More Related Content Similar to Environment Health and Safety Management in Jaipur Dairy Plant (20) 4. iv
Acknowledgements
The author is grateful to the Managing Director, Mr. J.R. Dhaka, for providing
permission, facilities and guidance to conduct the study. The quality time and
information provided by Mr. S.C. Gupta, Manager Engineering, Mr. Vijay Gupta,
Manager Personnel, Mr. Rahul Saxena, Manager Plant and Mr. Bajrang Dubey,
Manager ETP (Outsourced), is gratefully acknowledged. Special thanks are due to
the team of the Personnel Department for making available the documents
essential for the study.
Thanks are also due to the numerous workers of Jaipur Dairy who freely gave
their time, and shared their knowledge and experience.
(Dr. Alka Awasthi)
6. vi
Abbreviations Used
BMC Bulk Mick Chiller
CIP Clean In Place system
CPCB Central Pollution Control Board
DCS Dairy Cooperative Society
EPF Employee Provident Fund
ETP Effluent Treatment Plant
FSS Act Food Safety and Security Act
GoI Government of India
HACCP Hazard Analysis and Critical Control Points
MBRT Methylene Blue Reduction Test
MLD Million Litres per Day
ODS Ozone Depleting Substances
OHS Occupational Health and Safety
PHED Pubic Health Engineering Department
PPE Personal Protective Equipment
SCBA Self Confined Breathing Apparatus
SS Stainless Steel
UHT Ultra High Temperature
7. 1
Chapter 1 Company Profile
Jaipur Zila Dugdh Utpadak Sahkari Sangh Ltd. (or Jaipur Milk Union), also
popularly known as ‘Jaipur Dairy’, made a small beginning with a collection of
250 litres milk per day. It was established in the year 1970 without any
processing facility. The Dairy was registered in March 1975 and the processing
plant was commissioned in June 1981.
Over the years, there has not been looking back for Jaipur Dairy and the
significant growth has been made in all fields i.e. procurement, processing and
production of various milk and milk products and marketing thereof under the
brand name of SARAS. The plant is managed and operated by well- qualified,
competent and experienced managerial cadre and highly motivated work force
to provide highest quality of products and best of the services to our esteemed
customers. To further improve the efficiency and effectiveness of the plant
performance, Jaipur Dairy (Jaipur Zila Dugdh Utpadak Sahakari Sangh Ltd.,
Jaipur) had earlier obtained the Quality Management Systems Certification as
per ISO 9002:1994 in combination with IS: 15000 (HACCP) in the year 2000.
Now the dairy has upgraded the system in accordance with ISO: 9001: 2000 in
combination with (HACCP) as per IS: 15000: 1998.
Key activities of the Dairy include formation of DCS (village level Dairy
Cooperative Society), procurement of milk through a network of village level
cooperative societies, processing and manufacturing of milk and milk products,
marketing of milk and milk products under the brand name ‘Saras’. The Dairy
also undertakes capacity building of village level societies and their office
holders as wells as all milk producers on topics ranging from management,
accounts, leadership, clean milk production, animal health and nutrition, role of
women in dairy, etc. The milk shed or milk collection area of the Jaipur Dairy
falls in Jaipur and Dausa Districts of Rajasthan.
8. 2
The Dairy provides various services to the milk producers including animal
health services (first aid, health camps, immunization), breeding improvement
services, feed inputs (cattle feed, mineral mixture, urea molasses bricks), and
fodder seeds.
The average daily milk procurement in the FY 2015-16 was 1029 TKPD
(thousand kilogram per day). The key aspects of milk procurement are tabulated
below:
Table 1 Key Features of Jaipur Dairy
Dairy Plant capacity 500 TLPD (capacity enhancement in
process)
Asceptic packaging station 60 TLPD
Powder Plant 50 Metric tons per day
Milk Chilling Centres 5 with total capacity of 295 TLPD
Bulk Milk Chillers 357 collecting from 331 DCS
Cattle Feed Plant 1 of 300 MT per day capacity
No. of DCS (2015-16)* 1785
No. of DCS members* 1,50,080 (including 76,587 females)
Payment to Milk Producers* Rs. 1194.66 crore
9. 3
Table 2 Products of Jaipur Dairy
Packed Milk Milk Products
Toned Curd
Double Toned Lassi
Standard Chaach
Gold Ghee
UHT Milk Butter
Paneer
Shrikhand
Flavoured ice creams
Rasgulla
Organizational Structure
The Jaipur Dairy is headed by a Chairman and Board of Directors. The Jaipur
Dairy situated in Jaipur has a staff of 290 permanent and more than 1000
contractual staff. These include staff ranging from senior management to dairy
supervisors working at village level.
Figure 1 Organizational Structure
Chairman & BOD
Manager
Deputy Manager
Assistant Manager
Managing Director
Clerks, Operators,
Dairy Supervisors (in field)
11. 5
Chapter 2 Review of Literature
International Scenario: The application of occupational health and safety (OHS)
legislation in the dairy industry varies throughout the world1. Generally there is
no specific OHS legislation that applies to the dairy industry and mostly in
countries the current OHS legislation applies to all workplaces with specific
guidelines that apply to agricultural industries. The main difference between
countries is in the application of OHS legislation specifically in relation to the size
of the farms. In the USA, the OHS legislation, and therefore enforcement, does
not, in most cases, apply to farms with less than 11 employees, whereas in the
United Kingdom and Australia it covers all people who work on the farm. The
other area of difference is in the use and publication of guidelines for the
industry; some countries have a wide range of guidelines whereas other counties
have few. Generally, this relates to the jurisdiction of the OHS legislation, which
in several countries is not at a national level such as USA, Canada, and Australia.
OHS legislation throughout of Asia varies significantly in respect to its design and
implementation, but the majority is risk based. In many cases, it only applies to
large organization or worksites, in particular mining sites, and manufacturing
and construction industries. As the dairy industry in most Asian countries is
relatively small and in most cases is family based, little OHS legalization applies.
The World Bank Group2 has formulated the ‘Environmental, Health, and Safety
Guidelines for Dairy Processing’. The Guidelines for Dairy Processing facilities
applies to the reception, storage, and industrial processing of raw milk and the
handling and storage of processed milk and dairy products. The EHS Guidelines
are tailored into the environment and social safeguards of Bank supported
projects on the basis of the results of an environmental assessment in which site-
specific variables, such as host country context, assimilative capacity of the
environment, and other project factors, are taken into account. The Jaipur Dairy
has availed of funds from GoI and World Bank through the ‘National Dairy Plan I’
as a result of which the Dairy staff have been sensitized on the relevant
occupational, health, safety and environment guidelines.
12. 6
National Scenario: The constitution of India enshrines detailed provisions for
the rights of the citizens and other persons and for the principles in the
governance of the country labeled as “Directive Principles of State Policy”. These
Directive Principles provide for securing the health and strength of employees,
men and women, that the tender age of children are not abused, that citizens are
not forced by economic necessity to enter avocations unsuited to their age or
strength (Article 39), just and humane conditions of work and maternity relief
are provided (Article 42), that the Government shall take steps, by suitable
legislation or in any other way, to secure the participation of employee in the
management of undertakings, establishments or other organizations engaged in
any industry.
On the basis of these Directive Principles and international instruments, the
Government of India Government is committed to regulate all economic
activities within the country with a view to ensuring that every working
employee is provided with safe and healthful working conditions. Accordingly,
Government of India enacted the statutes relating to Occupational Safety &
Health (OSH) at workplaces viz., The Mines Act, 1952 and Rules and Regulations
framed thereunder; The Factories Act, 1948 and Rules framed thereunder; Dock
Workers (Safety, Health and Welfare) Act, 1986 and Regulations and Rules
framed thereunder; The Building and Other Construction Workers (Regulation of
Employment and Conditions of Service) Act, 1996 and Rules framed thereunder;
The Dangerous Machines (Regulation) Act, 1983 and Rules framed thereunder;
The Shops and Establishments Act of State Governments; The Municipal Solid
Waste (Management and Handling) Rules, 2000 notified under the Environment
(Protection) Act, 1986; The Manufacture, Storage & Import of Hazardous
Chemicals Rules, 1989, etc. These are some of the important statutes covering
OSH aspects of workers. At present, comprehensive safety and health statutes
for regulating OSH at work places exist only in respect of the four sectors
namely, mining, factories, ports, and construction3.
The subjects of environment health and safety relevant to the Dairy Sector are
covered in The Factories Act, 1948 (amended 1987 and 2007). As Dairy Industry
13. 7
is categorized as non-hazardous industry, the applicable environmental
regulations include The Water (Prevention and Control of Pollution) Rules 1975,
The Air (Prevention and Control of Pollution) Rules, 1982, and The Ozone
Depleting Substances (Regulation and Control) Rules, 2000. The Building and
Other Construction Workers (Regulation of Employment and Conditions of
Service) Rules 1998 are applicable during construction activities.
The main health and safety legislation in India is the Factories Act 1948. In
essence, it places a general duty on factory owners to ensure, as far is reasonably
practicable, the health, safety and welfare of their staff, through steps such as the
provision of safe plant and systems of work, and suitable information,
instruction, training and supervision. It also contains specific duties on issues
such as registering factories, maximum working hours, working temperature,
machinery guarding, fire safety and sanitation. In addition, the Act prohibits the
employment of children under 14 in any factory, requires factories employing
more than 1,000 people to appoint internal safety officers and requires factories
with more than 500 workers to appoint welfare officers.
The Management Systems Certification (MSC) activities of the Bureau of Indian
Standards (BIS) include the following:
• IS/ISO 14001: This standard comes under Environmental Management
Systems Certification Scheme (EMSCS) and is identical to ISO 14001 -
Environmental Management Systems. This standard helps the organizations
to achieve and demonstrate sound environmental performance.
• IS 18001:2000: This standard comes under Occupational Health and Safety
Management Systems and helps in good health and safety performance
ensuring an accident-free industrial environment. This also improves
organization's smooth and effective functioning.
After the formation of World Trade Organization (WTO), there were some
instances where foreign buyers refused to accept Indian processed food
products from Indian food processing industries that did not follow HACCP
(Hazard analysis and critical control points) system. Now HACCP is
15. 9
9. Personal Protective Equipment’s (PPEs)
10. Emergency Control Centre
Richa Brahmbhatt (2016)5 has studied Employee Health, Safety and Welfare at
Sumul Dairy, Surat, Gujarat. Following a quantitative approach Ms. Brahmbhatt
studied variables including welfare facility, comfort area, working environment,
health facility, necessities, policy, and safety policy. Her study showed that Sumul
is providing most of the health, safety and welfare measures. Sumul Dairy
provides leave policy, training for handling any kind of things, first aid treatment
for the workers and employees. Factors rated satisfactory by the workers
include training before handling difficult machines; unsatisfactory services
included transport facility.
16. 10
Chapter 3 Methodology
Objective of the Study: To study health, safety and environment management in
Jaipur Dairy
Methodology: A literature review was undertaken to understand the regulations
for health, safety and environment management, with particular reference to the
dairy sector. Publications available in the public domain on Dairy sector in India
were perused to understand the safety and environment issues in the sector.
Primary sources of information were key informant interviews, focussed
discussions with managers and workers of different plants, site visits and
perusal of records and documents.
Different plants under the Jaipur Dairy including pasteurization plant, processing
plant, boiler plant, refrigeration plant, ghee, paneer, shrikhand, UHT milk
production and packaging plants, testing laboratory and ETP were visited. Safety
information, knowledge and practices were observed and discussed.
Photography was not done inside the plants in accordance with the regulations
of the Dairy.
17. 11
Chapter 4 Findings
Dairy Establishment should be located away from environmentally polluted
areas and industrial activities which produce disagreeable or obnoxious odour,
chemical or biological emissions and pollutants, and which pose a serious threat
of contaminating food; areas subject to flooding; areas prone to infestations of
pests; and areas where wastes, either solid or liquid, cannot be removed
effectively. Adequate land should be available for effluent treatment. The Jaipur
Dairy was established following the siting rules (registered in 1975), but now the
Jaipur city has spread and grown to the extent that the Dairy is now located in
the city itself. Nevertheless, the location is still far from industrial activities
producing obnoxious odour and biological emissions. There are no flood or
infestation prone areas. Enough land is still available for scaling up of the
processing plant as wells as effluent treatment system.
4.1 Health and Welfare
The Jaipur Dairy has staff strength of 290 permanent workers including 21
females. In addition more than 1000 workers are on contract since recruitments
have not been possible since many years.
Health and Medical Care of workers: Newly recruited staff undergo medical
check-up at the SMS Hospital. Health check-up camps are organised 6 monthly
for staff including contract labour. Several local hospitals such as Metromas,
Agrawal Eye Hospital, EHCC also hold health check up camps (eye, dental,
general). The Dairy itself has designated 25 hospitals for medical treatment of
all its employees, and all medical expenses covered.
All leave benefits including leave encashment benefit, and maternity leave are
available to the permanent employees. Staff quarters are available. Staff
members can avail loans from cooperative. They are entitled to EPF.
First Aid/ medical Room: A Medical and Ambulance Room is situated in the main
office building. Every day (2-3pm) one allopathic doctor, and one homoeopathic
18. 12
doctor are available for consultation. First aid is provided and when needed
workers are referred and transported to designated hospitals including EHCC
and Jaipuria Hospital for treatment. Dairy vehicles are used for medical
emergencies. A Rest room constructed, but is not in use.
Employee Welfare: Safe drinking water (cooled when needed) is provided at
appropriate places throughout the premises. There are separate toilets for men
and women. The Dairy runs a canteen which is open till mid-night for the benefit
of workers as three shifts are operated per day.
Health of consumers: The Dairy complies with the FSS Act and HACCP system. A
Food Safety Management System based on IS 15000:1998 has been prepared on
21 July 2010, (regularly updated, latest update 26/12/2011). The objective of
the manual is to ensure that food products processed, stored and distributed by
the Jaipur Dairy are safe for human consumption. The HACCP plan covering all
classes of hazards – physical, chemical or biological likely to appear singly or in
combination in all stages of food chain segment. It also lays down the training
plan for HACCP team and staff at various levels on principles of maintaining
cleanliness and hygiene. Audit and verification is done immediately after
deviation. Monitoring and validation of critical control points is done once a year.
Hazards identified for milk are adulterants, foreign matter, high bacterial load,
survival of micro-organism growth due to faulty operation of pasteurizer, or
residual detergents. The Critical Control Points for pasteurization of milk are
pasteurisation temperature, milk storage temperature, and MBRT time.
Hygiene practise among workers is critical for safety of food products. Workers
are made aware of personal hygiene measures including cutting of hair and nails,
hand washing with iodophore, wearing clean clothes, using gloves, masks and
hair caps.
At the level of cooperative societies, the Dairy trains milk producers on clean
milk production including use of SS (stainless steel) milk cans, hand washing
before milking, prevention of mastitis in cows etc.
19. 13
Health of Milk Producers at village level: Rural Milk Producers are not employees
of the Jaipur Dairy, but the Union provides many benefits to the cooperative
members. Through its animal health services the Dairy raises awareness of
zoonotic diseases (diseases that can spread between animals and humans) such
as tuberculosis and brucellosis. This knowledge safeguards the health of milk
producers and their milch animals.
The Dairy provides benefits to members of its village level cooperative societies
through health and accidental insurance and scholarship for children. The
schemes implemented include (Saras Suraksha Kavach: life insurance for
member + scholarship for 2 children, Saras Arogya Bima Scheme: mediclaim
scheme, Saras Lado Yojna: payment of Rs. 1 Lakh for girl child at marriage).
4.2 Safety
According to the Factories Act 1948, it is the duty of the employer to provide safe
working environment to all workers by providing proper safeguards to
dangerous parts of machines, by training the workers in safe operating
procedures, by providing adequate information about the hazardous properties
of the chemicals and process, by providing proper safety systems in the plant
such as pressure / temperature controllers, interlocks, safety valves, by
providing flameproof electrical fitting in case of handling of flammable chemicals
etc. and to get the lifting machines, tackles and pressure plants examined by a
competent person, to provide proper fire fighting arrangements etc.
A safety Committee should be formed comprising of senior management as well
as staff, safety officer should be appointed; responsibilities should be delegated
to members; meetings should be regularly conducted and their records should
be maintained; trainings should be conducted on safety aspects and inspections
and safety audits should be conducted.
21. 15
premises. Visitors are accompanied by staff who appraise the visitors about the
dairy processes as well as safety procedures.
Personal Protective Equipment: The staff working in the plants use following
PPEs:
1. Safety helmets
2. Goggles
3. Ammonia half face mask
4. (SCBA) Self-confined breathing apparatus
5. Gloves
6. Gum boots/shoes
7. Aprons
8. Safety belts
Showering and cooling facilities are available for workers who experience dust
or spillage of chemicals. In some of the plants the noise level was high so as to
deter normal conversation. Ear muffs were not in use, these may help workers to
perform better.
Floors of all plants are maintained in good condition for easy washing. Drains are
covered to avoid entry of lies and rodents. Roads are well maintained for
facilitating movement of vehicles without raising dust.
Awareness and Capacity Building for Safety: Signs for necessary safety
precautions to be taken are prominently and clearly displaced at appropriate
places in different plants. The technical workers met know about the precautions
to be taken in working with pressure machines and ammonia containers, as well
as the first aid measures. However, a large part of the workforce in plants
comprises contract labour workers with high turnover. The management takes
precautions while engaging such workers. New workers are assigned to
peripheral jobs such as crate lifting and gradually as they are shifted to
packaging, and then for operating machines. Whenever new machines are
installed, the workers are given training on their safe operation. Afterwards, new
22. 16
recruits are trained on the job, and the plant managers inspect their work and
enhance their capacity on safe operation during regular plant visits.
Security guards, workers working with ammonia, refrigeration, boilers, and
those responsible for fire safety and electrical safety receive trainings in
different centres of the National Productivity Council. Trainings are conduced on
working with pressure machines, SCBA handling, ammonia, and on first aid.
Safety inspections and certification of boilers and other machines are done
regularly. Critical Control Points are displayed prominently and strictly followed.
Safety audit was done during the last year.
However, the Safety Officer has not been appointed and the meetings of the
Safety Committee are not taking place. The plant/section-in-charges are aware
of the location of the first-aid boxes.
Emergency Plan: After the incident of Bhopal gas disaster, the Factories Act 1948
has been amended and a new chapter. Preparation of On-site Emergency Plan by
the occupier is mandatory. The occupier shall ensure a mock drill of the onsite
emergency plan is conducted at least one in every six months. The Dairy
identifies the main hazards to be fire, ammonia leakage, and injuries. The Jaipur
Dairy has an on-site emergency management plan. In case of emergency an
alarm is sounded. Workers meet at an assembly point just outside the main gate
so as not to disrupt movement of emergency vehicles. Mock drills are conducted
for the security staff.
4.3 Environment Management
The Dairy industry is categorized as non-hazardous industry. The Dairy is
required to comply with Water Pollution abatement measures.
24. 18
The raw water passes through stages of screening, equalization, pH treatment,
anaerobic and aerobic digestion, fat removal, clarification, gas removal, filtration
and chlorination. The treated wastewater is testing for emission standards and is
used in gardening and in toilets. This use of water has resulted in a green and
pleasant environment in the dairy premises.
Water quality monitoring is automated and every 5 minutes the parameters are
communicated on-line to the CPCB. In case of variation the Dairy receives SMS
promptly. The sludge is dewatered and dry sludge is transported to the landfill
site of the Nagar Nigam.
Outside the Dairy premises, the Dairy ensures proper wastewater disposal from
BMCs. In villages the wash water from BMCs is disposed in drains to that it flows
away from the habitations. Where the soil conditions permit, and enough land is
available, suitable soak pits are constructed to manage the wastewater.
4.3.3 Air Pollution abatement: The Dairy utilizes the usual end of pipe
measures including scrubbers, flare stacks at recommended height etc. Village
level BMCs also follow recommended noise and air emission standards.
There is potential of diffuse air pollution from the large scale transport of raw
milk and finished products. But the Dairy ensures pollution control through
appropriate clauses in the contracts with transport providers. All vehicles are
required to maintain valid pollution control certificates and use of vehicles more
than 15 years old is not permitted.
The Dairy has to comply with the Ozone Depleting Substances (Regulation and
Control) Rules, 2000. The rule regulates the production and use of Ozone
depleting substances (ODS). The use of R22 in BMCs is being phased out, and all
new BMCs are required to have compressors compatible with the permissible
substances.
27. 21
References
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Colosio, C., and Singh, T. 2013. Occupational Health and Safety regulations in the
Dairy Industry, Journal of Agro-Medicine, 18:210-218.
2 IFC and World Bank Group. 2007. Environment, Health, and Safety Guidelines –
Dairy Processing, pp. 15.
3 Government of India, Ministry of Labour and Employment. 2011. Report of the
Working Group on Occupational Safety and Health for the Twelfth Five Year Plan
(2012-2017).
4 B.N. Kumar and Sabarinath, P. 2015. Preparation of Safety Manual for Dairy
Industry – a Review, SSRG International Journal of Industrial Engineering, (2-3):
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5 R. Brahmbhatt, 2016. To Study Employee Health, Safety and Welfare at Sumul
Dairy’. Summer Internship Project. S.R. Luthra Institute of Management,
Ahmedabad.
