ACKNOWLEDGEMENT

This is my first experience in the corporate world and it has been a truly learning experience for me. This training assigns to me a great learning and tremendeous scope of application. There have been many people who have supported me throughout the training and i got this opportunity to thank them for their time and effort. I would like to thank Mr. Balwinder Singh (M.D.) and Mrs. G

FUNDAMENTAL KNOWLEDGE OF MILK

Milk is the secretion derived after complete milking of healthy milk animal, excluding that obtained within 15 days before or after 10 days of calving.

COMPOSITION OF MILK
01. Milk Fat Milk fat is the mixtures of 19 fatty acids. The bulk of fat in milk exist in the form of small globules with size approx. 0.1 to 22microns. It is an oil-in-water type emulsion.

02.

Proteins Protein is the most complex organic substances. They are vital for living organisms as they constitute an indispensable part of the individual body cell. The protein of milk consists of Casein, Lacto globulin and Lacto albumin. It is in colloidal state. Casein is only found in milk. It is easily coagulated by heat treatment.

03.

Water

It provides the medium in which all the milk constitutes are either dissolved or suspended. Most of it is free and only a small portion is in bound form, being firmly by protein and phospholipids.

04.

Lactose(Milk Sugar) It is found only in milk. It exist in true solution phase and is fermented by bacterial to yield lactic acid. It is very important for cultured milk products. It can also cause souring in milk and its products.

05.

Mineral Matter: Although it is present in small quantity, it is very essential for human body. These are mostly salts like Mg, Na, P, N etc. It influences physio-chemical properties of milk and also affects the nutritive value.

06.

Phospholipids: There are three types of phospholipids (Lecithin, Cephalic and Sphingomylein). Lecithin is important constituent as it helps in the formation of outer membrane of fat globules.

07.

Pigment: There are two type of pigment present in milk, Fat Soluble and Fat insoluble. Carotene is fat soluble and is responsible for the yellow color of milk. The other two are Xanthophylls and riboflavin. Carotene also acts as an anti oxidant and as a source of Vitamin A.

08.

Milk Enzymes The important milk enzymes and their specific action are as follows:

Anise (diasterase) Lipase Phosphatase Protease Catalase

Starch Fat splitting, leads to rancid flavor It is capable of splitting certain phosphoric esters. It is capable of splitting proteins. decomposed hydrogen peroxides.

09.

Vitamins

Vitamins are present in minute quantities in milk or any other food but play a very important role in vital functioning of human body. There are 25 vitamins present in milk. These are fat soluble e.g. Vit. A, D, E,K. apart from fat soluble there are water soluble vitamins as Bcomplex(B1, riboflavin or B2, pantothenic acid, niacin, pyridoxine or B6.)

Role of milk in human life

Milk is one of the most complete food available in nature for human consumption. Milk contains all nutrients in balanced proportions to meet the demand of humans. It is not only necessary for children but it is every essential for adults too. Milk proteins are one of the most high quality proteins. It is essential proper growth of body. Casein, the milk protein, is only found in milk. Milk contains lactose (milk sugar) which is only found in milk and on hydrolysis gives galactose and glucose. Lactose on fermentation gives butter, cheese and dahi, which have high nutritive value and thus is very important for human life.

 1 Liter of Cow s milk gives 720 Calorie (3000J) of energy.  1 Liter of Buffalo s milk gives 1100 Calorie (4600J) of energy.  1 gm of milk fat gives 9 Calorie of energy.  1 gm of Protein gives 4 Calorie of energy  1 gm of Carbohydrate gives 4 Calorie of energy

Most milk is composed of 80 to 90 percent water. The remaining 10 percent consists of an abundance of the major nutrients needed by the body for good health, including fats, carbohydrates, proteins, minerals, and vitamins.

Cow milk typically contains about 3.5 to 5 percent fat, which is dispersed throughout the milk in globules. In addition to providing milk s characteristic taste and texture, fat supplies vitamins A, D, E, and K, as well as certain fatty acids that the body cannot produce on its own.

Lactose, a kind of sugar found only in milk, gives milk its sweet taste. Making up about 5 percent of milk s content, lactose is a carbohydrate that is broken down by the body to supply energy. Infants digest lactose easily, but many adults, especially those of Asian and African ancestry, have lost some of their ability to digest this sugar. When these adults drink milk, they often suffer gastric distress and diarrhea.

The most important protein in milk is casein, accounting for 80 percent of milk protein. Casein is a complete protein, meaning that it contains all of the essential amino acids, which the body cannot manufacture on its own. Casein molecules and globules of fat deflect light rays passing through milk, giving milk its opalescent appearance. Other proteins present in milk include albumin and globulin.

Milk contains many minerals, the most abundant of which are calcium and phosphorus, as well as smaller amounts of potassium, sodium, sulfur, aluminum, copper, iodine, manganese, and zinc. Milk is perhaps the best dietary source of calciumone liter (about 1 qt) of milk supplies as much calcium as 21 eggs, 12 kg (26 lb) of lean beef, or 2.2 kg (5 lb) of whole wheat bread. Milk is an excellent source of vitamins A and B2 (see riboflavin). All other vitamins are present also, but in lower doses. Vitamin D is typically added to commercially sold milk. Vitamin A, which is found in the globules of fat, is removed when fat is skimmed away to make low-fat or skim milk. Generally, vitamin A is replaced during the production of commercially sold low-fat milk.

Milk-Processing

Unprocessed milk may contain small dirt particles invisible to the naked eye. In order to remove these particles the milk has to be processed.

In any kind of industry various processes are undertaken to process the raw materials to obtain the final product. So each such process can be divided into discrete steps which when undertaken one by one lead to the complete process.

In our case at Mother Dairy, the process is to process the raw milk in the required standard conditions and to reach the final processed milk at the desired standards. The milk processing plant at the Patparganj unit is engaged in receiving any kind of the raw milk from the state dairy federations and processes it to produce Toned Milk, after doing the pasteurization. The standards for the processed Toned Milk are as follows:

  

Fat contents: Solid non-Fat contents: Temperature: 8.58%

3.05%

2-40C

Methyl blue re-coloration (MBR) time: 4 hours (minimum)

Before reaching the final state the raw milk is subject to various processes shown below:

FLOW AND PROCESSING OF MILK:

stage the raw milk being received from the dairy federation tankers/ milk being received from distant federations by the rail route, milk prepared at the dairy plant after reconstitution/ high fat processing is chilled and stored in the Raw Milk Silos. When a Silo is full, then a sample is taken in the process lab and is tested for its constituents.

MOTHER DAIRY PLANT SPECIFICATION

Equipment Pasteurizer Homogenizer Clarifier Silos Ice Silos Raw milk Silos Processed milk silo

Number of unit installed 05 05 06 14 02 05 07

PLATFORM TESTS
1. CHECK FOR CLEANLINESS First of all cleanliness of containers is checked and appropriateness of seal is also checked.

2.

PRESENCE OF FOREIGN MATTER The milk is taken, filtered and seen for presence of any foreign matter. Physical condition of milk is also noted from top i.e. for presence of any flies.

3.

TEMPERATURE Temperature of milk is then tested and should not be greater than 10C

4.

ORGANOLEPTIC EVALUATION Check., taste and flavor of milk

5.

COB TEST Conduct COB test by taking about 2 ml milk in a test tube, boil on the flame of a spirit lamp formation of clots in the test tube indicates COB positive milk and is unacceptable.

6.

ACIDITY TEST Taking 10 ml milk in 10 ml conical flask. Titrate against N/10 NaOH using phenolphthalein indicator to check acidity. Acidity above .153% is not acceptable or use acidometer for titrable acidity.

7.

ROSALIC ACID TEST To 2 ml rosalic acid in a test tube add 2 ml of milk . Rose red color development indicates neutralizer presence in milk and formation of flakes indicates disturbed salt balance.

8.

ALCOHOL Alcohol test is done to know the quality of milk. To 2 ml milk in a test tube add 2 ml 68% alcohol. The presence of flakes indicates alcohol positive and such milk is rejected. The alcohol test determines the susceptibility of milk to coagulation due to developed acidity, salt unbalance or high albumen content.

9.

FAT & SNF Fat & SNF can be determined using Gerber s method or using a milcoscan.

SNF can also be determined using lactometer reading and Fat value and putting the formula CLR/4 +Fat x .2 + .29
Milkoscan is the latest technology machine for scanning of milk and uses infra red rays to analyze the milk for

y y y y 10.

Fat Protein Lactose SNF

MBRT TEST
To 10 ml of milk in a sterilized MBR tube add 1 ml of MBR dye Plug with a sterilized cork, invert the tube to mix the contents and incubate at 37C in a water bath. Check the tube for decolorization just after 10 minutes Next time after 30 minutes and subsequently every hour. Milk with MBR time of less than 10 minutes is unacceptable.

11.

TEST FOR PRESENCE OF UREA Take 2 ml milk in a test tube add 2 ml DMAB solution and mix the contents. Appearance of yellow color indicates the presence of urea making the milk unacceptable.

12.

SUGAR TEST Take 3 ml of milk add 5 ml dilute HCL(1:2 containing resorcinol 0.1 gm resorcinol dissolved in 100 ml dilute HCL) Mix well and keep the test tube in boiling water for 5 minutes. Brick red color formation indicates sugar positive.

13.

STARCH TEST Take 3 ml milk in a test-tube, boil and cool under tap water. add 2 drops of 1% Iodine solution. Appearance of blue color indicates the presence of starch.

14.

SALT TEST Take 5 ml of silver nitrate (0.134%) solution in a test tube and ad 2 drops of potassium dichromate (10%) solution. It will give brick red color. To this add exactly 1 ml of milk and mix. Observe the color if yellow color appears then it shows salt test positive. If not then the salt test is negative.

15.

B.R. READING Extract ghee from milk by centrifuging about some milk in centrifuge for 5 minutes and creamy layer is separated and melted and heated and ghee is prepared. Put few drops of melted ghee on clean prism of butyro-refracto-meter and close it gently. Allow it to stand for 1 minute. Note down the reading at 40C. If B.R. reading comes in the range of 40 to 45 then only milk is accepted otherwise rejected. After use clean the prism with rectified spirit.

16.

MINERAL OIL TEST (HOLDERS TEST)

Take 1 gm of ghee extracted from milk in a 250 ml conceal flask and to this add 22 ml alcoholic KOH and keep the flask on boiling water bath or hot plate and saponify it till there is no oil droplets. To this add 25 ml boiling distilled water and swirl the flask. Development of turbidity indicates the presence of mineral oil. Such milk is unacceptable. No turbidity indicates absence of mineral oil.

MAIN LABORATORY TESTING

For collecting samples allow cotton soaked in alcohol on the sampling cock to sterilize it. Allow approximately 2 litters of milk to flow into bucket then collect the sample in sterilized sample bottle.
 FAT & SNF

Fat & SNF of milk is tested for each batch for each silo milk for standardization purpose and also for finished milk so as to ensure that milk is ready for dispatch.

Fat and SNF is tested using a milcoscan. The temperature of the sample should be 40+-2 degree centigrade. It is a latest technical machine for scanning of milk and uses I.R rays to analyze milk for Fat, SNF, Protein, Carbohydrate, TS.

HOMOGENIZATION EFFICIENCY

1. Draw milk sample from outlet valve and note the homogenization pressure. 2. Take 10 ml milk in centrifuge and see for any fat separation 3. If doubtful, prepare a slide and observe under micro scope the size of fat globule should not be more than 2 microns 4. In case unsatisfactory, the matter and cause is seen into.

PHOSPHATASE TEST

Principle

Raw milk contains phosphatase enzyme. It destroyed when the heat treatment (pasteurization) of milk is done. But when the milk containing phosphatase is incubated with p nitro phenyl disodium orthophosphate, the liberated para-nitro phenol gives yellow color under alkaline condition of the test. The yellow color indicates the presence of phosphatase and that the milk has been contaminated after the heating process by raw milk.

Procedure: 1. Draw milk sample from the silo in a clean sterile sample bottle. 2. 3. 4. 5. Take 1 ml of milk in each of the two sterilized MBR test tube. Heat One Tube to boil to act as control sample. Add 5 ml of Phosphatase dye in each Tube and mix well. Incubate at 37C in water bath, observe the color after 10 minutes, 30 minutes and finally after two hours. Yellow color indicates positive test result.

Phosphatase dye: Dissolve 0.15gm of p-nitro phenyl disodium orthophosphate salt in 100ml of buffer solution. Buffer solution: Dissolve 3.5gm of sodium carbonate and 1.5gm of sodium bicarbonate to make 1liter of solution in distilled water. Keep the buffer solution in cool place.

METHYL BLUE REDUCTION TEST (MBRT)

Principle:

This test is based on the principle that methyl blue (an oxidationreduction dye or indicator) which is blue in its oxidized state, is reduced to colorless compound (leuco form) as a result of the metabolic activities of bacteria in milk. When a solution of dye is added, the organisms present in milk consume the dissolved oxygen and lower O-R potential to a level where methyl blue or similar indicators are reduced or decolorized.

Procedure:

Take 10 ml of milk in a sterilized MBR tube. Add 1 ml of MBR dye. Plug with a sterilized cork. Invert the tube to mix the contents and incubate at 370C in a water bath. Check the tube for de-coloration first after 10 minutes and subsequently every hour milk. For pasteurized milk time should be 5 hrs or at least 4 hrs. Whereas for raw milk time is 30 min.

KEEPING QUALITY OF MILK

TITRABLE ACIDITY Take 10 ml milk sample to it add 10 ml distilled water add Phenolphthalein and titrate against N/10 NaOH . Acidity% = titrate value x.09

Titrable acidity of milk from PM silo should not be greater than .14.

COB Take 2 ml milk in a test tube and kept in a boiling water bath for 5 min. The formation of curd indicates the poor heat stability and hence the positive COB test.

NEUTRALIZERS
To 2 ml Rosalic acid in a test tube add 2 ml of milk. Rose red color indicates neutralizer present in milk and formation of flakes indicates disturbed salt balance. The neutralizer test results of processed milk should be negative so as to ensure that there is no misappropriation or mishandling during processing.

After ensuring that fat percentage is 3.05 and SNF 8.58 minimum and all other tests are giving satisfactory results the milk is send or marked for dispatch.

Procedure for Final Inspection & Testing of Milk

(1)

Samples are drawn from filled dispatch tankers parked in the hard parking bay. Normally temperature of milk in tanker is checked from the sample drawn from delivery

valve. If temperature is found more than 7C it is confirmed by taking sample from the top. Sample of few tankers is checked from top also for observation, temperature and MBR. (2) The sample are tested for neutralizer test and for fat and SNF. If sample meets the requirements, the tanker is accepted and recorded. Few tankers are also tested for MBRT and if the MBRT of a tanker is found to be less than 4 hrs, milk of tanker is called back from retain outlets. (3) If it fails to meet Mother Dairy dispatch standards, the tanker is rejected and shift in charge is informed. (4) The system is so made that weighment of milk for dispatch is done only when the test results are found correct so as to ensure that quality milk leaves Mother Dairy.

(1) Regeneration-I : The milk is pumped to the balance tank from there the milk is pumped to regeneration-I wherein it gets heated to about 40-45C because of outgoing milk and hence reducing its temperature. Regeneration system helps in energy saving both for heating as well as cooling milk

(2) Clarification: Clarification is the process of removing suspended foreign by centrifugal sedimentation clarifies are used for this purpose.

(3) Regeneration-II The milk from clarifier is sent to regeneration-II wherein the milk is further heated by the pasteurized milk hence raising the temperature of incoming milk and reducing the temperature of outgoing milk and also regeneration-II raises the temperature of milk so as to enable efficient homogenization which is the next step.

(4) Homogenization: - Homogenization is a process wherein fat globules are broken down to 2 microns or less under high pressure Homogenizer is a machine which causes sub-diversion of fat globules. It consists of a high-pressure piston pump that forces the milk and thereby subdivided into smaller particles of more uniform size.

Effect of homogenization

The fat globules of milk are surrounded by a membrane 5-10 mm thick. The membrane has properties of an emulsifier and keeps the emulsion, milk stable. During homogenization the original membrane is destroyed and the first result is a rise in interfacial tension soon falls again. The new emulsion therefore remains stable even after homogenization.

Homogenization effect is produced by three collaborating factors:

(a) Passage through the narrow gap in the homogenizer head at high velocity subjects the fat globules to very powerful shear forces, which deforms elongate and shatter the spherical globules.

(b) The acceleration of the liquid in the gap is accompanied by a pressure drop. This creates cavitations in which the globules are subjected to powerful implosive forces.

(c) Further shattering takes places when the fat globules impact at high velocity in the homogenizing head.

Make Capacity I Stage Pressure II Stage Pressure Motor

APV GAULIN 18000 LPH 1800-2400psi (140 bar) 500-700psi (14bar) 125 HP

(5) Pasteurization:. Here milk is heated using plate-heat chiller to a temperature of 76-78C and the temperature should not be less than 75C so as to ensure proper pasteurization and not greater than 79C so as to ensure that overheating has not taken place as overheating may harm the nutrients present in milk. Pasteurization of milk is done with the help of hot water. The water in a small tank is passed through a heater steam wherein the water is heated using steam. The hot water is then passed through PHE to heat up milk to the desired temperature. After the milk is heated the milk pass over to the holding section wherein it pass for 15 seconds at that temperature. The temperature of the outgoing milk is transmitted with the help of a temperature transmitter, which is connected to temperatures indicating controller, which controls the flow of steam according to the temperature. If the temperature is too high it limits steam injection in heater and if too low the steam level is enhanced through a system of pneumatic valves. The milk then passes through the flow diversion valve which decides the forward or deflected flow of milk. If the temperature of milk is below 75 C the FDV diverts the flow of milk to balance tank and if above 75C the forward milk flow is maintained. But by continuous monitoring it is ensured that the temperature is maintained at 76-77C. At the same time it is also seen that the temperature do not exceed 79C and according to the fluctuation the steam injection is controlled. From the pasteurization section milk flows to regeneration II and then regeneration I and finally chilling.

(6) Chilling:

Here milk is finally chilled to 4-5C using chilled water which are being pumped

from ice silos. The chilled water temperature ranges from 1.5 - 3C and chilled milk temperature from 4 - 6C. If the chilled milk temperature exceeds 9C the milk will be again circulated through the systems so a temperature transmitter continuously displays the temperature on monitor so that continuous monitoring can be done and if temperature raises continuously the refrigeration section take necessary action in this regard so as to reduce the temperature. After chilling, milk is pumped to the silos.

(7) Vitamin A addition: Toned milk during processing is fortified with vitamin A. Vitamin A addition is done using vitamin A acetate. Vitamin acetate is added in the balance tank for each shift. The amount added is 180 ml of vitamin A acetate in one lakh liters of milk so that the milk contains 2000 IU of vitamin A. (8) Standardization The milk, which reaches the raw milk silos, is of different fat and SNF composition. Normally raw milk silo 1, 2, 3 contains mixed milk and 4 & 5 comprises of skim milk which may contain different proportion of fat and SNF. Now to obtain toned milk of 3% fat and 8.5% SNF different proportion of milk from different silos is calculated and processed and are directed to processed milk silos. For this first total amount of batch of milk is determined or fixed and amount of SNF and fat requirement for this batch is calculated. Now amount of mixed milk and skim milk is processed and diverted to processed milk silos and now the remaining quantity i.e. quantity decided is made up using chilled UV water directly into the process milk silo hence obtaining a batch of appropriate fat and SNF values. For complete mixing of different batches of milk, agitators are provided. Now after this sample is drawn from PM silo and tested for fat and SNF and if found unsatisfactory it can be again corrected using calculated amounts of water or skim milk. After assuring that the fat and SNF valves are up to the mark silo is marked for dispatch. (9) DISPATCH
After the fat SNF and quality testing of PM silo is done and the quantity is full, the Silo is marked for dispatch. Before dispatch milk is pumped over to glycol chillers and the milk is chilled to 2C in glycol chillers. Here instead of chilled water, chilled glycol of

 PANEER
Appearance: -Shall be clear and free from dirt, surface discoloration and insect's contamination. It shall not have any free moisture. Flavor: -It shall have pleasant odor and characteristic mild acid flavor Texture; - It shall have a closely-knit smooth texture and spongy body.

Standards

Moisture Milk fat T.A.

Max.60 Min.50(db) Max.0.5

Moisture

2 gm-shredded paneer is weighed in a dish. Mix with 4 ml hot distilled water with glass rod. Wash off the particles on glass rod using 1 ml water. Mix the contents thoroughly. Heat the dish at 102 + 1 C for 4 hrs. Cool in dessicator. Weigh with cover on. Replace for 30 min. again at 102 and 1 C. Weigh. Repeat till difference between successive weighing is less than 1 milligram.

Calculation:

Moisture % =

100 (W1 - W2) (W1 W) W1 = dish + sample before drying W2 = dish + sample after drying W = Mass of empty dish

Fat Reagents

Gerber s Method Sulphuric acid (1.8 1.812 sg), Amyl Alcohol (0.85 as Specific gravity)

Procedure:

Acidity

Take exactly 10 ml of Gerber s Sulphuric acid in butyrometer Weigh accurately 1.69 Gms of shredded paneer and added in 10 ml Sulphuric acid. Add 1 ml amyl alcohol Make up the volume by distilled water Close the butyrometer with rubber stopper and mix the contents until completely digested. Centrifuge the butyrometer for 5 min. at 1000 rpm. Place in water bath. Read the fat column.

Reagents: N/10 NaOH and phenolphthalein indicator

Procedure Calculation Grind paneer pieces in mortar and pestle Weigh 2 gram of paneer sample in a conical flask Add 20 ml hot water slowly and mix properly using a glass rod Add 10 ml NaOH and 1 ml phenolphthalein indicator Titrate against N/10 HCl. End point is disappearance of pink color.

Titrate able acidity % = (10 - Vol. Of HCl) x 0.9 2

 DAHI/MISHTI DOI
Color: - Shall be white, uniform without showing any sign of visible foreign mater.

Body and Texture: -Should be firm solid and uniform with negligible whey separation

Flavor It shall have a pleasant and cream acid taste. It should be free from bitterness, saltiness or other off flavors.

Standard Fat % TS% (Min). Dahi Misty Doe TA (Max). 4.6 15 31% 1.2

Fat Determination

Reagents: -

25% Ammonia, Gerber s Sulphuric Acid, amyl alcohol.

To 100 gm of curd in a beaker add 5 ml of strong ammonia to the weighed sample and shake well to make it homogenous. Pipette out 10.75 ml of well-mixed sample of dahi and transfer it to butyrometer containing 10 ml Sulphuric acid. To this add 1 ml amyl alcohol. Close the butyrometer with a rubber stopper, mix so as to digest the contents and centrifuge for 5 minutes. Adjust the fat column and take reading. Multiply the result with dilution factor (here 1/20) and add the same to the obtained result.

Acidity

Weigh accurately 10 gm of Dahl in 40 ml beaker. To it add 20 ml distilled water and acidity can be determined using acidometer.

 LASSI
Color: - White, uniform, without showing any sign of visible foreign matter. Body & Texture: - Smooth and free from gas bubbles Flavor: flavors. Pleasant and sweetish aroma. It should be free from bitterness, saltiness or other off

Specifications

Fat% TS% TA

3.1 (Min) 20 (Min) 0.8 (Max)

Incubation Test

PH variation TA -

0.3 max 0.02 max

Bulging Test - Negative

i) Fat determination Gerbers Method Carefully dispense 10 ml of Gerber s Sulphuric acid in a butyrometer. Pipette out 10.75 ml of lassie into it. Add 1 ml of amyl alcohol. Mix the contents well. Centrifuge for 5 minutes. Place in a water bath of 65 C and take the reading.

ii) Total Solids Total solids can be determined using gravimetric method. Same as that of milk.

iii) Acidity Weigh accurately 10 Gms of lassie in a 50 ml beaker. Add about 30 ml distilled water. Determine the acidity under the curd mode in the acidometer.

QUALITY ASSURANCE
Mother Dairy follow a strict system of quality assurance to maintain a high quality of milk provided to the consumer. Every batch of incoming milk is tested for Fat, SNF, Acidity and bacteriological quality, adulterants and presence of any preservative or neutralizer which are not permitted by the law. The outgoing milk is also checked for bacteriological and keeping quality besides Fat and SNF.

QUALITY POLICY

Our commitment is to excellence. The evolving needs of our customers drive our continuous innovation in product development, application of state-of-the art technology and selection of appropriate processes to be used by our employees and our vendors. To ensure that we are second to none:

y We maintain a vibrant work environment that encourages excellence. y We empower our people that lead to continuous improvements in our processes and systems.

y We choose such processes that ensure quality at competitive price while protecting the environment, in which we work and live. y We apply HACCP (Hazard Analysis Critical Control Points) principles for safety of our products to customers.
We shall constantly strive to be leaders in the dairy industry in Delhi, in India and in the World.