1. THE BALLABGARH CO-OPERATIVE MILK PRODUCER’S
UNION LIMITED
(A Unit of Haryana Dairy Development Co-operative Federation Limited)
MILK PLANT , BALLABGARH
District Faridabad , Haryana – 121004
(An ISO 9001:2008 & ISO 22000:2005 Certified Unit)
SUBMITTED TO :- SUBMITTED BY :-
DR. T.V RANGANATHAN NITYA BHARGAVA
(HEAD OF DEPARTMENT – (UR14FP052)
FOOD PROCESSING AND ENGINEERING)

2. INTRODUCTION
HARYANA is one of the mostprogressivestates of Republic of India. In the domain
of dairy development it is well known for its productivemilch cattle particularly
the 'Murrah'Buffaloes and Haryana Cows. Theeconomy of the state is
predominantly based on agriculture. People rear and breed cattle as a subsidiary
occupation.
The essence of various programmes launched in the State has been to adopt the
Anand pattern of Milk Co-operatives. Under this system, all the functions of
dairying like milk procurement, processing and marketing are controlled by the
Milk Producers themselves. Ithas three tier systemcomprising milk Producers
Societies at the village level, Milk Producers Co-operativeUnion at the district
level and the state Milk Federation as an apex body at the State level.
he Haryana Dairy Development Corporation was formed in 1970 which continued
active functioning till 31.03.1977. Thereafter its business was taken over by
Haryana Dairy DevelopmentCooperative Federation Limited to promote socio-
economic interests of milk producers of Haryana Stateparticularly belonging to
economically weaker section thereof by purchaseand processing milk into milk
products and marketing through affiliated milk unions. Dairy Cooperatives in
Haryana works as per the following three tier system:- i) Milk Producers
Cooperative Societies at village level ii) Milk Unions at District level iii) State Dairy
Federation at state level

3. MILK PROCESSING
RECEIVING
The milk is received from various individualfarmers as well as co-operative
societies. All facilities for the storageand transportof milk are provided by the
industry .
As the milk is received , the tanks are unloaded manually fromthe truck and the
samples fromeach lot are sent for a quick lactometer test. The tanks are
conveyed through the chain conveyer belt and are dumped into larger tanks
The trays and cans are washed on an alternate conveyer belt using chlorinated
water and can scrubbers in a can washing tank .
The reception of milk starts at 8:30 in the morning and 6:00 in the evening. The
mil handling capacity is 8 lakh litres per day .
CHILLING
The milk is chilled to a temperature of 5°C to 7°C , by plate heat exchanger type
chillers. Water maintained at a temperature of 1°Cto 1.5°Cis used as a chilling
agent . The water conveying piping systemis insulated with thermocol.
The chilled milk is then stored in silos , maintained at a temperature of 5°C. The
industry has a total of 30 silos of capacities ranging from20000-80000 litres.
STANDARDIZATION
The milk is standardized according to the required fat and SNF concentration
prescribed for the specific category of milk to be processed, by the FSSAI. This can
be achieved by the addition of skim milk powder or cream.
Itis either done in the storagetanks after chilling or in a tank attached to the
pasteurizing system.
FCM TM DTM STANDARD
FAT 6 3 1.5 4.5
SNF 9 8.5 9 8.5

4. PASTEURIZATION
The chilled milk maintained at a temperature of 5°C or less after standardization
is sent to a HTST pasteurizer. The plant consists of 3 pasteurizers , one having a
capacity of 20000 litres and other two of 10000 litres each.
Milk is pasteurized at a temperature of 71.8°Cfor 15 seconds.
The pasteurizer consists of 5 units :
Standardization tank constitutes the firstunit
Four regeneration sections in which the temperature of the milk is increased in
steps to 37°C, 47°C, 65°C , 80°C. This provides the flexibility of sending the mil for
separation or homogenization between the regeneration sections.
FILTERATION
The milk fromthe 4th
regeneration section of pasteurizer is taken to a duplex
filter, which is a closed cylindrical body. The milk enters fromthe top and passes
out frombottom which is connected to a separator.
The body consists of two layers of metallic filters.
CLARIFIER
The milk is distributed in thin layers over conical disks of a centrifuge which
revolveat high speed. The impurities (sediment, body cells from udder, bacteria)
differ in molecular density frommilk, and separate due to centrifugal force.
SEPERATOR
The milk is separated into cream and skimmilk. The slime deposited is to be
cleaned and removed manually after the operation is stopped.

5. HOMOGENIZATION
Homogenization is the process of breakdown or dispersion of fat globules evenly
throughoutthe milk , giving it a smooth texture and thick consistency. Itbasically
forms a uniformemulsion . A two stage homogenizer systemis installed.
FirstStage - 500 psi
Secon Stage – 2500 ps
The milk after being processed is maintained at a temperature of 5 °C in an
overhead storagetank
PACKAGING
Packaging is an importantoperation for the protection of the productas well as
enhancing its attractiveness , thus making it marketable.
The milk is packed by the means of a Form,Filling, Sealing(FFS) machine which is
fully automate and electrically powered. The capacity of the machine is 45
packets/minute.
1.The packing material (polythenefilm) is loaded at the rear side of the machine
in a rotary motor.
2. As the operation begins, pouches are formed according to the prescribed
required size.
3. Milk flows into the pouches from the overhead tanks by gravity and are
the filled pouches are immediately sealed by Teflon coated electrode.
4. The packed pouches are stacked in crates and through a conveyer belt sent to
the cold storageroommaintained at a temperature of 1°C.
The packets are checked for leakage. The leaked packets are removed and the
milk is recirculated.The productis dispatched and circulated in the market as soon
possible.

6. PANEER
Paneer is formed by standardizing buffalo milk to 5% fat and 9%SNF and further
coagulation by citric acid.
Buffalo Milk (5% fat and 9% SNF)
↓
Heating (80°C-85°C)
↓
Addition of Citric Acid (0.2% at 74°C)
↓
Formation of Coagulum
↓
Drainage of Whey( Used to make jaljeera during summers)
↓
Filling into Hoops
↓
Pressing (15-20 mins at 5kg/cm square)
[This is an automated mechanism]
↓
Immerse in chilled water [salt 0.1%](3 hours)
↓
Cut into required sizee
↓
Packing and Sealing of required quantity ( VaccumPacking)
↓
Storage (Deep Freeze at -17°C)
 The processed paneer has a shelf life of 4-5 days.

7. DAHI
Also known as Indian curd. Itis a well fermented product. Itis processed using
buffalo milk standardized to 6.7% - 6.8% fat and 9.1% SNF.
Buffalo Milk
↓
Pre-Heating(35°C-40°C)
↓
Standardization (6.8%Fat and 9.1%SNF)
↓
Heating(60°C)
↓
Pateurization and Homogenization (80°C-90°C for 20 minutes)
↓
Cooling (40°C)
↓
Inoculation ( lactobacillus culture at 40°C)
↓
Packaging
(cups of required quantity and size are filled, packed and sealed by an automated
mechanism)
↓
Incubation (25°C for 16-18 hours)
↓
Setting and Formation of Dahi( 30-40 kg per batch)
↓
Cold Storage (5°C)

8. GHEE
The milk received is separated into skim milk and cream. The cream obtained is
used for the production of butter and this butter is used for ghee manufacture.
The ghee is produced by creamery butter method.
White Butter
↓
Melting
(70°C - 80°C steam pressure – 0.5kg/cm square)
↓
Cooking
(105°C-109°C steam pressure – 1.5kg/cm square)
↓
Settling of ghee residue(dark brown)
↓
Filteration/Clarification (separation of residue and ghee)
↓
Packaging (40°C)
(Ghee is filled in 1 litre tanks or pouches of required quantity)
↓
Storage
(Ambient Temperature)

9. KAJU PINNI
Itis a traditional Indian sweet.Thedark brown residueformed during ghee
preparation is used for the preparation of kaju pinni .
Ghee residue (heated in a karahi)
↓
Addition Flour and gond (edible glue)
↓
Heating (155°C) and stir for 2-3 minutes
↓
Transfer to another vessel and add Sugar/Jaggery(78°C)
↓
Add kaju (Cashewnuts )
↓
Mix the ingredients well and leave for cooling
When the mixture is cool enough to handle , it is moulded into specific shape and
decorated by cashews.
The pinnis are left for further cooling and stored at ambient temperature

10. BUTTER
Butter is manufactured by cream (53-54%fat) of buffalo or cow milk , or a
combination of both. Vita dairy processes whiteas well as table( yellow) butter. A
CBMM (Continuous Butter Making Machine) is used for production.
WHITE BUTTER
Itis generally not marketed and used for the production of ghee.
Pateurised cool cream
↓
Ageing (3-4 hours at 10-15°C)
↓
CBMM(9°C - 10°C0
↙↘
White Butter Butter Milk
↓ ↓
Packaging Chilling
↓ ↓
Cold Storage Butter Milk Tank
(-10°Cto -15°C)
CBMM OPERATION
 Primary Churning – The butter grains are formed by the action of high
speed beaters. The cylinder is provided with chilled water jackets to
maintain temperature.
 Secondary Churning – There is a provision for butter washing. In this
cylinder butter clumps are formed due to the action of dasher blade ,
washing and separation fromButter milk.
 Working Cylinder – Itconsists of two working blades with chilled water
jacketed cylinder . In this part continuous mass of butter is formed due to
the action of working blades.

11. TABLE BUTTER
Itis generally marketed and processed by the addition of salt and color.
Cream (10°C to 12°C)
↓
Addition of Annato color @ 0.055%
↓
Churning @ 20rpm for 30 minutes
↓
Churning @ 16rpm for 30 minutes → Butter Milk
↓
Addition of wash water
↓
Washing at 12rpm for 30 minutes → Water Drain
↓
Addition of salt @2.5%
↓
Working @ 6rpm for 1hour
↓
Butter is drawn
↓
Packaging
↓
Storage in deep freezer (-5°C to -10°C)

12. POWDER PRODUCTION
The plant comprises of a powder production unit having a capacity of 30
tons powder per day. The unit is accomplished with evaporator assembly
which mainly used for the production of SKIMMILK POWDER(SMP).
CIP OF THE MILK STORAGE TANK OR SYLOS
 Empty Tank
 Flush for 3 minutes with Distilled water
 Add .8% to .12% Caustic mixture at 75°C for 10 minutes
 Heat water to 80°C and keep for 5 minutes.
 0.8% to 1% strong acid at 65°C for 5 minutes
 80°C water for 10 minutes
 Again flush with distilled water
WATER SOFTENING PLANT
 Open air vent.
 Open suction valve.
 Close air vent when water starts coming out of it.
 Open drain valve
 Collect sample
 Send to the lab for testing.
 Close drain valve.
 Open discharge valve .
 Maintain soft water at not more than 10ppm hardness.

13. QUALITY CONTROL
Various sampletests and analysis areperformed to check the quality of milk and
milk products.
LACTOSCAN – Itis a device used to check the fat and SNF content of a given
milk sample and it is a basic platformtest performto judgethe quality of milk .
COB TEST – The milk is heated and the taste and odour is checked
LABORATORY TESTS
 NEUTRALIZER TEST – Take 2ml Rosalic acid in a test tube and add 2ml
milk to it. Mix the contents well and observethe color.
Appearanceof rosered color – positive test
Or
Take 5ml milk in a test tube and add 5ml neutralizer reagent – 1, followed
by a few drops of neutralizer reagent-2 and mix well.
Appearanceof rosered color – positive test
 UREA TEST – Take 2ml milk and add 2ml DMAB solution. Mix and
observe. Yellow color – positive test
Or
Take 2ml milk and add 2ml urea reagent. Mix and observe.
Dark yellow – Urea positive
 MALTOSE TEST – Take 20mlmilk and add 1ml lactic acid and 1ml
enzyme. Keep at 62°Cfor 5 minutes. Immersediastic strip in the curdled
milk for 1-2 seconds. Wipe the excess. Wait for 30 seconds and compare
with the color chart .
Slight cream color – negative test
No color change – positive test

14.  DETERGENT TEST – Take 10 ml milk in a 50mlcylinder .Add 25 ml
Methylene Blue and 15ml Chloroform. Mixwell after inverting 5 times.
Allow for 10minutes and comparethe color of the 2 layers.
If the color at the bottom is persistentas compared to the upper layer –
positive test.
 BUTYRO REFRACTOMETER TEST AT 40°C – Centrifuge the milk. Add a
drop of clear fat on butyro refractometer prismmaintained at 40°C.
Acceptable range– 40 to 43
 SALT TEST – Take 5ml salt reagent- 1 and add a few drops of salt reagent-
2 followed by 1ml milk.
Immediate changefrom chocolate to yellow – positivetest
Deep red color – negative test
 FORMALIN TEST – Take 10ml of milk and add 5ml formalin
Appearanceof violet color – negative test
No change in color – positive test
 AMMONIA TEST – Take 1ml of milk and add 2mlammonia
Appearanceof brownish color after missing – positive test
Appearanceof grey color – negative test
 SUGAR TEST – Take 1ml milk and add 1ml sugar reagent Keep in a boiling
water bath for 5 minutes .
Brick red color – positivetest
Orangish – negative test
Appearanceof dark blue color after addition of 1ml glucosereagent-2 –
positive test .
 GLUCOSE TEST – Take 1 ml of milk and add 1ml of glucosereagent-1.
Keep in a boiling water bathfor 3 minutes and cool
Appearanceof dark blue color after the addition of 1ml glucosereagent –
2- positive test

15.  NITRATE TEST – Take 1ml milk and add 1ml nitrate .
Appearanceof dark blue color – positivetest
Light brownish color – negative test
 H₂O₂ TEST – Take 1ml of milk and add a few drops of H₂O₂reagent.
Appearanceof pink red / blue color after mixing – positive test
Light cream color – negative test
 STARCH TEST – Take 5ml milk and boil. Cool and few drops of starch
reagent .
Appearanceof blue color – positivetest
Cream color – negative test
 ALCOHOL TEST – Take 5ml of milk and add 5ml of 605 alcohol. This test is
performed to check how old the milk is .
 ACIDITY TEST – Take 10mlmilk and pour in a small flask. Add a few drops
of phenolphthalein indicator and 10mlof distilled water. Titrate against
N/10 NaOH.
 LACTOMETER READING –
FCM – 28.25 TO 28.5 +1.75
TM – 28.75 TO 29 +1.75
DTM - 31.75 TO 32+2.00
STD – 27.5 TO 27.75 +1.75
SM – 2.00

16. CONCLUSION
Vita dairy production plantis a large scale dairy industry
which majorly focuses on the processing of milk followed
by paneer. The other dairy products are processed on
demand. The productionof DAHI is increased during
summers and is reduced during winters.
The plantefficiently utilizes the waste products, such as
the formation of JALJEERA from waste whey during paneer
productionand KAJU PINNI from the ghee residue
obtainedduring the processing of ghee.