aavin project.pdf

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INTRODUCTION
Milk is nutrient rich food that provides a large number of
nutrients relative to the Calories Consumed milk is delicious
as a beverage and can be used as a base or other drink such
as hot Chocolate.
The milk of domesticated animals is also an important food
source for humans. Most milk Consumed in western counties
in from cows; other important sources include sheep, goats,
water buffalo, and camels. Milk is essentially an emulsion of
fat and protein in water, along with dissolved sugar, minerals
(including calcium and phosphorous), and vitamins,
particularly vitamin B complex. Commercially processed
cow’s milk is commonly enriched with vitamins A and D.
Many counties require pasteurization to protect against naturally occurring and artificially
Introduced microorganisms. Cooling further prevents spoilage (sourcing and curdling). Fat
Rom whole milk (about 3.5% fat content) can be removed in a separator to produce cream
and Leave low- fat milk (1-2 fat) or skim milk (0.5% fat). Milk is usually homogenized,
forced Under high pressure through small openings to distribute the fat evenly. It may also
be Condensed, evaporated, or dehydrated for preservation and ease of transport. Other dairy
Products include butter, cheese, and yogurt.
World wide
June 1 world milk day by FAO = food and agricultural organization. It gives to children to
Promote the growth of their muscles, bones, teeth, and brain Pediatricians &Nutritionist
Agree that the balanced with a proportion of the necessary carbohydrate & proteins
moreover, the high content of vitamin d in milk is key component to milk bone structure,
bone recovery and bone health. In Addition maintain the health of the teeth.
The Day provides an opportunity to focus attention on milk and raise awareness of dairy’s
part in healthy diets, responsible food production, and supporting livelihoods and
communities. This is supported by FAO data showing that more than one billion people's
livelihoods are supported by the dairy sector and that dairy is consumed by more than six
billion people globally. The fact that many countries choose to do this on the same day lends
additional importance to individual national celebrations and shows that milk is a global
food.

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Demand for dairy products in the region has more than tripled since 1980 and despite the
spectacular growth in production, production has lagged behinddemand in many countries.
As a result, dependency on the importation of milk and dairy products has increased
and, with the recent global increase in prices for dairy products, the cost of imports has
surged.
Around 80 percent of milk in Asia is produced by smallholder’s farmers. In addition, there
are tens of millions of traders and dairy entrepreneurs – small and large – involved in the
dairy sector.
Some countries in the developing world have a long tradition of milk production, and milk or
its products have an important role in the diet. Other countries have established significant
dairy production only recently.
Most of the former countries are located in the Mediterranean and Near East, the Indian
subcontinent, the savannah regions of West Africa, the highlands of East Africa and parts of
South and Central America. Countries without a long tradition of dairy production are in
Southeast Asia (including China) and tropical regions with high ambient temperatures and/or
humidity.

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INDUSTRY PROFILE
Today, India is 'The Oyster' of the global dairy industry. It offers opportunities galore to
Entrepreneurs worldwide, who wish to capitalize on one of the world's largest and fastest
Growing markets for milk and milk products.
India is ranked 1st in milk production contributing 23 per cent of global milk production.
Milk production in the country has grown at a compound annual growth rate of about 6.2 per
cent to reach 209.96 million tonnes in 2020-21 from 146.31 million tonnes in 2014-15.
India s dairy sector is expected to triple its production in the next 10 years in view of
Expanding potential for export to Europe and the West. Moreover with WTO regulations
Expected to come into force in coming years all the developed countries which are among
big
Exporters today would have to withdraw the support and subsidy to their domestic milk
Products sector. Also India today is the lowest cost producer of per liter of milk in the world,
at 27 cents, compared with the U.S' 63 cents, and Japan s $2.8 dollars.
The urban market for milk products is expected to grow at an accelerated pace of around
33% per annum to around Rs.43, 500 crores by year 2005. This growth is going to come
from
The greater emphasis on the processed foods sector and also by increase in the conversionof
Milk into milk products. By 2005, the value of Indian dairy produce is expected to be
Rs 10,00,000 million. Presently the market is valued at around Rs7, 00,000mn
Dairy plays a significant part in numerous aspects of Indian society,
including cuisine, religion, culture, and the economy.
India has the world's largest dairy herd with over 300 million bovines, producing over 187
million tonnes of milk. India is first among all countries in both production and consumption
of milk. Most of the milk is domestically consumed, though a small fraction is also exported.
Dairy production in the Indian subcontinent has historical roots that go back 8,000 years to
the domestication of zebu cattle. Dairy products, especially milk, were consumed on the
subcontinent at least from the Vedic period. In the mid- to late 20th century, Operation
Flood transformed the Indian dairy industry into the world's largest. Previously, milk
production in India occurred mainly on household farms.

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COMPANY PROFILE
HISTORY OF AAVIN
The dairy development was established in 1958 in Tamil nadu. The administration
and statuary controls over all the milk cooperatives in the state were transferred to the
dairy development department on 1.8.1965. The commissioner for milk production and
dairy development was made as the functional register under the Tamilnadu cooperative
societies act. With the adoption of an and pattern in the state of Tamilnadu. Tamilnadu co-
operative milk producers federation limited was registered in the state of 1 st February
1981.
The commercial activities of the department such as milk procurement, chilling,
processing, packing and sale of milk to the consumer etc. hitherto dealt with by the Tamil
nadu dairy development cooperation limited, were transferred to the newly registered
Tamil nadu co-operative milk producers federation limited popularly known as Aavin.
Tamil nadu co-operative milk producers federation limited was constitution 1 st
February 1981. Federation is procuring, processing and marketing of milk and milk
products federation has implemented the dairy development activities under operation
flood programmed with a financial and technical assistance of national dairy development
board. Chennai metro is having four dairies. Milk procurement, processing and
distribution are being attended by the district union in the respective areas.
In the wake of liberalization policy, private dairies have also entered into the field
of the honorable chief minister of Tamil nadu high priority has been given for improving
the performance of milk co-operatives by adopting a symmetric approaching and proper
strategy in milk co-operatives. Significant achievement has been made by milk Producers
co-operatives societies, unions and federation in the state of Tamil nadu.
The cattle population in India is approximately 15% of total cattle population in the
world. India stood No.1 position in milk production. Tamil nadu is one of the leading
states in. The milk production in Tamil nadu per day is 145.88 lakhs Liters.

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VISION:
• To ensure prosperity of the rural milk producers who are ultimate owners of the
Federation.
• To promote producer oriented viable co-operative society to impart an impetus
to the rural income, dairy productivity and rural employment.
MISSION:
1. “Heralding economic, social and cultural prosperity in the lives of our milk
producer members by promoting vibrant, self-sustaining and holistic co-
operative dairy development in Tamil Nadu State”
VELLORE DISTRICT CO-OPERATIVE MILK PRODUCER UNION LIMITED:
The District area operation covers totally 1944 revenue villages, 13 taluks, and 39 Blocks
and 4,165 villages in both Vellore and Thiruvanamalai districts. The milk procurement
activities are being carried out by 6 teams namely at Vellore, Ambur, Koddakat, Polur,
Thiruvanamalai and Cheyyar. With existing facilities, the union is providing Animal Health
Cover once a week to 564 DCS through 9 veterinary routes. AI facilities to 305 DCS and
Foot &Mouth Disease vaccination programs are being carried periodically.
1. Name of the District Union: The Vellore District Co-op. Milk Producers Union Ltd.,
Vellore.
2. Head Quarters: Vellore
3. a) Month and Year of Registration: October 1982
b) Year by which dairy activities of the State Federation taken: Feb. 1981 to Sep
1984
c) Year by which Dairy activities of the district taken over by the Union.01.10.1984
4. Source of Finance: Operation Flood Programmes.
5. Monitoring Agency: National Dairy Development Board.

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6. Name of the Apex Body: The Tamil nadu Co. op. milk Prods. Federation.Ltd.
Chennai-51.
7. No. of Dairies – 01
8. No. of Chilling Centers: 04
1) Ambur in Vellore District.
2) Kodakkal in Vellore District.,
3) Thiruvanamalai
4) Anakkavur in Thiruvanamalai District.
9. Total No. of Rural Milk Collection Routes: 45
10. No. of milk Distribution Routes: 11
11. Total No. of Mobile Veterinary Routes: 09
12. Total No. of milk Procurement Team Routes: 06
13. Total No. of staff strength: 451
OBJECTIVES OF THE DAIRY DEVELOPMENT DEPARTMENT:
• Assure a remuneration price for the milk produced by the member of the milk producers
co-operative societies through a stable, steady and well organized market support.
• Distribution of quality milk products to the consumers at reasonable price.
• Keeping the objectives in mind a number of activities are undertaken by the dairy
development department.
• Provision of free veterinary health cover to all animals owned by the members of milk
cooperatives.
• Implementation of artificial insemination program supply of balanced cattle feed and
inculcation of farmers with modern animal husbandry methods and practice
• All activities which are essential for the up gradation of the Mitch animals and improving
their productivity in the long run have been undertaken.
• Provision of necessary infrastructure facilities for marketing milk products and supply
of quality milk to the consumer has been made by way of establishing new chilling
centres, pasteurization plants and adoption of modern processing system

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District Unions of federations:
There are about 17 district co-operative milk producers’ unions functioning in Tamil
nadu covering 30 districts. They are:
1. Kancheepuram-tiruvallur
2. Villupuram
3. Vellore
4. Dharmapuri
5. Salem
6. Erode
7. Coimbatore
8. Nilgiris
9. Madurai
10.Dindigul
11.Trichy
12.Thanjavur
13.Pudukkottai
14.Sivagangai
15.Virudhunagar
16.Tirunelveli
17.kanyakumari
Functions of co-operative milk producers union:
1. Establishment of chilling centers.
2. Formation of new milk routes to collect milk produced by the members of
the societies.
3. Collections of milk from societies, process, and pack in modern dairy.
4. Supply of quality milk.
5. Fixation of procurement and selling price of milk.
6. Supply of inputs to the members of the societies.

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PRODUCT PROFILE
The Aavin Dairy industry produces about 65,000 liters of milk during the summer period
and 80,000 liters of milk during the winter period. This happens because during the dry
summer months there will be a low availability of green fodder for the cattle for the fall
in milk production.
The company is also engaged in the manufacture of milk products such as
THE DIFFERENT PRODUCTS BY AAVIN IS LISTED IN THE
FOLLOWING LIST:
1. Gulab jamun
2. Milk khoa
3. Butter milk
4. Mysore Pak
5. Curd
6. Ice-creams
7. kulfi bar
8. Ghee
9. Yogurt

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FLOW CHART OF PRODUCTIONS PROCESS

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Collection of milk
Collection of milk collected by village of societies of farmers. The milk is collected from
many villages. The milkers give their milk through dairy form situated on their village.
Therefore, both societies and milk givers can earn money with some profits. The collection of
milk which is directly got from the milk-giver is known as the "Raw Milk". The milk can be
collected in the morning and evening.
The perishable nature of milk increases the storage and transportation problems in
developing village where access to electricity is challenging. Handling raw milk from the
farm to the dairy processing plant requires a cold chain to preserve its quality. In a large
dairy farming system in developed village,
Milk is immediately cooled and stored in a refrigerated tank during the milking. In a small-
scale system, investing in a cooling tank at the farm level is unrealistic and financially
unfeasible. Farmers have only two choices, transporting and supplying a milk collection
center or selling directly to the urban market or households as raw milk.
There are a few milk collection system models, but the choice to implement each model
depends on the quantity of milk produced, the geographical distribution of dairy farmers, and
the availability of financing.
Establishing a milk collection center requires a building, an investment in a cooling tank, a
connection to electricity, which runs the cooling system, and a few milk-testing materials
and products. Each model also depends on who owned and managed these milk collection
centers.
The milk is collected from many villages. The milker gives their milk through dairy from
situation on their village. Therefore both societies and milk givers can earn money with some
profits. The collection of milk which is directly gets from the milk giver is known as the raw
milk. The milk can be collected at morning and evening.0
To collecting all milk from farmers to measures the milk the raw milk arrives at the dairy in
insulated road tankers. The milk must be kept well chilled, free from air and treated as gently
as possible.
For example, tanks should be well filled to prevent the milk from sloshing around in the
container.
Dairy production faces multiple challenges in SSA as in other developing countries. Most of
them are related to the dairy industry itself, while others are shared with other industries in
the agricultural sector.
Milk collections 80,000 liters from village to factory area production day to day

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TRANSPORTING
In Vellore depot, processing the milk is to types as described follows. The process of
pasteurization is carried out. Then, transported milk is streamed at about 71˚Cand then
chilling at 4˚C to kill harmful bacteria.
Then the bacteria free milk is stored in silo (Large Milk Storage Tank) at 6˚C. This milk is
then packed in 1/4, ½, 1 liter packets and then stored of about 7C to 8C. Finally these packet
milk are distributed to various market places for sale.
As previously stated, the initial stage in the process is cow feeding on grass in a field. Twice a
day, the cows are taken from the pasture to a milking facility where they are milked by an
automated milking machine.
The resulting milk is kept fresh in large refrigerated storage tanks. On a daily basis, the milk
is collected by a milk tanker and transported to a dairy factory where further processes are
applied to it in order to create a range of products.
Milk is stored in a great variety of storage tanks, first near to villages as Bulk milk cooling
units, then transported by Road Tankers and then to Raw Milk Storage tanks in dairy plants.
Processing, to large urban centers. Further, there may be requirement for processing
operations like mixing, ripening, culturing, aging etc, which require further special features
in storage tanks.
Finally storage tankers are
locked and sealed to reach
the dairy of industry.

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RECEIVING MILK PRODUCTION AREA
Good receiving, transportation and storage practices help ensure that food reaches its
destination in a safe condition without compromising quality.
By providing an environment that reduces the risk of contamination and protects food from
physical damage and temperature
General guidelines:
To control any hazards that could enter the plant, it's important to control incoming
materials:
• Keeping records of all shipments received at the plant.
• Creating and maintaining a list of approved suppliers for ingredients, packaging
materials and non-food chemicals that are delivered to your plant.
• Before approving ingredient and packaging suppliers, consider auditing reports of
their food safety program.
• Give your receiving staff a list of approved suppliers for non-food chemicals,
ingredients and packaging.
• Make sure the area where you receive incoming materials is separated from your
processing area to prevent contamination of food products.
Define specifications for incoming materials to make sure that they are food grade and free
of any biological, chemical, or physical hazards.
For example, cocoa powder can sometimes contain Salmonella, a known biological hazard.
When receiving these materials, make sure they meet your specifications.
This may involve one or more of the following:
• Analyze the material through a regular monitoring program (for example, grading raw
milk and testing it for antibiotics).
• Ask your supplier for a "Certificate of Analysis" prior to or with each shipment and
lot. A Certificate of Analysis demonstrates that your ingredients meet theappropriate
specifications.
• Periodically sample and test incoming ingredients to verify they aremeeting
specifications.
• Visually inspect the material.

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Pumping systems:
• If you receive pasteurized dairy products in bulk tank-trucks, you will have to re-
pasteurize them in your plant.
• This is because the tank-truck and the loading and unloading equipment (pipelines,
hoses and pumps) Are commonly shared with raw milk and cannot be guaranteed
to have beenproperly cleaned to prevent cross-contamination from raw milk.
• You must have specific vehicles, tanks, product transfer lines and transfer pumps
dedicated to pasteurized product only at both the shipping and receivingfacilities.
• These systems must be inspected and approved by your local governmentinspection
agency.
• This practice can only be applied to certain products that would be subjected to a"kill
step" during further processing such as drying or cooking.
• This practice is not acceptable for fluid milk and cream.
• Have written policies and procedures to reduce any identified risks and make surethat
pasteurized product does not become contaminated. These include:
• where the pasteurized product can be held before it is processed
• how long and at what temperature it can be held before it needs to be re-pasteurized
• how the product is protected from cross-contamination by raw product in the facility
• how the dedicated tank-truck is cleaned and sanitized
• If the tank-truck has been sealed, check the records to make sure the sealing program
was followed. If any seals are missing and unaccounted for,
• If the load is have tampered reject the load.
• Do not receive pasteurized dairy products in re-useable plastic totes, since they cannot
be effectively cleaned.
• Collapsible totes with single-use plastic bag liners are acceptable.
• When you receive pasteurized dairy products, document the temperature ofthe
pasteurized dairy products (and the inside of the vehicle, if appropriate).
• If products are delivered in a refrigerated truck, check the vehicle records to confirm
the product was kept at between 1°C and 4°C throughout the entire journey.

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STORAGE OF TANKS
They are usually cylindrical and mostly insulated. They may be horizontal or vertical types,
depending on availability of floor space. For extremely large quantity of storage, Vertical
SILO TANKS are provided outside the Processing section, to avoid tall buildings to
accommodate them.
The inner shell of storage tank is of Stainless Steel, and covered with suitable insulation,
and then an outer shell, which may be Stainless Steel or Mild steel. Outer shell of mild
steel is used to reduce cost. The outer mild steel shell will be painted to prevent
corrosion, which may be of two coats of antirust and two coats of enamel paint of
suitable colour, especially cream yellow.
The inner shell of storage tank should be smooth in surface finish, and should not have any
sharp corners, to aid in proper cleaning. The edges must have a knuckle radius of at least
25mm. Any welds present should be properly packed to have smooth finish .The shell will
have drain from lowest point, preferably from the center of the bottom. If this is not
possible, the bottom of the vessel should be sloped towards the outlet valve side of the
bottom to ensure complete drainage. The slope is at least 1:12.5 towards the outlet.
The shell will have other openings like for Agitator, non-foaming type milk inlet, inlet for
cleaning solutions through a spray device, air outlet etc. It will also have fittings for sight
glass and light glass, to inspect measurement level, to ensure proper cleaning etc. The
glass should be made up of non-splinter type. The opposite end of sight glass will have the
level marked by food grade paint, or buffing of the surface to indicate level markings and
values marked adjacent to it. The tank is fabricated usually 15% over capacity than the
nominal capacity of the tank.

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PRECAUTIONS WHILE STORING MILK IN TANKS.
• Store bulk pasteurized dairy products in dedicated tanks or silos. Never store them in a
tank or silo that was previously used for raw milk.
• If you use tanks to store pre-pasteurized product that you are not going to re-
pasteurize, empty and clean them no more than 24 hours after filling.
• While the pasteurized product is in storage tanks or silos, monitor the temperature and
make sure it stays between 1°C and 4°C.
• If you receive pasteurized dairy products in containers (such as cartons, bags or totes),
store these containers in a refrigerated area, monitor the temperature and make sure it
stays between 1°C and 4°C.
• Have a written procedure and keep records to make sure the refrigerated area is
cleaned and sanitized regularly to minimize the risk of contamination fromspills.
• Rotate inventory so that oldest product is used first.
• Controlling the storage time and temperature of pasteurized dairy products helps to
minimize the growth of micro-organisms.
SILO-TANK
A structure, typically cylindrical, in which fodder or forage is kept: The dairy farm's two
biggest buildings were the barn and the silo full of feed for the cows. A pit or underground
space for storing grain, green feeds, etc. an underground installation constructed of concrete
and steel, designed to house a ballistic missile and the equipment for firing it. A group, unit,
enterprise, etc., that is isolated from others or functions independently, typically viewed as
not deriving the benefits of interrelationships or collaboration: Fundraising department silos
happen when different teams don't share their ideas and plans.
Advantages of Storage Silos
1. Storage silos consume less storage space compared to horizontal storage warehouses.
2. The materials or products are stored under optimal conditions.
3. Storage silos cost less compared to other storage options.
Disadvantages of Storage Silos
1. Storage of fumigants and pesticides in the silos results in intoxication.
2. Silos result in the accumulation of carbon-di-oxide, which causes suffocation while
opening it.
3. The decomposition of grains stored in silos results in inflammable vapors. These vapors
bring suffocation and may result in poisoning if inhaled.

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MILK SILO TANK PROCESS
Layout of outdoor silo tanks with their manholes in alcoves in the walls of a covered control
station.
Silo tank alcove with manhole and motor for propeller agitator.

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Dairy processing
CLARIFICATION
The milk collected from the chilling centers are brought to the dairy and are kept for
assessing the quality. Some of the types of milk viz., standardized milk, high fat, high
protein milk, are being produced for the requirements of the consumers; the surplus fat is
converted into ghee. The high fat and high protein milk are packed in 250ml and 500ml
sachets. In the dairy, milk. Ghee, ice-cream flavored milk, rose milk, butter milk etc., are
being manufacturing and marketing.
HOMOGENIZATION
In first the homogenization is a process that reduces the size of fat globules by forcing
pressurized hot milk through small whole causing turbulence, the break up the larger fact
globules so that they remain suspended rather than separating in a cream layer at the top
homogenization effects the development of atherosclerosis, coronary, heart diseases, milk
allergy, diabetes.
PASTEURIZATION
It is a process by which the disease causing bacteria in the milk are destroyed without loss
in its nutritive values. The milk is boiled at 60˚C for thirty minutes and cooled quickly.
Whatever the method is used for preservations of food, cleanliness and general sanitary
conditions are important.
Before pasteurization, milk is homogenized to separate the solids (fat) from the liquid, which
ends within the pasteurized milk having a whiter look as compared to raw milk
Pasteurization destroys 100% of pathogenic bacteria, yeast and mold and 95% to 99% of
other bacteria.
Types of milk
Full cream milk:
Full cream milk, also called whole milk is usually given to children, teenagers, and body
builders. This milk is called so because it contains all the milk fat without adding or
removing anything. It is collected from the dairy herd and it undergoes various processing
techniques like pasteurized ion to kill potentially harmful bacteria before it reaches the
general public. One glass would generally contain 3.5% milk at, which provides about 150
calories. Full cream milk is also creamier and full of flavor.
This further can be divided into two parts:

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Whole standardized milk:
In this milk, the fat is contained to a minimum of 3.5%.
Whole homogenized milk:
Fat globules are broken down and made to spread throughout the milk to prevent the
formation of the creamy layer at the top.
Single toned milk:
Adding skimmed milk powder and water to whole milk makes single toned milk. It has
about 3% fat and minimizes body's absorption of cholesterol from the milk. It contains
almost the same nutrition as whole milk except the fat-soluble vitamins. One glass of toned
milk provides around 120 calories.
Skimmed milk:
Skimmed milk has 0.3% to 0.1% fat content. Though skimmed milk contains all the nutrients
found in whole milk like the vitamins and minerals, it gives you just half the calories of full
cream milk (around 80 calories per glass of milk). It contains slightly more calcium than
whole milk and even lower levels of fat-soluble vitamins. Particularly vitamin in A, as this is
lost when the fat is removed.
Colour indication and Composition of Milk
Aavin Blue milk packet
• Homogenized pasteurized STANDARDIZED MILK with 4.5 % fat and 8.5% SNF
content
• Homogenized pasteurized full cream milk with Min. 6.0% fat and 9.0 %SNF content
• Pasteurized toned milk with 3.0% fat and 8.5% SNF
Aavin Green milk packet
Homogenized pasteurized STANDARDIZED MILK with 3.5% fat and 8.5% SNF content
Aavin Orange milk packet
Homogenized pasteurized full cream milk with 6.0% fat and 8.5% SNF content
Percentage of fat in milk
Milk Fat % Snf %
Toned milk 3.0 8.5
Standardized Milk 4.5 8.5
Full cream milk 6.0 9.0

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Butter milk
MANUFACTURING MILK PROCESS
• Traditional buttermilk is what is left over after butter is made from sour cream. During
the churning of the milk, the milk fat globule membranes break, making the milk fat
curdle together.
• The coagulated milk fat then floats, like butter, on top of the buttermilk. Phospholipids
from these milk fat globule membranes are very sensitive to oxidation, making the
buttermilk spoil quickly.
• Nowadays, for this reason, almost all buttermilk is produced by adding lacticacid
bacteria to pasteurized skimmed milk.
• In general, skimmed milk is used as a base for buttermilk production. This milkmust
be of a high microbiological quality and not contain any antibiotics
• Disinfectants. For the best flavor it is recommended to use milk with a fat content of
at least 1 to 1.8%.
Curd
• Most common as well as traditional dairy based product, Curd, locally known asDahi,
is consumed widely all over the world.
• Curd falls under the category of fermented dairy product, produced from heattreated
milk after inoculation with certain Lactic Acid Bacteria (LAB) in the form of starter
culture. Lactic acid bacteria multiply,
• Grow and produce lactic acid, acetic acid, and carbon dioxide by utilizing available
lactose in milk.
• Some bacteria use citric acid of milk to produce certain volatile organic compounds
mainly diacetyl, which is mainly responsible for flavor of Dahi.
Process Flow chart of Curd:

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Curd Processing Steps:
1. Reception of milk: Fresh, good quality milk is received and analyzed for SNF and
fat%.
2. Pre-heating: Done at 30-40°C
3. Standardization: 5% to 3.0% fat and 10% solids not fat.
4. Preheating (Optional): It is an optional step to heat milk up to 60°C
5. Homogenization: Milk is subjected to high pressure pump forcing milk through
extremely small orifice for even distribution of fat globules. Homogenization reduces
the cream layer formation during incubation and single-stage Homogenizer, or double
stage homogenizer can be used as per process requirement. After homogenization all
the fat globules of the milk has an average size below 1 micron.
6. Pasteurization: Milk is heated to 85-90°C for 15-30 minutes and temperature bought
down to 3-4°C.
7. Pre-heating: Pasteurized milk is preheated to 40-45°C and transferred to inoculation
tank.
8. Inoculation: Milk is inoculated with 1-2% of specific curd starter culture at 37°C. The
incubation tanks are insulated, to ensure that the temperature remains constant during
the incubation period. The tanks can be fitted with pH meters to check the
development of acidity (4.2 – 4.5)
9. Packaging: The inoculated milk is then packaged in separate cups with lids. Dahi is
generally packaged in polyethylene, polypropylene, polystyrene packaging material
and plastic cups
10.Incubation: Cups are arranged in crates which are then transferred to hot room (37˚C)
while the fermentation process proceeds. In case of set curd, incubation is done when
the product is in its final retail container at 30-42°C for around 4-5 hours, while for
stirred types of products it can be done within the inoculum/incubation tank and then
packed in pouches.
11.Cooling: The pH of the milk in the cups should be regularly checked and when it
reaches 4.4-4.5, these crates are transferred to room with temperature 3-4o
C for proper
setting
12.Storage: It is stored in the cold store below 6°C

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Milk khoa
• Khoa is prepared by different methods depending on the location and quantity ofmilk
available for conversion.
• Khoa is manufactured by the following four basic methods viz. traditional method,
improved batch method, mechanized method and use of membrane technology.
• Generally buffalo milk is preferred for manufacture of khoa as it results inhigher
yield, smooth texture and soft body with sweet taste.
• Where buffalo milk is not available, cow milk is used for khoa making but itresults
in pasty body and slightly saltish taste due to higher chlorides in the product.
• A continuous khoa making machine was developed which consists of a preheating
cylinder and two cascading pans. The preheater is a steam jacketed cylinder
containing rotary scrapers which rotate at 120 rpm.
• The cascading pans are covered steam jacketed pans with open holes provided with
spring loaded reciprocating type scrapper knives operating at 30 strokes per min. The
milk is taken into the preheater and heated by steam at 3 kg/cm2 pressure.
• Here the milk is concentrated to about 30 to 35 per cent of total solids within 10 to12
min. From the preheater, the milk enters the first cascading pan.
• Here the milk is further concentrated to about 50 to 55 per cent total solids within 7 to
8 min. The product then moves to the second cascading pan where its concentrationis
raised to the desired level i.e., 65-70 percent in 6 to 7 min.
• The steam pressures maintained in the two pans are 2 kg in this machine. The steam
requirement is 50kg/cm2 and electric power requirement is 4 KW per hour.
Kulfi bar
• Kulfi is a typical indigenous frozen dessert sold by small vendors in many parts of this
country. It is characterized by slight whitish to brownish appearance,
• compact body, icy texture and nutty,
• It is popular in northern, central and western parts of India. In the traditionalprocess,
milk is thickened in a shallow pan with constant agitation.

22
• Sugar, nuts, essence and colour are added towards the finishing stages.Concentrated
mass is poured into metallic moulds and frozen in a mixture of ice and salt.
EXPERIMENT
I. Principal
• Cow, buffalo or mixed milk either as such or skimmed partially is concentrated in a
large open pan kept over a fire hearth and then stirred with required amount ofsugar,
colour and flavor.
• The addition of nuts is optional. The mix after cooling is filled in suitable conical
containers.
• The containers with kulfi mix are then immersed in salt – ice mixture in an earthen
pot and frozen.
II. Requirement
• Machinery/ Instrument
• Steam kettle/ Shallow pan
• Batch freezer
• Manual-dairy Metallic (Aluminum or stainless steel) kulfi moulds Brine tank (at -23
to -30 C)
Chemical/materials
• Milk
• Cream Skim
• milk powder
• Sugar
• Stabilizer
• Flavouring and colouring ingredients
• Coarse Salt
• Ice
III. Procedure
Traditional method:
1. Fresh, clean whole milk is standardized to 5% fat and 9% MSNF.
2. Cane sugar at the rate of 10% level by weight of milk is added.
3. The milk is then concentrated in a shallow pan with constant agitation to aboutone
half its original volume.

23
Industrial method:
1. In the industrial process the ingredients used are the same as for ice cream – milk,
cream, skim milk powder, sugar and stabilizer.
2. Water is added to dilute the mixture (not having stabilizer and a small amount of
sugar).
3. And the fat: MSNF ratio is maintained at 1.4:1. Usually the fat in thefinished
product is about 16%.
4. The required quantity of ingredients are taken in an open steam kettle and the
contents heated with vigorous agitation
IV. Observations
1. Kulfi mix record
2. Date
3. Standard desired
4. Amount required
Kulfi ice cream moulds diagram

24
CLEANING IN PLACES
Cleaning in Place, usually abbreviated to CIP, is a technique in which tanks (or other
production components) are automatically cleaned without the need to detach or move parts
of the tank. These CIP systems are increasingly replacing manual cleaning processes in a
diversity of industries. Self-cleaning systems bring about big time savings and can attain a
higher level of hygiene than manual cleaning.
CIP systems have a vital role in processing because of the need to keep processing
components free of bacteria. Cleaning occurs in process piping, tanks, heat exchangers, and
other equipment to prevent product contamination and maintain processing efficiency
For effective Cleaning the following aspects are important:
i. Design of plant, material used and ancillary equipment should be suitable forCIP
cleaning.
ii. Cleaning procedure to be adopted depending on soil type, detergent type,concentration,
temperature, contact time, type of surface.
iii. CIP cycle must effectively and automatically controlled with minimum of intervention,
or unauthorized alteration
Advantage of a CIP systems:
• Minimizes Mistakes: Automating cleaning reduces the chance of human error that
can contribute to an unsafe product.
• Keeps Employees Safe: Reduces chemical exposure by containing cleaning solutions
within the system.
• More Production Time: As less production time is lost to cleaning, more time is
spent making product.
• Product Quality: Reliable and repeatable cleaning means sustainable productquality
and consistency. Less contamination means fewer product recalls and higher brand
confidence.
• Utility Savings: Water and energy usage is reduced through repeatable cycle control.

25
CIP –SYSTEMS
TYPES OF CIP WASHING TANKS:
1. ACID
2. Caustic soda
3. hot water
4. waste water
Steps of CIP Washing tanks
3 steps methods:
1. softener water
2. hot water
3. softener water
5 steps methods:
1. softener water
2. caustic soda
3. softener water
4. hot water
5. softener water
7 Steps methods:
1. softener water
2. nitric acid
3. softener water
4. caustic soda

26
5. softener water
6. hot water
7. softener water
Conditions using CIP washing systems:
1. 3 steps:
Milk emergency and critical path and 30.min
2. 5 steps:
Regular washing 50.min
3. 7 steps:
Acid day to day by using 1.hr 20.min

27
QUALITY CONTROL
Quality system
• PLAN
• DO
• CHECK
• ACT
The concept of PDCA is based on the scientific method, as developed from the work of
Francis Bacon in 1620. The scientific method can be written as Hypothesis - experiment
evaluation or as plan do-check. Walter A. Shewhart described manufacture under control -
under statistical control as a three step process of specification, production and inspection.
Any organization collecting and evaluating data for the particular program must be
conceded with the quality of results organization must be have a results meet a well-
defined need use or purpose comply with program requirements and reflects consideration
of cost and economics to meet the objective the organization should be control the technical
administrative and human factors affecting the quality of results control should be oriented
toward the appraisal reduction elimination and preventive of affect quality control.
Different kinds of Test:
• REDUCTION TEST
It access whether the bacteria are present or not in the milk. It bacteria are present
it will the bacteria in that milk. MBR test (methylene blue dye)
• LACTASE TEST
It is used to determine the lactic acid concentration in milk and milk product since
its value has to be kept under fixed law limits.
• CHLORIDE TEST
It is used to measure the quality of salt in different dairy products.
• AMMONIA TEST
It is used to measure the ammonia concentration and it determines the good
quality milk. Ammo acid degradation of soft cheese

28
Quality Control Activities:
• Milk is tested at BMC/CC/District union Dairy/Metro Dairy laboratory,
chemically and bacteriologically to ensure procurement of quality of milk.
• Quality milk procurement from the societies is essential before the milk is sentfor
processing manufacturing of milk products.
• All quality standards of milk and milk products are to be ensured in thebest
interest of the consumers.
• Adequate training is being imparted at all levels including milk producers, society
staffs, district Union staffs and federation staffs to acquire knowledge in testing
of milk during collection at society / BMC / CC / Dairy / FBD / Metro dairies.
• The milk procured by the primary milk Producer’s Co-operative Societies is being
tested thoroughly and duly ensured that the Milk Producers are getting reasonable
price for the milk on quality basis.
• To distribute, hygienic and quality milk and milk products to consumers, the
Federation and District Cooperative Milk Producers dairies are conducting
• various quality tests at various levels from the initial stage of milk collection
through their quality control units by using modernized testing equipment to
ensure the quality milk and milk products to the consumers
Quality Management:
All units (Dairy Plant) of TCMPF Ltd. are committed to process milk received from apex
co-operative societies in a clean and hygienic environment adhering to Good
Manufacturing Practices (GMP) and Food Safety management system.
• Ensure safe consumption of milk products conforming to standards by following Food
Safety Management System in our activities
• Meeting all statutory and regulatory requirements related to food safety in allour
activities
• Ensure mutually agreed food safety requirements of our customers
• Communicate food safety aspects both internally and externally
• Continually review and update our Food Safety Management System

29
PACKING
The packaging of milk is an important aspect to protect, carry, and market, to sustain its
freshness and convenience. Various types of packaging are used for packaging milk, such
as bag. The packaging trends vary with respect to the place
Packing Section (Pre Pac - Sec)
Packing machine
Pipes filler
transfer to
production – finally
packing area
This machine pre pack section-1 under two packing parts
• When you receive ingredients, visually inspect them to make sure:
• there are no signs of tampering such as broken seals on the packaging materials
• the ingredients or packaging you have received are what you ordered
• there is no opened packaging
• there is no physical damage to the ingredients
• there is no dust, debris or signs of pest activities on the ingredients
• there is no sign of any water damage
• there is no sign of any contamination from other materials that may be in the
vehicle
• The ingredients have been transported at the temperature recommended by the
manufacturer. Use infrared thermometers to check the surface temperature, or
open a package and use an immersion-type thermometer to check the internal
temperature.
• If you open a package to check the temperature, throw the material away
afterwards unless you can process it to get rid of any contamination that may
have been introduced.
• From time to time, take samples of your ingredients and test them to make surethey
meet your specifications.

30
machine
Conveyor machine container
Leak milk tank:
• To check the milk packets which are damaged will be returned to production
departments
• To check the temperature of milk.
• To check quality control of milk
Packing
Milk packed

31
Storage of products:
• All ingredients should be stored:
• According to the manufacturer's instructions
• In a way that protects their integrity
• In a way that minimizes the risk of contamination
• Make sure all ingredients are clearly identified.
• Be aware of any ingredients that are allergens or contain allergens. Handle and store
these ingredients in a way that does not contaminate other ingredients.
• In general, if an ingredient needs to be refrigerated, store it between 1°C and 4°C.
Store frozen ingredients at -18°C or lower. Monitor and record these temperatures
regularly.
• Each day, only bring out the ingredients needed for that day's processing. Thisreduces
clutter in the processing and packaging areas, makes cleanup easier at the end of the
day and prevents ingredients from getting wet or contaminated. Packaging material
such as cardboard boxes may be a source of yeast and mould, so limiting the amount
of ingredients you bring into the area helps to minimize the exposure to these micro-
organisms.
• Any unused materials should be properly covered, labelled and returned to their
appropriate storage conditions. Use up any partially used materials before opening a
fresh package or container.
• Rotate ingredients in storage where appropriate so that the oldest product isused first
to help make sure all products are used before their "best before" date. This usually
means first in, first out (also known as FIFO).
• Protect ingredients stored at room temperature against contamination andconditions
that could cause deterioration. This includes:
• direct sun
• excessive heating
• moisture
• external contaminants
• rapid temperature changes that could affect their safety or quality
• If you stack your ingredients, make sure:
• there is not too much weight on any containers at the bottom on the stack

32
• there is no danger the stacks could fall and damage the containers or expose
ingredients to the environment
• Store materials in a way that allows you to clean the area effectively and control pests.
For example, store items off the floor and approximately 45 cm (18 in.) away from the
walls.
• Keep refrigerated storage areas at the proper humidity to prevent condensation, and
keep them clean and sanitized to help prevent mould.
• Make sure condensate pipes emptied into a drain to reduce contamination.
• Keep refrigeration units including their condensate collection trays and drain lines
clean and maintained on a regular schedule to prevent the growth of mold,spoilage
bacteria and pathogens.
• Treat condensate trays with sanitizer to prevent the growth of harmful bacteria that
could cross-contaminate employees' clothing or skin or other areas of your plant and
eventually food products.
STORAGE COLD ROOM
A cold room is a type of refrigeration chamber or insulated space designed to maintain an
artificially generated temperature or range of temperatures. Cold rooms are used for storing
temperature-sensitive, perishable items, such as food items and pharmaceutical products like
vaccines. Cold rooms can vary in size from very small walk-in rooms to very large
warehouse storage.
The basic purpose of cold storage is to store the perishable food products at optimum
temperature to enhance the self-life of the products. In dairy plants, cold storages are
required for storage of milk, butter, cheese, ice-cream etc. The condition of storage in these
cold storages is different depending upon the nature of the product. For example, ice-cream
is stored at - 25 ºC while milk is stored at 3-4 ºC. Similarly, many fruits and vegetables are
also stored in cold storages.

33
Classification based on the use of cold store:
• Milk cold storage
• Cheese cold storage
• Butter cold storage
Cold storage is a basic requirement for the storage of perishable dairy and food products.
For example milk is stored at around 4 °C in
Cold storage while ice cream is stored at -30 ºC . The design of cold storage requires
information on the following aspects.
(i) Size of the cold storage
(ii) Products to be stored
(iii) Incoming temperature of the product
(iv) Storage temperature
(v) Ambient temperature
(vi) Air change load
(vii) Numbers of persons working in the cold storage.
Milk packed blue-green-orange identity:
• Green color packed
• blue color packed
• orange color packed

34
DISPATCH
Finished products must be properly protected during shipping. The type of vehicle or
containers required depends on the type of product and the conditions under which it has to
be transported.
Unless you take effective control measures, finished products may become contaminated
during shipping or may not reach their destination in a suitable condition for consumption.
This can happen even when proper hygiene control measures were taken when you made the
product.
• protecting product from potential sources of contamination
• separating product from non-compatible products on the same load
• protecting product from damage that could make it unsuitable for consumption
• keeping the product at the right temperature to prevent the growth of spoilage micro-
organisms that may shorten the shelf life of the product.
Transport Vehicles:
The vehicles and containers used to transport food should be kept clean and in good
condition. If you use the same vehicle or container for transporting different foods or for
transporting non-food products, it must be effectively cleaned and disinfected (if necessary)
between loads.
Dispatch of details of products:
• under the Vellore milk dispatch
• village and near and long places
• morning milk packed dispatch liters 1/2, 200ml,
• nights milk packed dispatch liters 1.litre

35
CONCLUSION
“A STUDY ON OBERVATIONAL OF MILK PRODUCTION AT VELLORE AAVIN
INDUSTRY” means brings life which is known as the newly appointed project visits
training under the factory. Which was offered by Vellore aavin industry which is very
useful for finally project based
AT THIS TIME I THANK MY DEPARTMENT STAFFS, HOD, for helping us for letting
know about VELLORE AAVIN INDUSTRY projects programs which will be very help
full in future. By studying them it will be little bit easy for us to attend a campus and we
learned about production process in milk dairy industry by innovative of the organizations
by very useful our life starting-to-ending every activities

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