The document discusses the process of establishing and operating a dairy/milk processing plant. It covers selecting a suitable site near milk production and transportation. It then discusses constructing facilities with proper ventilation and drainage. Equipment is installed for milk collection, processing like pasteurization and separation, producing products like milk, butter, cheese, and their storage and marketing. Key steps involve collecting, processing, producing, and distributing dairy products.

1. DAIRY / MILK PROCESSING PLANT
Introduction
Site
Civil Work / Construction
Plant Set up
Operations & Production.
I. Collection.
II. Processing.
Products
Marketing

2. INTRODUCTION
 Milk is widely considered as one of the most valuable and well-known Food.
 Milk is used as food by all age group.
 In industry has standard capacity of Milk processing and milk handling
1,000 – 5 Lac liters per day.
 Milk Processing plant can operate 20 hours in a day.
 Fat content Whole or full-fat milk contains about 3.5% fat Semi-skimmed
contains about 1.7% fat Skimmed milk contains 0.1 to 0.3% fat Some
supermarkets sell milk with a 1% fat content which has almost half the fat
of semi-skimmed milk but retains a more creamy flavor.
 In India Organized(Private, Cooperatives & Govt.) and Unorganized Dairies.

3. SITE
 The plant should be located as centrally as possible within a given milk-
producing area, near a source of water, or in a place where water is
available.
 The transportation facility must be nearer to the plant i.e. Road, Market
connectivity.
 The site should be cool and well-ventilated. It always influenced by their
environment The most important factor is availability of water.
 It should be remembered that on average five liters of water are required to
process one liters of milk.
 Electricity and workers availability.
Site and requirement of Milk Processing Plant.

4. CIVIL WORK AND CONSTRUCTION
 An unused building can be purchased or leased and adapted for milk
processing operations. New building can be constructed. It is not
uncommon to find in some remote milk-producing areas.
 The walls should be built of local stone and the inner walls lined with a
lime-cement mixture for easy cleaning.
 The cement floor should have a 2 to 3 percent slope for draining water used
in cleaning.
 Windows should be sufficient to provide adequate ventilation.
 Building size will of course depend on the quantity of milk received during
the peak production period. An average quantity of milk which can be
processed by a small-scale unit amounts to 100 to 500 liters per day.

5. PLANT SET UP
 Plant set up. When civil work completed equipment are ready to install.
 The equipment needed to run the dairy processing plant depends on
several factors.
How much milk is to be collected ?
How far and how scattered are the milk producers ?
What kind of product is to be produced ?
 In the standard milk processing pattern, commencing with milk collection
and ending with the sale of the dairy products.

6. OPERATIONS AND PRODUCTION
 An unused building can be purchased or leased and adapted for milk
processing operations. New building can be constructed. It is not
uncommon to find in some remote milk-producing areas.
 Milk processing operations will take place far from urban consumption
centers. In these areas the quantities of milk hardly exceed an average of
500 liters per day.
 The products made must be able to withstand long periods of
transportation, often under difficult climatic conditions.
 Standardization: Standardization is an operation producing milk with a
constant butterfat content through partial, manual skimming. The operation
makes it possible to standardize the composition of the finished product
and to set aside part of the cream for butter.

7. OPERATIONS AND PRODUCTION
 Heat treatment: Pathogenic germs in milk are destroyed by heating the milk
to a minimum temperature of 63°C for 30 minutes.
 Inoculation: Due to heat treatment, which destroys a large number of lactic
bacteria, cheese or yoghurt-making requires the addition of lactic bacteria
to the milk. These bacteria are selected according to the type of finished
product required.
 Clotting: Milk changes from a liquid to a solid state through the use of a
coagulant: rennet.
 Curd-Separation: In cheese-making, the milk after coagulation is cut and
separated into a liquid whey, and cheese curd.
 Ripening: This phase of cheese-making allows cheese texture to become
homogeneous and the aroma to develop.

8. OPERATIONS AND PRODUCTION
 Churning: In this operation, cream is churned to produce a semi-solid
product which becomes butter.
 Melting and emulsification: Defective cheeses are melted and emulsified
with salts to obtain a solid consistency and, after cooling forms processed
cheese.

9. COLLECTION
 Stainless steal milking pails are often an improvement on the utensils
commonly used.
 The producer should use small aluminum milk
 cans of 5–10 liter capacity for transporting the milk, while the collector
should use 30–50 liter cans.
 If the milk needs to be collected, the following will be needed: the use of a
bicycle, a 50 liter milk can, a graduated cylinder lacto-densitometer and a
measuring pail.

10. PROCESSING
 Reception: the following equipment is needed for the reception of milk
brought in by producers themselves and by the collector: a milk scale and a
pail.
 Storage: a milk funnel and 50 liter milk cans.
 Standardization/Cream separation: a manual cream separator has to be
used to skim a portion of the milk received.
 Heat treatment: there are several possibilities for heat
treatment, depending on the available power source. Under the least
favorable circumstances, the sole available energy source is wood or peat.
The best thing to use in this case is a “boiler/water bath”
 Cooling: the milk is cooled with the help of milk chillers.

11. PROCESSING
 Clotting: The cheese vat can be of aluminum with a tap for draining the
whey
 Pressing: different kinds of cheese (curd) presses can be made. The
simplest press is made by placing weights or cement block on the molded
cheese (curd) as shown in the following diagram:

12. PROCESSING
 Milk Collection Centre :
1. Milk Collection from Farm Level to Milk Collection Centers.
2. Transfer of Milk from Farmer to Milk Centers
3. Measuring and Buying of Milk at Small Collection Center
Measuring
4. Pouring of Milk in Milk Silo Front View of Milk Silo

13. PROCESSING
Milk Producers Milk Collection
Centers
Bulk Milk CoolerMilk Chilling
Milk Clarifier Raw Milk Storage

14. PROCESSING
 Pasteurizers : Pasteurization of Milk Pasteurization or pasteurization
is a process of heating a food, which is usually a liquid, to a specific
temperature for a predefined length of time and then immediately
cooling it. This process slows spoilage caused by microbial growth
in the food/ Milk.
Raw Milk Storage
Pasteurization

15. PROCESSING
 Cream Separator : It separate cream from milk and cream is used for Bi
products manufacturing.
Pasteurization Cream Separator
Standardization
Homogenization
Pouch Packing Section

16. PRODUCTS
 Types of Milk : Pasteurized, Homogenized, Whole, Skimmed, Single
Toned, Double Toned, Full Cream milk contain.
Pasteurized - Heated at high temperatures in order to the kill the harmful
bacteria without losing out on the flavor or nutritional content of Milk.
Homogenized - Process where the fat globules in it are broken, which spreads
the fat evenly, preventing the formation of the creamy layer on top.
However, the fat content and other factors remain the same.
Skimmed - All the nutrients found in whole milk like the vitamins and
minerals.

17. PRODUCTS
Whole – full cream milk is usually consumed by children, teenagers and body
builders. Whole milk is called so because it contains all the milk fat found
them. One glass of whole milk contains 3.5% milk fat, which provides about
150 calories. Whole milk is also creamier and full of flavor
Single Toned - obtained by adding skimmed milk powder and water to whole
milk. It contains about 3.0% fat and toned milk restricts the body from
absorbing cholesterol from the milk to minimum
Double Toned -obtained by adding skimmed milk power to whole milk and
has about 1.5% fat content. Double toned milk is ideal for those trying to
maintain weight as it keeps the calorie intake under check and aids weight
loss.

18. PRODUCTS
Cream –the fat layer of milk is separated to make different types of cream.
Yogurt - a very popular dairy product made by the fermentation of milk by
lactic acid bacteria.
Butter - is a water-in-oil emulsion made from 'cream by phase inversion.
Cheese - is made from curdled milk by removal of the whey part (liquidly
part) and then ripening of the curd part (solids part) using particular
microbial cultures.
Ice cream - It is another universally popular dairy product, made from milk of
varying fat contents.

19. PRODUCTS
Paneer – The curds are drained in muslin or cheesecloth and the excess water
is pressed out
Shrikhand - Shrikhand, yogurt is tied in a cotton cloth and left under pressure
to drain
Ghee - Ghee is the pure butterfat left over after the milk solids and water are
removed from butter.
Khoa - Made of either dried whole milk or milk thickened by heating in an
open iron pan.
Lassi - Lassi is a blend of yogurt, water, spices. Sweet Lassi, Mango Lassi &
Bhang Lassi.

20. CONTACT US
“Turnkey Solutions Provider”
Head Office
Office No. 202, Swastik Chamber, Above ICICI Bank,
Near Ranka Jewelers, Karve Road, Erandwane, Pune
Maharashtra, India
Ph. No. +91- 20-25450480, Fax No. 020-25450479
Mob. No. +91-8600022256
Email - contact@indotechindustries.com
Website – www.indotechindustries.com
Indotech Industrial
Solutions Pvt. Ltd