka follows an exacting arrangement of value confirmation to keep a

high quality of milk gave to the buyer

2 The milk is gotten from neighborhood social orders at town level, where

chilling centers are introduced

3. Based on some principle tests the milk is evaluated intoclassifications

.
GRADING OF RAW MILK:

QUALITY CONTROL AND ASSURANCE SECTION OR AREA :

Quality Assurance

DockLab Quality Lab

Chemical Microbiological AGMARK

MAIN LABS INSIDE PLANT

1 Quality Control lab

2. DockLab

ROLES OF DIFFERENT LABS

DOCK LAB

1. Grading of incoming raw milk

2. Raw milk testing

3. Testing of outgoing pasteurizedmilk

4. Testing of processed milk stored in storage tank or silo

5. Creamtesting

6. Buttermilk testing

7. Standardization of fluid milk

8. Checking of strength of detergent in crate washer

QUALITY CONTROL LAB

1.Sensory evaluation of milk and milk products

2. Checking the composition of milk products

3.Hardness of water

4. Checking the quality of reagents, packaging materials, glass wares for testing

5.Checking efficiency of waste water treatment

 TESTS PERFORMED IN LAB

1. DOCK LAB: Tests performed in a dock labare

Acidity test

► MBRTtest

► Fat and SNF test

► Adulteration test

ACIDITY TEST: Bacteria that normally develop in raw milk produce more or less of lactic acid in the
acidity test the acid is neutralized with Sodium hydroxide and the amount of alkaline is measured.
From this, the percentage of lactic acid can be calculated

Procedure:
► Take 10 ml of sample (can be milk, lassi, cream, Dahi etc) in 10 ml conical flask.
► Hold the flask against whitesurface
► Add 4-5 drops of phenolphthalein to the sample and stirgently
► Titrate against N/10 NaOHsolution
► Continue until the appearance of a 10-20 seconds and down the volume of NaOH used

So, % Acidity = volume of NaOH used (in ml)/10

Result : The milk with 0.15 acidity is best milk

 MBRT TEST: The methylene blue reduction test is based on the fact that the color imparted
to milk by the addition of a dye such as methylene blue will disappear more or less quickly. The
removal of the oxygen from milk and the formation of reducing substances during bacterial
metabolism causes the color to disappear .

Procedure:
1. It's the method of estimation of total bacterial count of milk.
2. To 10 ml of milk in a sterilized test tube a
dd 10 ml of methylene blue dye Plug with a sterilized cork, invert the tube to mix the contents.
3. Incubate at 37°C in a water bath. 3. Note down the time in which the colour of dye gets
disappear and that will give the MBRTtime
4. Note down the time in which the colour of dye gets disappear and that will give the MBRT time.

DETERMINATION OF FAT CONTENT BY GERBER METHOD:

The test is a volumetric method in which fat is separated from milk by centrifugal force
Sulphuric acid is used to dissolve the protein that forms the membrane around the fat (fat
globules) and amyl alcohol is added to improve the separation of fat from other solids

Procedure:

1. Take 10ml of Sulphuric acid (10% dilute for milk and 20% dilute for
lassi) inbutyrometer.
2. Add slowly 10.75 ml sample (can be lassi or milk) init.
3. Add 1 ml isoamyl alcohol and adjust level with distilledwater.
4. Cap butyrometer with lockstopper.
5. Centrifuge for about 5minutes.
6. Take reading of the % fat by reading thebutyrometer.

DETERMINATION OF SNF CONTENT BY LACTOMETER:

The method is based on the Archimedes Principle, which states that when a solid is
immersed in a liquid it is subjected to upward thrust equal to the weight of liquid
displaced by it and acting vertically upwards. Lactometers are variable immersion type
hydrometers and calibrated beforehand with liquid of known specific gravity.
Procedure:
► Warm milk in lactometer jar at about 40°C then cool at 15.5°C.
► Immerse lactometer in jar and takeC.L.R.
% SNF = CLR/4+0.2-fat+0.29
► Fat% & S.N.F% can also be estimated by using milko-scan before which the sample is
heated to temperature of 40degreeC.

Observations:

First and Third sample is of packaged milk and second sample is of rawmilk.

TESTS FOR DETECTION OFADULTERANTS:

ALCOHOL TEST:
The alcohol test is used on fresh milk to indicate whether it will coagulate on thermal
processing. This test is especially important for the manufacture of UHT milk, evaporated
milk and milk powders. This test is more sensitive than Clot-on Boiling (COB) test.

Procedure:
► Take 5.0 ml of milk in a test tube using graduatedpipette.

►Add equal amount of 70% ethylalcohol

►Close the mouth of the test tube with thumb and mix the contents well by inverting

►the test tube severaltimes.

Result: Formation of any flakes on the wall of the test tube indicates positive test.
DETECTION OF GLUCOSE:
Take strip for glucose detection and dip it in milk. If blue color persists, it indicates
positive glucose

DETECTION OF SALT:

Procedure
1. Take 2ml of Silver Nitratesolution.
2. Add few drops of potassium chromate and 2ml milksample.
3. Yellow color indicates positive salttest.

DETECTION OF UREA :

Procedure:
1 Take 2ml urea detecting agent (DMAB-Dimethyl Amino Benzaldehyde reagent) andadd
2ml milk
2 Deep yellow color indicates positive ureatest

PHOSPHATASE TEST:
Alkaline Phosphatase is an enzyme which is naturally present in milk but is destroyed at a
temperature just near to the pasteurization temperature Alkaline Phosphatase test is used
to indicate whether milk has been adequately pasteurized or whether it has been
contaminated with raw milk after pasteurization.
The alkaline phosphatase enzyme in raw milk liberates phenol from a disodium para-nitro phenyl
phosphate and forms a yellow-colored complex at alkaline ph. The intensity of yellow colour
produced is proportional to the activity of the enzyme

Procedure:
1. Take Al tubes and fill it withsample
2. Then keep these in centrifuge so that cream layer is formed ontop.
3. Then take the cream with the help of spatula and heat cream so as to makeghee
4.Then put drop of ghee inbutyrometer
5. Note down the value of BR reading.

ESTIMATION OF BR VALUE OF MILK SAMPLE:

Vegetable oils, hydrogenated fats, animal body fats and their blends have been reported as
adulterants in milk and milk fat products. The elevation of Butyro-refractometer (BR) reading of
milkfat by addition of different vegetable oils is used to detect adulteration of milk It should be
between40-43 for milk fat with no adulteration. The average BR reading of groundnut, cottonseed,
corn, sesame, sunflower, mustard, soya and castor oils are 59.81. 62 43, 64.50, 64.88, 65 25,65.64,
66.00and 73.00, respectively.

STEPS -:
1. Take Al tubes and fill it withsample
2. Then keep these in centrifuge so that cream layer is formed ontop.
3. Then take the cream with the help of spatula and heat cream so as to makeghee
4. Then put drop of ghee inbutyrometer
5. Note down the value of BR reading.

ESTIMATION OF SODIUM CONTENT OF A MILK SAMPLE:

Milk is being adulterated with sodium to increase S.N.F So, sodium content is checked by ISE
sodium analyzer Sodium analyzer is calibrated at 100 ppm & 1000 ppm of sodium. Sodium content
of milk should be between 350-450ppm.

STEPS:
1. Take 45 ml of milk and add 5 ml of ISA & then dip the probe of sodium analyzer in beaker
2. ON the stirrer & wait till reading is stable, when ready is displayed.
3. Note down thereading.

RM VALUE (REICHERT-MEISSEL VALUE)

It is the number of milli-litres of 0.1 N sodium hydroxide or alkali solution required to
neutralize the steam volatile, water soluble fatty acids distilled from 5g fat under precise
conditions specified in the method. Value should be between 28 to 32

STEPS:
1. Centrifuge the sample for 15min.
2. Separate the cream and heat it to makeghee.
3. Take 5g of ghee inflask
4. Add 20 g glycerol, 2ml of 50% NaOH and 6 to 8 glassbeads.
5. Heat clarify thesample
6. Add 93 ml boiling distilled water followed by 50 ml 1 NH2SO4.
7. Fix it with still head to distillationapparatus
8. Mildly heat the flask so as to form the golden ring ontop.
9. After that heat it properly so that distillation starts and 110 ml distillate is collected in
round bottomflask
10. Distillate is filtered andchilled
11. Titrate it against N/10 NaOH using phenolphthaleinindicator.
12. RM Value = (ml of NaOH used: 0.4) xl 1

QUALITY CONTROL LAB:

In quality control lab sensory evaluation of milk and milk products is done, in which there
is testing of shelf life
A check is put over cleanliness of dairy equipment's and overall sanitization of plant.
The products produced in the plant are checked for their quality and shelf life before they
aresent to the market.

Some of the main tests done in the labs are

1.Hardness of water
2. Curd aciditytest.
3. Moisture test for paneer.
4. Fat test forpaneer.
5. Total solid test for kheer
6. Ghee test/ Free fatacidity

HARDNESS OFWATER:
This test is performed to check the hardness of water 1.e., whether the water used in
various production units s suitable to use or not.

STEPS:
1. Take 100ml water sample in aflask.
2. Add 1-2ml NHbuffer
3. Add 2-3 drops of indicator (Phenolphthalein) toit.
4. Titrate it against 0.02N EDTAsolution.
5. Blue colour marks the end FORMULAE OF HARDNESS Hardness= T.V.x10

CURD ACIDITY TEST

Curd acidity test is a test to check the acidity in packed form of curd 1.e.. with increasing
time the acidity of curd increases and it becomes unfit to consume So, to check it the test
is performed Curd acidity test is same as in case of milk.

STEPS
1 Take 10 ml of curd sample in a China dish.
2 Put about 5 10 ml of water in the dish.
3. Mix it properly
4. Add few drops of Phenolphthalein indicator init.
5 Titrate it with NaOH.
6. Light Pink colour marks the end.

MOISTURE TEST FOR PANEER

This test is used to check the presence of moisture in paneer in packed form, as more
moisture may lead to microbial activity.
STEPS:-
1. Take an empty dish and take its weight as WI.
2. Put about 3g of crushed pancer in it, weigh it and mark it as W2.
3. Put the dish in oven for about 4hrs.
4. Measure the weight and mark it asW3.

FORMULAE USED
1 W2-W1=A
2 W3-W3=B
3. B/A x 10=Moisture

EAT TEST FOR PANEER

Fat test is carried out to determine the amount of fat in pancer
STEPS
1. Take a butyrometer and tearit
2. Take paneer sample intobutyrometer
3. Put 3g sample intobutyrometer.
4. Put 10 ml Sulphuric acid and Iml amyl alcohol and to maintain its level we have to add
hotwater.
5. Then centrifuge it for 5 mins for 12000pm.
6. Note the fatreading
FORMULAE USED -
Fat%= Fat x 11.26/W

TOTAL SOLID TEST FOR KHEER

This test is done to check the presence of total solids in kheer in packed form
STEPS
1 Take an empty dish and take its weight asW1
2 Put about 3g of kheer in it, and mark it asW2
3 Put the dish in oven (30 Degree Celsius) for about 4hrs
4 Measure the weight and mark it as W3
FORMULAE USED:-

1. W2-W1=A
2. W3-W2 B
3. B/A x 10 Moisture

GHEE TEST/FREE ACIDITY TEST

This is the test to check the quality of ghee/fat in terms of acidity

STEPS
1. Take the sample butter to betested.
2. Heat the sample until it gives brown goldenshades.

3. Prepare a solution by adding 50 ml ethanol and 2-3 drops ofphenolphthalein

4. Now neutralize it with N/9NaOH.
5. Take about 10g ofghee.
6. Mix the solution prepared in 10g ofghee.
7. Heat toboil.
8. Then add NaOH to that fortitration.

VARIOUS PROCESSING SECTIONS AT VERKA MOHALL DAIRY MILK PROCESSING

SECTION

Verka Milk is pouch packed and available in different variants for the better of its
consumers thus providing them fresh, healthy and wholesome milk every day. It is well
pasteurized at appropriate temperature in processing plants and meets the satisfactory
PFA standards. Pouch Milk is available in an array of variants; Full Cream, Standard Milk,
Toned, Double Toned, Skimmed, Cow Milk.
FLOW CHART OF MANUFACTURING OF PASTEURIZED AND STANDARIZED MILK

Milk from RMST

CreamSeparator Balance Tank

Cream Skim Milk MilkPasteurizer

Line MRL

Cream Raw MilkPasteurizer

balance Tank

PasteurizerLineCPL

Cream Raw Storage Tank Horizontal Milk Storage

Tank
EQUIPMENTS USED IN MILK PROCESSING SECTION

PASTEURIZER
It is device used to pasteurize the milk, to remove pathogenic microorganisms from milk
i.e. heating at 63 degrees Celsius for 30 min or 70 degrees Celsius for 15 sec in approved
and properly operated equipment. At one end of the device the temperature is 75-80
degrees Celsius and at the other end it is 4-5 degree Celsius i.c., instant cooling of milk is
done after exposure to high temperature which kills almost all germs in milk.
Pasteurization is of two types-

1. High Temperature short

2. Low Temperature Long Time

HOMOGENIZER
Homogenization is a process where in fat globules are broken down to 2 microns or less
under high pressure.
It consists of high-pressure piston pump that forces the milk and thereby subdivided into
smaller particles of more uniform size.

CREAM SEPARATOR
It is a device which separates cream from the milk by means of a set of plates which
rotate around a central axis using centrifugal force
1. There are 135 plates in each creamseparator
2. Cream and skim milk areobtained.
3. After extraction cream is chilled to 4-6 degree Celsius through platechiller

STORAGE TANK: To store the milk in different states like raw, chilled, pasteurized and
standardized. They have capacity of 10000-20000 liters

MILK PACKAGING
1 10 machines of packing are used each of which has two packingsections.
1. Each machine has capacity to pack 1000 liters of milk per hour 1.c. 2000 pouches of
500ml per hour.

FERMENTED DAIRY SECTION

1. DAHI

Verka Dahi is made from pasteurized milk and packed in advance Dahi packing facilities.
Made from pasteurized toned milk with 10.5% SNF Verka Dahi meets the requisite FSSAI
standards. It is ideal for daily consumption as it provides calcium for strong bones and
teeth. It provides protein for active life and growth and helps in improving digestion.

INGREDIENTS
1. Milk Fat 3% min, SNF 10 5% min.
2. Culture Freeze driedcultures
Companies providing cultures are CSL (Italy), CHR Hansen (Denmark), and Danisco
(France)
COMPOSITION OF DAHI

Nutritional Information Per 100 ml

Energy value (kcal) 67
Total fat (g) 3.0
Saturated Fat (g) 1.9
Trans Fat (g) 0.0
Cholesterol (mg) 7.2
Total Carbohydrate (g) 5.9
Added sugar (g) 0.0
Proteins (g) 3.7
Minerals (g) 0.9
Calcium (mg) 150

SHELF LIFE: 7 days from the date of manufacturing when stored in the refrigerator at
below 5 Degree Celsius.

FLOW DIAGRAM OF DAHI MAKING

Raw Chilled Milk

Pasteurization and standardization of milk (Fat- 3%min, S.N.F. 10.5%min)

Storage in PMST storage (Min 8 to Max 24hrs at below 5°C)

Heating to 90 +/-2°C for 5 mins with outlet temperature of milk at 43 +/-1°C with
homogenization at2000/500ps

Inoculation vat @ 200 units 2000lts of milk and mixing for minimum 20 mins before filling
starts
 Filling in Polystyrene cups/Pouches/Pot

Incubate in incubation room at 42 to 44°C till %1.A reaches 0.65-0.75%

Cold storage through Blast cold room till product reaches 5°C T

Dispatch in insulated vehicle

2.LASSI

Lassi is a cool invigorating milk-based beverage It's an ideal thirst cruncher and best
option for circulated air through drinks Likewise, Lassi contains Probiotic microscopic
organisms that helps support absorption.
Different variants of Verka Lassi

Pain Lussi
Verka Plain Lassi is a refreshing drink that can be savored anytime Made from Fresh Verka
Milk, Plain Lassi also makes for a great accompaniment to your food.

Sweet Lassi
Verka Sweet Lassi is renowned for its taste and is a best substitute for cold drinks during
summers. The lassi is processed using fresh curd and makes for the best of refreshments

Spiced Lassi
Verka Spiced Lassi contains jeera, chilly & ginger which makes for a great drink that is
both tasty and energizing. The lassi that best suits the palate of North Indians is a loved
drink during summers.

INGREDIENTS REQUIRED FOR LASSI MAKING

1. Dahi made from standardizedmilk

2. DVSculture

3. Pasteurized softwater.

4. Sugar

5. Spicedpowder

6. Edible commonsalt
MILK SPECIFICATIONS FOR LASSI MAKING
PARAMETRS Plain STANDARDS
Fat% 2.1±0.05 1.1+0.05
S.N.F% 8.50 0.05 7.80+ 0.05
Acidity % 0.13
MBRT in hours 6.00
Phosphatase test Negative

Shelf Life of Lassi: 6 days from date of manufacturing when stored in a refrigerator at
below 5 Degree Celsius.

FLOW DIAGRAM OF LASSI MANUFACTURING

Standardized pasteurized milk (Fat /SNF Min. 4.5/8.5%) for curd from PMST

Heating of milk by PHE 90=+2Degree Celsius for 5 min with outlet temperature of milk at
44degree C with homogenization at 2000 and 500 psi

Inoculation of culture at 42-44°C & setting the curd LA acidity 0.80-0.90%

Adding pasteurized water (equal to amount of water) & agitation with circulation of chilled
water in jacket to arrest acidity development
Addition of remaining pasteurized chilled water

Storage Tanks for packing in pouches

Packing in FFSmachines

Cold storage at max. 5°C

Dispatch in insulatedvant
KHEER MANUFACTURING SECTION

Kheer is an Indian Dessert prepared by the partial dehydration of whole milk in a karahi
over fire together with sugar and usually rice or occasionally semolina. It is very popular in
Punjab and whole northern region.
Verka Kheer is a perfect combination of taste and health. Made with finest ingredients,
Verka kheer is immensely liked and is gaining new heights of popularity It provides
calcium for strong bones &teeth and provides protein for active life and growth. Available
in affordable and convenient cups, itis a perfect on the go dessert.

INGREDIENTS

1. Pasteurized Standardized Milk which shall meet following specifications:

a) Fat 3.0% +/-0.05%

b) SNF 10.0% +/-0.05%

c) MBRT min 6.00hours

d) Phosphatase test: Negative) Acidity (LA) max.0.1452

2. Rice- Basmati half piece of reputed brand (6 months to 12 months). It should be

freefrom extraneousmatter

3. Sugar As per IS1151:2003

4. Green cardamom As per IS1877-1985

5. Sodium Benzoate (IP grade/ IS4447-1994)

SHELF LIFE: Shelf life of kheer is 10 days when stored refrigerated below 5 Degree
Celsius

FLOW DIAGRAM OF KHEER MANUFACTURE :

Pasteurized Standardized Milk (Fat 3.0 % +/-0.05%, SNF 10.0% +/-0.05%)

Heating with vigorous boiling and continuous stirring (for 1 hour)

Separate 15 to 20 kg milk and add 100g Cardamom powder, 12.8 kg sugar and 15 g
Sodium Benzoate

To rest of milk heat for 5 to 10 min., and add 7.2 g rice (properly washed)

Boil with continuous stirring till attains desired concentration (80% of total intake material)

To this after 1 hour add previously separated and prepared 15 to 20 kg milk after filtering

Gentle boiling with continuous stirring for about 15 min

Transfer to double jacketed hopper to cool to 50 to 55°C

Kheer filling and sealing machine

Storage below 5°C in cold store.

Packing in corrugated boxes and dispatch

PANNER MANUFACTURING SECTION

Pancer implies the item got from the cow or buffalo milk or a mix thereof by precipitation
with acrid milk, lactic corrosive or citrus extract. It will not contain more than70,0 percent
dampness and the milk fat substance will not be under 50.0 percent of the dry matter. Milk
solids may likewise be utilized in planning of this item Generally, Pancer is an assortment
of squeezed chhana, utilized for planning cooked vegetable dishes.

INGREDIENTS SPECIFICATIONS FOR PANNER

• Pasteurized Standardizedmilk
a. Fat 5.0010.05% and S.N.F 8.60 0.05%
b. MBRT min. 6.00 hours.
c Phosphatase test: Negative
d. Acidity (L.A.) 0.13 0.01%.
• Citric Acid as per IS13186:199
COMPOSITION OF PANNER MANUFACTURED BY VERKA

Fat 22.5%
Protien 18.5%
Carbohydrate 3%
Minerals 0.9%
Energy Value 289Kcal%

Shelf Life of Panner

6 days from the date of manufacturing when stored refrigerated below 5 degree Celsius.

FLOW DIAGRAM OF PANNER MANUFACTURING

Standardized milk for paneer fat-5% (Min.), SNF-8.6 %(Min.)

Heating by PHE 90 +2°Cwith outlet temperature of 76+2°C

Filtration and transfer of milk to straining vat

 Addition of Citric acid @0. 16% in water/whey at 74+/-2

Straining of coagulum and draining of whey

Hooping in Muslin cloth -lined hoops

Pressing for 5-6 mins at 3-4 kg/sq. cm under pneumatic pressure

Cutting into blocks

Dipped in pasteurized & chlorinated chilled water (At <10°C for min. 60-90 minutes)

Cut into pieces & weighing (200gm manually)

Packing of 200g paneer packets through Multivac machine

Cold storage at max 5°C

Dispatch in insulated van for local sale or Refrigerated van for distant place sale

BUTTER SECTION
1. Receiving of RawMilk
2. Pre heating andFiltration
3. Centrifugal Separation

5. Cooling ofCream
5. Ageing ofCream
6. Cream Feeding into Churn
7. Churning of Cream intoButter
8. Removal ofButtermilk

GHEE SECTION
Ghee means the pure clarified fat derived solely from milk or curd or from desi
(cooking) butter or from cream to which no coloring matter or preservative has been
added. The
standards of quality of ghee produced in Punjab as per FSSAI
1. Butyro-Refractometer reading at 40°C 40.0 to 43.0
2. Minimum Reichert Value:28
3. FFA as % oleic acid (max.): 3%
4. Moisture (max.):0.5%

Produced in utmost hygienic conditions, Verka ghee is a rich source of vitamins and
antioxidants that stimulate bone metabolism and body growth The ghee is made from
fresh cream and has a natural flavor and mouthwatering aroma.

SPECIFICATIONS FOR GHEE

Physical Properties

Parameters Standards
Colour Yellowish white
Body and Texture Granular without greasiness
Flavor and Taste Clean, Fresh and Pleasant
Residue No residue left
CHEMICAL SPECIFICATIONS

Parameters Standards
Moisture % (max) 0.30
FFA % (max) 3.00
B.R Reading at 40 Degree Celsius 40-43
R.M value (min) 28.0
Polenske Value 1.0-2.0
Baudouin Test Negative
Total Fat % (min) 99.70

FLOW DIAGRAM FOR GHEE PROCESS

Melted butter (Kettle 1 and 2)

Settle it for half an hour

Fat on upper layer and buttermilk settles down

cooking of fat at 108°C

Stand it for half an hour

Pump to Pre-Stratification tank

Keep it there for half an hour

Pass through clarifier

Keep it in ghee storage tank

Filling and Packing

 Storage of ghee in granulation room at 20-21°C

Storage and Dispatch

VARIANTS:-

1. Cekatainer (900 g)- 1litres

2. Tin (1litre)-900 g ghee at 45°C (Weight of container is 98g)
3. Tin 15 kg 16.65 litres at45°C

NUTRITIONAL INFORMATION

NUTRITIONAL INFORMATION Per 100g

Energy Value (kcal) 897
Total Fat (g) 99.7
Saturated fat (g) 64.0
Trans fat (g) and Added Sugar (g) 0.0
Cholesterol (mg) 240.0
Total Carbohydrate (g) 0.0
Proteins (g) andVitamins (g) 0.0

SHELF LIFE- 9 months of Cekatainer/Mono-cartons/pouches and 12 months of tin

packing when stored in cool and dry place

ENGINEERING SECTION
BOILERS
A boiler is a closed vessel in which water or other liquid is heated steam or vapor is
generated, steam is super heated or any combination there of, under pressure or vaccum
for external use to itself, by the direct application of energy from the combustion of fuels
or from electricity

Types of Boilers:

1. Fire tube boiler- Vertical tube and Horizontal tube

2. Water tube boiler
 In Verka Mohali Dairy Engineering Section there are three fire tube boilers -
1. P14605 Boiler. 4tons
2. P14492 Boiler- 3tons
3. Third boiler is of 6 tons with economizer fitted toit.

Economizer- Economizer is a mechanical device intended to reduce energy

consumption or to perform function such as preheating a fluid.

Various necessary Equipment and Parts fitted to boilers

1. FeedPump
2. Pressure Gauge
3. Water levelindicator
4. Oil Pump (Oil used is furnace oil andl. P G).
5. Photocell
6. Economizer
7. Safety Valve

Calorific Value for LPG- 11900 Kcal/Kg

Calorific Value for furnace oil - 9520 Kcal/kg

REFRIGERATION SYSTEM

There frigerationsystemcontains fourmajorcomponents Compressor,Condenser,

Expansion device and evaporator Refrigerant remains piped between these four
components and is
containedinrefrigerantloop.Therefrigerantbeginsasacoolvaporandheadstowardsthefirst
component which is compressor. In Verka Milk Plant, ammonia gas is used as a
refrigerant in refrigerationsystem.

Various important parts of refrigeration system at Verka Dairy Mohali

1. Compressor Motor
2. Compressor (Total 5 compressor are present at Verka Milk Plant,Mohali)
3. Discharge line
4. Oil Separator
5. Check Valve
6. Condenser (3 pieces of condenser with 367TR capacity are available and 2 pieces of
condenser with 470TR capacity is available)
7. Receiver (HPreceiverof6000litrecapacityisavailableandL.Preceiveroldoneof4000litre
and new one of 6000litre capacity is available)
8. Safety Value
9. Liquid Line
10. Expansion Valve
11. Chillers
12. Chilled Water Tank or Silos (2 silos are available of capacity 100000litre)
13. Agitator Fan
14. Evaporator
15. Chilled water Line
16. Suction Line
17. Cold Storage Room

EFFLUENT TREATMENT TANK

Capacity of 7.5 lakhs per day.

Oil and Grease

Collection Tank

Grip Chamber)
Sludge Bed
 Feed Tank

FeedPump

Anaerobic Tank (Anaerobic Sludge)

Primary Aeration

Clarifier I

Secondary Aeration

Clarifier 2

Polishing Tank (MLSS - Micro Liquid Suspended Liquids)

Settling Tank

Treated Water

CONCLUSION

After training at Verka Milk Plant, Mohali observation and conclusion came out to be
like the liquid milk items produced here are of excellent quality and are profoundly
worthy to the purchaser The administration is devoted to deal with the undertakings
effectively and precisely. There is appropriate coordination among the specialists and
the executives, which assists the plant to run the plant smoothly as expected. The
conduct, all things considered. and specialized staff and official staff is obvious and
very much appreciable.

Lately plant has expanded its acquiring and advanced its situation by making creative
methodologies

For further advancement and more success in future Verka milk plant need to focus on

1. Research and Development department which could contribute by upbringing and

introducing new products in a market.

2. Proper maintenance of machinery of milk plant so as to avoid productionlosses

3. Expand the marketing area within a country and abroad which will help in
raisingbrand name and will also generate a great revenue andprofit.

From the current situation of the Verka milk plant it can be said that with positive and
imaginative considering the board and a solid self-discipline of each staff of the plant,
can help the Mohalı milk association to rise with good pace in the dairy industry and
can give a tough competition to its competitors in a market.

With my overall experience as a trainee at Verka Milk Plant, I must confess that it is an
appropriate place for complete practical based training with an excellent work culture.